Jaguar XType WorkshopManual

Workshop Manual
X-TYPE
Sedan and Estate (Wagon)
2.0 L, 2.5 L and 3.0 L Gasoline;
2.0 L and 2.2 L, Diesel
2001 to 2009
www.JagDocs.com
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TABLE OF CONTENTS

1: General Information

100: Service Information

100-00: General Information
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
Identification Codes

100-02: Jacking and Lifting
Jacking
Lifting

100-04: Noise, Vibration and Harshness
Noise, Vibration and Harshness (NVH)
Diagnosis and Testing
Noise, Vibration and Harshness (NVH)
General Procedures
Exhaust System Neutralizing

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2: Chassis

204: Suspension

204-00: Suspension System - General Information
Specification
Wheel Alignment Angles
Suspension System
General Procedures
Front Toe Adjustment (57.65.01)
Rear Toe Adjustment (57.65.08)
Wheel Bearing Inspection

204-01: Front Suspension
Specification
Front Suspension
Front Suspension
Removal and Installation
Lower Arm (60.35.02)
Shock Absorber and Spring Assembly (60.30.02)
Front Stabilizer Bar (60.10.01)
Front Stabilizer Bar Bushing (60.10.04)
Front Wheel Bearing and Wheel Hub (60.25.03)
Wheel Knuckle (60.25.23)
Disassembly and Assembly
Shock Absorber and Spring Assembly (60.30.21)

204-02: Rear Suspension
Specification
Rear Suspension
Rear Suspension
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Damper
Front Lower Arm (64.35.51) - 4-Door
Front Lower Arm (64.35.51) - Wagon
Rear Lower Arm (64.35.52)
Spring (64.20.01)
Rear Stabilizer Bar (64.35.08)
Rear Stabilizer Bar Link (64.35.24)
Upper Arm (64.25.31)
Wheel Hub (64.15.14)
Wheel Knuckle (64.15.22)
Wheel Knuckle Front Bushing (64.15.28)
Wheel Knuckle Rear Bushing (64.15.30)

204-04: Wheels and Tires
Specification
Safety Precautions
Wheels and Tires
Wheels and Tires
Tire Low Pressure Sensor - VIN Range: J28493->V99999
Tire Pressure Monitoring System (TPMS) Front Antenna - VIN Range: J28493-
>V99999
Tire Pressure Monitoring System (TPMS) Main Antenna - VIN Range: J28493-
>V99999
Tire Pressure Monitoring System (TPMS) Module - VIN Range: J28493->V99999
Tire Pressure Monitoring System (TPMS) Rear Antenna - VIN Range: J28493-
>V99999
Wheel and Tire (74.20.05)

205: Driveline

205-00: Driveline System - General Information
Driveline System
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Driveline System

205-01: Driveshaft
Specification
Driveshaft
Driveshaft
General Procedures
Driveshaft Runout and Balancing
Driveshaft (47.15.01)

205-02: Rear Drive Axle/Differential
Specification
Rear Drive Axle and Differential
Rear Drive Axle and Differential
In-Vehicle Repair
Axle Shaft Seal (51.20.04) (51.20.36)
Drive Pinion Flange
Drive Pinion Seal (51.20.01)
Axle Assembly (51.25.13)

205-04: Front Drive Halfshafts
Specification
Front Drive Halfshafts
Front Halfshaft LH (47.10.15)
Front Halfshaft RH (47.10.16) - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA
V6 AJ27
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Front Halfshaft RH (47.10.16) - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi
(110kW/150PS) - Puma
Inner Constant Velocity (CV) Joint Boot (47.10.18)
Intermediate Shaft
Outer Constant Velocity (CV) Joint Boot (47.10.19)

205-05: Rear Drive Halfshafts
Specification
Rear Drive Halfshafts
Rear Halfshaft (47.10.13)
Outer Constant Velocity (CV) Joint Boot (47.10.32)

206: Brake System

206-00: Brake System - General Information
Specification
Brake System
Brake System
General Procedures
Brake Disc Runout Check
Brake System Bleeding (70.25.03)

206-03: Front Disc Brake
Specification
Front Disc Brake
Front Disc Brake
Brake Caliper (70.55.02)
Brake Disc (70.10.10)
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Brake Pads (70.40.02)

206-04: Rear Disc Brake
Specification
Rear Disc Brake
Rear Disc Brake
Brake Caliper (70.55.03) (70.55.25)
Brake Disc (70.10.11)
Brake Disc Shield (70.10.19)
Brake Pads (70.40.03)

206-05: Parking Brake and Actuation
Specification
Parking Brake
Parking Brake
General Procedures
Parking Brake Cable (70.35.29) - Vehicles With: Manually Adjusted Parking Brake
Parking Brake Cable (70.35.29) - Vehicles With: Self-Adjusting Parking Brake
Parking Brake Control (70.35.08) - Vehicles With: Manually Adjusted Parking
Brake
Parking Brake Control (70.35.08) - Vehicles With: Self-Adjusting Parking Brake

206-06: Hydraulic Brake Actuation
Specification
Hydraulic Brake Actuation
Hydraulic Brake Actuation
Brake Fluid Reservoir (70.30.16)
Brake Master Cylinder (70.30.08)
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Brake Pedal and Bracket (70.35.03)
Brake Pedal Cross-Shaft

206-07: Power Brake Actuation
Specification
Brake Booster
Power Brake System
Brake Booster (70.50.17) - LHD AWD/LHD FWD
Brake Booster (70.50.17) - RHD AWD/RHD FWD
Brake Vacuum Pump - 2.0L NA V6 - AJV6
Brake Vacuum Pump - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS)
Puma

206-09: Anti-Lock Control - Stability Assist
Specification
Anti-Lock Control - Stability Assist
Anti-Lock Control - Stability Assist - VIN Range: C00344->J12991
Anti-Lock Control - Stability Assist - VIN Range: J12992->V99999
Anti-Lock Brake System (ABS) Module (70.60.02) - VIN Range: C00001->J12991
Front Wheel Speed Sensor (70.60.03)
Hydraulic Control Unit (HCU) (70.60.18) (70.60.19) - VIN Range: C00001->J12991
Hydraulic Control Unit (HCU) (70.60.18) (70.60.19) - VIN Range: J12992->V99999
Rear Wheel Speed Sensor (70.60.04)
Stability Assist Module
Steering Wheel Rotation Sensor (86.56.58)
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
Yaw Rate Sensor (86.56.57) - 2.2L Duratorq-TDCi (110kW/150PS) Puma

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211: Steering System

211-00: Steering System - General Information
Specification
Steering System
Steering System
General Procedures
Power Steering System Filling
Power Steering System Flushing (57.15.08)

211-02: Power Steering
Specification
Power Steering
Power Steering
General Procedures
Start Up Procedure After Power Steering Pump/Gear Overhaul
Power Steering Control Valve Actuator (57.10.32) - 2.5L NA V6 - AJV6/3.0L NA
V6 - AJ27
Power Steering Fluid Cooler (57.15.11) - 2.0L Duratorq-TDCi
Power Steering Fluid Cooler (57.15.11) - 2.2L Duratorq-TDCi (110kW/150PS)
Puma
Power Steering Fluid Reservoir (57.15.08)
Power Steering Pump (57.20.14) - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA
V6 - AJ27
Power Steering Pump (57.20.14) - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi
Steering Gear (57.10.01) - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi
Steering Gear (57.10.01) - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6
AJ27
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211-03: Steering Linkage
Specification
Steering Linkage
Steering Linkage
Steering Gear Boot (57.10.29)
Tie Rod End (57.55.02)

211-04: Steering Column
Specification
Steering Column
Steering Column
Ignition Switch Lock Cylinder (57.40.29)
Steering Column (57.40.01)
Steering Column Coupling
Steering Wheel (57.60.01)

211-05: Steering Column Switches
Steering Column Switches
Steering Column Switches
Steering Column Multifunction Switch LH (86.65.78)
Steering Column Multifunction Switch RH (86.65.41)
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3: Powertrain

303: Engine

303-00: Engine System - General Information
Specification
Engine
Engine
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
Crankshaft Main Bearing Journal Diameter
Cylinder Block Distortion
Cylinder Bore Out-of-Round
Cylinder Head Distortion
Exhaust Manifold Cleaning and Inspection
Flywheel Inspection
Piston Diameter
Piston Inspection
Piston Pin Diameter
Piston Pin to Bore Diameter
Piston Ring End Gap
Piston Ring-to-Groove Clearance
Valve Seat Inspection
Valve Spring Free Length
Valve Stem Diameter
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Leakage Test Using Smoke Test Equipment

303-01A: Engine - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27
Specification
Engine
Engine
General Procedures
Valve Clearance Adjustment (12.29.48)
Valve Clearance Check (12.29.47)
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 LH (12.29.02)
Engine Front Cover (12.65.01)
Engine Front Mount (12.45.01)
Exhaust Manifold LH (30.15.55)
Flexplate (12.53.13)
Exhaust Manifold RH (30.15.56)
Flywheel (12.53.07)
Intake Manifold (30.15.01)
Lower Intake Manifold (30.15.61)
Oil Cooler (12.60.68)
Oil Pan (12.60.44)
Oil Pressure Sender
Oil Pump (12.60.26)
Timing Drive Components (12.65.13)
Valve Cover LH (12.29.43)
Valve Cover RH (12.29.44)

Removal
Engine (12.41.01) - Vehicles With: 5-Speed Manual Transmission - MT75/6-
Speed Manual Transaxle - MMT6
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Engine (12.41.01) - Vehicles With: 5-Speed Automatic Transaxle - JATCO/6-Speed
Automatic Transaxle - AWF21
Disassembly
Engine
Disassembly and Assembly of Subassemblies
Cylinder Head (12.29.22)
Piston (12.17.02)
Assembly
Engine
Installation
Engine (12.41.01) - Vehicles With: 5-Speed Manual Transmission - MT75/6-
Speed Manual Transaxle - MMT6
Engine (12.41.01) - Vehicles With: 5-Speed Automatic Transaxle - JATCO/6-Speed
Automatic Transaxle - AWF21

303-01B: Engine - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) - Puma
Specification
Engine
In-Vehicle Repair
Crankshaft Front Seal (12.21.14)
Crankshaft Rear Seal (12.21.20)
Engine Front Cover (12.65.01)
Engine Front Mount (12.45.01)
Flexplate (12.53.13)
Flywheel (12.53.07)
Intake Manifold (30.15.01)
Oil Pan (12.60.44)
Timing Chain
Valve Cover
Removal
Engine (12.41.01) - 2.0L Duratorq-TDCi
Engine (12.41.01) - 2.2L Duratorq-TDCi (110kW/150PS) - Puma
Disassembly
Engine
Assembly
Engine
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Installation
Engine (12.41.01) - 2.0L Duratorq-TDCi
Engine (12.41.01) - 2.2L Duratorq-TDCi (110kW/150PS) Puma

303-03A: Engine Cooling - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27
Specification
Engine Cooling
Engine Cooling
General Procedures
Cooling System Backflushing
Cooling System Draining, Filling and Bleeding
Cooling System Flushing
Block Heater (86.62.18)
Coolant Expansion Tank (26.15.01)
Cooling Fan Module (26.25.38)
Cooling Fan Motor (26.25.24)
Cooling Fan Motor and Shroud (26.25.25)
Cooling Module (26.40.16)
Radiator (26.40.01)
Thermostat (26.45.07)
Water Pump (26.50.01)
Water Pump Housing (26.50.07)

303-03B: Engine Cooling - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS)
Puma
Specification
Engine Cooling
General Procedures
Cooling System Draining and Vacuum Filling
Cooling Fan Motor and Shroud (26.25.25)
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Cooling Module (26.40.16)
Radiator (26.40.01)
Water Pump (26.50.01)

303-04A: Fuel Charging and Controls - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA
V6 - AJ27
Specification
Fuel Charging and Controls
Fuel Charging and Controls - 2.0L NA V6 - AJV6
Fuel Charging and Controls - 2.5L NA V6 - AJV6/3.0L NA V6 - AJ27, VIN Range:
E96603->J28492
Fuel Charging and Controls - 2.5L NA V6 - AJV6/3.0L NA V6 - AJ27, VIN Range:
J28493->V99999
Fuel Charging Wiring Harness (86.70.22)
Fuel Injection Supply Manifold (19.60.13)
Fuel Injectors (18.10.02)
Fuel Pulse Damper (18.30.98) - 2.5L NA V6 - AJV6/3.0L NA V6 - AJ27
Throttle Body (19.70.04)

303-04B: Fuel Charging and Controls - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi
Specification
General Procedures
Fuel Injection Component Cleaning
Fuel Injection Pump
Fuel Injection Supply Manifold (19.60.13)
Fuel Injector (18.10.01)
Fuel Metering Valve
Fuel Return Line Venturi
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303-04C: Fuel Charging and Controls - Turbocharger
Specification
Turbocharger
Turbocharger
Turbocharger

303-05: Accessory Drive
Specification
Accessory Drive
Accessory Drive
Accessory Drive Belt (12.10.40) - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi
Accessory Drive Belt (12.10.40) - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA
V6 - AJ27
Accessory Drive Belt Tensioner (12.10.41) - 2.0L Duratorq-TDCi/2.2L Duratorq-
TDCi (110kW/150PS) - Puma
Accessory Drive Belt Tensioner (12.10.41) - 2.0L NA V6 - AJV6/2.5L NA V6
Power Steering Pump Belt - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi
Power Steering Pump Belt Tensioner - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi
Water Pump Belt (12.10.44) - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6
AJ27
Water Pump Belt Tensioner (12.10.45) - 2.0L NA V6 - AJV6/2.5L NA V6

303-06: Starting System
Specification
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Starting System
Starting System - 2.0L NA V6 - AJV6
Starting System - 2.5L NA V6 - AJV6/3.0L NA V6 - AJ27
Starter Motor (86.60.01) - 2.0L Duratorq-TDCi
Starter Motor (86.60.01) - 2.2L Duratorq-TDCi (110kW/150PS) - Puma
Starter Motor (86.60.01) - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6
AJ27

303-07A: Engine Ignition - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27
Specification
Engine Ignition
Engine Ignition - 2.0L NA V6 - AJV6
Engine Ignition - 2.5L NA V6 - AJV6/3.0L NA V6 - AJ27
Ignition Coil-On-Plug LH (18.20.44)
Ignition Coil-On-Plug RH (18.20.43)

303-07B: Glow Plug System
Specification
Glow Plug System
Glow Plug System
Glow Plugs

303-08: Engine Emission Control - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi
Specification
Engine Emission Control
Engine Emission Control
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Exhaust Gas Recirculation (EGR) Cooler
Exhaust Gas Recirculation (EGR) Cooler to EGR Valve Tube
Exhaust Gas Recirculation (EGR) Valve (17.45.01)

303-12A: Intake Air Distribution and Filtering - 2.0L NA V6 - AJV6/2.5L NA V6
Intake Air Distribution and Filtering
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 - 2.0L Duratorq-TDCi/2.2L Duratorq-
TDCi (110kW/150PS) - Puma
Specification
Air Cleaner (19.10.05)
Air Cleaner Element (19.10.08)
Air Cleaner Outlet Pipe (19.10.31)
Charge Air Cooler - 2.0L Duratorq-TDCi
Charge Air Cooler - 2.2L Duratorq-TDCi (110kW/150PS) Puma

303-13: Evaporative Emissions
Specification
Evaporative Emissions
Evaporative Emissions - 2.0L NA V6 - AJV6
Evaporative Emissions - 2.5L NA V6 - AJV6/3.0L NA V6 - AJ27
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Evaporative Emission Canister (17.15.13) - 2.0L NA V6 - AJV6
Evaporative Emission Canister (17.15.13) - 2.5L NA V6 - AJV6/3.0L NA V6 - AJ27
Evaporative Emission Canister Purge Valve (17.15.30)

303-14A: Electronic Engine Controls - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA
V6 - AJ27
Specification
Electronic Engine Controls
Electronic Engine Controls - 2.0L NA V6 - AJV6
Electronic Engine Controls - 2.5L NA V6 - AJV6/3.0L NA V6 - AJ27, VIN Range:
E96603->J28492
J28493->V99999
General Procedures
Powertrain Control Module (PCM) Long Drive Cycle Self-Test
Powertrain Control Module (PCM) Short Drive Cycle Self-Test
Camshaft Position (CMP) Sensor (18.30.63)
Catalyst Monitor Sensor LH (18.30.81)
Catalyst Monitor Sensor RH (18.30.80)
Crankshaft Position (CKP) Sensor (18.30.12)
Engine Control Module (ECM) (18.30.01)
Fuel Temperature Sensor (18.30.99) - 2.5L NA V6 - AJV6/3.0L NA V6 - AJ27
Heated Oxygen Sensor (HO2S) LH (18.30.79)
Heated Oxygen Sensor (HO2S) RH (18.30.78)
Knock Sensor (KS) (18.30.69)
Mass Air Flow (MAF) Sensor (18.30.15)
Oil Temperature Sensor (18.31.01)
Throttle Position (TP) Sensor (18.30.17)
Variable Camshaft Timing (VCT) Oil Control Solenoid (18.30.90)

303-14B: Electronic Engine Controls - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi
Specification
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Camshaft Position (CMP) Sensor (18.30.63)
Catalytic Converter Temperature Sensor
Crankshaft Position (CKP) Sensor (18.30.12)
Cylinder Head Temperature (CHT) Sensor (18.30.97)
Diesel Particulate Filter (DPF) Temperature Sensor
Engine Control Module (ECM) (18.30.01)
Engine Oil Pressure (EOP) Sensor
Fuel Temperature Sensor (18.30.99)
Knock Sensor (KS) (18.30.69)
Manifold Absolute Pressure and Temperature (MAPT) Sensor
Manifold Absolute Pressure (MAP) Sensor (18.30.86)
Mass Air Flow (MAF) Sensor (18.30.15)

307: Automatic Transmission/Transaxle

307-01A: Automatic Transmission/Transaxle - Vehicles With: 5-Speed Automatic
Transaxle - JATCO
Specification
Transmission Description - Vehicles With: 5-Speed Automatic Transaxle - JATCO
Diagnostic Strategy - Vehicles With: 5-Speed Automatic Transaxle - JATCO
General Procedures
Transmission Fluid Drain and Refill (44.24.02)
Transmission Fluid Level Check
Transmission Range (TR) Sensor Adjustment (44.15.37)
In-Vehicle Repair
Halfshaft Seal LH (37.23.10)
Halfshaft Seal RH
Main Control Valve Body (44.40.01)
Shift Solenoids (SS) (44.15.50)
Transaxle Support Insulator (37.16.42)
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Transmission Control Module (TCM) (44.15.32)
Transmission Range (TR) Sensor
Removal
Transaxle (44.20.01)
Input Shaft Seal (44.32.07)
Installation
Transaxle (44.20.01)

307-01B: Automatic Transmission/Transaxle - Vehicles With: 6-Speed Automatic
Transaxle - AWF21
Specification
Transmission Description - Vehicles With: 6-Speed Automatic Transaxle - AWF21
Transmission Electronic Control System - Vehicles With: 6-Speed Automatic
Transaxle - AWF21
Diagnostic Strategy - Vehicles With: 6-Speed Automatic Transaxle - AWF21
General Procedures
Transmission Fluid Drain and Refill (44.24.02)
Transmission Fluid Level Check
In-Vehicle Repair
Main Control Valve Body (44.40.01)
Selector Shaft Seal
Transmission Control Module (TCM) (44.15.32)
Transmission Internal Wiring Harness (44.15.35)
Transmission Fluid Pan (44.24.04)
Torque Converter
Torque Converter Seal
Turbine Shaft Speed (TSS) Sensor
Removal
Transmission (44.20.01)
Installation
Transmission (44.20.01)
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307-02A: Transmission/Transaxle Cooling - Vehicles With: 5-Speed Automatic
Transaxle - JATCO
Specification
Transmission Cooling - Vehicles With: 5-Speed Automatic Transaxle - JATCO
Transmission Cooling
Transmission Fluid Cooler (44.24.10)
Transmission Fluid Cooler Tubes (44.24.19)

307-02B: Transmission/Transaxle Cooling - Vehicles With: 6-Speed Automatic
Transaxle - AWF21
Specification
Transmission Cooling - Vehicles With: 6-Speed Automatic Transaxle - AWF21
Transmission Cooling
Transmission Fluid Cooler (44.24.10)
Transmission Fluid Cooler Return Tube (44.24.13) (44.24.29)
Transmission Fluid Cooler Supply Tube (44.24.14) (44.24.28)

307-05A: Automatic Transmission/Transaxle External Controls - Vehicles With:
5-Speed Automatic Transaxle - JATCO
Specification
External Controls - Vehicles With: 5-Speed Automatic Transaxle - JATCO
External Controls
General Procedures
Selector Lever Cable Adjustment (44.15.07)
Selector Lever Cable and Bracket (44.15.08)
Selector Lever Assembly (44.15.04)
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307-05B: Automatic Transmission/Transaxle External Controls - Vehicles With:
6-Speed Automatic Transaxle - AWF21
Specification
External Controls - Vehicles With: 6-Speed Automatic Transaxle - AWF21
External Controls
General Procedures
Selector Lever Cable Adjustment (44.15.07)
Selector Lever Assembly (44.15.04)
Selector Lever Knob (44.15.06)

308: Manual Transmission/Transaxle, Clutch and Transfer Case

308-00: Manual Transmission/Transaxle and Clutch - General Information
Specification
Manual Transmission and Clutch
Manual Transmission and Clutch
General Procedures
Clutch System Bleeding (33.15.01) - Vehicles With: 5-Speed Manual
Transmission - MT75
Clutch System Bleeding (33.15.01) - Vehicles With: 6-Speed Manual Transaxle
MMT6
Gearshift Cable Adjustment (37.16.47)
Release Hub and Bearing Check

308-01: Clutch
Specification
Clutch
Clutch
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Clutch Disc and Pressure Plate (12.53.13) (33.10.01)

308-02: Clutch Controls
Specification
Clutch Controls
Clutch Controls
Clutch Master Cylinder (33.20.01)
Clutch Slave Cylinder (33.35.01) - Vehicles With: 5-Speed Manual Transmission
MT75
Clutch Slave Cylinder (33.35.01) - Vehicles With: 6-Speed Manual Transaxle
MMT6

308-03: Manual Transmission/Transaxle
Specification
Manual Transaxle - Vehicles With: 5-Speed Manual Transmission - MT75
Manual Transaxle - Vehicles With: 6-Speed Manual Transaxle - MMT6
Manual Transaxle
General Procedures
Transaxle Draining and Filling (44.24.02) - Vehicles With: 5-Speed Manual
Transmission - MT75
Transaxle Draining and Filling (44.24.02) - Vehicles With: 6-Speed Manual
Transaxle - MMT6
In-Vehicle Repair
Halfshaft Seal LH
Halfshaft Seal RH
Input Shaft Seal (37.23.09)
Selector Mechanism - Vehicles With: 5-Speed Manual Transmission - MT75
Selector Mechanism - Vehicles With: 6-Speed Manual Transaxle - MMT6
Support Insulator (37.16.42)
Removal
Transaxle (37.20.01) - 2.0L Duratorq-TDCi
Transaxle (37.20.01) - 2.2L Duratorq-TDCi (110kW/150PS) - Puma
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Transaxle (37.20.01) - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27
Installation
Transaxle (37.20.01) - 2.0L Duratorq-TDCi
Transaxle (37.20.01) - 2.2L Duratorq-TDCi (110kW/150PS) - Puma
Transaxle (37.20.01) - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27

308-06: Manual Transmission/Transaxle External Controls
Specification
External Controls
External Controls
Gearshift Cables (37.16.45) - Vehicles With: 5-Speed Manual Transmission
MT75
Gearshift Cables (37.16.45) - Vehicles With: 6-Speed Manual Transaxle - MMT6
Gearshift Lever (37.16.04) - Vehicles With: 5-Speed Manual Transmission - MT75
Gearshift Lever (37.16.04) - Vehicles With: 6-Speed Manual Transaxle - MMT6

308-07: Transfer Case
Specification
Transfer Case
General Procedures
Transfer Case Draining and Filling
In-Vehicle Repair
Halfshaft Seal RH (46.10.03)
Transfer Case Rear Output Shaft Seal (46.10.04)
Removal
Transfer Case (46.10.01)
Installation
Transfer Case (46.10.01)
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309: Exhaust System

309-00: Exhaust System
Specification
Exhaust System
Exhaust System
Catalytic Converter (17.50.05) - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi
Catalytic Converter LH (17.50.15) - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA
V6 - AJ27
Catalytic Converter RH (17.50.16) - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA
V6 - AJ27
Diesel Particulate Filter (DPF)
Diesel Particulate Filter (DPF) Differential Pressure Sensor
Exhaust Flexible Pipe (30.10.57) - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi
Front Muffler (30.10.18) - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi
Front Muffler (30.10.18) - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27
Muffler and Tailpipe (30.10.52) - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi
(110kW/150PS) - Puma, 2.0L
Muffler and Tailpipe (30.10.52) - 2.5L NA V6 - AJV6/3.0L NA V6 - AJ27
Muffler Inlet Pipe (30.10.06) - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6
AJ27
Muffler Inlet Pipe (30.10.06) - Vehicles With: Diesel Particulate Filter (DPF)

310: Fuel System

310-00: Fuel System - General Information
Specification
Fuel System
Fuel System
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General Procedures
Fuel System Pressure Check
Fuel System Pressure Release (19.50.02)
Fuel Tank Draining - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS)
Puma
Fuel Tank Draining - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27
Quick Release Coupling - Push Connect
Spring Lock Couplings

310-01: Fuel Tank and Lines
Specification
Fuel Tank and Lines
Fuel Tank and Lines
Fuel Filter (19.25.02) - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS)
Puma
Fuel Filter (19.25.02) - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27
Fuel Level Sender - 2.0L NA V6 - AJV6
Fuel Level Sender - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS)
Puma
Fuel Level Sender LH - 2.5L NA V6 - AJV6/3.0L NA V6 - AJ27
Fuel Level Sender RH - 2.5L NA V6 - AJV6/3.0L NA V6 - AJ27
Fuel Level Sensor (88.25.32) - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi
Fuel Pump Module (19.45.08) - 2.0L NA V6 - AJV6
Fuel Pump Module (19.45.08) - 2.5L NA V6 - AJV6/3.0L NA V6 - AJ27
Fuel Tank (19.55.01) - 2.0L NA V6 - AJV6
Fuel Tank (19.55.01) - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS)
Puma
Fuel Tank (19.55.01) - 2.5L NA V6 - AJV6/3.0L NA V6 - AJ27
Fuel Tank Filler Pipe (19.55.33)
Gas Fuel Tank Pressure Sensor (19.55.31)
Fuel Transfer Pump (19.45.21)
Inertia Fuel Shutoff (IFS) Switch (18.30.35)
Fuel Tank Filler Pipe Hose
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310-02: Acceleration Control
Specification
Acceleration Control
Acceleration Control
General Procedures
Accelerator Cable Adjustment (12.20.05) - 2.0L NA V6 - AJV6
Accelerator Cable (19.20.06) - 2.0L NA V6 - AJV6
Accelerator Pedal (19.20.01)

310-03: Speed Control
Specification
Speed Control
Speed Control - 2.0L NA V6 - AJV6
Speed Control - 2.5L NA V6 - AJV6/3.0L NA V6 - AJ27
Speed Control Deactivator Switch (19.75.20)
Speed Control Module (19.75.26)
Speed Control Switch (19.75.25)

4: Electrical

412: Climate Control System

412-00: Climate Control System - General Information
Specification
Climate Control System
Climate Control System
General Procedures
Air Conditioning (A/C) Compressor Leak Detection
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Air Conditioning (A/C) System Flushing
Air Conditioning (A/C) System Recovery, Evacuation and Charging (82.30.30)
Contaminated Refrigerant Handling
Discharging and Recovery (82.30.30)
Electronic Leak Detection
Inspection and Assembly Requirements
Leak Detection
Refrigerant Oil Adding
Refrigerant System Tests

412-01: Air Distribution and Filtering
Air Distribution and Filtering
Air Distribution and Filtering
Center Registers (82.20.38)
Driver Side Register (82.20.39)
Front Footwell Duct LH (82.20.91)
Front Footwell Duct RH (82.20.92)
Passenger Side Register (82.20.40)
Pollen Filter (76.10.09)

412-02A: Heating and Ventilation
Specification
Heating and Ventilation
Heating and Ventilation
Blower Motor (82.25.66)
Evaporator Core Housing (80.20.01)
Heater Core (80.20.29)
Evaporator Core Housing

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412-02B: Auxiliary Heating
Specification
Electric Booster Heater
Fuel Fired Booster Heater
Auxiliary Heater
Electric Booster Heater

412-03: Air Conditioning
Specification
Air Conditioning
Air Conditioning
Air Conditioning (A/C) Compressor (82.10.20) - 2.0L NA V6 - AJV6/2.5L NA V6
Air Conditioning (A/C) Compressor (82.10.20) - 2.0L Duratorq-TDCi/2.2L
Duratorq-TDCi (110kW/150PS) - Puma
Air Conditioning (A/C) Pressure Transducer (82.10.47)
Clutch and Clutch Field Coil (82.10.25) - 2.0L NA V6 - AJV6/2.5L NA V6
Condenser Core (82.15.07)
Evaporator Core (82.25.20)
Evaporator Core Orifice (82.25.67)
Suction Accumulator (82.17.02)

412-04: Control Components
Control Components
Control Components
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Air Discharge Temperature Sensor (82.20.64)
Ambient Air Temperature Sensor (82.20.02)
Climate Control Assembly (82.20.07)
Defrost Vent/Register Blend Door Actuator (82.20.84)
Footwell Vent/Duct Blend Door Actuator (80.20.20 or 82.20.85)
Sunload Sensor (82.20.70)
Temperature Blend Door Actuator (82.20.86)

413: Instrumentation and Warning Systems

413-00: Instrument Cluster and Panel Illumination
Instrument Cluster and Panel Illumination

413-01: Instrument Cluster
Instrument Cluster
Instrument Cluster
Instrument Cluster (88.20.01)

413-06: Horn
Horn
Horn
Horn (86.30.02) (86.30.10)
Horn Switch (86.30.01)

413-08: Information and Message Center
Information and Message Center
Information and Message Center
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Message Center
Message Center Switch (86.66.11)

413-09: Warning Devices
Warning Devices
Warning Devices
General Procedures
Oil Change Indicator Reset
Low Washer Fluid Warning Indicator Switch (84.10.17)

413-13: Parking Aid
Parking Aid
Parking Aid
Front Parking Aid Sensor (86.62.33)
Front Parking Aid Speaker (86.54.18) (86.62.34)
Parking Aid Module (86.80.39) - 4-Door
Parking Aid Module (86.80.39) - Wagon
Rear Parking Aid Sensor (86.54.14) (86.62.01)
Rear Parking Aid Speaker (86.54.19) (86.62.02) - 4-Door
Rear Parking Aid Speaker (86.54.19) (86.62.02) - Wagon, VIN Range: D86655-
>E43419
Rear Parking Aid Speaker (86.54.19) (86.62.02) - Wagon, VIN Range: E43420-
>V99999

414: Battery and Charging System

414-00: Battery and Charging System - General Information
Charging System
Battery Care
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Quiescent Drain
Charging System - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27
Charging System - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS)
Puma
General Procedures
Battery Charging

414-01: Battery, Mounting and Cables
Specification
Battery and Cables
Battery
General Procedures
Battery Connect (86.15.15)
Battery Disconnect and Connect
Battery (86.15.01)
Battery Cables (86.15.32) - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6
AJ27
Battery Cables (86.15.32) - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi
Battery Tray (86.15.11)

414-02: Generator and Regulator
Specification
Generator
Generator
Generator (86.10.02) - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27
Generator (86.10.02) - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS)
Puma

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415: Information and Entertainment Systems

415-00: Information and Entertainment System - General Information
Audio System

415-01: Audio Unit
Audio System
Audio System
Audio Unit (86.50.03)
Audio Unit Amplifier (86.50.10) (86.50.36) - 4-Door
Audio Unit Amplifier (86.50.10) (86.50.36) - Wagon
Compact Disc (CD) Changer (86.50.06) - 4-Door
Compact Disc (CD) Changer (86.50.06) - Wagon
Steering Wheel Audio Controls (86.50.42)

415-02: Antenna
Specification
Antenna
Antenna
Antenna (86.51.17.60) - Wagon
Module

415-03: Speakers
Speakers
Speakers
Front Door Speaker (86.50.13)
Front Door Tweeter Speaker (86.50.63)
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Parcel Shelf Speaker (86.51.06)
Rear Door Speaker (86.50.14)
Rear Door Tweeter Speaker (86.50.62)

417: Lighting

417-01: Exterior Lighting
Specification
Exterior Lighting
Headlamps
General Procedures
Headlamp Adjustment (86.40.18)
Ballast (86.41.52)
Front Fog Lamp (86.40.96)
Headlamp Assembly (86.41.33)
Headlamp Bulb (86.42.14) - Vehicles With: High Intensity Discharge Headlamps
Headlamp Leveling Module
Headlamp Leveling Sensor (86.42.15)
Headlamp Switch (86.65.26)
High Mounted Stoplamp (86.41.01) (86.41.32) - 4-Door
High Mounted Stoplamp (86.41.01) (86.41.32) - Wagon
Rear Lamp Assembly (86.40.70) - 4-Door
Rear Lamp Assembly (86.40.70) Wagon

417-02: Interior Lighting
Interior Lighting
Interior Lighting
Front Interior Lamp (86.45.12)
Rear Interior Lamp (86.46.03)
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417-04: Daytime Running Lamps (DRL)
Daytime Running Lamps (DRL)
Daytime Running Lamps (DRL)

418: Electrical Distribution

418-00: Module Communications Network
Communications Network
Communications Network - VIN Range: E96603->J28492
Communications Network - VIN Range: J28493->V99999

418-01: Module Configuration
Module Configuration
General Procedures

418-02: Wiring Harnesses
Wiring Harness
General Procedures
Wiring Harness Repair

419: Electronic Feature Group

419-01A: Anti-Theft - Active
Anti-Theft - Active
Anti-Theft - Active
Anti-Theft Alarm Horn (86.52.03)
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419-01B: Anti-Theft - Passive
Anti-Theft - Passive
Anti-Theft - Passive
General Procedures
Anti-Theft Security Access
Key Programming Using Diagnostic Equipment
Passive Anti-Theft System (PATS) Transceiver (86.52.30)

419-02: Remote Convenience
Universal Transmitter
Universal Transmitter
General Procedures
Universal Transmitter Programming

419-07: Navigation System
Navigation System
Navigation System
Navigation System Antenna (86.62.06) - 4-Door, VIN Range: E96603->J39905
Navigation System Antenna (86.62.06) - 4-Door, VIN Range: J39906->V99999
Navigation System Antenna (86.62.06) - Wagon
Navigation System Display Module (86.62.07)
Navigation System Module (86.62.05) - 4-Door
Navigation System Module (86.62.05) Wagon

419-08: Cellular Phone
Specification
Cellular Phone
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Cellular Phone
Cellular Phone - Vehicles With: Bluetooth
Bluetooth Module
Handset Holder (86.51.12)
Module - 4-Door
Module Wagon

419-10: Multifunction Electronic Modules
Specification
Module Controlled Functions
Multifunction Electronic Module
Generic Electronic Module (GEM) (86.55.75) (86.80.38)
Multifunction Voice Activated Module (86.53.13) (86.80.40) - 4-Door
Multifunction Voice Activated Module (86.53.13) (86.80.40) Wagon

5: Body and Paint

501: Body and Paint

501-02: Front End Body Panels
Front End Body Panels
Air Deflector (76.11.41) - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS)
- Puma
Cowl Vent Screen (76.10.01)
Fender Splash Shield (76.10.90)
Radiator Splash Shield (76.22.90)

501-03: Body Closures
Specification
Body Closures
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General Procedures
Door Alignment
Hood Alignment (76.16.02)
Liftgate Alignment (76.19.54.60)
Luggage Compartment Lid Alignment (76.19.03)
Weatherstrip

501-05: Interior Trim and Ornamentation
Specification
Interior Trim
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 Trim Panel (76.13.73) - 4-Door
C-Pillar Trim Panel (76.13.73) - Wagon
D-Pillar Trim Panel (76.13.73.60)
Front Door Trim Panel (76.34.01)
Front Scuff Plate Trim Panel (76.13.81)
Headliner (76.64.01) - 4-Door
Headliner (76.64.01) - Wagon
Liftgate Trim Panel (76.19.65.60)
Loadspace Scuff Plate Trim Panel (76.19.90.60)
Loadspace Trim Panel (76.13.73.60)
Parcel Shelf (76.67.06)
Rear Door Trim Panel (76.34.04)
Rear Scuff Plate Trim Panel (76.13.82)
Rear Window Blind (76.14.04)
Sun Visor (76.10.48)

501-08: Exterior Trim and Ornamentation
Specification
Exterior Trim
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Door Moulding (76.43.72)
Liftgate Moulding (76.43.79)
Radiator Grille (76.55.03)
Rear Spoiler (76.19.86.60) - Wagon
Rocker Panel Moulding (76.11.36)
Roof Rail (76.43.86.60)
Window Moulding (76.43.20)

501-09: Rear View Mirrors
Specification
Rear View Mirrors
Rear View Mirrors
Auto-Dimming Interior Mirror (76.10.56)
Exterior Mirror (76.10.52)
Exterior Mirror Control Switch (86.65.75)
Exterior Mirror Cover (76.10.55)
Exterior Mirror Glass (76.10.53)
Exterior Mirror Motor (76.10.57) (76.11.09)
Interior Mirror (76.10.51)

501-10: Seating
Specification
Seats
Seats
Front Seat (76.70.01)
Front Seat Backrest (76.70.06)
Front Seat Cushion (76.70.11)
Front Seat Front Height Adjustment Motor (86.75.31)
Front Seat Rear Height Adjustment Motor (86.75.32)
Front Seat Recliner Motor (86.75.04)
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Front Seat Track Motor (86.75.33)
Lumbar Assembly (86.75.12)
Rear Seat Backrest (76.70.38) - 4-Door
Rear Seat Backrest (76.70.38) - 4-Door, Vehicles With: 70/30 Split Seat
Rear Seat Backrest (76.70.38) - Wagon, Vehicles With: 70/30 Split Seat
Rear Seat Backrest Latch (76.70.62.60) - Wagon
Rear Seat Bolster (76.70.67) - 4-Door
Rear Seat Bolster (76.70.67) - Wagon
Rear Seat Cushion (76.70.37)
Seat Base (76.70.08)
Seat Control Switch (86.75.23)
Front Seat Backrest (76.70.23)
Front Seat Cushion (76.70.34)
Rear Seat Backrest (76.70.48) - 4-Door, Vehicles With: 70/30 Split Seat
Rear Seat Backrest (76.70.48) - Wagon, Vehicles With: 70/30 Split Seat
Rear Seat Backrest (76.70.48)
Rear Seat Bolster
Rear Seat Cushion (76.70.47)

501-11: Glass, Frames and Mechanisms
Specification
Glass, Frames and Mechanisms
Glass, Frames and Mechanisms
General Procedures
Door Window Motor Initialization
Liftgate Window Glass Adjustment
Front Door Window Glass (76.31.01)
Front Door Window Regulator and Motor (76.31.45)
Liftgate Window Glass (76.31.22) (76.81.11.60)
Rear Door Fixed Window Glass
Rear Door Window Glass (76.31.02)
Rear Door Window Regulator (76.31.46)
Rear Door Window Regulator and Motor (86.25.09)
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Rear Quarter Window Glass (76.31.31)
Rear Window Glass Using Cheese Wire (76.81.41)
Rear Window Glass Using Cutting Tool
Window Control Switch (86.25.08)
Windshield Glass Using Cheese Wire (76.81.40)
Windshield Glass Using Cutting Tool (76.81.01)

501-12: Instrument Panel and Console
Instrument Panel
Floor Console (76.25.01)
Instrument Panel (76.46.01)
Overhead Console (76.13.69)
Overhead Console Switch Moulding

501-14: Handles, Locks, Latches and Entry Systems
Specification
Handles, Locks, Latches and Entry Systems
Locks, Latches and Entry Systems
General Procedures
Remote Transmitter Programming
Exterior Front Door Handle (76.58.01)
Front Door Lock Actuator (76.37.74)
Front Door Lock Cylinder (76.37.71)
Fuel Filler Door Release Handle and Cable (76.11.39) - 4-Door
Fuel Filler Door Release Handle and Cable (76.11.39) - Wagon
Liftgate Latch Actuator (86.25.65.60)
Liftgate Window Glass Release Switch (76.19.59.60)
Luggage Compartment Lid Latch Actuator (76.19.25)
Rear Door Lock Actuator (76.37.09)

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501-16: Wipers and Washers
Specification
Wipers and Washers
Wipers and Washers
Headlamp Washer Pump (84.20.21)
Rain Sensor (84.12.10) (86.56.62)
Rain Sensor Module (86.56.60)
Rear Window Wiper Motor (84.15.48.60) (84.35.12)
Windshield and Rear Window Washer Pump (84.10.21.60)
Windshield Washer Pump (84.10.21)
Windshield Washer Reservoir (84.10.01) (84.10.03)
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
Specification
Roof Opening Panel
Roof Opening Panel
General Procedures
Motor Synchronization (76.82.48)
Roof Opening Panel Alignment
Air Deflector (76.82.07)
Lifter Arms (76.82.57)
Roof Opening Panel Control Switch (86.76.05)
Roof Opening Panel Drain Hose (76.82.26)
Roof Opening Panel Frame (76.82.01)
Roof Opening Panel Glass (76.82.05)
Roof Opening Panel Motor (86.76.01)
Roof Opening Panel Shield (76.82.06)
Roof Opening Panel Weatherstrip (76.82.15)
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501-19: Bumpers
Specification
Bumpers
Front Bumper Cover (76.22.78)
Front Bumper Cover Insert (76.22.73)
Rear Bumper (76.22.27) (76.22.52) - 4-Door
Rear Bumper (76.22.27) (76.22.52) - Wagon
Rear Bumper Cover (76.22.74) (76.22.77) - 4-Door
Rear Bumper Cover (76.22.74) (76.22.77) - Wagon
Rear Bumper Cover Insert (76.22.75) - 4-Door
Rear Bumper Cover Insert (76.22.75) Wagon

501-20A: Safety Belt System
Specification
Safety Belt System
Safety Belt System
Front Safety Belt Retractor (76.73.10)
Front Safety Belt Shoulder Height Adjuster (76.73.12)
Rear Center Safety Belt Retractor (76.73.20) - 4-Door
Rear Center Safety Belt Retractor (76.73.20) - Wagon
Rear Safety Belt Buckle (76.73.50)
Rear Safety Belt Retractor (76.73.18) - 4-Door
Rear Safety Belt Retractor (76.73.18) - Wagon
Safety Belt Buckle and Pretensioner (76.73.49)

501-20B: Supplemental Restraint System
Specification
Air Bag Supplemental Restraint System (SRS)
Air Bag Supplemental Restraint System (SRS)
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General Procedures
Air Bag Disposal
Clockspring (86.65.92)
Crash Sensor (76.73.55)
Driver Air Bag Module (76.73.39)
Driver Lower Air Bag Module (76.73.75)
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 Curtain Module (76.73.64) - 4-Door
Side Air Curtain Module (76.73.64) - Wagon
Side Impact Sensor (76.73.53)

502: Frame and Mounting

502-00: Uni-Body, Subframe and Mounting System
Specification
Frame Assembly
General Procedures
Underbody Misalignment Check (57.65.20)
Front Subframe (76.10.05) - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6
AJ27
Front Subframe (76.10.05) - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi
Front Subframe Front Bushing (60.35.51)
Front Subframe Rear Bushing (60.35.26)
Rear Axle Crossmember Bushing (64.25.02)
Rear Subframe (64.25.01)
Rear Subframe Bushing (64.25.04)

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Published: 11-May-2011
General Information - About This Manual
Notes, Cautions and Warnings
Throughout this manual, important information is highlighted by the use of notes, cautions and warnings. NOTES give additional information
on a topic or procedure, CAUTIONS are given to prevent damage to the vehicle, and WARNINGS are given to prevent personal injury.
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General Information - Application and Use of Specifications
Torque Specifications
Torque specifications are shown in the torque specifications chart located at the front of the relevant section.
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General Information - General Service Information
Repairs and Replacements
When service parts are required, it is essential that only genuine Jaguar/Daimler replacements are used.
Attention is drawn to the following points concerning repairs and the fitting of replacement parts and accessories:
Safety features embodied in the vehicle may be impaired if other than genuine parts are fitted. In certain territories, legislation
prohibits the fitting of parts which are not produced to the vehicle manufacturer's specification.
Torque wrench setting figures given in this manual must be strictly adhered to. Locking devices, where specified, must be fitted. If
the efficiency of a locking device is impaired during removal it must be renewed.
Owners purchasing accessories while travelling abroad should make sure that the accessory and its fitted location on the vehicle
conform to mandatory requirements existing in their country of origin.
The vehicle warranty may be invalidated by the fitting of other than genuine Jaguar/Daimler parts. All Jaguar/Daimler replacements
have the full backing of the factory warranty.
Jaguar/Daimler dealers are obliged to supply only genuine service parts.
Vehicle Specifications
Purchasers are advised that the specification details set out in this manual apply to a range of vehicles and not to any specific one. For the
specification of a particular vehicle, purchasers should consult their dealer.
The Manufacturer reserves the right to vary the specifications, with or without notice, and at such times and in such manner as the
Manufacturer thinks fit. Major as well as minor changes may be involved, in accordance with the Manufacturer's policy of continuous
improvement.
Whilst every effort is made to make sure the accuracy of the particulars contained in this manual, neither the Manufacturer nor the Dealer,
by whom the manual is supplied, shall in any circumstances be held liable for any inaccuracy or the consequences thereof.
Service Repair Operation Numbering
A master index of numbered operations has been compiled for universal application to all vehicles manufactured by Jaguar Cars Ltd.
Each operation is allocated a number from the master index and cross-refers with an identical number in the Repair Operation Times
schedule. The number consists of six digits arranged in three pairs.
Each maintenance procedure in this manual is described in the sequence necessary to complete the operation in the minimum time, as
specified in the Repair Operation Times schedule.
References to Bank-1 and Bank-2
References to Bank-1 and Bank-2 are made with regard to the engine. When viewed from the flywheel the right-hand bank will be Bank-1
and the left-hand bank will be Bank-2.
Special Tools
Any special tools and equipment required to perform a maintenance procedure, are shown at the beginning of each procedure. When
possible, illustrations are given to assist in identifying the tool needed.
Disconnecting/Connecting the Battery
Always stop the engine before disconnecting the battery negative lead and make sure the battery positive lead is isolated i.e. wrapped in a
suitable cloth.
WARNING: Radio code saving devices must not be used when conducting work on Air Bag or Fuel systems. It must be noted that,
when using these devices, the vehicle electrical system is still live albeit with a reduced current flow.
NOTE: Before disconnecting the battery make sure that the radio receiver/cassette player/mini disc player and compact disc player
keycodes are known and, that no data is required from the engine control module (ECM) as battery disconnection will erase any fault codes
and idle/drive values held in the Keep Alive Memory (KAM). It is not necessary to disconnect or remove electronic control modules.
Always disconnect the battery before commencing repair operations which require:
The vehicle to be jacked up
Work on the engine
Work underneath the vehicle
Arc welding
Alternatively a Radio Code Saver may be used. With the battery disconnected, a Radio Code Saver will allow sufficient current to pass to
maintain the radio receiver/cassette player/mini disc player and compact disc player memory, operate the clock and supply the door
operated interior lights while isolating the battery in the event of a short circuit.
Reconnecting the Battery
WARNING: If the battery has been on bench charge the cells may be giving off explosive hydrogen gas. Avoid creating sparks, and if in
doubt cover the vent plugs or covers with a damp cloth.
Always make sure that all electrical systems are switched OFF before reconnecting the battery to avoid causing sparks or damage to
sensitive electrical equipment.
Always reconnect the battery positive lead first and the negative last, ensuring that there is a good electrical contact and the battery
terminals are secure.
Restart the clock (where fitted) and set it to the correct time.
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Re - enter the radio receiver/cassette player/mini disc player and compact disc player keycodes and preset' frequencies, if known.
Following reconnection of the battery, the engine should be allowed to idle until it has reached normal operating temperature as the stored
idle and drive values contained within the ECM have been lost. Allow the vehicle to idle for a further three minutes. Drive the vehicle at
constant speeds of approximately 48 km/h (30 mph), 64 km/h (40 mph), 80 km/h (50 mph), 96 km/h (60 mph) and 112 km/h (70 mph) for
three minutes each. This may cause a driveability concern if the procedure is not carried out. This will allow the ECM to relearn idle values.
Connecting a Slave Battery Using Jump Leads
WARNING: If the slave battery has recently been charged and is gassing, cover the vent plugs or covers with a damp cloth to reduce
the risk of explosion should arcing occur when connecting the jump leads.
CAUTIONS:
A flat battery condition may have been caused by an electrical short circuit. If this condition exists there will be an apparently live
circuit on the vehicle even when all normal circuits are switched off. This can cause arcing when the jump leads are connected.
Whilst it is not recommended that the vehicle is jump started, it is recognized that this may occasionally be the only practical way to
mobilize a vehicle. In such an instance the discharged battery must be recharged immediately after jump starting to avoid permanent
damage.
Always make sure that the jump leads are adequate for the task. Heavy duty cables must be used.
Always make sure that the slave battery is of the same voltage as the vehicle battery. The batteries must be connected in parallel.
Always make sure that switchable electric circuits are switched off before connecting jump leads. This reduces the risk of sparks
occurring when the final connection is made.
WARNING: Make sure that the ends of the jump leads do not touch each other or ground against the vehicle body at any time while
the leads are attached to the battery. A fully charged battery, if shorted through jump leads, can discharge at a rate well above 1000 amps
causing violent arcing and very rapid heating of the jump leads and terminals, and can even cause the battery to explode.
Always connect the jump leads in the following sequence.
Slave battery positive first then vehicle battery positive.
Slave battery negative next and then vehicle ground at least, 300 mm (12 in) from the battery terminal e.g. engine lifting bracket.
Always reduce the engine speed to idle before disconnecting the jump leads.
Before removing the jump leads from the vehicle that had the discharged battery, switch on the heater blower (high) or the heated rear
screen, to reduce the voltage peak when the leads are removed.
Always disconnect the jump leads in the reverse order to the connecting sequence and take great care not to short the ends of the leads.
Do not rely on the alternator to restore a discharged battery. For an alternator to recharge a battery, it would take in excess of 8 hours
continuous driving with no additional loads placed on the battery.
Component Cleaning
To prevent ingress of dirt, accumulations of loose dirt and greasy deposits should be removed before disconnecting or dismantling
components or assemblies.
Components should be thoroughly cleaned before inspection prior to reassembly.
Cleaning Methods:
Dry Cleaning
Removal of loose dirt with soft or wire brushes.
Scraping dirt off with a piece of metal or wood.
Wiping off with a rag.
CAUTION: Compressed air is sometimes wet so use with caution, especially on hydraulic systems.
Blowing dirt off with compressed air. (Eye protection should be worn when using this method).
Removal of dry dust using vacuum equipment. This method should always be used to remove friction lining material dust (asbestos
particles).
Steam Cleaning
Calibration of Essential Measuring Equipment
WARNING: Failure to comply may result in personal injury or damage to components.
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It is of fundamental importance that certain essential equipment e.g. torque wrenches, multimeters, exhaust gas analysers, rolling roads
etc., are regularly calibrated in accordance with the manufacturers instructions.
Use of Control Modules
Control modules may only be used on the vehicle to which they were originally fitted. Do not attempt to use or test a control module on any
other vehicle.
Functional Test
On completion of a maintenance procedure, a thorough test should be carried out, to make sure that the relevant vehicle systems are
working correctly.
Preparation
Before disassembly, clean the surrounding area as thoroughly as possible. When components have been removed, blank off any exposed
openings using grease-proof paper and masking tape. Immediately seal fuel, oil and hydraulic lines when separated, using plastic caps or
plugs, to prevent loss of fluid and the entry of dirt. Close the open ends of oilways, exposed by component removal, with tapered hardwood
plugs or readily visible plastic plugs. Immediately a component is removed, place it in a suitable container; use a separate container for
each component and its associated parts. Before dismantling a component, clean it thoroughly with a recommended cleaning agent; check
that the agent will not damage any of the materials within the component. Clean the bench and obtain marking materials, labels,
containers and locking wire before dismantling a component.
Dismantling
Observe scrupulous cleanliness when dismantling components, particularly when parts of the brake, fuel or hydraulic systems are being
worked on. A particle of dirt or a fragment of cloth could cause a dangerous malfunction if trapped in these systems. Clean all tapped holes,
crevices, oilways and fluid passages with compressed air. Do not permit compressed air to enter an open wound. Always use eye protection
when using compressed air.
Make sure that any O-rings used for sealing are correctly refitted or renewed if disturbed. Mark mating parts to make sure that they are
replaced as dismantled. Whenever possible use marking materials which avoid the possibilities of causing distortion or the initiation of
cracks, which could occur if a center punch or scriber were used. Wire together mating parts where necessary to prevent accidental
interchange (e.g roller bearing components). Tie labels on to all parts to be renewed and to parts requiring further inspection before being
passed for reassembly. Place labelled parts and other parts for rebuild in separate containers. Do not discard a part which is due for renewal
until it has been compared with the new part, to make sure that the correct part has been obtained.
Inspection
Before inspecting a component for wear or performing a dimensional check, make sure that it is absolutely clean; a slight smear of grease
can conceal an incipient failure. When a component is to be checked dimensionally against figures quoted for it, use the correct equipment
(surface plates, micrometers, dial gauges etc.) in serviceable condition. The use of makeshift equipment can be dangerous. Reject a
component if its dimensions are outside the limits quoted, or if damage is apparent. A part may be refitted if its critical dimension is
exactly to the limit size and it is otherwise satisfactory. Use Plastigauge 12 Type PG-1 for checking bearing surface clearance, e.g. big end
bearing shell to crank journal. Instructions for the use of Plastigauge and a scale giving bearing clearances in steps of 0,0025 mm (0.0001
in) are supplied with the package.
On-Board Diagnostics (OBD)
This vehicle uses programmed electronic control systems to provide engine management and emission regulation, automatic transmission
operation and anti-lock braking control. These control systems are integral with the On-Board Diagnostics (OBD) facility which is used in
conjunction with either the Jaguar approved diagnostic system or the more restricted scan tools.
The OBD information in this manual provides diagnostic and rectification procedures for emission related electrical and mechanical systems.
The information is intended to facilitate fault diagnosis and the subsequent rectifi cation of the vehicle without recourse to the Jaguar
approved diagnostic system.
The manual covers the following OBD topics:
General Information
Engine Management System
Automatic Transmission
Anti-lock Braking System
Each section comprises one or more of the following sub-sections as required.
The Description and Operation sub-section includes:
A general illustration and parts list to help the identification of the particular system or component.
A brief description of the system operating characteristics and monitoring procedure accompanied by a component illustration.
Additional information, where appropriate, is provided in the form of component calibrations, characteristics and cross sectional
views.
A localized circuit diagram is included to provide circuit identification, connectors, splices, fuses, wire gauge and colors. See Circuit
Diagrams.
The Diagnosis and Testing sub-section is dedicated to fault analysis and rectification, and includes:
Recommended special tools.
Symptom chart; a chart containing all relevant Diagnostic Trouble Codes (DTC), their possible causes and an indication of the
appropriate test.
Specific pinpoint test(s), designed so that fault diagnosis can be carried out in a logical and efficient manner.
The Removal and Installation sub-section covers:
Removal procedure(s), formatted in the recommended sequence.
Illustrated guide to the use of special tools.
Illustrations to support the relevant text.
Installation procedure as above and including special recommendations for processes, lubricants and tightening torques.
Circuit Diagrams
To understand the relationship between the vehicle electrical system and the system circuit diagrams, Refer to the Electrical Guide.
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In the interest of clarity, single lines may represent multiple wires. Refer to the color code (1st alpha) followed by the wire reference
(numeric/alpha/numeric) to trace origin and destination.
e.g. BW 647B002. BW (black with white trace) 647 (wire reference) B002 (stage from origin).
Glossary of Terms
This glossary of terms is intended to cover mainly emissions-related (to SAE J 1930) terminology, and other abbreviations that may be used
in this manual.
The required term may be looked-up in the left-hand column, and subsequent columns give the standard acronym, unit or abbreviation, and
definition.
Term(s)
Acronym / Unit /
Abbreviation Definition
Accelerator Pedal AP
Accelerator Pedal Position
Sensor
APP Is a multitrack sensor which inputs the drivers demand into the engine control module
(ECM)
After Bottom Dead Center ABDC Event occurring after BDC
After Top Dead Center ATDC Event occurring after TDC
Airbag / Supplementary
Restraint System
Airbag, SRS Airbag restraint system for driver and front seat passenger
Air Cleaner ACL
Air Conditioning A/C
Air Conditioning Control
Module
A/CCM Module controlling air conditioning, heating and ventilation
Air Conditioning Signal ACS Air conditioning compressor clutch operation is signalled to the ECM which induces idle
speed corrections to compensate for engine load changes
Alternating current ac
Air Fuel Ratio AFR Nominally 14.7 parts air to one part fuel
Ampere A SI unit of current
Ampere hour Ah
ABS Control Module ABS CM System which prevents wheel lock-up under braking by sensing lack of rotation of a
wheel(s) and diverting fluid pressure away from it (them)
ABS / Traction Control
Control Module
ABS/TCCM System which prevents wheel lock-up under braking by sensing lack of rotation of a
wheel(s) and diverting fluid pressure away from it (them)
Atmosphere atm Unit of pressure (1.01325 bar)
Barometric Absolute
Pressure Sensor
BARO Sensor Sensor measuring the pressure of surrounding air at any given temperature and altitude
Battery positive voltage B+ The positive voltage from a battery or any circuit connected directly to it
Before Bottom Dead Center BBDC Event occurring before BDC
Before Top Dead Center BTDC Event (usually ignition) occurring before TDC
Blower BLR Device which supplies a current of air at moderate pressure, e.g. heater or A/C blower
Body Processor Module BPM Control module for body electrical systems, e.g. interior lamps, windshield wash / wipe
control
Bottom Dead Center BDC Lowest point of piston travel in a reciprocating engine
Brake horsepower BHP Effective horsepower developed by an engine or motor, as measured by a brake applied to
its output shaft
Brake Mean Effective
Pressure
BMEP The part of the effective pressure developed in a cylinder that would result in a cylinder
output equal to the bhp of the engine
Brake On/Off BOO Indicates the position of the brake pedal
British Standard BS Standard specification issued by the British Standards Institution
British Standard
Automotive
BSau
Bus Topology of a
communication
network
Bypass Air BPA Mechanical control of throttle bypass air
Camshaft Position Sensor CMP Sensor Indicates camshaft position
Canadian Motor Vehicle
Safety Standard
CMVSS
Canister Purge CANP Controls purging of the EVAP canister
Carbon dioxide CO2 Colorless gas with a density of approximately 1.5 times that of air
Carbon monoxide CO Poisonous gas produced as the result of incomplete combustion
Case Ground CSE GND Control module casing ground
Catalytic converter In-line exhaust system device used to reduce the level of engine exhaust emissions
Celsius C SI term for the Centigrade scale, with freezing point at zero and boiling point at 100
degrees
Central Processor Unit CPU The section of a computer that contains the arithmetic, logic and control circuits. It
performs arithmetic operations, controls instruction processing, and provides timing
signals and other housekeeping operations
Cylinder Head Temperature
Sensor
CHT Sensor A sensor for measuring the temperature of the cylinder head
Closed Loop CL
Closed Loop System CL System Control system with one or more feedback loops
Column/Mirror Control
Module
C/MCM A self-contained group of electrical /electronic components, designed as a single
replaceable unit, and controlling one or more processes
Controller Area Network CAN A communication system which allows control modules to be linked together.
Crankshaft Position Sensor CKP Sensor Generates crankshaft position information in conjunction with the CKPTR (also generates
speed information in certain applications)
Crankcase Ventilation
System
CV System which scavenges camshaft cover and crankcase emissions and feeds them into the
inlet manifold
Cubic centimeter cm
Curb weight Weight of vehicle with fuel, lubricants and coolant, but excluding driver, passengers or
payload
Data Link Connector DLC Connector providing access and/or control of the vehicle information, operating conditions,
and diagnostic information
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Term(s)
Acronym / Unit /
Data Output Line DOL Circuit that sends certain information from the ECM to the instrument cluster
Degree deg, Angle or temperature
Department of
Transportation (US)
DOT Which is a fibre optic ring network, can be diagnosed through the SCP network, and with
the optical bus tester.
Deutsche Institut fur
Normung
DIN German standards regulation body
Diagnostic Module DM Supplemental Restraint System (non -controlling) module for diagnostics overview
Diagnostic Test Mode DTM A level of capability in an OBD system. May include different functional states to observe
signals, a base level to read DTCs, a monitor level which includes information on si gnal
levels, bi-directional control with on/off board aids, and the ability to interface with
remote diagnosis
Diagnostic Trouble Code DTC An alpha/numeric identifier for a fault condition identified by the On-Board Diagnostic
(OBD) system
Differential pressure Pressure difference between two regions e.g. between intake manifold and atmospheric
pressures
Differential Pressure
Feedback EGR
DPFE An EGR system that monitors differential EGR pressure across a remote orifice to control
EGR flow
Direct current dc Current which flows in one direction only, though it may have appreciable pulsations in its
magnitude
Domestic Data Bus D2B
Exhaust Gas Recirculation
Temperature Sensor
EGRT Sensing EGR function based on temperature change
Engine Management
System
EMS The engine management system conditions and reads inputs, supplies processing
capability, and provides output drivers to control actuators as directed by software and
calibration
Engine Oil Pressure EOP
EGR Vacuum Regulator EVR Controls EGR flow by changing vacuum to the EGR valve
EGR Valve Position EVP An EGR system that directly monitors EGR valve position to control EGR flow
Electrically Erasable
Programmable Read-Only
Memory
EEPROM
Electrically Programmable
Read-Only memory
EPROM
Electronic Secondary Air
Injection
EAIR A pump-driven system for providing secondary air using an electric air pump
Engine Control Module ECM
Engine Coolant Level ECL
Engine Coolant
Temperature
ECT
ECT Sensor ECTS Thermistor which provides engine coolant temperature signal to the ECM to trigger
enrichment circuits which increase injector 'on' time for cold start and warm-up
Engine speed RPM
Environmental Protection
Agency
EPA
Evaporative Emission EVAP System designed to prevent fuel vapor from escaping into the atmosphere. Typically
includes a charcoal filled canister to absorb fuel vapor
Evaporative Emission
Control Valve
EVAPP
Exhaust Gas Recirculation EGR System which reduces NOx emissions by adding exhaust gases to the incoming fuel/air
charge
Solenoid Vacuum Valve
EGRS
Temperature Sensor
EGRT Sensor
Valve
EGR Valve
Fan Control FC Engine cooling fan control
Federal Motor Vehicle
Safety Standard (US)
FMVSS
Figure Fig. Illustration reference
Flash Electrically Erasable
Memory
FEEPROM
Flash Erasable
Memory
FEPROM
Flywheel Sensor CKFS Sensor mounted so as to be triggered by each flywheel ring gear tooth to give an engine
speed signal
Fuel Injection FI Solenoid operated devices that spray a metered quantity of fuel into the inlet ports
Fuel Pressure Regulator
Control
FPRC Controls fuel pressure regulator; used primarily to give extra fuel at cold start-up
Fuel Pump FP Pumps fuel from the fuel tank to the fuel injection system
Fuel Pump Monitor FP Module Monitors operation of fuel pump
Fuel Pump Relay FP Relay Relay which controls electrical current to fuel pump
Fuel rich/lean Qualitative evaluation of air/fuel ratio based on a ratio known as stoichiometry,or 14.7:1
(Lambda)
Generic Electronic Module GEM
Generator GEN Rotating machine which converts mechanical energy into electrical energy
Gramme centimeter gcm
Gramme (force) gf
Gramme (mass) g
Ground GND Electrical conductor used as a common return for an electrical circuit or circuits, and with a
relative zero potential
Hard fault A fault currently present in the system
Headlamp HL
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Term(s)
Acronym / Unit /
Heated Oxygen Sensor HO2S Electrically heated oxygen sensor which induces fueling corrections
Hertz (frequency) Hz Frequency, one cycle per second
High Mounted Stoplamp HMSL
High tension HT
Hour hour
Hydrocarbon HC
Idle Air Control IAC Stepper motor driven device which varies the volume of air by-passing the throttle to
maintain the programmed idle speed
Ignition amplifier IA Device which amplifies the ignition system output
Ignition ground IGN GND
Injection Pressure Sensor IPS
Inertia Fuel Shut-off IFS An inertia system that shuts off the fuel supply when activated by pre-determined force
limits brought about by (e.g.) collision
Inertia Fuel Shut-off Switch IFS Switch Shuts down fuel and ignition systems in the event of a vehicle impact
Intake air Air drawn through a cleaner and distributed to each cylinder for use in combustion
Intake Air Temperature IAT Temperature of intake air
Intake Air Temperature
Sensor
IAT Sensor Device used to measure IAT
Sensor Ignition
IAT Sensor Ignition Thermistor which signals the ECM to retard the ignition timing in response to high i nlet air
temperatures
Sensor Injection
IAT Sensor Injection Thermistor which inputs air density information to the ECM
Internal diameter i.dia
International Standards
Organisation
ISO
Kilogramme (mass) kg
Kilogramme (force) kgf
Kilogramme force per
square centimeter
kgf/cm
Kilometer km
Kilometer per hour km/h
Kilopascal kPa
Kilovolt kV
Knock Sensor KS Sensor which detects the onset of detonation, and signals the ECM to retard the igni tion
Left-hand LH
Left-hand drive vehicle LHD
Left-hand thread LHthd
Liquid Crystal Display LCD Optical digital display system, applied voltage to which varies the way the crystals reflect
light, thereby modifying the display
Litre L
Low Tension LT Primary circuit of the ignition system, linking the battery to the primary winding in the
ignition coil
Malfunction Indicator Lamp MIL A required on-board indicator to alert the driver of an emission related malfunction
Manifold Absolute Pressure MAP Absolute pressure of the intake manifold air
Manifold Absolute Pressure
Sensor
MAP Sensor Sensor located in the ECM and ported to the intake manifold
Manifold Surface
Temperature
MST
Mass Air Flow MAF System which provides information on the mass flow rate of the intake air to the engine
Mass Air Flow Sensor MAF Sensor Hot-wire sensor which monitors air flow into the intake manifold for fueling and ignition
control
Maximum max.
Meter (measurement) m
Metric (screw thread, e.g.
M8)
M
Microfarad MFD Unit of electrical capacitance, one millionth of a farad
Millimeter mm
Millimeter of mercury mmHg
Millisecond ms
Minimum min.
Minute minute
Model year MY
Motorized In-Car Aspirator MIA Device which constantly samples cabin temperature by passing air over a sensor, and
communicates with the A/CCM to modify A/C system performance to suit
Multi Protocol Adapter MPA An interpreter for the various data languages present on a vehicle
National Institute of
Occupational Safety and
Health (US)
NIOSH
Newton N SI unit of force. 1 N = 0.2248 pounds force
Newton Meter Nm SI unit of torque. Must not be confused with nm (nanometer)
Nox Compounds of nitrogen and oxygen formed at high temperatures. Major source of
exhaust-gas air pollution
Non-Volatile Random
Access Memory
NVRAM RAM which retains memory even if power supply is interrupted
Normally aspirated N/A Fueling system using intake air at atmospheric pressure; not supercharged or
turbocharged
Normally Closed NC
Normally Open NO
North American
Specification
NAS Vehicles for sale in the USA and Canadian markets
Number No.
Occupational Safety and
Health Administration (US)
OSHA
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Term(s)
Acronym / Unit /
On-Board Diagnostic OBD A system that monitors some or all computer input and output control signals. Signal(s)
outside the pre-determined limits imply a fault in the system or a related system
Original Equipment
Manufacturer
OEM
Outside Diameter o. dia
Oxides of nitrogen Nox
Oxygen Sensor O2S A sensor which detects oxygen content in the exhaust gases
Parameter Identification PID An index number referring to a parameter within a module without knowledge of its
storage location
Park Neutral Position PNP
Park Neutral Position
Switch
PNP Switch Indicates the selected non-drive modes of the (automatic) transmission
Part number part no.
Pulse Width Modulated PWM
Programmable Electronic
Control Units System
PECUS Process whereby a common ECM is programmed on the production line to suit the market
requirements of a particular vehicle
Programmable Read-only
Memory
PROM ROM with some provision for setting the stored data after manufacture
Random Access Memory RAM Fast access memory store which is accessible for entry or extraction of data
Read-Only Memory ROM Fast access memory in which data is fixed and may not be changed
Reservoir RES Container, usually for oils, coolants or hydraulic fluids
Rest Of The World ROW
Return RTN A dedicated sensor ground circuit
Revolutions Per Minute RPM Shaft speed of a device, usually an engine or motor
Right-hand RH
Right-hand drive RHD
Scan Tool ST Device that interfaces with and communicates information on a data link
Seat Control Module SCM Module controlling the seat motor systems (not electric raise/lower-only seats)
Secondary Air Air provided to the exhaust system
Secondary Air AIR System used for a period of time each time the engine is started, unless certain
temperature criteria are met. Pumps air directly into the exhaust system which generates
extra heat and reduces the time taken for the catalytic converters to reach operating
temperature
Secondary Air Injection
Bypass
AIR Bypass Vents secondary air to atmosphere
Check Valve
AIR Check Valve Valve which prevents back-flow of exhaust gas to the AIR system when the system is
inoperative
Diverter
AIR Diverter Diverts secondary air to either the catalyst or exhaust manifold
Magnetic Clutch
AIR Clutch Clutch mounted on the AIRP drive shaft
Pump
AIR Pump Mechanically driven rotary vane pump, driven through the AIRPC
Relay
AIR Relay Controls the injection of air into the exhaust system
Switching Valve
AIR Switching Valve Vacuum operated valve backing-up the AIRC
Security & Locking Control
Module
SLCM Module controlling the vehicle's security and closure-locking functions
Sensor S Generic name for a device that senses either the absolute value or a change in a physical
quantity such as temperature, pressure or flow rate, and converts that change into an
electrical quantity signal
Service Repair Operation
(number)
SRO Number generated by Jaguar Methods & Techniques system which relates to the time
allowed to complete a repair operation. Further information on the system can be found in
the separate Jaguar Publications (for each model range) entitled 'Repair Operation Times'
Shift Solenoid SS Controls shifting in an automatic transmission
Signal return SIG RTN
Sliding Roof Control Module SRCM
Society of Automotive
Engineers
SAE
Speed Control Control
Module
SCCM Module controlling Speed Control System
Square centimeter cm
Standard std
Standard Corporate
Protocol
SCP A high-speed, serial communications system linking all body system control modules.
Control messages and data are passed between modules at up to 786 messages per
second
Supercharger SC An intake system which utilizes a supercharger (mechanically driven device that
pressurizes intake air, thereby increasing density of charge air and the consequent power
output from a given displacement)
Supercharger Bypass SCB
Tachometer TACH A circuit that provides input for an electronic tachometer display
Thermal Vacuum Valve TVV Controls vacuum levels or routing based on temperature
Throttle Body TB Device containing the throttle
Throttle Position TP
Throttle Position Sensor TP Sensor Interprets throttle position and movement to identify idle, acceleration and full-power
demands
Throttle Manifold Absolute
Pressure Sensor
TMAP Combines the inlet air temperature and manifold pressure sensor in one component
Top Dead Center TDC
Torque Converter Clutch TCC
Transmission Control
Module
TCM Controls the shifting pattern of the (automatic) transmission
Transmission Control
Switch
TCS Modifies the operation of electronically controlled transmissions
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Term(s)
Acronym / Unit /
Transmission Oil
Temperature
TOT Indicates temperature of transmission fluid
Transmission Range TR The range in which the transmission is operating
Turbine Shaft Speed TSS Indicates rotational speed of transmission output shaft or turbine shaft
Vacuum Solenoid Valve VSV Vacuum operated valve used in the speed control system
Vacuum Solenoid Valve
(atm)
VSV(VA) Vacuum atmospheric valve used in the speed control system
(rel)
VSV(VR) Vacuum release valve used in the speed control system
(vac)
VSV(VV) Vacuum valve used in the speed control system
Variable Valve Timing VVT A system by which the relationship of the crankshaft and camshaft may be altered during
engine running
Vehicle Battery Adapter VBA Provides electrical power to the Jaguar approved diagnostic system and supplies a battery
reference level
Vehicle Control Monitor VCM Instrument panel display which warns of faults
Vehicle Emission Control
Information Label
VECI Label
Vehicle Identification
Number
VIN Number assigned to the vehicle by the manufacturer, primarily for licensing and
identification purposes
Vehicle Interface Adapter VIA Extends the Jaguar approved diagnostic system capability and provides a parallel interface
to vehicle harnesses and ECMs
Vehicle Speed Sensor VSS Sensor which provides vehicle speed information
Viscosity Index VI
Voltage Regulator VR Device which regulates the variable output voltage of a generator
Watt W SI unit of power (1 hp = 745.7 watts)
Wide Open Throttle WOT Full throttle position
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General Information - Health and Safety Precautions
Prolonged and repeated contact with mineral oil will result in the removal of natural oils from the skin, leading to dryness, irritation and
dermatitis. In addition, used engine oil contains potentially harmful contaminants which may cause skin cancer. Washing facilities and
adequate means of skin protection should be provided.
Observe these recommendations:
Wear protective clothing, including impervious gloves where practicable.
Do not put oily rags in pockets. Avoid contaminating clothes, particularly underwear, with oil.
Overalls must be cleaned regularly. Discard oil impregnated clothing and footwear which cannot be washed or cleaned.
First Aid treatment should be obtained immediately for open cuts or wounds.
Use barrier creams, applying before each work period, to enable easier removal of dirty oil and grease from the skin.
Wash with soap and water to make sure that all oil is removed (skin cleaner and a nail brush will help). The use of preparations
containing lanolin will help to replace the natural skin oils which have been removed.
Do not use petrol, kerosene, gas oil, thinners or solvents for washing skin.
If skin disorders develop, obtain medical advice immediately.
Where practical, degrease components prior to handling.
Where there is a risk of fluids coming into contact with the eyes, eye protection should be worn, for example, goggles or a face
shield. An eye wash facility should be provided.
The Health and Safety Precautions subsection refers to some commonly used chemicals and materials, hazards associated with their use,
and safety measures to be taken. Some of these chemicals may be included in the following list either in their own right or as an ingredient
in a sealer or adhesive.
Acids and Alkalis
See also Battery Acids.
e.g. caustic soda, sulphuric acid.
Used in batteries and cleaning materials.
Irritant and corrosive to the skin, eyes, nose and throat. Cause burns. Can destroy ordinary protective clothing.
Avoid splashes to the skin, eyes and clothing. Wear suitable protective impervious apron, gloves and goggles. Do not breath mists.
Ensure access to eye wash bottles, shower and soap are readily available for splashing accidents.
Display Eye Hazard sign.
Air Bags
See also Fire, Chemical Materials - General
Highly flammable, explosive observe No Smoking policy.
Used as a safety restraint system mounted in the steering wheel.
The inflator contains a high - energetic propellant which, when ignited, produces a VERY HOT GAS (2500 C).
The gas generant used in air bags is Sodium Azide. This material is hermetically sealed in the module and is completely consumed during
deployment. No attempt should be made to open an air bag inflator as this will lead to the risk of exposure to Sodium Azide. If a gas
generator is ruptured, full protective clothing should be worn when dealing with the spillage.
After normal deployment, gloves and safety goggles should be worn during the handling process.
Deployed air bags should be disposed of in a plastic bag in accordance with local regulations at an approved chemical waste site.
Following any direct contact with gas generant.
Wash affected areas thoroughly with water.
Seek medical assistance if necessary.
Air Bags - Do's
Do store in an airbag safe when not fitted to the vehicle.
Do store modules in an upright position.
Do keep modules dry.
Do carry modules with the cover side pointing away from the body.
Do place modules with their cover side upwards.
Do carefully inspect modules for damage.
Do stand to one side when connecting modules.
Do make sure all test equipment is properly calibrated and maintained.
Do wash you hands after handling deployed air bags.
Air Bags - Do Nots
Do not store highly flammable material together with modules or gas generators.
Do not store gas generators at temperatures exceeding 80 C.
Do not store modules upside down.
Do not attempt to open a gas generator housing.
Do not expose gas generators to open flame or sources of heat.
Do not place anything on top of a module cover.
Do not use damaged modules.
Do not touch a fired module or gas generator for at least 10 minutes.
Do not use any electrical probes on the wiring circuit.
Air Conditioning Refrigerant
See also Chlorofluorocarbon, Chemical Materials
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Highly flammable, combustible observe No Smoking policy.
Skin contact may result in frostbite.
Instructions given by the manufacturer must be followed. Avoid naked lights, wear suitable protective gloves and goggles.
If refrigerant comes into contact with the skin or eyes, rinse the affected areas wi th water immediately. Eyes should also be rinsed with an
appropriate irrigation solution and should not be rubbed. SEEK MEDICAL ASSISTANCE IF NECESSARY.
Air Conditioning Refrigerant - Do Nots
Do not expose refrigerant bottles to sunlight or heat.
Do not stand refrigerant bottles upright; when filling, hold them with the valve downwards.
Do not expose refrigerant bottles to frost.
Do not drop refrigerant bottles.
Do not vent refrigerant to atmosphere under any circumstance.
Do not mix refrigerants i.e. R12 (Freon) and R134a.
Antifreeze
See also Fire, Solvents.
e.g. isopropanol, ethylene glycol, methanol.
Highly flammable, flammable, combustible.
Used in vehicle coolant systems, brake air pressure systems, screenwash solutions.
Vapors may be given off from coolant antifreeze (glycol) when heated. Avoid breathing these vapors.
Antifreeze may be absorbed through the skin in toxic or harmful quantities. Antifreeze, if swallowed can be fatal and medical attention
should be sought immediately.
These products must not be used in any cooling or industrial water system which is connected or linked to general, food preparation or
drinking water supplies.
Asbestos
Used in brake and clutch linings, transmission brake bands and gaskets. Jaguar original production and replacement items are asbestos
free.
See also Warning Symbols on Vehicles at the end of this subsection.
Breathing asbestos dust may cause lung damage or, in some cases, cancer.
The use of drum cleaning units, vacuum cleaning or damp wiping is preferred.
Asbestos dust waste should be dampened, placed in a sealed container and marked to make sure safe disposal. If any cutting or drilling is
attempted on materials containing asbestos the item should be dampened and only hand tools or low speed power tools used.
Battery Acids
See also Acids and Alkalis.
Gases released during charging are explosive. Never use naked flames or allow sparks near charging or recently charged batteries.
Ensure adequate ventilation.
Brake and Clutch Linings and Pads
See Asbestos.
Brakes Fluids (Polyalkylene Glycols)
See also Fire.
Splashes to the skin and eyes may cause irritation. Avoid skin and eye contact as far as possible. Inhalation vapor hazards do not arise at
ambient temperatures because of the very low vapor pressure.
Brazing
See Welding.
Chemical Materials
See also Legal Aspects.
Chemical materials such as solvents, sealers, adhesives, paints, resin foams, battery acids, antifreeze, brake fluids, fuels, oils and grease
should always be used with caution and stored and handled with care. They may be toxic, harmful, corrosive, irritant or highly flammable
and give rise to hazardous fumes and dusts.
The effects of excessive exposure to chemicals may be immediate or delayed; briefly experienced or permanent; cumulative; superficial; life
threatening; or may reduce life - expectancy.
Chemical Materials - Do's
Do carefully read and observe hazard and precaution warnings given on material containers (labels) and in any accompanying
leaflets, posters or other instructions. Material health and safety data sheets can be obtained from manufacturers.
Do remove chemical materials from the skin and clothing as soon as practical after soiling. Change heavily soiled clothing and have
it cleaned.
Do organise work practices and protective clothing to avoid soiling of the skin and eyes, breathing vapors, aerosols, dusts or fumes,
inadequate container labelling fire and explosion hazards.
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Do wash before breaks, before eating, smoking, drinking or using toilet facilities when handling chemical materials.
Do keep work areas clean, uncluttered and free of spills.
Do store chemical materials according to national and local regulations.
Do keep chemical materials out of the reach of children.
Chemical Materials - Do Nots
Do not mix chemical materials except under the manufacturer's instructions; some chemicals can form other toxic or harmful
chemicals, give off toxic or harmful fumes or become explosive when mixed together.
Do not spray chemical materials, particularly those based on solvents, in confined spaces e.g. when people are inside a vehicle.
Do not apply heat or flame to chemical materials except under the manufacturer's instructions. Some are highly flammable and some
may release toxic or harmful fumes.
Do not leave containers open. Fumes given off can build up to toxic, harmful or explosive concentrations. Some fumes are heavier
than air and will accumulate in confined areas, pits etc.
Do not transfer chemical materials to unlabeled containers.
Do not clean hands or clothing with chemicals. Chemicals, particularly solvents and fuels, will dry skin and may cause irritation
leading to dermatitis or be absorbed through the skin in toxic or harmful quantities.
Do not use emptied containers for other materials except when they have been cleaned under supervised conditions.
Do not sniff or smell chemical materials. Brief exposure to high concentrations of fumes can be toxic or harmful.
Chlorofluorocarbons (CFC)
There is concern in the scientific community that CFCs and Halons are depleting the upper ozone layer which filters out harmful ultraviolet
radiation. Decreased filtration of ultraviolet radiation may result in increases in skin cancer, cataracts and immune system suppression in
humans, as well as decreased productivity of crops and aquatic systems.
CFCs are used primarily as refrigerants in vehicle air conditioning systems and as aerosol propellants. Halons are used as fire
extinguishants.
Jaguar supports worldwide elimination of CFC usage and it is recommended that Company subsidiaries and affiliates should phase out CFC
usage as soon as acceptable substitutes are commercially available.
Clutch Fluids
See Brake fluids.
Clutch Linings and Pads
See Asbestos.
Corrosion Protection Materials
See also Solvents, Fire.
Highly flammable, flammable observe No Smoking policy.
These materials are varied and the manufacturer's instructions should be followed. They may contain solvents, resins, petroleum products
etc. Skin and eye contact should be avoided. They should only be sprayed in conditions of adequate ventilation and not in confined spaces.
Cutting
See Welding.
Dewaxing
See Solvents and Fuels (Kerosene).
Dusts
Powder, dusts or clouds may be irritant, harmful or toxic. Avoid breathing dusts from powdery chemical materials or those arising from dry
abrasion operations. Wear respiratory protection if ventilation is inadequate.
Fine dusts of combustible material can present an explosion hazard. Avoid explosive limits and/or sources of ignition.
Electric Shock
Electric shock can result from the use of faulty electrical equipment or from the misuse of equipment in good condition.
Ensure that electrical equipment is maintained in good condition and frequently tested. Faulty equipment should be labelled and preferably
removed from the work station.
Ensure that flexes, cables, plugs and sockets are not frayed, kinked, cut, cracked or otherwise damaged.
Ensure that electrical equipment and flexes do not come into contact with water.
Ensure that electrical equipment is protected by the correct rated fuse.
Never misuse electrical equipment and never use equipment which is in any way faulty. The results could be fatal.
Ensure that the cables of mobile electrical equipment cannot get trapped and damaged, such as in a vehicle hoist.
Ensure that the designated electrical workers are trained in basic First Aid.
In cases of electrocution:
Switch off the power supply before approaching the victim.
If this is not possible push or drag the victim from the source of electricity using dry non - conductive material.
Commence resuscitation if trained to do so.
SUMMON MEDICAL ASSISTANCE.
Engine Oils
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See Lubricants and Grease.
Exhaust Fumes
These contain asphyxiating, harmful and toxic chemicals and particles such as carbon oxides, nitrogen oxides, aldehydes, lead and aromatic
hydrocarbons. Engines should be run only under conditions of adequate exhaust extraction or general ventilation and not in confined spaces.
Gasolene (petrol) engine
There may not be adequate warning of odour or of irritation before toxic or harmful effects arise. These may be immediate or delayed.
Fibre Insulation
See also Dusts.
Used in noise and sound insulation.
The fibrous nature of surfaces and cut edges can cause skin irritation. This is usually a physical and not a chemical effect.
Precautions should be taken to avoid excessive skin contact through careful organization of work practices and the use of gloves.
Fire
See also Welding, Foams, Legal Aspects.
Many of the materials found on or associated with the repair of vehicles are highly flammable. Some give off toxic or harmful fumes if burnt.
Observe strict fire safety when storing and handling flammable materials or solvents, particularly near electrical equipment or welding
processes.
Ensure, before using electrical or welding equipment, that there is no fire hazard present.
Have a suitable fire extinguisher available when using welding or heating equipment.
First Aid
Apart from meeting any legal requirements it is desirable for someone in the workshop to be trained in First Aid procedures.
Splashes in the eye should be flushed carefully with clean water for at least ten minutes.
Soiled skin should be washed with soap and water.
Individuals affected by inhalation of gases, fumes etc. should be removed to fresh air immediately. If effects persist, consult a doctor.
If liquids are swallowed inadvertently, consult a doctor giving him the information on the container or label. Do not induce vomiting unless
this action is indicated on the label.
Fluoroelastomer
See Viton.
Foams - Polyurethane
See also Fire.
Used in sound and noise insulation. Cured foams used in seat and trim cushioning.
Follow manufacturer's instructions.
Unreacted components are irritating and may be harmful to the skin and eyes. Wear gloves and goggles.
Individuals with chronic respiratory diseases, asthma, bronchial medical problems, or histories of allergic diseases should not work in or
near uncured materials.
The components, vapors or spray mists can cause direct irritation, sensitivity reactions and may be toxic or harmful.
Vapors and spray mists must not be inhaled. These materials must be applied with adequate ventilation and respiratory protection. Do not
remove the respirator immediately after spraying, wait until the vapor/mists have cleared.
Burning of the uncured components and the cured foams can generate toxic and harmful fumes. Smoking, naked flames or the use of
electrical equipment during foaming operations and until vapors/mists have cleared should not be allowed. Any heat cutting of cured foams
or partially cured foams should be conducted with extraction ventilation.
Freon
See Air Conditioning Refrigerant.
Fuels
See also, Fire, Legal Aspects, Chemicals and Solvents.
Avoid skin contact with fuel where possible. Should contact occur, wash the affected skin with soap and water.
Gasoline (Petrol)
Highly flammable - observe No Smoking policy.
Swallowing can result in mouth and throat irritation and absorption from the stomach can result in drowsiness and unconsciousness. Small
amounts can be fatal to children. Aspiration of liquid into the lungs e.g. through vomiting, is a very serious hazard.
Gasoline dries the skin and can cause irritation and dermatitis on prolonged or repeated contact. Liquid in the eye causes severe pain.
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Motor gasoline may contain appreciable quantities of benzene, which is toxic upon inhalation, and the concentration of gasoline vapors must
be kept very low. High concentrations will cause eye, nose and throat irritation, nausea, headache, depression and symptoms of
drunkenness. Very high concentrations will result in rapid loss of consciousness.
Ensure there is adequate ventilation when handling and using gasoline. Great care must be taken to avoid the serious consequences of
inhalation in the event of vapor build up arising from spillages in confined spaces.
Special precautions apply to cleaning and maintenance operations on gasoline storage tanks.
Gasoline should not be used as a cleaning agent. It must not be siphoned by mouth. See First Aid.
Gas - oil (Diesel Fuel)
See warnings and cautions in relevant manual sections.
Combustible.
Gross or prolonged skin contact with high boiling point gas oils may also cause serious skin disorders including skin cancer.
Kerosene (Paraffin)
Used also as heating fuel, solvent and cleaning agent.
Flammable - observe No Smoking policy.
Irritation of the mouth and throat may result from swallowing. The main hazard from swallowing arises if liquid aspiration into the lungs
occurs.
Liquid contact dries the skin and can cause irritation or dermatitis. Splashes in the eye may be slightly irritating.
In normal circumstances the low volatility does not give rise to harmful vapors. Exposure to mists and vapors from kerosene at elevated
temperature should be avoided (mists may arise in dewaxing). Avoid skin and eye contact and make sure there is adequate ventilation.
Gas Cylinders
See also Fire.
Gases such as oxygen, acetylene, argon and propane are normally stored in cylinders at pressures of up to 13.790 kPa, (2000 lb/in2) and
great care should be taken in handling these cylinders to avoid mechanical damage to them or to the valve gear attached. The contents of
each cylinder should be clearly identified by appropriate markings.
Cylinders should be stored in well ventilated enclosures, and protected from ice and snow, or direct sunlight. Fuel gases (e.g. acetylene and
propane) should not be stored in close proximity to oxygen cylinders.
Care should be exercised to prevent leaks from gas cylinders and lines, and to avoid sources of ignition.
Only trained personnel should undertake work involving gas cylinders.
Gases
See Gas Cylinders.
Gaskets (Fluoroelastomer)
See Viton.
General Workshop Tools and Equipment
It is essential that all tools and equipment are maintained in good condition and the correct safety equipment is used where required.
Never use tools or equipment for any purpose other than that for which they were designed. Never over load equipment such as hoists,
jacks, axle and chassis stands or lifting slings. Damage caused by overloading is not always immediately apparent and may result in a fatal
failure the next time that the equipment is used.
Do not use damaged or defective tools or equipment, particularly high speed equipment such as grinding wheels. A damaged grinding wheel
can disintegrate without warning and cause serious injury.
Wear suitable eye protection when using grinding, chiselling or sand blasting equipment.
Wear a suitable breathing mask when using abrasive blasting equipment, working with asbestos-based materials or using spraying
equipment.
Ensure adequate ventilation to control dusts, mists and fumes.
High Pressure Air, Lubrication and Oil Test Equipment
See also Lubricants and Greases.
Always keep high pressure equipment in good condition, and regularly maintained, particularly at joints and unions.
Never direct a high pressure nozzle, e.g. diesel injector, at the skin as the fluid may penetrate to the under - lying tissue etc., and cause
serious injury.
Halon
See CFCs.
Legal Aspects
Many laws and regulations make requirements relating to health and safety in the use and disposal of materials and equipment in
workshops. Some of these laws which apply in the U.K. are listed. Similar laws exist for other territories:
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The Factories Act (1961).
The Asbestos Regulations (1969).
Highly Flammable Liquids and Liquified Petroleum Gases Regulations (1972).
Control of Pollution Act (1974).
Health and Safety at Work Act (1974).
The Classification, Packaging and Labelling of Dangerous Substances Regulations (1978, 1981, 1983, 1984).
Control of Lead at Work Regulations (1980).
Control of Substances Hazardous to Health (COSHH) Regulations (1989).
Abrasive Wheels Regulations (1970).
Reporting of injuries, diseases and dangerous occurrences regulations 1985 (RIDDOR).
Workshops should be familiar, in detail, with these and associated laws and regulations.
Consult the local factory inspectorate if in any doubt.
Lubricants and Greases
Avoid all prolonged and repeated contact with mineral oils. All lubricants and greases may be irritating to the eyes and skin.
Used Engine Oil
Prolonged and repeated contact with mineral oil will result in the removal of natural oils from the skin, leading to dryness, irritation and
dermatitis. In addition, used engine oil contains potentially harmful contaminants which may cause skin cancer. Adequate means of skin
protection and washing facilities must be provided.
Do not employ used engine oils as lubricants or for any application where appreciable skin contact is likely to occur.
There are publications describing the problems and advising on precautionary measures. For the UK a typical Health and Safety Executive
publication is: SHW 397: Cautionary Notice: Effects of mineral oil on the skin.
Health Protection Precautions
Avoid prolonged and repeated contact with oils, particularly used engine oils.
Wear protective clothing, including impervious gloves where practicable.
Do not put oily rags into pockets.
Avoid contaminating clothing.
Heavily soiled clothing and oil - impregnated footwear should not be worn. Overalls must be cleaned regularly.
First Aid treatment should be obtained immediately for open cuts and wounds.
Use barrier creams, applying them before each work period, to help the removal of oil from the skin.
Wash with soap and water to make sure all oil is removed (skin cleansers and nail brushes will help). Preparations containing
lanoline replace the natural skin oils which have been removed.
Do not use gasoline (petrol), kerosene (paraffin), diesel fuel (gas oil), thinners or solvents for cleaning skin.
If skin disorders develop, obtain medical advice without delay.
Where practical, degrease components prior to handling.
Where there is a risk of eye contact, eye protection should be worn, for example, chemical goggles or face shields; in addition an
eye wash facility should be provided.
Environmental Precautions
Burning used engine oil in small space heaters or boilers can be recommended only for units of approved design. In the UK the heating
system must meet the requirements of HM Inspectorate of Pollution for small burners of less than 0.4 MW. If in doubt check with the
appropriate local authority and/or manufacturer of approved appliances.
Dispose of used oil and used oil filters through authorized waste disposal contractors or licensed waste disposal sites, or to the waste oil
reclamation trade, batterys should also be disposed off under similar arrangments. If in doubt, contact the relevant local authority for
advice on disposal facilities.
It is illegal to pour used oil, antifreeze and automatic transmission fluid on to the ground, down sewers, drains, or into water courses.
Noise
Some operations may produce high noise levels which could, in time, damage hearing. In these cases, suitable ear protection must be worn.
Noise Insulation Materials
See Foams, Fibre Insulation.
0-Rings (Fluoroelastomer)
See Viton.
Paints
See also body and paint manual.
See also Solvents, Chemical Materials.
Highly flammable, flammable - observe No Smoking policy
Pressurized Equipment
See High Pressure Air, Lubrication and Oil Test Equipment.
Solder
Solders are mixtures of metals such that the melting point of the mixture is below that of the constituent metals (normally lead and tin).
Solder application does not normally give rise to toxic lead fumes, provided a gas/air flame is used. Oxy - acetylene flames should not be
used, as they are much hotter and will cause lead fumes to be produced.
Some fumes may be produced by the application of any flame to surfaces coated with grease etc. and inhalation of these should be
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avoided.
Removal of excess solder should be undertaken with care, to make sure that fine lead dust is not produced, which can give toxic effects if
inhaled. Respiratory protection may be necessary.
Solder spillage and filings should be collected and removed promptly to prevent general air contamination by lead.
High standards of personal hygiene are necessary in order to avoid ingestion of lead or inhalation of solder dust from clothing.
Solvents
See also Chemical Materials, Fuels (Kerosene), Fire.
e.g. acetone, white spirit, toluene, xylene, trichloroethane.
Used in cleaning and dewaxing materials, paints, plastics, resins, thinners etc.
Some may be highly flammable or flammable.
Skin contact will degrease the skin and may result in irritation and dermatitis following repeated or prolonged contact. Some can be
absorbed through the skin in toxic or harmful quantities.
Splashes in the eye may cause severe irritation and could lead to loss of vision.
Brief exposure of high concentrations of vapors or mists will cause eye and throat irritation, drowsiness, dizziness, headaches and, in the
worst circumstances, unconsciousness.
Repeated or prolonged exposure to excessive but lower concentrations of vapors or mists, for which there might not be adequate warning
indications, can cause more serious toxic or harmful effects.
Aspiration into the lungs (e.g. through vomiting) is the most serious consequence of swallowing.
Avoid splashes to the skin, eyes and clothing. Wear protective gloves, goggles and clothing if necessary.
Ensure good ventilation when in use, avoid breathing fumes, vapors and spray mists and keep containers tightly sealed. Do not use in
confined spaces.
When spraying materials containing solvents, e.g. paints, adhesive, coatings, use extraction ventilation or personal respiratory protection in
the absence of adequate general ventilation.
Do not apply heat or flame except under specific and detailed manufacturer's instructions.
Sound Insulation
See Fibre Insulation, Foams.
Suspended Loads
CAUTION: Never improvise lifting tackle.
There is always a danger when loads are lifted or suspended. Never work under an unsupported, suspended or raised load e.g. suspended
engine, etc.
Always make sure that lifting equipment such as jacks, hoists, axle stands, slings, etc., are adequate and suitable for the job, in good
condition and regularly maintained.
Transmission Brake Bands
See Asbestos.
Underseal
See Corrosion Protection.
Viton
In common with many other manufacturers' vehicles, some components fitted to the Jaguar range have 'O' rings, seals or gaskets which
contain a material known as 'Viton'.
Viton is a fluoroelastomer, that is a synthetic rubber type which contains Fluorine. It is commonly used for 'O' rings, gaskets and seals of all
types. Although Viton is the most well known fluoroelastomer, there are others, including Fluorel and Tecmoflon.
When used under design conditions fluoroelastomers are perfectly safe. If, however, they are exposed to temperatures in excess of 400 C,
the material will not burn, but will decompose, and one of the products formed is hydrofluoric acid.
This acid is extremely corrosive and may be absorbed directly, through contact, into the body.
'O' rings, seals or gaskets which have been exposed to very high temperatures will appear charred or as a black sticky substance.
DO NOT, under any circumstances touch them or the attached components.
Enquiries should be made to determine whether Viton or any other fluoroelastomer has been used in the affected 'O' ring, seal or gasket. If
they are of natural rubber or nitrile there is no hazard. If in doubt, be cautious and assume that the material may be Viton or any
fluoroelastomer.
If Viton or any other fluoroelastomers have been used, the affected area should be decontaminated before the commencement of work.
Disposable heavy duty plastic gloves should be worn at all times, and the affected area washed down using wire wool and a limewater
(calcium hydroxide) solution to neutralize the acid before disposing of the decomposed Viton residue and final cleaning of the area. After
use, the plastic gloves should be discarded carefully and safely.
Welding
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See also Fire, Electric Shock, Gas Cylinders.
Welding processes include Resistance Welding (Spot Welding), Arc Welding and Gas Welding.
Resistance Welding
This process may cause particles of molten metal to be emitted at a high velocity, and the eyes and skin must be protected.
Arc Welding
This process emits a high level of ultra - violet radiation which may cause arc - eye and skin burns to the operator and to other persons
nearby. Gas - shielded welding processes are particularly hazardous in this respect. Personal protection must be worn, and screens used to
shield other people.
CONTACT LENS WEARERS ARE ADVISED TO REVERT TO ORDINARY SPECTACLES WHEN ARC WELDING as the arc spectrum is believed to
emit microwaves which dry out the fluid between the lens and the eye. This may result in blindness when the lens is removed from the eye.
Metal spatter will also occur, and appropriate eye and skin protection is necessary.
The heat of the welding arc will produce fumes and gases from the metals being welded, the rods and from any applied coatings or
contamination on the surfaces being worked on. These gases and fumes may be toxic and inhalation of these should be avoided. The use of
extraction ventilation to remove the fumes from the working area may be necessary particularly in cases where the general ventilation is
poor, or where considerable welding work is anticipated. In extreme cases or confined spaces where adequate ventilation cannot be
provided, air-fed respirators may be necessary.
Gas Welding (and Cutting)
Oxy - acetylene torches may be used for welding and cutting, and special care must be taken to prevent leakage of these gases, with
consequent risk of fire and explosion.
The process will produce metal spatter and eye and skin protection is necessary.
The flame is bright, and eye protection should be used, but the ultra - violet emission is much less than that from arc welding, and lighter
filters may be used.
The process itself produces few toxic fumes, but such fumes and gases may be produced from coatings on the work, particularly during
cutting away of damaged body parts, and inhalation of the fumes should be avoided.
In brazing, toxic fumes may be produced from the metals in the brazing rod, and a severe hazard may arise if brazing rods containing
cadmium are used. In this event particular care must be taken to avoid inhalation of fumes and expert advice may be required.
SPECIAL PRECAUTIONS MUST BE TAKEN BEFORE ANY WELDING OR CUTTING TAKES PLACE ON VESSELS WHICH HAVE CONTAINED
COMBUSTIBLE MATERIALS, E.G. BOILING OR STEAMING OUT OF FUEL TANKS.
Warning Symbols on Vehicles
Decals showing warning symbols will be found on various vehicle components.
These decals must not be removed. The warnings are for the attention of owners/operators and persons carrying out service or repair
operations on the vehicle.
The most commonly found decals are reproduced below together with an explanation of the warnings.
1. Components or assemblies displaying the warning triangle and open book symbol advise consultation of the relevant section of
the owners handbook before touching or attempting adjustments of any kind.
1.
2. Components or assemblies displaying the warning triangle with the electrified arrow and open book symbol give warning of
inherent high voltages. Never touch these with the engine running or the ignition switched on. See Electric Shock in this
subsection.
2.
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3. Jaguar vehicles and replacement parts which contain asbestos are identified by this symbol. See Asbestos in this subsection. 3.
4. Components or assemblies displaying this symbol give warning that the component contains a corrosive substance. See Acids and
Alkalis in this subsection.
4.
5. Vehicles displaying the caution circle with a deleted lighted match symbol, caution against the use of naked lights or flames
within the immediate vicinity due to the presence of highly flammable or explosive liquids or vapors. See Fire in this subsection.
5.
6. All vehicles fitted with the passenger air bag from the factory have a warning sticker attached to the instrument panel, prohibiting
the use of rear facing child seats in the front seating position. Failure to follow this instructions may result in personal injury.
6.
White Spirit
See Solvents.
Safety Precautions
WARNINGS:
Working on the fuel system results in fuel and fuel vapor being present in the atmosphere. Fuel vapor is extremely flammable, hence
great care must be taken whilst working on the fuel system. Adhere strictly to the following precautions:
Do not smoke in the work area.
Display 'no smoking' signs around the area.
Disconnect the battery before working on the fuel system.
Do not connect/disconnect electrical circuits, use electrical equipment or other tools or engage in working practices which in any way
may result in the production of sparks.
Ensure that a CO2 fire extinguisher is close at hand.
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Ensure that dry sand is available to soak up any fuel spillage.
Empty fuel using suitable fire proof equipment into an authorized explosion proof container.
Do not empty fuel while working in a workshop or a pit.
Ensure that working area is well ventilated.
Ensure that any work on the fuel system is only carried out by experienced and well qualified maintenance personnel.
Ensure that fume extraction equipment is used where appropriate.
Fume extraction equipment must be in operation when solvents are used e.g. Trichloroethane, white spirit, sbp3, methylene chloride,
perchlorethylene. Do not smoke in the vicinity of volatile degreasing agents.
Whenever possible, use a ramp or pit whilst working beneath a vehicle, in preference to jacking. Position chocks at the wheels as well as
applying the parking brake. Never rely on a jack alone to support a vehicle. Use axle stands, or blocks carefully placed at the jacking points,
to provide a rigid location. Check that any lifting equipment used has adequate capacity and is fully serviceable. Ensure that a suitable form
of fire extinguisher is conveniently located. When using electrical tools and equipment, inspect the power lead for damage and check that it
is properly earthed. Disconnect the earth (grounded) terminal of the vehicle battery. Do not disconnect any pipes of the air conditioning
refrigeration system unless you are trained and instructed to do so. A refrigerant i s used which can cause blindness if allowed to come into
contact with the eyes. Ensure that adequate ventilation is provided when volatile degreasing agents are being used.
Adhere strictly to handling and safety instructions given on containers and labels. Keep oils and solvents away from naked flames and other
sources of ignition. Do not apply heat in an attempt to free seized nuts or fittings; as well as causing damage to protective coatings, there
is a risk of damage from stray heat to electronic equipment and brake lines. Do not leave tools, equipment, spilt oil etc. around the work
area. Wear protective overalls and use barrier cream when necessary.
Environmental Protection
In some countries it is illegal to pour used oil onto the ground, down sewers or drains, or into water courses. The burning of used engine oil
in small space heaters or boilers is not recommended unless emission control equipment is fitted. Dispose of used oil through authorized
waste disposal contractors, to licensed waste disposal sites or to the waste oil reclamation trade. If in doubt, contact the Local Authority
for advice on disposal facilities.
www.JagDocs.com
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General Information - How To Use This Manual
Copyright Statement
Copyright. Jaguar Cars Ltd. 1999
All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or transmitted in any form, electronic,
mechanical, photocopying, recording or other means, without prior written permission of Jaguar Cars Ltd., Customer Service Department,
Browns Lane, Coventry, CV5 9DR, England.
Workshop Manual Organization
This manual covers descriptive, diagnostic (including OBD), and repair aspects to service the vehicle effectively.
The manual is arranged in sections, each section dealing with a specific part of a vehicle system. For example, Section 412-03 covers air
conditioning, which is part of the climate control system.
The first digit of the section number indicates the group. There are five groups:
General Information.
Chassis.
Powertrain.
Electrical.
Body and Paint.
The second and third digits of the section number indicate the vehicle system.
The last two digits of the section number indicate the part of the system covered by the section.
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General Information - Important Safety Instructions
Safety Notice
Appropriate service methods and correct repair procedures are essential for the safe, reliable operation of all motor vehicles, as well as the
safety of the person doing the work. This manual provides general directions for accomplishing service and repair work with tested effective
techniques. Following them will help assure reliability.
There are numerous variations in procedures, techniques, tools, and parts for servicing vehicles, as well as in the skill of the person doing
the work. This manual cannot possibly anticipate all such variations and provide advice or cautions as to each. Accordingly, anyone who
departs from the instructions provided in the manual must first establish that neither personal safety or vehicle integrity is compromised
from choices of methods, tools or parts.
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General Information - Road/Roller Testing
Road or roller testing may be carried out for various reasons and a procedure detailing pre - test checks, through engine starting and
stopping, pre - driving checks, on - test checks to final checks on completion of the test is given overleaf.
Unless complete vehicle performance is being checked, the full road test procedure need not be carried out. Instead, those items
particularly relevant to the system/s being checked can be extracted.
Pre - Test Checks
WARNING: If the brake system hydraulic fluid level is low, pedal travel is excessive or a hydraulic leak is found, do not attempt to
road test the vehicle until the reason for the low fluid level, excessive pedal travel or hydraulic leak is found and rectified.
It is suggested that pre - test checks, and functional tests of those systems/circuits which affect the safe and legal operations of the
vehicle, such as brakes, lights and steering, should always be carried out before the road or roller test.
Engine oil level
Engine coolant level
Tires, for correct pressure, compatible types and tread patterns, and wear within limits.
There is sufficient fuel in the tank to complete the test.
All around the engine, transmission and under the vehicle for oil, coolant, hydraulic and fuel leaks. Make a note of any apparent
leaks and wipe off the surrounding areas to make it easier to identify the extent of the leak on completion of the test.
Starting the Engine
NOTE: On initial drive away from cold and within the first 1.5 km (1 mile), do not depress accelerator pedal beyond half travel until the
vehicle has attained a minimum speed of 25 km/h (15 miles/h). Never operate at high engine speed or with the accelerator pedal at full
travel whilst the engine is cold.
With the ignition switched off, check:
The handbrake is applied.
The gear lever is in neutral.
All instrument gauges (except fuel gauge) read zero.
With the ignition switched on, check:
Ignition controlled warning lights come on.
Engine temperature gauge registers a reading compatible with the engine temperature.
Fuel gauge registers a reading appropriate to the fuel level in the tank.
The operation of the handbrake warning light and fluid level warning indicator light.
On Road or Roller Test Check:
CAUTION: If road testing, check the brake operation while still travelling at low speed before continuing with the test. If the brakes
pull to one side, or appear to be otherwise faulty, do not continue with the road test until the fault has been found and rectified.
Clutch pedal operation is not stiff or heavy.
Initial gear engagement is smooth and there is no evidence of clutch drag.
Handbrake control operates smoothly and the handbrake releases quickly and completely.
Clutch takes up the drive smoothly, without slip or judder.
The engine power output is satisfactory, full power is achieved, acceleration is smooth and pedal operation not stiff or heavy, and
engine speed returns to idle correctly.
There is no excessive or abnormally colored smoke from the engine under normal driving, heavy load or overrun conditions.
Steering operation, including power steering where fitted, is smooth, accurate, not excessively heavy or with excessive free play or
vibration. Does not pull to one side and self centres smoothly after cornering.
Speedometer, oil pressure warning lamp, coolant temperature gauge and tachometer (where fitted) register the correct readings or
operate correctly.
Switches and controls operate smoothly and positively, warning or indicator lights operate correctly and the direction indicator control
self cancels when the steering is returned to the straight ahead position.
Heating and ventilation systems work correctly and effectively.
Brake operation and efficiency.
Brake Testing
WARNING: When brake testing, avoid breathing the smoke or fumes from hot brakes, this may contain asbestos dust which is
hazardous to health, see Health and Safety Precautions.
Avoid brake testing on busy roads where it can cause inconvenience or danger to other road users.
CAUTION: Brake testing which includes heavy brake applications should not be carried out with new brake pads/discs or linings/drums
until the components have bedded - in. New brake friction components will not reach full efficiency until the bedding - in process is
complete.
Test the brakes at several speeds within the normal operating range using both light and heavy pedal pressure. Note any tendency to
snatch, pull or drag, and any undue delay in application or release.
Allow the vehicle to coast and note any tendency to pull to one side, or evidence that the brakes are binding.
After stopping the vehicle (not immediately after a period of heavy braking), carefully check the brake temperature. A disc which feels hot,
or appreciably hotter than the others, indicates that the brake is binding.
After completion of the test, check for:
Oil, coolant, hydraulic, air and fuel leaks.
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Abnormal temperature of any moving components or assemblies, e.g. wheel hubs, transmission, axle etc., which might indicate
overtightness or lack of lubrication.
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General Information - Solvents, Sealants and Adhesives
WARNING: Always handle all solvents, sealers and adhesives with extreme care. Some contain chemicals or give off fumes which can
be dangerous to health. Always follow the manufacturers instructions. If in doubt about any substance, particularly a solvent, DO NOT use
it.
CAUTION: If in doubt about the suitability of any proprietary solvent or sealer for a particular application, contact the manufacturer of
the product for information regarding storage, handling and application.
The Solvents, Sealers and Adhesives subsection refers to some commonly used chemicals and materials, hazards associated with their use,
and safety measures to be taken.
Adhesives and Sealers
Highly flammable, flammable, combustible observe No Smoking policy.
Generally should be stored in No Smoking' areas. Cleanliness and tidiness in use should be observed e.g. disposable paper covering
benches; should be dispensed from applicators where possible; containers, including secondary containers, should be labelled appropriately.
Solvent - based Adhesives/Sealers - See Solvents
Follow manufacturer's instructions.
Water - based Adhesives/Sealers
Those based on polymer emulsions and rubber latexes may contain small amounts of volatile toxic and harmful chemicals. Skin and eye
contact should be avoided and adequate ventilation provided during use.
Hot Melt Adhesives
In the solid state, they are safe. In the molten state they may cause burns and health hazards may arise from the inhalation of toxic
fumes.
Use appropriate protective clothing and a thermostatically controlled heater with a thermal cut - out and adequate extraction.
Resin - based Adhesives/Sealers e.g. Epoxide and Formaldehyde Resin - based
Mixing should be carried out in well ventilated areas, as harmful or toxic volatile chemicals may be released.
Skin contact with uncured resins and hardeners can result in irritation, dermatitis, and absorption of toxic or harmful chemicals through the
skin. Splashes can damage the eyes.
Provide adequate ventilation and avoid skin and eye contact.
Anaerobic, Cyanoacrylate (Super - glues) and other Acrylic Adhesives
Many are irritant, sensitizing or harmful to the skin and/or respiratory tract. Some are eye irritants.
Skin and eye contact should be avoided and the manufacturer's instructions followed.
Cyanoacrylate adhesives (super-glues) MUST NOT contact the skin or eyes. If skin or eye tissue is bonded, cover with a clean moist pad and
seek immediate medical attention. Do not attempt to pull tissue apart. Use in well ventilated areas as vapors can cause irritation to the
nose and eyes.
For two - pack systems see Resin - based and Isocyanate Adhesives/Sealers.
Isocyanate (Polyurethane) Adhesives/Sealers
See also Resin - based Adhesives
Individuals suffering from asthma or respiratory allergies should not work with or near these materials as sensitivity reactions can occur.
Over exposure is irritating to the eyes and respiratory system. Excessive concentrations may produce effects on the nervous system
including drowsiness. In extreme cases, loss of consciousness may result. Long term exposure to vapor concentrations may result in adverse
health effects.
Prolonged contact with the skin may lead to skin irritation and, in some cases, dermatitis.
Splashes entering the eye will cause discomfort and possible damage.
Any spraying should preferably be carried out in exhaust ventilated booths removing vapors and spray droplets from the breathing zone.
Wear appropriate gloves, eye and respiratory protection.
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General Information - Standard Workshop Practices
Protecting the Vehicle
Always install covers to protect the fenders before commencing work in the engine compartment. Always install the interior protection kit,
wear clean overalls and wash hands or wear gloves before working inside the vehicle. Avoid spilling hydraulic fluid, antifreeze or battery acid
on the paintwork. In the event of spillage, wash off with water immediately. Use polythene sheets in the luggage compartment to protect
carpets. Always use the recommended service tool, or a satisfactory equivalent, where specified. Protect temporarily exposed screw threads
by replacing nuts or installing caps.
Vehicle in Workshop
When working on a vehicle in the workshop always make sure that:
The parking brake is applied or the wheels are securely chocked to prevent the vehicle moving forwards or backwards
If the engine is to be run, there is adequate ventilation, or an extraction hose to remove exhaust fumes is installed
There is adequate room to jack up the vehicle and remove the wheels, if necessary
Fender covers are always installed if any work is to be carried out in the engine compartment
The battery is disconnected if working on the engine, underneath the vehicle, or if the vehicle is jacked up
CAUTION: When electric arc welding on a vehicle, always disconnect the generator wiring to prevent the possibility of a surge of
current causing damage to the internal components of the generator.
If using welding equipment on the vehicle, ensure a suitable fire extinguisher is readily available.
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Identification Codes - Identification Codes
Vehicle Identification Number (VIN)
The official VIN is stamped on the right hand side of the boot compartment floor. An additional quick reference and anti forgery
identification number is stamped onto a metal plate and fastened to the instrument panel. It is positioned close to the left-hand side of the
vehicle and is visible from the outside.
The vehicle identification number is also located on a vehicle certification label or vin plate which is mounted on the bottom of the 'B' Post.
Item Part Number Description
1 Quick reference plate
2 Certification label (Europe and Rest of the World)
3 Certification label (USA)
4 Official VIN plate
Vehicle Identification Number (Example)
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1 World manufacturer identifier
2 Market, air bag specification
3 Transmission and steering code
4 Body code
5 Engine emission system
6 Check digit
7 Model year
8 Assembly plant, model line
9 Production sequence number
World Manufacturer Identifier
VIN Positions 1, 2 and 3
Codes Manufacturer Make Type
SAJ Jaguar Cars Limited, England Jaguar Passenger Car
Market, Air Bag Specification
VIN position 4
VIN code Description
A Rest of World with twin air bags, side air bags and curtain air bags
K Japan with twin air bags, side air bags and curtain air bags
W USA with twin air bags, side air bags and curtain air bags
X Canada with twin air bags, side air bags and curtain air bags
Y Mexico with twin air bags, side air bags and curtain air bags
Transmission, Steering Code
VIN Position 5
VIN Code Description
A AWD Automatic LHS
B AWD Manual LHS
C AWD Automatic RHS
D AWD Manual RHS
E FWD Automatic LHS
F FWD Manual LHS
G FWD Automatic RHS
H FWD Manual RHS
Body Code
VIN Position 6 and 7
51 4-Door, 5 seat saloon high series
52 4-Door, 5 seat saloon entry series
53 4-Door, 5 seat saloon sport series
54 5-Door, 5 seat wagon high series
55 5-Door, 5 seat wagon entry series
56 5-Door, 5 seat wagon sport series
Engine Emission System
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VIN Position 8
NOTE: *1 EU. Includes the following markets; Austria, Belgium, Cyprus, Czech Rep, Denmark, Estonia, Finland, France, Germany, Greece,
Netherlands, Hungary, Italy, Latvia, Lithuania, Luxembourg, Malta, Poland, Portugal, Rep. of Ireland, Slovenia, Slovakia, Spain (including
Canary Islands), Sweden, Bulgaria, Romania and UK.
NOTE: *2 East Europe. Includes the following markets; Croatia and Serbia.
NOTE: *3 Russia. Includes the following markets; Belarus, Kazakhstan, Ukraine and Uzbekistan.
NOTE: *4 Middle East. Includes the following markets; Abu Dhabi, Bahrain, Dubai, Jordan, Kuwait, Lebanon, Oman, Quatar, Saudi Arabia.
VIN
Code Engine Market
F 2.5L Argentina, Dominican Rep, Guatemala, *4 Middle East, Panama, Uruguay, Philippines and Taiwan
E 3.0L
N 2.0L
M 2.5L *2 East Europe, Morocco, *3 Russia and Chile
L 3.0L
S 2.0L
M 2.5L *1 EU, Israel, Norway, Switzerland, and Turkey
L 3.0L
N/A 2.0L
K 2.5L Brazil
J 3.0L
N/A 2.0L
H 2.5L Egypt, Syria and South Korea
G 3.0L
P 2.0L
M 2.5L Japan
L 3.0L
S 2.0L
N/A 2.5L USA
A 3.0L
N/A 2.0L
N/A 2.5L Canada
A 3.0L
N/A 2.0L
N/A 2.5L Mexico
L 3.0L
N/A 2.0L
F 2.5L Indonesia, Malaysia, Singapore, Sri Lanka and Thailand
E 3.0L
N 2.0L
M 2.5L Australia, Hong Kong and New Zealand
L 3.0L
S 2.0L
H 2.5L South Africa (includes Trinidad and Tobago)
G 3.0L
P 2.0L
M 2.5L Cyprus, Malta and UK (and Eire)
L 3.0L
N/A 2.0L
1 2.0L Diesel Argentina, *2 East Europe, *1 EU, Morocco, Norway, Switzerland, Turkey, Uruguay and *3 Russia
1 2.2L Diesel Argentina, *2 East Europe, *1 EU (except Belgium), Morocco, Norway, Switzerland, Turkey, Uruguay and *3
Russia
2 2.2L Diesel Belgium (110 Kw engine only)
1 2.0L Diesel Cyprus, Malaysia, Malta, UK (and Eire), South Africa (includes Trinidad and Tobago)
1 2.2L Diesel Cyprus, Malaysia, Malta, UK (and Eire), South Africa (includes Tobago)
3 2.2L Diesel +
cDPF
*1 EU, Norway, Switzerland, and Turkey
Check Digit
VIN Position 9
0 - 9 or X Calculated in accordance with American standard CFR part 565
Model Year
VIN Position 10
6 2006 Model Year
7 2007 Model Year
Assembly Plant and Model Line
VIN Position 11
W Halewood 3.0L
X Halewood 2.5L
Y Halewood 2.0L
6 Halewood 2.0L Diesel
B Halewood 2.2L Diesel
Production Sequence Number
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VIN Position 12 through 17
Sequence Number
C00001 - C99999
D00001 - D99999
E00001 - E99999
J00001 - J99999
K00001 - K99999
S00001 - S99999
T00001 - T99999
V00001 - V99999
Vehicle Certification Label
The vehicle certification label also contains the 17 character vehicle identification number. This number is used for warranty identification of
the vehicle.
Vehicle Certification Number (Europe and Rest of the World)
1 WVTA number printed here when applicable
2 Vehicle identification number
3 Gross vehicle weight
4 Gross train weight
5 Maximum permitted front axle loading
6 Maximum permitted rear axle loading
7 Date of manufacture
8 Interior trim code
9 Paint code
Vehicle Identification Label (USA)
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6 Type
8 Paint code
Vehicle Identification Label (Saudi Arabia and Gulf States)
4 Paint code
Vehicle Identification Label (Canada)
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6 Paint code
8 Type
Automatic Transmission Number
The serial number of the automatic transmission unit is displayed on a metal label or bar code (where equipped) attached to the
transmission casing.
Manual Transmission Number
The serial number of the manual transmission unit is displayed on a metal label or bar code (where equipped) attached to the transmission
casing.
Engine Number (V6)
The engine number is stamped on an engine web on the right hand side of the cylinder block behind the engine mounting..
Engine Number (Diesel)
The engine number is contained on a bar code label on the front cover and is also stamped in the cylinder block casting.
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Jacking and Lifting - Jacking
Safety Precautions
CAUTION: The jack provided with the vehicle is intended to be used in an emergency for changing a deflated tire. To avoid damage to
the vehicle, never use the jack to raise the vehicle for any other purpose. Refer to the Driver Handbook when using the jack supplied with
the vehicle. Failure to follow these instructions can result in personal injury.
The following safety precautions must be observed when raising the vehicle to carry out service operations:
Never rely on a jack alone to support a vehicle; use suitable vehicle stands to provide rigid support.
When working beneath a vehicle, whenever possible, use a vehicle hoist instead of a jack and vehicle stands.
Make sure that the vehicle is standing on firm, level ground before using a jack.
Do not rely on the parking brake alone; chock the wheels and put the automatic transmission into PARK if possible.
Check that any lifting equipment used has adequate capacity for the load being lifted and is in correct working order.
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Jacking and Lifting - Lifting
Lifting PointsTwin-Post Hoist and Floor Jack
CAUTIONS:
Do not allow the hoist adapters to contact the steering linkage, suspension arms, stabilizer bar, rear subframe stabilizer brackets or
to compress the lower suspension arm stabilizer bar insulator. Damage to the suspension, exhaust and steering linkage components may
occur if care is not exercised when positioning the hoist adapters of two-post hoists prior to lifting the vehicle.
Never use the differential housing as a lift point. Damage to the differential housing and cover may occur.
When using a floor jack, a cushioned pad must be utilized to avoid body damage.
Vehicle Support Points
CAUTION: When using vehicle support stands a cushioned pad must be utilized to avoid body damage.
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Vehicle Recovery
NOTE: Prior to vehicle recovery, make sure that the vehicle keys are available and the security system is disarmed.
Vehicle recovery methods are:
By flat-bed transporter.
By front suspended tow.
Transporter or Trailer Recovery
When the vehicle is being recovered by transporter or trailer:
The parking brake must be applied and the wheels chocked.
The gear selector lever must be in NEUTRAL. Do not select PARK on automatic transmission vehicles, as the parking lock mechanism
may be damaged by the forward and backward rocking motion of the vehicle.
The vehicle must be securely tied down to the transporter or trailer.
Front Suspended Tow
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When the vehicle is being recovered by front suspended tow:
CAUTION: The driveshaft must be disconnected.
The ignition key must be removed from the ignition switch to lock the steering.
The front wheels must be correctly positioned in the lifting cradle and securely tied down.
Emergency Towing-Vehicles fitted with manual transmission:
WARNING: If the engine is not running, the steering will become heavy and the force necessary to effectively apply the brakes will be
greatly increased.
CAUTION: A vehicle with a defective transmission must be towed by front suspended tow.
When the vehicle is being towed with all four wheels on the ground:
Local regulations for the towing of vehicles must be followed. In some countries the registration number of the towing vehicle and an
'On Tow' sign or warning triangle must be displayed at the rear of the towed vehicle.
The gear selector lever must be in NEUTRAL.
The ignition switch must be in the RUN position to release the steering lock and make the direction indicators, horn and stop lamps
operate.
A distance of 48 kms (30 miles) must not be exceeded.
A speed of 48 km/h (30 mph) must not be exceeded.
The tow rope must be attached to the front towing eye.
Emergency Towing-Vehicles fitted with automatic transmission:
WARNING: If the engine is not running, the steering will become heavy and the force necessary to effectively apply the brakes will be
greatly increased.
CAUTION: A vehicle with a defective transmission must be towed by front suspended tow.
When the vehicle is being towed with all four wheels on the ground:
Local regulations for the towing of vehicles must be followed. In some countries the registration number of the towing vehicle and an
'On Tow' sign or warning triangle must be displayed at the rear of the towed vehicle.
The gear selector lever must be in NEUTRAL.
The ignition switch must be in the RUN position to release the steering lock and make the direction indicators, horn and stop lamps
operate.
A distance of 0.8 kms (0.5 miles) must not be exceeded.
A speed of 48 km/h (30 mph) must not be exceeded.
The tow rope must be attached to the front towing eye.
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Noise, Vibration and Harshness - Noise, Vibration and Harshness (NVH)
Noise, vibration and harshness (NVH) is becoming more important as vehicles become more sophisticated and passenger comfort levels
increase. This section is designed to aid in the diagnosis, testing and repair of NVH concerns.
noise is defined as sounds not associated with the operation of passenger compartment equipment that interface with customer
satisfaction.
vibration is defined as impulses felt by the customer that are not caused by road surface changes.
harshness is a ride quality issue where the customer feels that the vehicle response to the road surface is sharply transmitted to the
customer.
Diagnostic Theory
Diagnosis is more than just following a series of interrelated steps in order to find the solution to the specific condition. It is a way of
looking at systems that are not functioning the way they should and finding out why. Also it is knowing how the system should work and
whether it is working correctly.
There are basic rules for diagnosis. If these rules are followed, the cause of the condition is usually found the first time through the system.
Know the System
know how the parts go together.
know how the system operates as well as its limits and what happens when the system goes wrong.
sometimes this means checking the system against one that is known to be working correctly.
Know the History of the System
A clue in any one of these areas may save time:
how old or new is the system?
what kind of treatment has it had?
has it been repaired in the past in such a manner that might relate to the present condition?
what is the repair history?
Know the History of the Condition
did it start suddenly or appear gradually?
was it related to some other occurrence such as a collision or previous part renewal?
know how the condition made itself known; it may be an important clue to the cause.
Know the Probability of Certain Conditions Developing
Look for the simple rather than the complex.
For example:
- Electrical conditions usually occur at connections rather than components.
- An engine no-start is more likely to be caused by a loose wire or small adjustment rather than a sheared-off camshaft.
Know the difference between impossible and improbable. Certain failures in a system can be improbable but still happen.
New parts are just that, new. It does not mean they are always good functioning parts.
Do Not Cure the Symptom and Leave the Cause
Lowering the pressure in a front tire may correct the condition of a vehicle leaning to one side, but it does not correct the original condition.
Be Positive the Cause is Found
double check the findings.
what caused a worn component?
a loose transmission or engine mount could indicate that other mounts are also loose.
Diagnostic Charts
Charts are a simple way of expressing the relationship between basic logic and a physical system of components. They help discover the
cause of a condition in the least time. Diagnostic charts combine many areas of diagnosis into one visual display:
probability of certain things occurring in a system
speed of checking certain components or functions before others
simplicity of carrying out certain tests before others
elimination of checking huge portions of a system by carrying out simple tests
certainty of narrowing down the search to a small portion before carrying out in-depth testing
The fastest way to find a condition is to work with the tools that are available. This means working with proven diagnostic charts and the
correct special equipment for the system.
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Noise, Vibration and Harshness - Noise, Vibration and Harshness (NVH)
Inspection and Verification
1. Verify the customer concern. 1.
2. Visually inspect for obvious signs of mechanical damage. 2.
3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next
step.
3.
4. If the concern(s) remains after the inspection, determine the symptom(s) and go to the Symptom Chart. 4.
How To Use This Diagnostic Procedure Section
Noise, vibration and harshness (NVH) concerns have become more important as vehicles have become more sensitive to these
vibrations. This section is designed as an aid to identifying these situations.
The section provides diagnostic procedures based on symptoms. If the condition occurs at high speed, for instance, the most likely
place to start is under High Speed Shake.
The road test procedure will tell how to sort the conditions into categories and how to tell a vibration from a shake.
A series of Road Test Quick Checks is provided to make sure that a cause is either pinpointed or eliminated.
Name the condition, proceed to the appropriate section and locate the correct diagnosis. When the condition is identified, the job is
partly done.
Follow the diagnostic procedure as outlined.
Quick Checks are described within the step, while more involved tests and adjustments are outlined in General Procedures.
Always follow each step exactly and make notes to recall important findings later.
Customer Interview
The road test and customer interview (if available) provide information that will help identify the concerns and will provide direction to the
correct starting point for diagnosis.
Identify the Condition
NVH usually occurs in a number of areas:
tires
engine accessories
suspension
driveline
air leakage (wind noise)
squeaks and rattles
Heating ventilation and air conditioning (HVAC)
electrical (e.g. motor noise)
It is important, therefore, that an NVH concern be isolated into its specific area(s) as soon as possible. The easiest and quickest way to do
this is to carry out the Road Test as outlined.
Noise Diagnostic Procedure
Non-Axle Noise
The five most important sources of non-axle noise are exhaust, tires, roof racks, trim and mouldings, and transmission.
Therefore, make sure that none of the following conditions are the cause of the noise before proceeding with a driveline teardown and
diagnosis.
In certain conditions, the pitch of the exhaust may sound very much like gear noise. At other times, it can be mistaken for a wheel
bearing rumble.
Tires, especially snow tires, can have a high pitched tread whine or roar, similar to gear noise. Radial tires, to some degree, have
this characteristic. Also, any non-standard tire with an unusual tread construction may emit a roar or whine type noise.
Trim and mouldings can also cause whistling or a whining noise.
Clunk may be a metallic noise heard when the automatic transmission is engaged in reverse or drive, or it may occur when the
throttle is applied or released. It is caused by backlash somewhere in the driveline.
Bearing rumble sounds like marbles being tumbled. This condition is usually caused by a damaged wheel bearing.
Noise Conditions
Gear noise is typically a howling or whining due to gear damage or incorrect bearing preload. It can occur at various speeds and
driving conditions, or it can be continuous.
Chuckle is a particular rattling noise that sounds like a stick against the spokes of a spinning bicycle wheel. It occurs while
decelerating from 64 km/h (40 mph) and can usually be heard all the way to a stop. The frequency varies with vehicle speed.
Knock is very similar to chuckle, though it may be louder and occurs on acceleration or deceleration. The teardown will disclose what
has to be corrected.
Check and rule out tires, exhaust and trim items before disassembling the transmission to diagnose and correct gear noise.
The noises described under Road Test usually have specific causes that can be diagnosed by observation as the unit is disassembled. The
initial clues are the type of noise heard on the road test and the driving conditions.
Vibration Conditions
NOTE: New constant velocity (CV) joints should not be installed unless disassembly and inspection revealed unusual wear.
Clicking, popping or grinding noises may be caused by the following:
cut or damaged drive half shaft joint boots resulting in inadequate or contaminated lube in the outboard or inboard CV joint bearing
housings
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loose drive half shaft joint boot clamps
another component contacting the drive half shaft
worn, damaged or incorrectly installed wheel bearing, suspension or brake component
Vibration at highway speeds may be caused by the following:
out-of-balance front or rear wheels
out-of-round tires
driveline imbalance
driveline run-out (alignment)
NOTE: Drive half shafts are not balanced and do not contribute to rotational vibration disturbances.
Shudder or vibration during acceleration may be caused by the following:
Excessively worn or damaged outboard or inboard CV joint shaft pilot bearing housing
Excessively high CV joint operating angles caused by incorrect ride height. Check ride height, verify correct spring rate and check
items under Inoperative Conditions
Leakage Conditions
1. Inspect the CV joint boots for evidence of cracks, tears or splits. 1.
2. Inspect the underbody for any indication of grease splatter in the vicinity of the front or rear wheel drive half shaft joints and
boots. If any grease is present this indicates damage to the half shaft joint boot or boot clamp.
2.
3. Inspect the inboard CV joint stub shaft pilot bearing housing seal for leakage at the inboard CV joint pilot bearing housing. 3.
Inoperative Conditions
If a CV joint or half shaft pull-out occurs, check the following:
suspension components for correct location, damage or wear
bushings for wear
subframe for damage
bent or worn components:
- stabilizer bar link
- left-hand rear suspension lower arm and bushing
- right-hand rear suspension lower arm and bushing
- rear wheel hub and half shaft
- left-hand front suspension lower arm and bushing
- right-hand front suspension lower arm and bushing
- front wheel hub and half shaft
Road Test
A gear-driven unit will produce a certain amount of noise. Some noise is acceptable and may be audible at certain speeds or under various
driving conditions as on a newly paved blacktop road. The slight noise is in no way detrimental and must be considered normal.
The road test and customer interview (if available) provide information needed to identify the condition and give direction to the correct
starting point for diagnosis.
1. Make notes throughout the diagnosis routine. Make sure to write down even the smallest bit of information, because it may turn
out to be the most important.
1.
2. Do not touch anything until a road test and a thorough visual inspection of the vehi cle have been carried out. Leave the tire
pressures and vehicle load just where they were when the condition was first observed. Adjusting tire pressures, vehicle load or
making other adjustments may reduce the conditions intensity to a point where it cannot be identified clearly. It may also inject
something new into the system, preventing correct diagnosis.
2.
3. Make a visual inspection as part of the preliminary diagnosis routine, writing down anything that does not look right. Note tire
pressures, but do not adjust them yet. Note leaking fluids, loose nuts and bolts, or bright spots where components may be rubbing
against each other. Check the luggage compartment for unusual loads.
3.
4. Road test the vehicle and define the condition by reproducing it several times during the road test. 4.
5. Carry out the Road Test Quick Checks as soon as the condition is reproduced. This will identify the correct diagnostic procedure.
Carry out the Road Test Quick Checks more than once to verify they are providing a valid result. Remember, the Road Test Quick
Checks may not tell where the concern is, but they will tell where it is not.
5.
Road Test Quick Checks
1. 24-80 km/h (15-50 mph): With light acceleration, a moaning noise is heard and possibly a vibration is felt in the front floor pan. It
is usually worse at a particular engine speed and at a particular throttle setting during acceleration at that speed. It may also
produce a moaning sound, depending on what component is causing it. Refer to Tip-In Moan in the Symptom Chart.
1.
2. Acceleration/Deceleration: With slow acceleration and deceleration, a shake is sometimes noticed in the steering wheel/column,
seats, front floor pan, front door trim panel or front end sheet metal. It is a low frequency vibration (around 9-15 cycles per
second). It may or may not be increased by applying brakes lightly. Refer to Idle Boom/Shake/Vibration in the Symptom Chart.
2.
3. High Speed: A vibration is felt in the front floor pan or seats with no visible shake, but with an accompanying sound or rumble,
buzz, hum, drone or booming noise. Coast with the clutch pedal depressed or shift control selector lever in neutral and engine
idling. If vibration is still evident, it may be related to wheels, tires, front disc brake discs, wheel hubs or front wheel bearings.
Refer to High Speed Shake in the Symptom Chart.
3.
4. Engine rpm Sensitive: A vibration is felt whenever the engine reaches a particular rpm. It will disappear in neutral coasts. The
vibration can be duplicated by operating the engine at the problem rpm while the vehicle is stationary. It can be caused by any
component, from the accessory drive belt to the clutch or torque converter which turns at engine speed when the vehicle is
stopped. Refer to High Speed Shake in the Symptom Chart.
4.
5. Noise and Vibration While Turning: Clicking, popping, or grinding noises may be due to the following: 5.
worn, damaged, or incorrectly installed front wheel bearing
worn, damaged or incorrectly installed half shaft.
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1
Road Conditions
An experienced technician will always establish a route that will be used for all NVH diagnosis road tests. The road selected should be
reasonably smooth, level and free of undulations (unless a particular condition needs to be identified). A smooth asphalt road that allows
driving over a range of speeds is best. Gravel or bumpy roads are unsuitable because of the additional road noise produced. Once the route
is established and consistently used, the road noise variable is eliminated from the test results.
NOTE: Some concerns may be apparent only on smooth asphalt roads.
If a customer complains of a noise or vibration on a particular road and only on a particular road, the source of the concern may be the road
surface. If possible, try to test the vehicle on the same type of road.
Vehicle Preparation
Carry out a thorough visual inspection of the vehicle before carrying out the road test. Note anything which is unusual. Do not repair or
adjust any condition until the road test is carried out, unless the vehicle is inoperative or the condition could pose a hazard to the
technician.
After verifying the condition has been corrected, make sure all components removed have been installed.
Lift Test
After a road test, it is sometimes useful to do a similar test on a lift.
When carrying out the high-speed shake diagnosis or engine accessory vibration diagnosis on a lift, observe the following precautions:
WARNING: If only one drive wheel is allowed to rotate, speed must be limited to 55 km/h (35 mph) indicated on the speedometer
since actual wheel speed will be twice that indicated on the speedometer. Speed exceeding 55 km/h (35 mph) or allowing the drive wheel to
hang unsupported could result in tire disintegration, differential failure, constant velocity joint and driveshaft failure, which could cause
serious personal injury and extensive vehicle damage. Failure to follow these instructions may result in personal injury.
CAUTION: The suspension should not be allowed to hang free. When the CV joint is run at a very high angle, extra vibration as well as
damage to the seals and joints can occur.
The suspension lower arms should be supported as far outboard as possible. To bring the vehicle to its correct ride height, the full weight of
the vehicle should be supported in the rear by floor jacks. For additional information, refer to
REFER to: Jacking (100-02 Jacking and Lifting, Description and Operation).
1. Raise and support the vehicle. For additional information, refer to
REFER to: Lifting (100-02 Jacking and Lifting, Description and Operation).
1.
2. Explore the speed range of interest using the Road Test Quick Checks as previously described. 2.
3. Carry out a coast down in neutral. If the vehicle is free of vibration when operating at a steady indicated speed and behaves very
differently in drive and coast, a transmission concern is likely.
3.
Note, however, that a test on the lift may produce different vibrations and noises than a road test because of the effect of the lift. It is not
unusual to find vibrations on the lift that were not found in the road test. If the condition found on the road can be duplicated on the lift,
carrying out experiments on the lift may save a great deal of time.
Symptom Chart
Symptom Possible Sources Action
High-speed shake Wheel end vibration
Engine/gearbox/transfer box
Driveline
GO to Pinpoint Test A.
Tip-in moan Air cleaner
Power steering (PS)
Powertrain
Engine mounts
Exhaust system
GO to Pointpoint Test B.
Idle boom/shake/vibration, or shudder Cable(s)/hoses(s)
Engine mounts
Exhaust system
Belt/pulleys
GO to Pinpoint Test C.
Wheel end vibration analysis Suspension/front or rear wheel drive half shaft and joints
Tires/wheels
Wheel bearings
Front or rear wheel drive half shaft joint boots
GO to Pinpoint Test D.
Non-axle noise Trim/mouldings
A/C system
Accessories
GO to Pinpoint Test E.
Pinpoint Tests
NOTE: These Pinpoint Tests are designed to take the technician through a step-by-step diagnosis procedure to determine the cause of a
condition. It may not always be necessary to follow the chart to its conclusion. Carry out only the Pinpoint Test steps necessary to correct
the condition. Then check operation of the system to make sure the condition is corrected.
After verifying that the condition has been corrected, make sure all components removed have been installed.
PINPOINT TEST A : HIGH-SPEED SHAKE
TEST CONDITIONS DETAILS/RESULTS/ACTIONS
A1: NEUTRAL COAST
Carry out the neutral coast test.
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Does the vibration disappear during the neutral coast test?
Yes
CHECK and INSTALL new engine/gearbox/transfer box mounts as necessary. REPEAT Road Test as outlined.
No
GO to D1.
PINPOINT TEST B : TIP-IN MOAN
TEST
CONDITIONS
DETAILS/RESULTS/ACTIONS
B1: CHECK THE AIR CLEANER
Check the air cleaner.
Check the air cleaner, inlet tube, outlet tube, resonators and all other components associated with the air
induction system for correct installation and tightness of all connections.
Are the components OK?
Yes
GO to B2.
No
CORRECT the condition. REPEAT the Road Test as outlined.
B2: CHECK THE EXHAUST SYSTEM
Carry out the exhaust system neutralizing procedure in this section.
Is the exhaust system OK?
Yes
GO to B3.
No
REPAIR as necessary. RESTORE vehicle. REPEAT the Road Test as outlined.
B3: CHECK THE POWER STEERING
Remove the auxiliary drive belt and test for tip-in moan.
Is the tip-in moan OK?
Yes
REPAIR the power steering as necessary. For additional information, refer to
REFER to: Power Steering Pump - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27 (211-02 Power Steering,
Removal and Installation).
No
PINPOINT TEST C : IDLE BOOM/SHAKE/VIBRATION/SHUDDER
TEST
CONDITIONS
C1: CHECK CABLE/HOSES
Check the engine compartment for any component that may be grounding between the engine and body or chassis.
Example: air conditioning (A/C) hoses.
Are the components OK?
Yes
GO to C2.
No
C2: CHECK THE DRIVER AIR BAG MODULE.
Remove the driver air bag module and visually inspect the for correct installation or any touch condition.
Is the driver air bag module OK?
Yes
GO to C3.
No
C3: CHECK THE COOLING RADIATOR
Check the engine cooling radiator mountings and bushings for security and condition. Check the radiator installation
for any component that may have a touch condition.
Are the installation and bushings OK?
Yes
GO to C4.
No
C4: CHECK THE EXHAUST SYSTEM
Carry out the exhaust system neutralizing procedure in this section.
Is the exhaust system OK?
Yes
No
REPAIR as necessary. REPEAT Road Test.
PINPOINT TEST D : WHEEL END VIBRATION ANALYSIS
D1: INSPECT THE TIRES
Inspect the tires.
Raise and support the vehicle. For additional information, refer to
inspect the tires for:
correct tire size
tire/wheel compatibility
wear or damage
tire beads correctly seated
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Are the tires OK?
Yes
GO to D2.
No
INSPECT the wheels. For additional information, refer to
REFER to: Wheels and Tires (204-04 Wheels and Tires, Diagnosis and Testing).
D2: INSPECT WHEEL BEARINGS
Inspect the wheel bearings. For additional information, refer to
REFER to: Wheel Bearing Inspection (204-00 Suspension System - General Information, General Procedures).
Are the wheel bearings OK?
Yes
GO to D3.
No
REPAIR as necessary. REPEAT the Road Test as outlined.
D3: INSPECT THE REAR WHEEL DRIVE HALF SHAFT JOINT BOOTS
Inspect the rear wheel drive half shaft joint boots.
spin the rear tire by hand
inspect for evidence of cracks, tears, splits or splattered grease
Are the rear wheel drive half shaft joint boots OK?
Yes
GO to D4.
No
D4: INSPECT THE FRONT WHEEL DRIVE HALF SHAFT JOINT BOOTS
Inspect the front wheel drive half shaft joint boots
spin the front tire by hand
inspect for evidence of cracks, tears, splits or splattered grease
Are the front wheel drive half shaft joint boots OK?
Yes
GO to D5.
No
REPAIR as necessary. REPEAT the Road Test as outllined.
D5: INSPECT WHEEL AND TIRE RUNOUT
Inspect the wheel and tire runout.
Carry out the Wheel and Tire Check procedure. For additional information, refer to
REFER to: Wheels and Tires (204-04 Wheels and Tires, Diagnosis and Testing).
Is the wheel and tire runout OK?
Yes
Balance the wheels and tires. Refer to the wheel balance equipment manufacturers instructions.
No
PINPOINT TEST E : NON-AXLE NOISE
TEST
CONDITIONS
E1: INSPECT VEHICLE TRIM
Check the grille and trim mouldings to see if they are the source of the noise.
Are the vehicle trim components causing the noise?
Yes
INSTALL new trim or REPAIR as necessary. For additional information, refer to
REFER to: Exterior Trim (501-08 Exterior Trim and Ornamentation, Description and Operation).
No
GO to E2.
E2: CHECK THE A/C SYSTEM FOR NOISE
Check the A/C system components for noise by turning the A/C system on and off.
Is the A/C system causing the noise?
Yes
Diagnose the A/C system. For additional information, refer to
REFER to: Climate Control System (412-00 Climate Control System - General Information, Diagnosis and Testing).
No
GO to E3.
E3: CHECK NON-FACTORY ACCESSORIES
Inspect any accessories for being the source of the noise. Example: grounding body-to-frame, antennas, visors, bug
deflectors and fog lights?
Are the accessories the cause of the noise?
Yes
ADJUST, REPAIR or INSTALL new accessories or fasteners as required.
No
Verify the customer concern
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Noise, Vibration and Harshness - Exhaust System Neutralizing
General Procedures
1. Loosen the muffler inlet pipe and resonator pipe to exhaust manifold
fasteners at the flanges and the muffler inlet connection.
2. Place a stand to support the muffler parallel to the vehicle frame with
the muffler pipe bracket free of stress.
3. Tighten the muffler connection.
4. Position the exhaust pipes to the manifolds and tighten. Make sure that
the catalytic converters and heat shields do not contact the frame rails.
5. With the complete exhaust system tight (and cooled) the rear hanger
insulator should be angled forward, to allow the system to expand
rearward when heated during normal running.
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Suspension System - General Information -
General Specifications
Item Specification
Clear Vision
Clear vision (negative value is counterclockwise) 0 3
Ride Height
Front 371 mm 15 mm
Rear 370 mm 15 mm
Ball Joint Radial Play
Lower ball joint maximum 0.8 mm
Wheel Alignment - Front
2001.50 MY onwards VIN - C00344 to Current
Item LH RH Split LH-RH
Castor Decimal degrees 2.25 0.75 2.25 0.75 0 0.75
Degrees/minutes 2 15' 45' 2 15' 45' 0 45'
Camber Decimal degrees -0.54 0.75 -0.54 0.75 0 0.75
Degrees/minutes -0 32' 45' -0 32' 45' 0 45'
Total toe Decimal degrees -0.1 0.20
Degrees/minutes -0 6' 12'
Wheel Alignment - Rear
2001.50 MY onwards VIN - C00344 to Current
Item LH RH
Camber Decimal degrees -0.70 0.75 -0.70 0.75
Degrees/minutes -0 42' 45' -0 42' 45'
Toe Decimal degrees 0.125 0.14 0.125 0.14
Degrees/minutes 0 8' 8' 0 8' 8'
Total toe Decimal degrees 0.25 0.20
Degrees/minutes 0 15' 12'
Rear thrust angle Decimal degrees 0 0.14
Degrees/minutes 0 8'
All the above figures are measured at "kerb" height -all fluids at full and a full fuel tank.
Tires must be inflated to normal pressure
For additional information, refer to: Specifications (204-04 Wheels and Tires, Specifications).
Rear thrust angle = (LH toe - RH toe) 2
Ride height is measured from the centre of the wheel to the apex of the wheel arch, through the wheel centre line.
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Suspension System - General Information - Wheel Alignment Angles
Toe is adjustable on the front and rear suspension system. The front toe is adjusted by use of the front tie-rod. The rear toe is adjusted by
the use of cam bolts in the lower control arm to the rear crossmember.
Toe
Positive Toe (Toe-In)
Negative Toe (Toe-Out)
The vehicle toe setting:
Affects tire wear and directional stability.
Ride Height
NOTE: All ride height measurements are carried out with vehicle empty and 9 litres of fuel in the tank (showroom condition).
Front Ride Height Measurement
Item Description
1 Front ride height measurement
Rear Ride Height Measurement
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Item Description
1 Rear ride height measurement
Wheel Track
Item Description
1 Front track
2 Rear track
Crabbing
Item Description
1 Front track
2 Rear track crabbing
Crabbing is the condition in which the independent rear suspension (IRS) system is not square to the chassis. Heavily crowned roads can
give the illusion of crabbing.
Wander
Wander is the tendency of the vehicle to require frequent, random left and right steering wheel corrections to maintain a straight path down
a level road.
Shimmy
Shimmy, as observed by the driver, is large, consistent, rotational oscillations of the steering wheel resulting from large, side-to-side
(lateral) tire/wheel movements.
Shimmy is usually experienced near 40 miles/hour (64 km/h), and can start or be amplified when the tire contacts pot holes or irregularities
in the road surface.
Nibble
Sometimes confused with shimmy, nibble is a condition resulting from tire interaction with various road surfaces and observed by the driver
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as small rotational oscillations of the steering wheel.
Poor Returnability of the Steering
Poor returnability of the steering is used to describe the poor return of the steeri ng wheel to center after a turn or the steering correction is
completed.
Drift/Pull
Pull is a tugging sensation, felt by the hands on the steering wheel, that must be overcome to keep the vehicle going straight.
Drift describes what a vehicle with this condition does with hands off the steering wheel.
A vehicle-related drift/pull, on a flat road, will cause a consistent deviation from the straight-ahead path and require constant
steering input in the opposite direction to counteract the effect.
Drift/pull may be induced by conditions external to the vehicle (i.e., wind, road crown).
Vague On-Center Feel
Vague on-center feel is characterized by little or no build up of turning effort felt in the steering wheel as the wheel is rocked slowly left
and right within very small turns around center or straight-ahead (under 20 degrees of steering wheel turn). Efforts may be said to be "flat
on center."
In the diagnosis of a road ability problem, it is important to understand the difference between wander and vague on-center feel.
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Suspension System - General Information - Suspension System
1. Verify the customer's concern by carrying out a road test on a smooth road. If any vibrations are apparent, refer to Section 100-04
Noise, Vibration and Harshness.
1.
Visual Inspection Chart
Mechanical
Damaged tires
Wheel bearing(s)
Loose or damaged front or rear suspension components
Loose, damaged or missing suspension retainer(s)
Incorrect spring usage
Damaged or sagging spring(s)
Damaged or leaking shock absorber(s)
Damaged or leaking strut(s)
Worn or damaged suspension bushing(s)
Loose, worn or damaged steering system components
Damaged axle components
3. If an obvious cause for an observed or reported condition is found, correct the cause (if possible) before proceeding to the next
step.
3.
4. If the fault is not visually evident, verify the symptom and refer to the following Symptom Chart. 4.
Symptom Chart
Crabbing Incorrect rear thrust angle. CHECK the rear subframe alignment. For additional information, refer toSection
502-00 Uni-Body, Subframe and Mounting System.
Front or rear suspension
components.
INSPECT the front and rear suspension systems. REPAIR or INSTALL new
suspension components as necessary. For additional information, refer toSection
204-01 Front Suspension orSection 204-02 Rear Suspension.
Drive axle damaged. INSTALL a new drive axle. For additional information, refer toSection 205-02 Rear
Drive Axle/Differential.
Drift/Pull Unequal tire pressure. CHECK and ADJUST the tire pressures. INSPECT the tire for excessive wear. For
additional information, refer to Section 204-04 Wheels and Tires.
Incorrect wheel alignment. CHECK and ADJUST the wheel alignment. For additional information, refer to Toe
AdjustmentFront in this section.
Tires. CHECK and ADJUST the tire pressures. INSPECT the tire for excessive wear. For
Unevenly loaded or overloaded
vehicle.
NOTIFY the customer of incorrect vehicle loading.
Damaged steering components. CHECK the steering system. For additional information, refer to Section 211-00
Steering System - General Information.
Brake drag. CHECK the brakes. For additional information, refer toSection 206-00 Brake
System - General Information.
Front Bottoming or
Riding Low
Spring(s). CHECK the ride height. INSTALL new springs as necessary. For additional
information, refer to Section 204-01 Front Suspension.
Incorrect Tire Wear Incorrect tire pressure (rapid
center rib or inner and outer
edge wear).
CHECK and ADJUST the tire pressure. INSPECT the tire for excessive wear. For
Excessive front or rear toe
(rapid inner or outer edge
wear).
CHECK and ADJUST the wheel alignment. For additional information, refer toToe
AdjustmentFront or Toe AdjustmentRear in this section.
Tires out of balance (tires
cupped or dished).
BALANCE the tires.
Rough Ride Spring(s). CHECK and INSTALL new springs as necessary. For additional information, refer
to Section 204-01 Front Suspension orSection 204-02 Rear Suspension.
Shock absorber(s). CHECK and INSTALL new shock absorbers as necessary. For additional
information, refer to Section 204-01 Front Suspension orSection 204-02 Rear
Suspension.
Shimmy or Wheel
Tramp
Loose wheel nut(s). CHECK and TIGHTEN the wheel nuts to specification. For additional information,
refer to Section 204-04 Wheels and Tires.
Loose front suspension
retainers.
CHECK and TIGHTEN the suspension retainers to specification. For additional
information, refer to Section 204-01 Front Suspension.
Front wheel bearing(s). CHECK the wheel bearings. For additional information, refer to Wheel Bearing
InspectionFront and Rear in this section.
Wheels/tires. CHECK the wheels/tires. BALANCE or INSTALL new wheels/tires as necessary. For
Suspension.
Spring(s). CHECK and INSTALL new springs as necessary. For additional information, refer
Loose, worn or damaged ball
joint(s).
CHECK the Ball Joint(s). For additional information, refer to Ball Joint inspection
in this section.
Loose, worn or damaged
steering components.
CHECK and INSTALL new components as necessary. For additional information,
refer to Section 211-00 Steering System - General Information.
Front wheel alignment. CHECK and ADJUST the front wheel alignment. For additional information, refer
to Toe AdjustmentFront in this section.
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* *
* *
* *
* *
* *
* *
* *
* *
* *
* *
* *
* *
* *
* *
* *
*
*
*
*
*
*
*
* *
* *
* *
* *
* *
* *
* *
Poor Returnability of
the steering.
Ball joints. CHECK the Ball Joint(s). For additional information, refer to Ball Joint inspection
in this section.
Steering components. CHECK and INSTALL new components as necessary. For additional information,
Steering wheel
off-center
Unequal front or rear toe
settings.
CHECK and ADJUST the wheel alignment. For additional information, refer toToe
AdjustmentFront or Toe AdjustmentRear in this section.
Steering components. CHECK and INSTALL new components as necessary. For additional information,
Sway or roll Overloaded, unevenly or
incorrectly loaded vehicle.
Loose wheel nut(s). CHECK and TIGHTEN the wheel nut(s) to specification. For additional
information, refer to Section 204-04 Wheels and Tires.
Suspension.
Loose front stabilizer bar or
rear stabilizer bar.
CHECK and TIGHTEN the stabilizer bar to specification. For additional
Suspension.
Worn lower suspension arm
stabilizer bar bushing.
INSTALL new lower suspension arm stabilizer bar bushing as necessary. For
additional information, refer to Section 204-01 Front Suspension orSection
204-02 Rear Suspension.
Vehicle Leans to One
Side
Unevenly loaded or overloaded
vehicle.
Front or rear suspension
components.
INSPECT the front and rear suspension systems. REPAIR or INSTALL new
suspension components as necessary. For additional information, refer toSection
204-01 Front Suspension orSection 204-02 Rear Suspension.
Suspension.
Incorrect ride height. Lateral
tilt out of specification.
CHECK the ride height. INSTALL new springs as necessary. For additional
Suspension.
Vibration/Noise Tires/wheels.
Wheel bearings.
Wheel hubs.
Brake components.
Suspension components.
Steering components.
CHECK and INSTALL new components as necessary. For additional information,
refer to Section 100-04 Noise, Vibration and Harshness.
Wander Unevenly loaded or overloaded
vehicle.
Ball joint(s). CHECK the Ball Joint(s). For additional information, refer to Ball Joint inspection
in this section.
Front wheel bearing(s). CHECK the wheel bearings. For additional information, refer to Wheel Bearing
InspectionFront and Rear in this section.
Loose, worn or damaged
suspension components.
CHECK and INSTALL new suspension components as necessary. For additional
Suspension.
Loose suspension retainers. CHECK and TIGHTEN the suspension retainers to specification. For additional
Suspension.
Steering components. CHECK and INSTALL new steering components. For additional information, refer
toSection 211-00 Steering System - General Information.
Wheel alignment (excessive
total front toe-out).
CHECK and ADJUST the front wheel alignment. For additional information, refer
to Toe AdjustmentFront in this section.
Component Tests
Ball Joint Inspection
1. Raise and support the vehicle. For additional information, refer toSection 100-02 Jacking and Lifting. 1.
2. Prior to carrying out any inspection of the ball joints, inspect the wheel bearings. For additional information, refer to Wheel
Bearing InspectionFront and Rear.
2.
3. Position a safety stand beneath the jacking point to test the lower arm. 3.
4. While an assistant pulls and pushes the top and bottom of the tire, observe the relative movement between the ball joint and the
suspension lower arm. Any movement at or exceeding the specification indicates a worn or damaged ball joint.Install a new lower
arm as necessary. For additional information, refer toSection 204-01 Front Suspension orSection 204-02 Rear Suspension.
4.
5. Remove the safety stand. 5.
6. Lower the vehicle. 6.
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Suspension System - General Information - Front Toe Adjustment
General Procedures
NOTE: The checking and subsequent adjustment of the front toe setting should be carried out on a flat surface and in accordance with the
manufactures instructions for the wheel alignment equipment used.
1. Start the engine and centralize the steering wheel.
2. Turn the engine off, and hold the steering wheel in the 'straight ahead'
position by attaching a rigid link from the steering wheel to the brake
pedal.
3. Using suitable four wheel alignment equipment, check the toe setting.
4. NOTE: Right-hand shown, left-hand similar.
Loosen the tie rod end locknuts.
Reposition the steering gear boot outer clamps.
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Rotate the tie-rods an equal amount in either a clockwise or a
counterclockwise direction to adjust the toe setting.
Tighten the tie-rod end locknuts.
Tighten to 40 Nm.
Reposition the steering gear boot outer clamps.
9. Check the toe setting.
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Suspension System - General Information - Rear Toe Adjustment
General Procedures
NOTE: The checking and subsequent adjustment of the rear toe setting should be carried out on a flat surface and in accordance with the
manufactures instructions for the wheel alignment equipment used.
1. NOTE: Final tightening of the rear suspension components should be
carried out when the vehicle weight is on the road wheels.
Using suitable four wheel alignment equipment, check the toe setting.
2. Raise and support the vehicle.
For additional information, refer to Section 100-02 Jacking and Lifting.
3. NOTE: Left-hand shown, right-hand similar.
Loosen the rear lower arm cam bolt nuts.
4. Rotate the the cam bolts equal amounts, in either a clockwise or a
counterclockwise direction, to adjust the toe setting.
5. CAUTION: The final tightening of the suspension components
should be carried out with the vehicle on its wheels. Failure to follow this
instruction may result in damage to the vehicle.
NOTE: Left-hand shown, right-hand similar.
Tighten the rear lower arm cam bolt nuts.
6. Lower the vehicle.
Bounce the vehicle to make sure that the suspension is in its
normal resting position.
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Tighten the rear lower arm cam bolt nuts.
Tighten to 115 Nm.
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Suspension System - General Information - Wheel Bearing Inspection
General Procedures
Section 100-02 Jacking and Lifting .
2. NOTE: Make sure the wheel rotates freely and the brake pads are
retracted sufficiently to allow movement of the wheel and tire.
Firmly hold the tire at the top and bottom and move the wheel inward
and outward while lifting the weight of the wheel and tire off the wheel
bearing.
3. If the wheel and tire is loose on the wheel hub assembly or does not
rotate freely, install a new front or rear wheel bearing as necessary. For
additional information, refer to Section 204-01 Front Suspension or
Section 204-02 Rear Suspension .
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Front Suspension -
Description Nm lb-ft lb-in
Lower arm front retaining bolt A A A
Lower arm rear retaining nut and bolt A A A
Lower arm ball joint retaining nut and bolt 83 61 -
Stabilizer bar to link bar retaining nuts 48 35 -
Stabilizer bar to subframe retaining bolts 48 35 -
Strut top mount retaining nuts 25 18 -
Subframe front mount retaining bolts 142 105 -
Subframe rear mount retaining bolts 142 105 -
Subframe reinforcement plate retaining bolts (M8) 35 26 -
Subframe reinforcement plate retaining bolts (M10) 70 52 -
Engine roll restrictor to engine retaining bolt 80 59 -
Wheel knuckle pinch bolt 85 63 -
Wheel hub retaining nut 270 200 -
Steering column lower retaining bolt 25 18 -
A = refer to the procedure for the correct torque sequence
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Front Suspension - Front Suspension
1 Front subframe mounting bush
2 Stabilizer bar
3 Stabilizer link bar
4 Suspension strut anti slip fin
5 Suspension strut spring
6 Wheel knuckle
7 Wheel hub bearing
8 Wheel hub
9 Lower arm
10 Ball joint heat shield
11 Subframe
The front suspension consists of two strut and spring assemblies and a subframe, attached to which are the lower arms and the stabilizer
bar.
The lower arm is of a pressed steel, fabricated construction which is attached to the subframe by bolts through horizontal and vertical
bushings. The lower arm also carries a ball joint that attaches the lower arm to the wheel knuckle. Each wheel knuckle mounts the halfshaft
in a double groove ball bearing which is secured on both sides by a snap ring.
The wheel knuckle also mounts to the strut and tie-rod end.
The stabilizer bar consists of a transverse bar with two ball jointed link bars.
The strut and spring assembly is supported from its upper mounting by a rubber insul ator fitted to the strut top mount. A coil spring is
located between two seats on the strut. A plastic shield is fitted around the piston to prevent dirt and water ingress. A rubber bump stop is
also fitted to protect the strut at its fully compressed condition.
As the road wheel rises, the movement is transmitted to the wheel knuckle, then through the ball joints to the lower arms and the strut and
spring assembly. The spring absorbs the shock and the damper damps any unwanted spri ng frequencies, which could lead to an unstable
vehicle.
A stabilizer bar is mounted via clamps and bushes to the front subframe and is connected via link bars to each of the strut and spring
assemblies.
When cornering, weight is naturally transferred to the outer wheel and there is a natural tendency for the inner wheel to lift. The stabilizer
bar helps to minimize this by transferring some of the apparent rise of outer wheel to the inner wheel through the link bars to the strut and
spring assemblies. This helps to provide a smoother ride.
Strut and Spring Assembly
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1 Spring assembly
2 Thrust bearing
3 Strut and spring top mount
4 Spring isolator
5 Bump stop
6 Damper piston gaiter
7 Damper assembly
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Front Suspension - Front Suspension
For additional information, refer to Section 204-00 Suspension System - General Information
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Front Suspension - Lower Arm
Special Tool(s)
Separator, Ball Joint
204-192 (JD-219)
Powertrain Assembly Jack
HTJ1200-2
Removal
All vehicles
1. Position the front wheels in a straight ahead position and centralize the
steering wheel.
Lock in position and remove the ignition key.
2. Detach the steering column.
Remove and discard the steering column lower retaining bolt.
3. Remove the front wheel and tire.
For additional information, refer to: Wheel and Tire (204-04 Wheels and
Tires, Removal and Installation).
4. Remove the wheel arch liner access cover.
5. Remove both the tie-rod end retaining nuts.
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6. NOTE: When the tie-rod end is separated from the wheel hub assembly,
the ball joint seal should be protected to prevent damage.
Using the special tool, detach the tie-rod end.
Vehicles with high intensity discharge headlamps
7. Detach the link rod from the headlamp leveling sensor.
All vehicles
8. Detach the steering gear supply pipe.
Vehicles with automatic transmission
9. Detach the selector lever cable.
All vehicles
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10. Install the special tool.
Position and adjust the special tool rear height adjuster.
Remove the front subframe reinforcement plate retaining bolts.
Remove the front subframe rear mount retaining bolts.
14. WARNING: Rotate the special tool height adjustment valve
slowly. Failure to follow this instruction may result in personal injury.
Using the special tool, lower the front subframe to a maximum of 50 mm
(1.97 inches).
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15. CAUTION: To prevent damage to the lower arm bushing, make
sure the subframe is lowered before detaching the lower arm ball joint.
Failure to follow this instruction may result in damage to the vehicle.
Detach the lower arm from the wheel knuckle.
1. Remove the lower arm ball joint retaining nut and bolt.
2. Reposition the lower arm.
3. Reposition the wheel knuckle.
16. Remove and discard the lower arm front retaining bolt.
17. Remove and discard the lower arm retaining nut.
19. Remove the lower arm.
Remove and discard the lower arm rear retaining bolt.
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Installation
All vehicles
1. Install the lower arm.
Install a new lower arm rear retaining bolt.
3. NOTE: Install a new retaining bolt.
Loosely install the lower arm front retaining bolt.
4. NOTE: Install a new retaining nut.
Attach the wheel knuckle.
2. Attach the wheel knuckle.
3. Install the lower arm ball joint retaining nut and bolt.
Tighten to 83 Nm.
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5. Using the special tool raise the front subframe.
Loosely install the front subframe rear mount retaining bolts.
Loosely install the front subframe reinforcement plate retaining bolts.
Tighten to 142 Nm.
Tighten the front subframe reinforcement bolts.
M8 to 35 Nm.
M10 to 70 Nm.
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10. Remove the special tool.
11. Attach the selector lever cable.
All vehicles
12. Attach the steering gear supply pipe.
13. Attach the link rod to the headlamp leveling sensor.
All vehicles
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Attach both the tie-rod ends.
Tighten to 35 Nm.
15. Install the right-hand wheel arch liner access cover.
16. Install the front wheels and tires.
Attach the steering column.
Install a new steering column lower retaining bolt.
Tighten to 25 Nm.
19. CAUTION: The final tightening of the lower arm front retaining
bolt, must be carried out with the vehicle on its wheels. Failure to follow
this instruction may result in damage to the vehicle.
NOTE: Right-hand shown, left-hand similar.
Fully tighten the lower arm front retaining bolt.
Stage 1: Tighten to 90 Nm.
Stage 2: Tighten 60 degrees.
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20. CAUTION: The final tightening of the lower arm rear retaining nut
and bolt, must be carried out with the vehicle on its wheels. Failure to
follow this instruction may result in damage to the vehicle.
Fully tighten the lower arm rear retaining nut and bolt.
21. Using the Jaguar approved diagnostic system, configure the steering
angle sensor.
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Front Suspension - Shock Absorber and Spring Assembly
Special Tool(s)
Separator, Ball Joint
204-192 (JD-219)
HTJ1200-2
Wheel hub puller
205-491
Adapter nuts
205-491-01
Forcing screw
204-269
Knuckle splitter
204-159
Removal
All vehicles
1. Loosen the wheel hub nut.
2. Remove the wheel and tire.
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3. Detach the brake hose retaining bracket.
4. Detach the stabilizer link bar.
5. Disconnect the front wheel speed sensor electrical connector.
6. CAUTION: Secure the brake caliper and anchor plate assembly to
one side.
Remove the brake caliper and anchor plate assembly.
7. Remove the tie-rod end retaining nut.
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All vehicles
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14. Using the special tool, lower the front subframe to a maximum of 30
mm (1.18 inches).
15. Remove and discard the wheel hub nut.
16. Using special tools, detach the halfshaft.
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Detach the wheel knuckle.
3. Detach the wheel knuckle from the halfshaft.
1. Remove and discard the lower arm ball joint shield.
18. Remove the wheel knuckle pinch bolt.
19. Using the special tool, remove the wheel knuckle.
Using the special tool, spread the wheel knuckle.
Remove the wheel knuckle.
20. NOTE: Note the orientation of the retaining stud marked with a paint
spot.
Remove the strut and spring assembly.
Installation
All vehicles
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1. NOTE: Make sure orientation arrow on the strut top rubber mount faces
from front to rear of the vehicle.
NOTE: Make sure the retaining stud marked with a paint spot is correctly
orientated.
Install the strut and spring assembly.
Tighten to 25 Nm.
2. Using the special tool, install the wheel knuckle.
3. Install the wheel knuckle pinch bolt.
Tighten to 85 Nm.
NOTE: Install a new lower arm ball joint shield.
2. Attach the wheel knuckle to the halfshaft.
Tighten to 83 Nm.
5. Loosely install the new wheel hub nut.
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Tighten the front subframe rear mount retaining bolts.
Tighten to 142 Nm.
M8 to 35 Nm.
M10 to 70 Nm.
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All vehicles
13. Attach the tie-rod end.
Tighten to 35 Nm.
14. Attach the brake caliper and anchor plate assembly.
Tighten to 133 Nm.
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15. Connect the front wheel speed sensor electrical connector.
16. Attach the stabilizer link bar.
Tighten to 48 Nm.
17. Attach the brake hose retaining bracket.
Tighten to 48 Nm.
18. Install the wheel and tire.
19. Tighten the wheel hub nut.
Tighten to 330 Nm. J
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Front Suspension - Front Stabilizer Bar
Removal
1. NOTE: Make sure the road wheels are in the straight ahead position.
Centralize the steering and lock it in position.
2. Remove the steering column lower retaining bolt.
3. Remove the front subframe. For additional information, refer toSection
4. Remove the stabilizer bar.
Installation
1. NOTE: Install new stablizer bar bushes when replacing the stablizer bar.
To install, reverse the removal procedure.
2. Tighten to 48 Nm.
3. Carry out front subframe alignment. For additional information, refer
toSection 502-00 Uni-Body, Subframe and Mounting System.
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Front Suspension - Front Stabilizer Bar Bushing
Special Tool(s)
Powertrain assembly jack
HTJ1200-02
Removal
All vehicles
1. Center the steering wheel.
Remove and discard the extension shaft lower retaining bolt.
3. Remove the front wheels and tires.
Vehicles with diesel engine
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Remove the wheel arch liner access panel.
6. Remove the air deflector.
For additional information, refer to: Air Deflector - 2.0L Duratorq-
TDCi/2.2L Duratorq-TDCi (110kW/150PS) - Puma (501-02 Front End Body
Panels, Removal and Installation).
All vehicles
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Using the special tool, lower the rear of the front subframe to a
maximum of 50 mm (1.97 inches).
Remove the stabilizer bar bush retaining bracket.
Remove the retaining bolts.
Remove the stabilizer bar bush.
Installation
All vehicles
Install the stabilizer bar bush.
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Install the stabilizer bar bush retaining bracket.
Tighten the retaining bolts to 48 Nm.
3. Using the special tool, raise the rear of the front subframe.
Tighten to 142 Nm.
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7. Tighten the front subframe reinforcement bolts.
M8 to 35 Nm.
M10 to 70 Nm.
9. Install the air deflector.
Install the wheel arch liner access panel.
All vehicles
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Tighten to 25 Nm.
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Front Suspension - Front Wheel Bearing and Wheel Hub
Special Tool(s)
Front hub carrier support
204-310
Hub flange remover
204-116-03
Bearing remover
204-262
Hub carrier support
204-309
Bearing support
204-313
Bearing guide
204-312
Bearing installer
204-311
Bearing receiver
501-063
Removal
1. Remove wheel knuckle. For additional information refer to, Wheel
Knuckle.
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2. NOTE: When removing the wheel hub from the wheel knuckle the
bearing will be destroyed and the bearing inner ring will remain on the
wheel hub.
Using special tools, remove the wheel hub.
3. Using a suitable tool, remove the bearing inner ring.
4. Using special tools, remove the wheel bearing.
Installation
1. NOTE: Insert special tool 204-312 in to 204-309.
Support the wheel knuckle on special tools.
2. CAUTION: Make sure wheel bearing is correctly orientated with the
colored side facing inboard.
Align the bearing over special tool.
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3. Using special tools, press bearing into wheel knuckle.
4. NOTE: Change special tool 204-312 to 204-313.
Align the bearing and wheel knuckle over special tool.
5. Slide wheel hub over the guide and align to the bearing.
6. Using special tools install the wheel hub.
7. Install the wheel knuckle. For additional information, refer to Wheel
Knuckle.
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Front Suspension - Wheel Knuckle
Special Tool(s)
Ball joint splitter
204-192
Wheel hub puller
205-491
Adapter nuts
205-491-01
Forcing screw
204-269
Knuckle splitter
204-159
Removal
3. CAUTION: Secure the brake caliper anchor plate assembly to one
side.
Remove the brake caliper and anchor plate assembly.
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4. CAUTION: Only one side of the subframe needs to be lowered to
detach the lower arm ball joint.
5. Loosen the front subframe rear mount retaining bolt.
6. Loosen the front subframe front mount retaining bolt.
Detach the wheel knuckle.
3. Detach the wheel knuckle.
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9. Using the special tools, detach the halfshaft.
10. Remove the wheel knuckle pinch bolt.
11. Remove the wheel knuckle.
1. Using the special tool, spread the wheel knuckle.
Installation
1. Attach the wheel knuckle to the strut and spring assembly.
1. Using the special tool, spread the wheel knuckle.
Tighten to 85 Nm.
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3. Attach the lower arm ball joint retaining nut and bolt.
3. Tighten the front subframe front mount retaining bolt.
Tighten to 142 Nm.
4. Loosely install the subframe rear mount retaining bolt.
5. Tighten the front subframe reinforcement plate retaining bolts.
Tighten to 35 Nm.
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7. Attach the brake caliper and anchor plate assembly.
8. Attach the stabilizer bar connecting link.
Tighten to 48 Nm.
9. Attach the brake hose retaining bracket.
Tighten to 48 Nm.
10. Install the new wheel hub nut.
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Tighten to 270 Nm.
13. Carry out front subframe alignment procedure.
For additional information, refer to: Underbody Misalignment Check
(502-00 Uni-Body, Subframe and Mounting System, General Procedures).
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Front Suspension - Shock Absorber and Spring Assembly
Special Tool(s)
Spring coil compressor
204-112
Spring adapters
204-167-01
Spring adapters
204-112-03
Disassembly
1. Remove the shock absorber and spring assembly.
For additional information, refer to: Shock Absorber and Spring Assembly
(204-01 Front Suspension, Removal and Installation).
2. WARNING: AS THE SPRING IS UNDER EXTREME TENSION CARE
MUST BE TAKEN AT ALL TIMES. FAILURE TO FOLLOW THESE
INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
Using the special tools, compress the spring.
3. Loosen the thrust bearing retaining nut.
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4. Disassemble the shock absorber and spring assembly.
1. Remove the thrust bearing nut.
2. Remove the spacer.
3. Remove the top mount.
4. Remove the thrust bearing.
5. Remove the spring seat.
6. Remove the spring.
7. Remove the bump stop.
8. Remove the gaiter.
9. Remove the shock absorber.
Assembly
CAUTION: Make sure the spring locates correctly against the spring seats
1. To assemble, reverse the disassembly procedure.
Tighten to 47 Nm.
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Rear Suspension -
Front lower arm to wheel knuckle retaining bolt 124 91 -
Front lower arm to subframe retaining bolt 124 91 -
Rear lower arm to wheel knuckle retaining bolt 124 91 -
Rear lower arm to subframe retaining bolt 124 91 -
Upper arm to wheel knuckle retaining bolt 124 91 -
Upper arm to subframe retaining bolt 124 91 -
Wheel knuckle to mounting bracket retaining nut* 115 85 -
Wheel knuckle mounting bracket to body retaining bolts 126 93 -
Wheel hub to wheel knuckle retaining bolts 63 46 -
Rear halfshaft to wheel hub retaining nut 270 200 -
Damper to wheel knuckle retaining bolt** 103 76 -
Damper to body retaining bolts 25 18 -
Stabilizer bar to subframe retaining bolts*** 20 15 -
Stabilizer bar link arm to rear lower arm retaining nut 35 26 -
*If you are re-using this fixing on a vehicle built prior to VIN J29473, then tighten to 130 Nm. If you are replacing a fixing on any vehicle,
then you must replace both nut and bolt and tighten to 115 Nm.
**If you are re-using this fixing on a vehicle built prior to VIN J24254, then tighten to 130 Nm. If you are replacing a fixing on any vehicle,
***If you are re-using this fixing on a vehicle built prior to VIN J24259, then tighten to 25 Nm. If you are replacing a fixing on any vehicle,
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Rear Suspension - Rear Suspension
1 Wheel knuckle mounting bracket
2 Subframe mount bushing
3 Upper arm
4 Shock absorber
5 Spring
6 Front lower arm
7 Stabilizer bar link
8 Subframe
9 Stabilizer bar
10 Rear lower arm
11 Wheel hub
12 Wheel knuckle
The independent rear suspension features an upper arm and front and rear lower arms which attach to the wheel knuckle. The rear lower
arm carries the spring and is used to adjust the rear wheel alignment.
Components
The wheel knuckle:
carries the wheel hub.
carries the brake caliper assembly.
carries the Anti-lock brake (ABS) sensor.
The wheel hub:
carries the brake disc.
is not a servicable item.
The stabilizer bar link:
is of a steel construction with a link at each end.
transmits vertical movements of the rear suspension to the stabilizer bar.
The stabilizer bar:
is mounted on the subframe.
is connected to the left-hand and right-hand rear lower arms by the stabilizer bar links.
is fitted to all models with or without sports suspension.
The upper arm:
is a one piece steel forging and incorporates rubber bushes with steel inserts at both ends.
is the upper support for the wheel knuckle.
The front lower arm:
is of a tubular steel design and incorporates a rubber bush with a steel insert at one end.
is the front lower support for the wheel knuckle.
The rear lower arm:
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is of a steel design and has cam bolts at the subframe mounting points to adjust wheel alignment.
is the rear lower support for the wheel knuckle.
carries the road spring.
is used to adjust the rear wheel alignment
Bushings:
are a moulded construction with aluminium inserts.
are incorporated within the subframe to isolate noise and vibrations.
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Rear Suspension - Rear Suspension
For additional information, refer toSection 204-00 Suspension System - General Information.
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Rear Suspension - Damper
Removal
For additional information, refer to: Lifting (100-02 Jacking and Lifting,
Description and Operation).
2. Detach the damper.
3. Remove the damper.
Installation
NOTE: The final tightening of the rear suspension components must be carried out with the vehicle on its wheels.
1. Install the damper.
2. Attach the damper.
NOTE: Carry out final tightening of the rear suspension components.
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Rear Suspension - Front Lower Arm4-Door
Removal
2. Detach the front lower arm.
3. Remove the front lower arm.
Installation
1. Install the front lower arm.
2. Attach the front lower arm.
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Rear Suspension - Front Lower ArmWagon
Removal
All vehicles
Vehicles with 2.0L engine
2. Remove the fuel tank protection bracket retaining bolt.
3. Remove the fuel tank protection bracket retaining bolt.
4. Reposition the fuel tank protection bracket.
Loosen the fuel tank protection bracket retaining bolt.
All vehicles
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6. Remove the front lower arm.
Installation
All vehicles
2. Attach the front lower arm.
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3. Loosely install the fuel tank protection bracket retaining bolt.
4. Using a suitable torx adaptor, 10 mm combination spanner and 3/8
drive torque wrench, install the fuel tank protection bracket retaining
bolt.
5. Using the torx adaptor, 10 mm combination spanner and 3/8 drive
torque wrench, tighten the fuel tank protection bracket retaining bolt.
To make sure the fuel tank protection bracket retaining bolt is
torqued to the correct specification, the following calculation steps
must be followed.
1. Step 1. Multiply 25 Nm by the effective length of the torque
wrench (1).
2. Step 2. Add the effective length of the special tool (2) to the
effective length of the torque wrench (1).
3. Step 3. Divide the total of step 1 by the total of step 2.
4. Step 4. Set the torque wrench to the figure arrived at in step 3.
Tighten the fuel tank protection bracket retaining bolt to the torque
given by the calculation.
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6. Using a suitable torx adaptor, 10 mm combination spanner and 3/8
drive torque wrench, install the fuel tank protection bracket retaining
bolt.
7. Using the torx adaptor, 10 mm combination spanner and 3/8 drive
torque wrench, tighten the fuel tank protection bracket retaining bolt.
To make sure the fuel tank protection bracket retaining bolt is
torqued to the correct specification, the following calculation steps
must be followed.
wrench (1).
Tighten the fuel tank protection bracket retaining bolt to the torque
given by the calculation.
All vehicles
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Rear Suspension - Rear Lower Arm
Removal
1. Remove the rear wheel and tire.
2. Using suitable tie straps, secure the spring to the subframe.
3. CAUTION: Make sure that excessive strain is not placed on the
rear lower arm.
Using a suitable transmission jack, support the rear lower arm.
4. Detach the stabilizer bar link.
5. Detach the rear lower arm.
6. CAUTION: Carefully lower the transmission jack.
Remove the rear lower arm.
Installation
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1. Install the rear lower arm.
2. Attach the rear lower arm.
3. Attach the stabilizer bar link.
4. Install the rear wheel and tire.
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8. Check the wheel alignment and adjust as necessary.
For additional information, refer to: Wheel Alignment Angles (204-00
Suspension System - General Information, Description and Operation).
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Rear Suspension - Spring
Removal
2. Using suitable tie straps, secure the spring to the subframe.
rear lower arm.
Loosen the rear lower arm from the subframe.
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7. Remove the spring.
Remove the isolator.
Installation
1. Install the spring.
Install the isolator.
2. Attach the rear lower arm.
3. Attach the anti roll bar link.
4. Install the wheel rear wheel and tire.
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Rear Suspension - Rear Stabilizer Bar
Removal
Section 100-02 Jacking and Lifting.
2. Detach the stabilizer bar links.
Right-hand shown, left-hand similar.
3. Remove the stabilizer bar.
Installation
1. To install, reverse the removal procedure.
Tighten to 25 Nm.
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Rear Suspension - Rear Stabilizer Bar Link
Removal
3. Remove the stabilizer bar link.
Installation
1. CAUTION: Make sure rubber boot does not twist while tightening.
Tighten to 50 Nm.
Tighten to 35 Nm.
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Rear Suspension - Upper Arm
Removal
2. Detach the upper arm.
3. Remove the upper arm.
Installation
1. Install the upper arm.
2. Attach the upper arm.
3. Install the wheel and tire assembly.
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Rear Suspension - Wheel Hub
Special Tool(s)
Puller, Wheel hub remover
205-491
Forcing Screw, Wheel hub remover
204-269
Adaptor Nuts, Wheel hub remover
205-491-01
Removal
All vehicles
1. Remove the rear brake disc.
For additional information, refer to: Brake Disc (206-04 Rear Disc Brake,
Vehicles with 2.5L or 3.0L engine
2. Remove and discard the rear halfshaft retaining nut.
3. Remove the wheel hub retaining bolts.
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4. Using the special tools, remove the wheel hub.
5. CAUTION: Failure to follow this procedure may result in damage to
the anti-lock brake system (ABS) components.
Disconnect the anti-lock brake system (ABS) sensor electrical connector.
6. Remove the wheel hub.
7. Remove the (ABS) sensor.
Remove the retaining bolt.
Installation
All vehicles
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1. Install the wheel hub.
Tighten to 63 Nm.
2. Install a new rear halfshaft retaining nut.
Tighten to 270 Nm.
3. Install the (ABS) sensor.
Tighten to 7 Nm.
4. Reconnect the (ABS) sensor electrical connector.
All vehicles
5. Install the rear brake disc.
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Rear Suspension - Wheel Knuckle
Removal
1. Remove the wheel hub.
For additional information, refer to: Wheel Hub (204-02, Removal and
Installation).
2. Remove the anti-lock brake system (ABS) wheel speed sensor wiring
harness retaining strap.
3. Detach the ABS wheel speed sensor wiring harness.
4. Detach the parking brake cable and conduit.
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7. Detach the upper arm.
lower arm.
10. Detach the wheel knuckle mounting bracket.
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Detach the rear lower arm.
12. CAUTION: Make sure correct position of the mounting bracket is
noted before removal.
Remove the wheel knuckle mounting bracket.
Installation
1. CAUTION: Make sure the mounting bracket is installed in the
correct position.
Install the wheel knuckle mounting bracket.
Tighten to 130 Nm.
2. Install the wheel knuckle.
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3. Attach the wheel knuckle mounting bracket.
5. Attach the upper arm.
6. Attach the damper.
7. Attach the parking brake cable and conduit.
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8. Attach the parking brake cable and conduit.
9. Attach the ABS wheel speed sensor wiring harness.
10. Install a new ABS wheel speed sensor wiring harness retaining strap.
11. Install the wheel hub.
For additional information, refer to: Wheel Hub (204-02, Removal and
Installation).
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Note: If you are re-using this fixing on a vehicle built prior to VIN
J29472, then tighten to 130 Nm. If you are replacing a fixing on
any vehicle, then you must replace both nut and bolt and tighten to
115 Nm.
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Rear Suspension - Wheel Knuckle Front Bushing
Special Tool(s)
Support Cup, Rear wheel knuckle front bush
204-300
Remover, Rear wheel knuckle front bush
204-301
Installer, Rear wheel knuckle front bush
204-302
Removal
1. Remove the wheel knuckle. For additional information, refer to For
additional information, refer to: Wheel Knuckle (204-02, Removal and
Installation)..
2. Using the special tools, remove the wheel knuckle front bushing.
Installation
1. Using the special tools, install the wheel knuckle front bushing.
2. Install the wheel knuckle. For additional information, refer to For
additional information, refer to: Wheel Knuckle (204-02, Removal and
Installation)..
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Rear Suspension - Wheel Knuckle Rear Bushing
Special Tool(s)
Forcing Screw, Rear Wheel Knuckle Rear Bush
204-246
Support Cup, Rear Wheel Knuckle Rear Bush
204-296
Remover, Rear Wheel Knuckle Rear Bush
204-298
Installer, Rear Wheel Knuckle Rear Bush
204-297
Removal
lower arm.
Using a suitable transmission stand, support the rear lower arm.
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Using the special tools, remove the wheel knuckle rear bushing.
Installation
1. Using the special tools, install the wheel knuckle rear bushing.
Align the bushing horizontally.
2. CAUTION: Carefully raise the transmission jack.
Attach the rear lower arm.
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3. Attach the stabilizer bar link.
4. Install the rear wheel and tire.
Suspension System - General Information, Description and Operation). J
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Wheels and Tires -
Tire Pressures
Wheel Size Tire Size Tire Manufacturer Rim Engine
Comfort Normal
Front Rear Front Rear
16" 205/55 R16
91 V
Pirelli P6000 6.5Jx162.0L 2.07 bar (30
lbf/in)
2.07 bar (30
lbf/in)
2.41 bar (35
lbf/in)
2.21 bar (32
lbf/in)
2.5L and 3.0L 2.21 bar (32
lbf/in)
2.21 bar (32
lbf/in)
2.62 bar (38
lbf/in)
2.41 bar (35
lbf/in)
2.0L and 2.2L
Diesel
2.21 bar (32
lbf/in)
2.07 bar (30
lbf/in)
2.41 bar (35
lbf/in)
2.21 bar (32
lbf/in)
205/55 R16
91 H
Continental CH95 6.5Jx162.5L and 3.0L 2.21 bar (32
lbf/in)
2.21 bar (32
lbf/in)
2.62 bar (38
lbf/in)
2.41 bar (35
lbf/in)
17" 225/45 R17
91 Y
Pirelli P Zero 7Jx17 2.5L and 3.0L 2.07 bar (30
lbf/in)
2.07 bar (30
lbf/in)
2.62 bar (38
lbf/in)
2.41 bar (35
lbf/in)
2.0L and 2.2L
Diesel
2.21 bar (32
lbf/in)
2.07 bar (30
lbf/in)
2.48 bar (36
lbf/in)
2.34 bar (34
lbf/in)
225/45 R17
91 H
Continental CH95 7Jx17 2.5L and 3.0L 2.07 bar (30
lbf/in)
2.07 bar (30
lbf/in)
2.62 bar (38
lbf/in)
2.41 bar (35
lbf/in)
225/45 R17
94 W
Continental
SportContact
7Jx17 2.5L and 3.0L 2.34 bar (34
lbf/in)
2.34 bar (34
lbf/in)
2.62 bar (38
lbf/in)
2.41 bar (35
lbf/in)
2.0L and 2.2L
Diesel
2.34 bar (34
lbf/in)
2.34 bar (34
lbf/in)
2.62 bar (38
lbf/in)
2.41 bar (35
lbf/in)
205/50 R17
93 Y
Pirelli P Zero Rosso 7Jx17 2.0L 2.34 bar (34
lbf/in)
2.34 bar (34
lbf/in)
2.48 bar (36
lbf/in)
2.34 bar (34
lbf/in)
18" 225/40 R18
92 Y
Pirelli P Zero Nero 7.5x18 2.0L 2.34 bar (34
lbf/in)
2.21 bar (32
lbf/in)
2.62 bar (38
lbf/in)
2.41 bar (35
lbf/in)
2.5L and 3.0L 2.48 bar (36
lbf/in)
2.34 bar (34
lbf/in)
2.76 bar (40
lbf/in)
2.41 bar (35
lbf/in)
2.0L and 2.2L
Diesel
2.34 bar (34
lbf/in)
2.21 bar (32
lbf/in)
2.62 bar (38
lbf/in)
2.41 bar (35
lbf/in)
16" (temporary use
spare wheel)
T125/85 R16
99 M
Pirelli 4Jx16 All Variants 4.14 bar (60 ibf/in)
Wheel nuts - Vehicles with steel wheels 80 59 -
Wheel nuts - Vehicles with aluminium wheels 103 76 -
Tire Specification
Tire Manufacturer Tire Size
Pirelli P6000 Powergy 205/55R16 91V
Continental CH95 205/55R16 91 H
Continental SportContact 225/45R17 94W
Pirelli P-Zero 225/45R17 91 Y
Continental CH95 225/45 R17 91 H
Pirelli P-Zero Rosso 205/50R17 93 Y
Pirelli P-Zero Nero 225/40R18 92 Y
Pirelli (Spare Tire) T125/85R16 99 M
Winter Tire Specification
Tire Manufacturer Tire Size
Pirelli Snowsport 205/55R16 91 H
Continental Winter Contact TS790 205/55R16 91 H
Continental Winter Contact TS790 225/40R18 92 H
Wheel Specification
Wheel Type Wheel Size
16 Inch - Steel 16x6.5J
16 Inch - Alloy 16x6.5J
17 Inch - Alloy 17x7J
18 Inch - Alloy 18x7.5J
Spare wheel - steel 4Jx16
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Wheels and Tires - Safety Precautions
WARNINGS:
Do not mix different types of tires on the same vehicle such as radial, bias or bias belted tires except in emergencies (temporary
spare usage). Failure to follow this instruction may result in personal injury.
Never run the engine with one wheel off the ground, for example when changing a wheel. The wheel resting on the ground may cause
the vehicle to move. Failure to follow this instruction may result in personal injury.
Aftermarket aerosol tire sealants are extremely flammable. Always question the customer to make sure that these products have not
been used. Failure to follow this instruction may result in personal injury.
Always wear safety goggles or a face shield when performing any work with wheel and tire assemblies. Failure to follow this
instruction may result in personal injury.
Retighten the wheel nuts at (500 miles) 800 Km after any wheel change or anytime the wheel nuts are loosened. Failure to follow this
Failure to retighten the wheel nuts at the specified mileage may cause the wheels to become detached while the vehicle is in motion.
Failure to follow this instruction may result in personal injury.
Each individual axle, wheel and tire has its own maximum weight or tire inflation rating. Do not overload or over-inflate beyond the
capacity of the lowest rated components of the system. Failure to follow these instructions may result in personal injury.
When changing a wheel, make sure that the vehicle cannot move. Always apply the parking brake and select the transmission park
position. Failure to follow these instructions may result in personal injury.
Reduce air pressure as much as possible by pushing the valve core plunger in before removing the valve core. Failure to follow this
CAUTION: Do not clean aluminium wheels with steel wool, abrasive type cleaners or detergents. Failure to follow these instructions
may result in damage to the vehicle.
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Wheels and Tires - Wheels and Tires
1 Locking wheel nut and wrench socket
Locking Wheel Nuts
Locking wheel nuts are fitted to all UK and Mexico vehicles with alloy wheels, and are available as an accessory in certain other markets.
One locking wheel nut is fitted to each road wheel and may only be removed by using the correctly coded socket.
Locking wheel nuts are available in one length only. The correct socket, and cover removal tool if required, is supplied with the vehicle tool
kit. Sets of sockets are available to Jaguar dealers.
Recommended Tires
The radial ply tires recommended by Jaguar meet the high speed performance of the vehicle. Only tires of identical specification may be
fitted as replacements. Under no circumstances must cross-ply tires be fitted.
Tire Inflation Pressures
All recommended tires, including winter tires, must be inflated to the pressures shown in the Specifications sub-section. Inflation pressures
must only be checked when the tires are cold.
If it is necessary to use non-recommended tires, they must be inflated to 0.14 bar (2 lbf/in) above the pressure for the recommended tires,
Jaguar specified tires are marked with a letter 'J' on the side wall.
Tire Replacement and Wheel-Interchanging
When the replacement of a tire is necessary, it is preferable to fit a complete set. If two replacement tires are fitted (to one axle), they
must be of the same manufacturer and type as those on the other axle.
No attempt must be made to interchange wheels from the front to the rear or vice-versa, as wear produces a characteristic pattern on each
tire depending upon its position on the vehicle. If this position is changed after wear has occurred, the performance of the tire will be
adversely affected.
New tires must be balanced before fitting to the vehicle.
Vehicles fitted with Tire Pressure Monitoring System
On vehicles fitted with TPMS, care must be taken when removing and refitting tires to ensure that the tire pressure sensor is not damaged.
Vehicles fitted with TPMS can be visually identified by an external metal locknut and valve of the tire pressure sensor on the road wheels.
Vehicles without TPMS will have rubber tire valve.
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1 - Tire valve and pressure sensor
2 - Tire fitting/removal tool initial start position
3 - High tire and bead tension area
4 - Low tire and bead tension area
When removing the tire, the bead breaker must not be used within 90 of the tire valve in each direction on each side of the tire.
When using the tire removal machine, the fitting arm start position must be positioned as shown in the tire changing illustration for each
side of the tire. The wheel can then be rotated through 180 degrees in a counter-clockwise direction. This will relieve tension from the tire
bead allowing the remaining 180 degrees of the tire to be manually pulled from the rim.
When refitting the tire, position the fitting arm as shown. Rotate the tire and take care that the bead on the low tension side of the tire
does not damage the sensor.
Winter (Snow) Tires
Winter tires must only be fitted in complete four-wheel sets of the same type and size. The maximum speed with winter tires fitted
(without snow chains) is 210 km/h (131 mile/h) for 'H' rated, and 240 km/h (150 mile/h) for 'V' rated.
When using snow chains, note that:
Snow chains must only be fitted to the driven wheels.
Only Jaguar approved snow chains should be used.
Snow chains must not be used on roads which are clear of snow.
The maximum speed with snow chains fitted is 48 km/h (30 mile/h).
Traction control (where fitted) must be switched OFF when using snow chains.
Rotational Indicators
Some recommended winter tires may have an arrow moulded in the sidewall to indicate the correct direction of rotation. It is essential that
these tires are fitted so that the arrow is pointing in the direction of rotation.
Some of the recommended tires for normal and winter use have an asymmetric tread pattern. These tires have inside and outside markers
which should be fitted appropriately to the wheel.
Temporary-Use Spare Wheel
In certain markets, the spare wheel supplied with the vehicle is of the temporary-use type; it is narrower than the normal road wheel and
takes up less room in the wheel luggage compartment.
When using this type of spare wheel note that:
Maximum speed must not exceed 80 km/h (50 mile/h).
The normal road wheel must be replaced as soon as possible.
Only one temporary-use wheel may be fitted to the vehicle at any time.
Traction control (where fitted) must be switched OFF.
Tread Wear Indicator
Tread wear indicators are molded into the bottom of the tread grooves across the width of the tire. The tire must be renewed when tread
wear indicators become visible, at the surface of the tread, in two or more adjacent tread grooves.
Note that tire tread depth and condition must comply with prevailing local legislation.
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Tire Pressure Monitoring System
The TPMS is a driver assistance system which assists the driver to maintain the tire pressures at the optimum level. The TPMS is a standard
fitment on NAS vehicles and an optional fitment in other markets. The TPMS system has the following benefits:
Improve fuel consumption
Maintain ride and handling characteristics
Reduce the risk of rapid tire deflation - which may be caused by under inflated tires
Comply with legislation requirements in relevant markets.
CAUTION: The TPMS is not intended as a replacement for regular tire pressure and tire condition checks and should be considered as
additional to good tire maintenance practices.
The TPMS measures the pressure in each of the tires on the vehicle and issues warnings to the driver if any of the pressures deviate from
defined tolerances.
NOTE: During a 'blow-out' a very rapid reduction in pressure is experienced. The system is not intended to warn the driver of a 'blow-out',
since it is not possible to give the driver sufficient warning that such an event is occurring, due to its short duration. The design of the
TPMS is to assist the driver in keeping the tires at the correct pressure, which will tend to reduce the likelihood of a tire 'blow-out' occurring.
The controlling software for the TPMS is located within a TPMS module. The software detects the following:
the tire pressure is below the recommended low pressure value - under inflated tire
the position of the tire on the vehicle
malfunction warning.
The system comprises a TPMS module, a RF antenna, 4 initiators and 4 tire pressure sensors (the space saver spare wheel is not fitted with
a sensor).
The TPMS module is located under the Right-Hand (RH) side of the rear seat. The RF antenna is located behind the rear bumper. The front
initiators are positioned at the front of the wheel arches. The rear initiators are positioned at the rear of the rear wheel arches.
The 4 initiators are hardwired to the TPMS module. The initiators transmit 125 KHz Low Frequency (LF) signals to the tire pressure sensors
which respond by modifying the mode status within the RF transmission. The 315 MHz RF signals are detected by the RF antenna which is
connected directly to the TPMS module. The received RF signals from the tire pressure sensors are passed to the TPMS module and contain
identification, pressure, temperature and acceleration information for each wheel and tire.
The TPMS module communicates with the instrument cluster via the high speed Controller Area Network (CAN) bus to provide the driver with
appropriate warnings. The TPMS module also indicates status or failure of the TPMS or components.
Tire Location and Identification
The TPMS can identify the position of the wheels on the vehicle and assign a received tire pressure sensor identification to a specific
position on the vehicle, for example FL (front left), FR (front right), RL (rear left) and RR (rear right). This feature is required because of the
different pressure targets and threshold between the front and rear tires.
The wheel location is performed automatically by the TPMS module using an 'auto-location' function. This function is fully automatic and
requires no input from the driver. The TPMS module automatically re-learns the position of the wheels on the vehicle if the tire pressure
sensors are replaced or the wheel positions on the vehicle are changed.
The TPMS software can automatically detect, under all operating conditions, the following:
one or more new tire pressure sensors have been fitted
one or more tire pressure sensors have stopped transmitting
reject identifications from tire pressure sensors which do not belong to the vehicle
two 'running' wheels on the vehicle have changed positions.
If a new tire pressure sensor is fitted on any 'running' wheel, the module can learn the new sensor identification automatically when the
vehicle is driven for more than 15 minutes at a speed of more than 20 km/h (12.5 mph).
The tire learn and location process is ready to commence when the vehicle has been stationary or traveling at less than 12 mph (20 km/h)
for 15 minutes. This is known as 'parking mode'. The learn/locate process requires the vehicle to be driven at speeds of more than 20 km/h
(12.5 mph) for 15 minutes. If the vehicle speed reduces to below 20 km/h (12.5 mph), the learn process timer is suspended until the vehicle
speed increases to more than 20 km/h (12.5 mph), after which time the timer is resumed. If the vehicle speed remains below 20 km/h (12.5
mph) for more than 15 minutes, the timer is set to zero and process starts again.
If the tire pressure sensors fitted to the running wheels vehicle are changed, the module can learn the new sensor identifications
automatically. The learn function requires no manual intervention by the driver.
Initiator
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The initiator is a passive LF transmitter. It transmits signals which are received by the tire pressure sensors prompting them to modify their
mode status.
The TPMS module energizes each initiator in turn using LF drivers. The corresponding tire pressure sensor detects the LF signal and
responds by modifying the mode status within the RF transmission.
Tire Pressure Sensor
The TPMS uses active tire pressure sensors which are located on each wheel, inside the tire cavity. The sensor incorporates the tire valve
and is secured in the wheel by a nut on the outside of the wheel. The sensor contains a Printed Circuit Board (PCB) which houses a Positive
Temperature Coefficient (PTC) sensor, a Piezo pressure sensor, a radio receiver and transmitter and a lithium battery.
The tire pressure sensors use the PTC sensor and the Piezo sensor to periodically measure the pressure and temperature of the air inside
the tire. The data is transmitted by RF data signals at 315 MHz.
The RF transmission from the sensor contains a unique identification code in its transmission data. This allows the TPMS to identify the
wheel on the vehicle. If the sensor is replaced on a 'running' wheel, the new sensor identification will be learnt when the vehicle is driven at
speed of more than 20 km/h (12.5 mph) for 15 minutes.
The tire pressure sensor can also detect when the wheel is rotating. In order to preserve battery power, the sensor uses different
transmission rates when the wheel is stationary or moving.
The care points detailed in 'Tire Changing' earlier in this section must be followed to avoid damage to the sensor. If a new sensor is fitted,
a new nut, seal and washer must also be fitted and the sensor nut tightened to the correct torque as given in the Removal and Installation
section of this manual.
Instrument Cluster
The warning indications to the driver are common on all vehicles fitted with TPMS. The driver is alerted to system warnings by a low tire
pressure warning indicator in the instrument cluster and an applicable text message in the message center.
The TPMS module passes system status information to the instrument cluster on the high speed CAN bus. The instrument cluster then
converts this data into illumination of the warning indicator and display of an appropriate message.
When the ignition is switched on, the warning indicator is illuminated for 3 seconds for a bulb check.
NOTE: If the vehicle is not fitted with the TPMS, the warning indicator will not illuminate.
The instrument cluster checks, within the 3 second bulb check period, for a CAN bus message from the TPMS. During this time the TPMS
performs internal tests and CAN bus initialization. The warning indicator will be extinguished if the TPMS module does not issue a fault
message or tire pressure warning message.
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If a TPMS fault warning message is detected by the instrument cluster at ignition on, the warning indicator will flash for 72 seconds after
the 3 second bulb check period and then remain permanently illuminated.
If a tire pressure warning message is detected by the instrument cluster at ignition on, the warning indicator will extinguish briefly after the
3 second bulb check period, before re-illuminating to indicate a tire pressure warning.
Principles of Operation
Each time the vehicle is driven the TPMS module activates each initiator in turn to transmit a LF 125 KHz signal to each tire pressure
sensor. The LF signal is received by the tire pressure sensor which responds by transmitting a 315 MHz signal which is received by the RF
antenna. The signal contains coded data which corresponds to sensor identification, air pressure, air temperature and acceleration data and
is passed to the TPMS module.
When the vehicle has been parked for more than 15 minutes and then driven at a speed of more than 12.5 mph (20 km/h), the initiators fire
in turn for 18 seconds in the following order:
Front left
18 second pause (for the TPMS module to detect a response from the tire pressure sensor)
Front right
18 second pause
Rear right
18 second pause
Rear left
18 second pause.
Each tire pressure sensor responds in turn which allows the TPMS module to establish the sensor positions at the start of the drive cycle.
This process is repeated up to 3 times but less if the sensor positions are already known. The process is known as 'Auto Location' and takes
2 to 5 minutes to complete.
During this period the tire pressure sensors transmit at regular intervals, once every 15 seconds. For the remainder of the drive cycle the
tire pressure sensors transmit once every 60 seconds or more often if a change of ti re pressure is sensed until the vehicle stops and the
TPMS returns to the parking mode.
Once the wheel positions have been established, the initiators stop transmitting the LF signal and do not transmit again until the vehicle
has been parked for more than 15 minutes.
The TPMS enters 'Parking Mode' after the vehicle speed has been less than 20 km/h (12.5 mph) for 15 minutes. In parking mode the tire
pressure sensors transmit a coded RF signal once every 13 hours. If the tire pressure decreases by more than 0.06 bar (1 lbf/in), the
sensor will transmit more often if pressure in the tire is being lost.
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Wheels and Tires - Wheels and Tires
General notes
Factory installed tires and wheels are designed to operate satisfactory when inflated to the recommended inflation pressures; refer to the
Specifications sub-section. The recommended pressures apply to vehicle loads up to and including full-rated load capacity.
Correct tire pressures and driving technique have an important influence on tire life. Heavy cornering, excessively rapid acceleration and
unnecessary sharp braking increase tire wear.
Replacement tires should follow the recommended:
Size.
Speed rating.
Load range.
Radial construction type.
The use of any other size or type may seriously affect:
Safety.
Ride.
Handling.
Speedometer and odometer calibration.
Vehicle ground clearance.
Tire clearance between body and chassis.
Wheel bearing life.
Brake cooling.
Wheels need to be renewed when:
Impact damaged.
Heavily corroded.
Porous.
Wheel stud holes or seats become damaged.
They have excessive radial or lateral runout.
Safety notes
WARNINGS:
Do not mix different types of tires on the same vehicle. Handling may be seriously affected resulting in loss of control. Failure to
follow these instructions may result in personal injury.
When using winter tires, observe the direction of the sidewall moulded indicators; correct tire rotational direction is critical. Failure to
A tire and wheel must always be correctly matched. Wider or narrower tires than recommended could cause danger through sudden
deflation. Failure to follow these instructions may result in personal injury.
When using the temporary spare wheel, maximum speed must not exceed 50 mile/h (80 km/h). Drive with caution and replace with
the specified wheel / tire assembly as soon as possible. Failure to follow these instructions may result in personal injury.
Traction control (if available) must not be engaged with a temporary spare wheel fitted. Failure to follow these instructions may result
in personal injury.
When changing a wheel, make sure that the vehicle cannot move. Always apply the parking brake and select the transmission park
position. Failure to follow these instructions may result in personal injury.
Never run the engine with one wheel off the ground, for example, when changing the wheel. The wheel resting on the ground may
cause the vehicle to move. Failure to follow these instructions may result in personal injury.
Tighten the wheel nuts to specification. Too tight may cause damage, too loose may allow the wheel to become detached. Failure to
Use only wheels and wheel nuts supplied by Jaguar. Aftermarket wheels or wheel nuts may not fit or function correctly and could
cause injury or damage. Failure to follow these instructions may result in personal injury.
1. Verify the customer's concern by driving the vehicle. 1.
2. Visually inspect for obvious signs of damage: 2.
Mechanical
Incorrect tire pressure
Wheel imbalance
Tires worn beyond tread wear indicators
Cuts
Abrasions
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Mechanical
Bulges (blister)
Ply separation
Embedded objects
Impact damage
Incorrect speed rating
Incorrect load rating
Incorrect rotational direction
step.
3.
4. If the concern is not visually evident, verify the symptom and refer to Symptom Chart. 4.
Tire Wear Inspection
To maximize tire performance, inspect the tires for signs of incorrect inflation and uneven wear which may indicate a need for balancing,
rotation or front suspension alignment. Tires should also be checked frequently for cuts, stone bruises, abrasions, blisters, and for objects
that may have become embedded in the tread. More frequent inspections are recommended when rapid or extreme temperature changes
occur or when road surfaces are rough or occasionally littered with debris.
Tire Wear Diagnosis
New tires should be installed if the wear indicators are exposed or if there is severe shoulder wear. Shoulder wear is usually caused by
either excessive camber or excessive toe on radial tires.
Sometimes incorrect rear toe settings or damaged struts will cause severe cupping' or scalloped' tire wear on non-drive wheels.
Incorrect rear toe alignment will also cause other unusual wear patterns.
Road Test
A tire vibration diagnostic procedure always begins with a road test. The road test and customer interview (if available) will provide much of
the information needed to find the source of a vibration.
During the road test, drive the vehicle on a road that is smooth and free of undulations. If vibration is apparent, note and record the
following:
The speed at which the vibration occurs.
What type of vibration occurs in each speed range.
- mechanical or audible.
How the vibration is affected by changes in the following:
- engine torque.
- vehicle speed.
- engine speed.
Type of vibration-sensitivity: torque sensitive, vehicle speed sensitive or engine speed sensitive.
The following explanations help isolate the source of the vibration.
Torque Sensitive
This means that the condition may be improved or made worse by accelerating, decelerating, coasting, maintaining a steady vehicle speed
or applying engine torque.
Vehicle Speed Sensitive
This means that the vibration always occurs at the same vehicle speed and is not affected by engine torque, engine speed or the
transmission gear selected.
Engine Speed Sensitive
This means that the vibration occurs at varying vehicle speeds when a different transmission gear is selected. It may sometimes be isolated
by increasing or decreasing engine speed with the transmission in NEUTRAL or by stall testing with the transmission in gear. If the
condition is engine speed sensitive, the cause is probably not related to the tires.
If the road test indicates that there is tire whine, but no shake or vibration, the noise originates with the contact between the tire and the
road surface.
A thumping noise usually means that the tire has a flat or soft spot making a noise as they slap the roadway. Tire whine may be
distinguished from axle noise. Tire whine remains the same over a range of speeds.
Symptom Chart
Tires show excess wear on edge
of treads
Tires under-inflated Correct pressure to specification.
Vehicle overloaded Correct as required.
Tires show excess wear on edge
of treads (having the correct tire
pressures).
Incorrect toe setting Set to specification. For additional information refer
toSection 204-00 Suspension System - General
Information
Tires show excess wear in center
of tread.
Tires over-inflated Correct pressure to specification.
Other excessive tire wear
problems
Incorrect tire pressure Correct pressure to specification.
Incorrect tire / wheel usage Install correct tire and wheel combination.
Loose or leaking dampers Tighten or install a new as necessary. For
additional information refer toSection 204-01 Front
Suspension or Section 204-02 Rear Suspension.
Geometry out of alignment Check and adjust.
Loose, worn or damaged suspension components Inspect, repair or install a new as necessary.
Wheel and tire assembly out of balance Balance wheel and tire assembly.
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Excessive lateral or radial runout of wheel or tire Check, repair or install a new as necessary. Refer to
the procedure in this section.
Wheel mounting is difficult Incorrect application or mismatched parts,
including wheel studs and wheel nuts. Corroded,
worn or damaged parts
Clean or install a new part.
Wobble or shimmy affecting
wheel runout
Damaged wheel (eventually damaging wheel
bearings and causing uneven tire wear)
Inspect wheel rims for damage and runout. Install a
new wheel rim as necessary.
Excessive vibration, rough
steering or severe tire wear
Loose or incorrect attaching parts Tighten or install new parts.
Vehicle vibrations Tires / wheels mismatched Install correct tire / wheel combination.
Inflation pressure too high or low Correct pressure to specification.
Uneven tire wear Refer to Diagnosis and Testing in this section.
Out-of-balance wheel, tire, wheel hub or disc
assembly
Determine the out-of-balance component and
balance or install a new part.
Damaged or distorted wheel from road impact
hazard or incorrect handling
Install a new wheel.
Excessive radial runout Install a new wheel or tire. Check for incorrect
wheel and tire specifications.
Excessive lateral runout Install a new wheel or tire.
Incorrectly seated tire Remount the tire.
Loose wheel mountings - damaged wheel studs,
wheel nuts, worn or broken wheel hub face or
foreign material on mounting faces
Tighten or install new parts. Clean mounting
surfaces.
Defective wheel bearings Install a new bearing set. For additional information
refer toSection 204-01 Front Suspensionor Section
204-02 Rear Suspension
Brake disc imbalance For additional information refer to SectionSection
206-00 Brake System - General Information
Water in tires Remove water.
Loose engine or transmission mounts Tighten or install a new mount.
Incorrect front end alignment Align front end. For additional information refer
toSection 204-01 Front Suspension
Loose or worn driveline or suspension parts Repair or install new parts.
Excessive driveshaft runout or imbalance Install a new driveshaft, for additional information
refer toSection 205-01 Driveshaft
Worn or damaged flexible drive joint Install a new drive shaft. For additional information
refer toSection 205-01 Driveshaft
Damaged wheel hub stud
threads
Sliding wheel across the wheel studs during
installation. Loose wheel nuts
Install new wheel studs.
Broken wheel studs Loose or overtightened wheel nuts Install new wheel studs.
Corrosion / contamination
streaks from the wheel hub
wheel stud holes
Loose wheel nuts Check complete assembly. Install new parts. Follow
correct torque procedure.
Wheel difficult to remove from
wheel hub
Corrosion Apply a small amount of grease to the wheel hub
face and spigot location.
Damaged wheel nuts Loose wheel assembly Install new wheel nuts. Follow correct torque
procedure.
Over-tightened wheel nuts Install new wheel nuts. Follow correct torque
procedure.
Frozen wheel nuts Corrosion or galling
CAUTION: Do not permit lubricant to
contaminate wheel hub stud holes or wheel nut seats.
If corrosion is light, wire brush away corrosion. If
corrosion is excessive install new wheel studs and
wheel nuts.
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Wheels and Tires - Tire Low Pressure SensorVIN Range: J28493->V99999
Removal
NOTE: It is strongly recommended that a new tire low pressure sensor O-ring seal, washer, nut, valve core and cap are installed each time
a tire is removed and installed. The O-ring seal, washer, nut, valve core and cap must be replaced if the tire low pressure sensor is
removed. Removal of the tire low pressure sensor retaining nut must be regarded as tire low pressure sensor removal. The tire low pressure
sensor valve cap must always be in place except when inflating, releasing pressure or checking pressure.
2. CAUTION: Make sure the tire bead is broken from the wheel rim
180 degrees from the tire low pressure sensor. Failure to follow this
instruction may result in damage to the tire low pressure sensor.
Remove the tire.
3. CAUTION: Make sure you do not push on the tire low pressure
sensor valve. Failure to follow this instruction may result in damage to the
valve.
Remove the tire low pressure sensor.
Remove and discard the tire low pressure sensor retaining nut,
valve core, valve cap, O-ring seal and washer.
Installation
1. CAUTION: The base of the valve stem must be held whilst pushing
on the new seal and washer. Failure to follow this instruction may result in
damage to the tire low pressure sensor.
NOTE: Make sure that the washer and O-ring seal are installed correctly.
The flat face of washer must be seated against the sensor housing. The
taper of O-ring seal points towards the wheel.
Install a new washer and O-ring seal.
Install a new valve core and valve cap.
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2. CAUTION: Make sure solvents or cleaning agents of any type are
not used to clean the tire low pressure sensor. Failure to follow this
instruction may result in damage to the tire low pressure sensor.
NOTE: If the tire low pressure sensor is replaced on a road wheel, the
new tire low pressure sensor identification code will be learnt when the
vehicle is first driven. If a new tire low pressure sensor is fitted to the
spare wheel the identification code for that tire low pressure sensor must
be programmed into the tire pressure monitoring system module. The
identification code is printed on the casing of each tire low pressure
sensor and is prefixed with ID.
Install the tire low pressure sensor.
1. Support the base of the valve stem when installing the tire
low pressure sensor.
2. Hold the tire low pressure sensor against the wheel rim when
tightening the retaining nut.
Install a new tire low pressure sensor retaining nut.
Tighten the nut to 8 Nm.
3. CAUTION: Make sure no damage occurs to the tire low pressure
sensor.
Install the tire and balance the wheel.
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Wheels and Tires - Tire Pressure Monitoring System (TPMS) Front AntennaVIN Range:
J28493->V99999
Removal
For additional information, refer to: Jacking (100-02 Jacking and Lifting,
Detach the wheel arch liner.
Disconnect the tire pressure monitoring system front antenna electrical
connector.
Remove the tire pressure monitoring system front antenna.
Installation
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Wheels and Tires - Tire Pressure Monitoring System (TPMS) Main AntennaVIN Range:
J28493->V99999
Removal
2. Detach the rear bumper cover.
3. Disconnect the tire pressure monitoring system main antenna electrical
connector.
4. Release the tire pressure monitoring system main antenna electrical
harness.
5. Remove the tire pressure monitoring system main antenna.
Installation
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Tighten to 5 Nm.
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Wheels and Tires - Tire Pressure Monitoring System (TPMS) ModuleVIN Range:
J28493->V99999
Removal
1. Remove the rear seat cushion.
For additional information, refer to: Rear Seat Cushion (501-10 Seating,
2. Remove the rear scuff plate trim panel.
For additional information, refer to: Rear Scuff Plate Trim Panel (501-05
Interior Trim and Ornamentation, Removal and Installation).
3. Reposition the floor covering.
4. Disconnect the tire pressure monitoring system module electrical
connectors.
5. Reposition the tyre pressure monitoring system module harness.
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6. Reposition the tire pressure monitoring system module.
Remove the retaining nuts.
7. Remove the tire pressure monitoring system module.
Disconnect the external antenna connector.
Installation
Tighten to 5 Nm.
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Wheels and Tires - Tire Pressure Monitoring System (TPMS) Rear AntennaVIN Range:
J28493->V99999
Removal
Disconnect the tire pressure monitoring system rear antenna electrical
connector.
Remove the tire pressure monitoring system rear antenna.
Installation
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Wheels and Tires - Wheel and Tire
Removal
1. CAUTION: Do not use heat to loosen a seized wheel nut,
excessive heat may cause damage to the wheel and the wheel bearings.
Loosen the wheel nuts.
2. Raise and support the vehicle. For additional information refer to
3. Remove the wheel and tire assembly.
Installation
Vehicles with steel wheels
1. WARNINGS:
Make sure that there is no contamination of the wheel, hub or brake
disc contact surfaces. Installation without metal to metal contact at the
mounting surfaces may cause the wheel nuts to loosen and allow the
wheel to detach while the vehicle is in motion. Failure to follow these
instructions may result in personal injury.
Apply a small amount of grease to the hub and wheel mating
surfaces before installation. Make sure that the grease does not come into
contact with the wheel studs or vehicle braking system components.
Failure to follow these instructions may result in personal injury.
Tighten to 80 Nm.
Vehicles with aluminium wheels
2. WARNINGS:
Make sure that there is no contamination of the wheel, hub or brake
disc contact surfaces. Installation without metal to metal contact at the
mounting surfaces may cause the wheel nuts to loosen and allow the
wheel to detach while the vehicle is in motion. Failure to follow these
Apply a small amount of grease to the hub and wheel mating
surfaces before installation. Make sure that the grease does not come into
contact with the wheel studs or vehicle braking system components.
Tighten to 103 Nm.
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Driveline System - General Information - Driveline System
The driveline transfers engine torque to the drive wheels. On vehicles with 2.0L or diesel engines the power is transmitted through the
transaxle to the front drive halfshafts. On vehicles with 2.5L and 3.0L engines the power is transmitted through the transaxle to the
transfer case. The transfer case then splits the torque 40% to the front drive halfshafts and 60% to the driveshaft which is connected to the
rear drive differential and the rear drive halfshafts.
For additional information, refer to: Wheels and Tires (204-04 Wheels and Tires, Description and Operation).
For additional information, refer to: Front Drive Halfshafts (205-04 Front Drive Halfshafts, Description and Operation).
For additional information, refer to: Driveshaft (205-01 Driveshaft, Description and Operation).
For additional information, refer to: Transfer Case (308-07 Transfer Case, Description and Operation).
For additional information, refer to: Rear Drive Halfshafts (205-05 Rear Drive Halfshafts, Description and Operation).
For additional information, refer to: Rear Drive Axle and Differential (205-02 Rear Drive Axle/Differential, Description and Operation).
For additional information, refer to: Manual Transaxle - Vehicles With: 6-Speed Manual Transaxle - MMT6 (308-03 Manual
Transmission/Transaxle, Description and Operation).
For additional information, refer to: Transmission Description (307-01 Automatic Transmission/Transaxle, Description and Operation).
The engine is installed at a specific angle. This is determined by the engine mounts. If the engine angle is out of specification, the engine
mounts must be inspected for damage and new ones installed if necessary.
Driveline Vibration
Driveline vibration exhibits a higher frequency and lower amplitude than high-speed shake. Driveline vibration is directly related to the
speed of the vehicle and is usually noticed at various speed ranges. Driveline vibration can be felt as a tremor in the floorpan or is heard as
a rumble, hum or boom. Driveline vibration can exist in all drive modes, but may exhibit different symptoms depending upon whether the
vehicle is accelerating, decelerating, cruising or coasting. Check the driveline angles if the vibration is particularly noticeable during
acceleration or deceleration, especially at lower speeds.
In order to diagnose vibrations in the driveshaft, refer to the Jaguar Approved Diagnostic System.
Driveline Angle
On vehicles with 2.0L or diesel engines the driveline angularity is the angular relationship between the transaxle and the halfshafts. On
vehicles with 2.5L and 3.0L engines the driveline angularity is the angular relationship between the transfer case drive pinion, the driveshaft
and the rear differential drive pinion. On all engines variations the factors determining driveline angularity include ride height and engine
mounts.
If the wheels and tires and driveline angle are not the cause, carry out the NVH tests to determine whether the concern is caused by a
condition in the driveline.
For additional information, refer to: Noise, Vibration and Harshness (NVH) (100-04 Noise, Vibration and Harshness, Description and
Operation).
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Driveline System - General Information - Driveline System
Certain driveline conditions are also common to the engine, transaxle, transfer case, wheel bearings, wheels and tires and other parts of
the vehicle. For this reason, make sure the cause of the trouble is in the driveline before adjusting, repairing or installing any new
components. For additional information, refer to Section 100-04 Noise, Vibration and Harshness.
1. Verify the customer concern by carrying out a road test of the vehicle. 1.
step.
3.
4. If the concern is not visually evident, verify the symptom and refer to the Symptom Chart. 4.
Transfer Case, Front Transaxle and Axle Noise
Gear Howl and Whine
Howling or whining of the ring gear and drive pinion are due to an incorrect gear pattern, gear damage or incorrect bearing preload.
Bearing Whine
Bearing whine is a high-pitched sound similar to a whistle. It is usually caused by worn/damaged pinion bearings. Bearing noise occurs at
all driving speeds. This distinguishes it from gear whine which is speed dependent.
As noted, pinion bearings make a high-pitched, whistling noise, usually at all speeds. If however there is only one pinion bearing that is
worn/damaged, the noise may vary in different driving phases.
A wheel bearing noise can be mistaken for a pinion bearing noise.
Knock
Knock, which can occur on all driving phases, has several causes including damaged teeth or gearset.
A gear tooth damaged on the drive side is a common cause of the knock.
Clunk
Clunk is a metallic noise heard when the automatic transaxle is engaged in REVERSE or DRIVE. The noise may also occur when the throttle
is applied or released. Clunk is caused by backlash in the driveline or loose suspension components.
Bearing Rumble
Bearing rumble is usually caused by a worn/damaged wheel bearing. The lower pitch is because the wheel bearing turns at only about
one-third of the driveshaft speed. Wheel bearing noise may also be high-pitched, similar to gear noise, but will be evident in all four driving
modes.
Symptom Chart
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1
2
Noise is at constant tone
over a narrow vehicle speed
range. Usually heard on
light driving and coasting
conditions
Rear drive differential.
Transfercase.
Transaxle.
For additional information, refer to Pinpoint Test A
Noise is the same on
driving or coasting.
Road.
Wheel bearing.
Normal conditions.
CHECK and INSTALL a new wheel bearing as necessary. For
additional information, refer to Section 204-02 Rear
Suspension.
Worn or damaged driveshaft joint. INSTALL new components as necessary.
Driveshaft center bearing. INSTALL new components as necessary.
Noise is produced with the
vehicle standing and driving
Engine For additional information, refer to Section 303-00 Engine
System - General Information.
Transmission For additional information, refer to Section 307-01A
Automatic Transmission/TransaxleSection 307-01B
Automatic Transmission/Transaxle. For additional
information, refer to Section 308-03 Manual
Transmission/Transaxle.
Noise is more pronounced
while turning
Front or rear differential side gears and pinion
gears.
For additional information, refer to Section 205-02 Rear
Drive Axle/Differential and Section 308-07 Transfer Case.
Loud clunk in the driveline
when Shifting from Reverse
to Drive.
Engine idle speed set too high.
Engine mount.
CHECK and adjust as necessary.
INSPECT and INSTALL new engine mounts as necessary.
Transaxle Mount. INSPECT and INSTALL new transaxle mounts as necessary.
Transaxle. For additional information, refer to Section 307-01A
Automatic Transmission/TransaxleSection 307-01B
Automatic Transmission/Transaxle andSection 308-03
Manual Transmission/Transaxle.
Suspension. INSPECT and INSTALL new suspension components as
necessary.
Backlash in the driveline. INSTALL new components as necessary.
Clicking, popping or
grinding noises
Inadequate or contaminated lubrication in the
constant velocity (CV) joints.
Another component contacting the axle shaft.
Wheel bearings, brakes or suspension
components.
INSPECT, CLEAN and LUBRICATE with new grease as
necessary.
INSPECT and REPAIR as necessary.
INSPECT and INSTALL new components as necessary.
Vibration at high speeds. Out-of-balance wheels and tires. INSTALL new wheels and tires as necessary. For additional
information, refer toSection 204-04 Wheels and Tires.
Driveline out of balance/misalignment. For additional information, refer to the approved Jaguar
diagnostic system.
Shudder or vibration during
acceleration.
Powertrain/driveline misalignment. CHECK for misalignment. INSTALL new components as
necessary.
High CV joint operating angles caused by
incorrect ride height.
CHECK the ride height and VERIFY the correct spring rate.
INSTALL new components as necessary.
Lubricant leak. Transaxle, transfer case or rear drive
differential vent.
Transaxle halfshaft seal, transfer case
halfshaft seal, transaxle to transfer case
O/ring seal, transfer case drive pinion seal,
rear drive differential pinion seal or rear drive
halfshaft seal.
Filler plug. INSTALL new components as necessary.
Axle rear cover joint. INSTALL new components as necessary.
PINPOINT TEST A : EXCESSIVE DRIVELINE NOISE
TEST
CONDITIONS
A1: CHECK NOISE FROM VEHICLE ON ROAD TEST
Road test vehicle to determine load and speed conditions when noise occurs.
Assess the noise with different gears selected.
Does the noise occur at the same vehicle speed?
Yes
INSTALL a new final drive. TEST the system for normal operation
No
REFER to Section 204-04 Wheels and Tires, Section 205-01 Driveshaft,Section 205-04 Front Drive Halfshafts, Section
205-05 Rear Drive Halfshafts, Section 303-00 Engine System - General Information, Section 307-01A Automatic
Transmission/TransaxleSection 307-01B Automatic Transmission/Transaxle, Section 308-03 Manual
Transmission/Transaxle andSection 308-07 Transfer Case.
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Driveshaft -
Driveshaft center bearing retaining bolts 25 18 -
Driveshaft front universal joint retaining bolts 44 32 -
Driveshaft rear universal joint retaining bolts 44 32 -
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Driveshaft - Driveshaft
1 Link washer
2 Driveshaft universal joint retaining bolt
3 Driveshaft front collapsible tube
4 Driveshaft center bearing
5 Driveshaft universal joint retaining bolt
6 Link washer
7 Paper gasket
8 Driveshaft rear universal joint
9 Driveshaft rear tube
10 Driveshaft front universal joint
11 Paper gasket
WARNING: Under no circumstances must a 2004.25 MY or earlier driveshaft assembly be fitted to a later vehicle. Failure to follow this
CAUTION: To preserve 'drive line' refinement, individual parts, other than fixings, MUST NOT be renewed. In the event of any balance
or driveshaft component related concern, the complete assembly must be renewed. Under no circumstances may the universal joint be
removed from the driveshaft (or its fixings be loosened). Do not drop or subject the driveshaft to damage.
NOTE: 2004.25 MY driveshaft assemblies may be fitted to earlier model year vehicles. For modification details refer to Driveshaft in this
section.
NOTE: All driveshaft assemblies are balanced. If undercoating the vehicle, protect the driveshaft, universal joints and the drive half shafts
to prevent over-spray of the undercoating material.
The driveshaft consists of the following:
A two piece welded steel tube.
A center bearing.
Two universal joints.
Universal Joint
The universal joints are:
A lubed-for-life design and require no lubrication in service.
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For additional information, refer toSection 205-00 Driveline System - General Information.
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Driveshaft - Driveshaft Runout and Balancing
General Procedures
1. For additional information, refer to the approved Jaguar diagnostic
system.
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Removal
NOTE: Removal of the driveshaft rear universal joint shown, removal of the driveshaft front universal joint similar.
2. NOTE: Mark the position of the driveshaft in relation to the drive pinion
flange.
Remove two opposing driveshaft universal joint retaining bolts.
3. Loosen the remaining driveshaft universal joint retaining bolts.
Using a suitable tool, detach the driveshaft from drive pinion
flange.
4. CAUTION: Make sure the outer casing of the driveshaft universal
joint is secured to the driveshaft universal joint through the securing
holes. Failure to follow this instruction may invalidate the warranty of the
driveshaft.
Using suitable tie straps, secure the outer casing of the driveshaft
universal joint.
5. CAUTION: Make sure the front and rear driveshaft sections are
supported.
NOTE: If installed, remove and discard the gasket.
Detach the driveshaft universal joint.
Remove and discard the driveshaft retaining bolts and link washers.
6. Repeat the above procedure for the driveshaft front universal joint.
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supported.
Remove the driveshaft.
Remove driveshaft center bearing retaining bolts.
Installation
supported.
Install the driveshaft.
Loosely install the driveshaft center bearing retaining bolts.
2. CAUTIONS:
INSTALLING A NEW DRIVESHAFT. If a new driveshaft is to be
installed, no gasket is required between the driveshaft and the drive
pinion flange. Failure to follow this instruction may result in damage to
the vehicle.
INSTALLING THE ORIGINAL DRIVESHAFT. If a gasket was
removed from between the driveshaft and the drive pinion flange on the
driveshaft removal procedure, make sure to install a new gasket. If no
gasket was removed from between the driveshaft and the drive pinion
flange on the driveshaft removal procedure, a new gasket is not required.
NOTE: If a new driveshaft is to be installed align the H on the rear
drive axle flange with the paint mark on the driveshaft.
NOTE: Remove and discard the tie straps.
Attach the driveshaft rear universal joint.
1. Install new driveshaft retaining bolt link washers.
2. Install new driveshaft retaining bolts.
3. Repeat the above procedure for the driveshaft front universal joint.
4. Fully tighten the driveshaft center bearing retaining bolts.
Tighten to 25 Nm.
5. Carry out a driveshaft alignment check using specifications found in
underbody misalignment checks.
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Rear Drive Axle/Differential -
Item Specification
Oil type M2C192A synthetic
Oil capacity 1.2 liters
Driveshaft front universal joint retaining bolts 40 30 -
Driveshaft rear universal joint retaining bolts 40 30 -
Axle front retaining bolts 90 66 -
Axle rear retaining bolt stage one A - -
Driveshaft center bearing retaining bolts 25 18 -
Vibration damper retaining bolt 40* 30 -
Drive pinion flange preload lower than specification on used bearings 1.7 - 15
Drive pinion flange preload higher than specification on used bearings 1.7 - 15
A = refer to the procedure for the correct torque sequence.
*Tighten existing fittings on vehicles prior to VIN J24258 to 48 Nm.
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Rear Drive Axle/Differential - Rear Drive Axle and Differential
1 Vibration damper bracket
2 Axle shaft oil seal
3 Axle housing
4 Axle shaft oil seal
5 Drive pinion seal
6 Drive pinion collapsible spacer
7 Drive pinion flange
8 Drive pinion flange retaining nut
9 Vibration damper
The rear axle drive pinion receives power from the engine through the transaxle and driveshaft. The drive pinion gear rotates the differential
drive gear which is bolted to the axle housing outer flange. Inside the axle housing, two differential pinion gears are mounted on a
differential shaft which is pinned to the axle housing. These differential pinion gears are engaged with the differential side gears to which
the axle shafts are splined. As the differential gear turns, it rotates the axle shafts and rear wheels.
When it is necessary for one wheel and axle shaft to rotate faster than the other, the faster turning differential side gear causes the
differential pinion gears to roll on the slower turning differential side gear. This allows differential action between the two axle shafts.
The vibration damper is designed to damp driveshaft boom. It is bolted to the rear differential vibration damper bracket which in turn is
bolted to the rear axle.
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Rear Drive Axle/Differential - Rear Drive Axle and Differential
For additional information, refer to Section 205-00 Driveline System - General Information.
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Rear Drive Axle/Differential - Axle Shaft Seal
In-vehicle Repair
Special Tool(s)
Remover, Axle Shaft Oil Seal
308-208
Installer, Oil Seal
204-264
Removal
1. Remove the rear halfshaft. For additional information, refer to Section
205-05 Rear Drive Halfshafts.
2. Using the special tool, remove and discard the axle shaft oil seal.
Installation
1. Using the special tool, install the axle shaft oil seal.
2. Install the halfshaft. For additional information, refer toSection 205-05
Rear Drive Halfshafts.
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Rear Drive Axle/Differential - Drive Pinion Flange
In-vehicle Repair
Special Tool(s)
Torque To Turn Rotary Tool
205-518
Wrench, Flange
205-053
Remover, Flange Plate
204-295
Remover, Flange Boss
204-266
Remover, Flange Shaft
204-268A
Installer, Oil Seal
204-264
Removal
1. CAUTION: The following step must be carried out to make sure the
correct drive pinion flange retaining nut torque is achieved.
Remove the rear brake pads.
For additional information, refer to: Brake Pads (206-04 Rear Disc Brake,
2. Remove the driveshaft.
For additional information, refer to: Driveshaft (205-01 Driveshaft,
3. Remove the vibration damper.
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4. Remove the vibration damper retaining bolt.
5. NOTE: Support the axle assembly.
Remove the axle front retaining bolts.
Remove the vibration damper bracket.
6. Remove the axle assembly rear retaining bolt.
7. CAUTION: Make sure CV joints do not exceed 18 degrees from the
center line.
Lower the differential.
8. Install the special tool to the drive pinion flange.
9. Install a Nm (pound/inch) torque wrench on the special tool and record
the torque necessary to maintain rotation of the drive pinion gear
through several revolutions.
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10. Using the special tool, install a breaker bar and remove and discard
the drive pinion flange retaining nut.
11. NOTE: Mark the pinion flange in relation to the drive pinion stem to
ensure correct alignment during installation.
Using the special tools, remove the drive pinion flange.
12. Using a suitable tool, remove and discard the drive pinion seal.
Installation
1. CAUTIONS:
Installation without the correct tool can result in early seal failure.
If the drive pinion seal becomes misaligned during installation ,
remove it and install a new one.
NOTE: Lubricate the lips of the new drive pinion oil seal. Use a long life
grease or equivalent.
Using the special tool, install the drive pinion seal.
2. CAUTION: Inspect the pinion flange seal journal for rust or
nicks/scratches prior to installing the pinion flange. Polish the seal journal
with a fine crocus cloth, if required.
Install the drive pinion flange.
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3. CAUTION: Do not under any circumstance, loosen the pinion nut to
reduce preload, if preload is exceeded install a new collapsible spacer and
pinion nut.
Using the special tool, hold the pinion flange while tightening the drive
pinion retaining nut.
4. CAUTION: If the preload recorded prior to disassembly is lower
than the specification (1.7 Nm / 15 lb-in) for used bearings, tighten the
companion flange nut until the pinion preload reaches the specification
(1.7 Nm / 15 lb-in). If the preload recorded prior to disassembly is higher
than the specification for used bearings, tighten the companion flange nut
to the original reading as recorded.
NOTE: Rotate the pinion to allow the pinion bearing to seat correctly.
Take frequent pinion bearing torque preload measurements by rotating the
pinion with a (Nm / lb-in) torque wrench.
Using the special tool, carry out a pinion bearing preload check.
5. Install the axle assembly.
6. Loosely install the axle assembly rear retaining bolt.
7. Loosely install the axle assembly front retaining bolts.
Install the vibration damper bracket.
8. Install the vibration damper bracket retaining bolt.
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9. Tighten the axle assembly front retaining bolts to 90 Nm.
10. Tighten the axle assembly rear retaining bolt to 110 Nm and then
slowly tighten to 135 Nm.
11. Install the vibration damper.
Tighten to 48 Nm.
12. Install the driveshaft.
13. Install the rear brake pads.
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Rear Drive Axle/Differential - Drive Pinion Seal
In-vehicle Repair
Special Tool(s)
Torque To Turn Rotary Tool
205-518
Wrench, Flange
205-053
Remover, Flange Plate
204-295
Remover, Flange Boss
204-266
Remover, Flange Shaft
204-268A
Installer, Oil Seal
204-264
Removal
1. CAUTION: The following step must be carried out to make sure the
correct drive pinion flange retaining nut torque is achieved.
Remove the rear brake pads.
For additional information, refer to: Driveshaft (205-01, Removal and
Installation).
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4. Remove the vibration damper retaining bolt.
Remove the axle front retaining bolts.
7. CAUTION: Make sure CV joints do not exceed 18 degrees from the
center line.
Lower the differential.
8. Install the special tool to the drive pinion flange.
9. Install a Nm (pound/inch) torque wrench on the special tool and record
the torque necessary to maintain rotation of the drive pinion gear
through several revolutions.
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10. Using the special tool, install a breaker bar and remove and discard
the drive pinion flange retaining nut.
11. NOTE: Mark the pinion flange in relation to the drive pinion stem to
ensure correct alignment during installation.
Using the special tools, remove the drive pinion flange.
12. Using a suitable tool, remove and discard the drive pinion seal.
Installation
1. CAUTIONS:
Installation without the correct tool can result in early seal failure.
If the drive pinion seal becomes misaligned during installation ,
remove it and install a new one.
NOTE: Lubricate the lips of the new drive pinion oil seal. Use a long life
grease or equivalent.
Using the special tool, install the drive pinion seal.
2. CAUTION: Inspect the pinion flange seal journal for rust or
nicks/scratches prior to installing the pinion flange. Polish the seal journal
with a fine crocus cloth, if required.
Install the drive pinion flange.
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3. CAUTION: Do not under any circumstance, loosen the pinion nut to
reduce preload, if preload is exceeded install a new collapsible spacer and
pinion nut.
Using the special tool, hold the pinion flange while tightening the drive
pinion retaining nut.
4. CAUTION: If the preload recorded prior to disassembly is lower
than the specification (1.7 Nm / 15 lb-in) for used bearings, tighten the
companion flange nut until the pinion preload reaches the specification
(1.7 Nm / 15 lb-in). If the preload recorded prior to disassembly is higher
than the specification for used bearings, tighten the companion flange nut
to the original reading as recorded.
NOTE: Rotate the pinion to allow the pinion bearing to seat correctly.
Take frequent pinion bearing torque preload measurements by rotating the
pinion with a (Nm / lb-in) torque wrench.
Using the special tool, carry out a pinion bearing preload check.
6. Loosely install the axle assembly rear retaining bolt.
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9. Tighten the axle assembly front retaining bolts to 90 Nm.
10. Tighten the axle assembly rear retaining bolt to 110 Nm and then
slowly tighten to 135 Nm.
11. Install the vibration damper.
Tighten to 48 Nm.
For additional information, refer to: Driveshaft (205-01, Removal and
Installation).
13. Install the rear brake pads.
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Rear Drive Axle/Differential - Axle Assembly
Removal
1. Remove the left-hand rear halfshaft.
For additional information, refer to: Rear Halfshaft (205-05 Rear Drive
Halfshafts, Removal and Installation).
2. Loosely install the rear wheel knuckle retaining bolts.
3. CAUTION: Support the driveshaft front and rear sections. Failure
to follow this instruction may result in damage to the vehicle.
Detach the driveshaft front universal joint.
1. Remove and discard the driveshaft front universal joint
retaining bolts.
2. Remove and discard the driveshaft retaining bolts link
washers.
3. Detach the driveshaft front universal joint.
1. Remove and discard the gasket.
4. Detach the driveshaft rear universal joint.
1. Remove and discard the driveshaft rear universal joint
retaining bolts.
2. Remove and discard the driveshaft retaining bolts link
washers.
3. Detach the driveshaft rear universal joint.
1. Remove and discard the gasket.
5. CAUTION: Support the driveshaft front and rear sections.
Remove the driveshaft.
Discard the retaining bolts.
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7. Remove the vibration damper bracket retaining bolt.
Remove the axle assembly front retaining bolts.
9. Remove and discard the axle assembly rear retaining bolt and lower the
axle assembly.
Remove and Discard the axle assembly washer.
10. NOTE: The halfshaft is retained in the differential by a spring clip.
Remove the axle assembly.
1. Using a suitable pry tool detach the rear halfshaft.
2. Remove the axle assembly.
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Installation
NOTE: When installing the halfshaft make sure the spring clip is fully
engaged in the differential.
Install the axle assembly.
2. Install the halfshaft into the axle assembly.
2. NOTE: Install a new axle assembly washer.
Loosely install new axle assembly rear retaining bolt.
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7. CAUTION: Slowly tighten the axle retaining bolt to final torque.
Tighten to 150 Nm. If you are refitting an old fixing (before VIN J24258),
tighten to 135 Nm.
9. CAUTION: Support the driveshaft front and rear sections.
Loosely install the driveshaft center bearing retaining bolts.
10. Attach the driveshaft front universal joint.
1. Install a new gasket.
2. Install new driveshaft retaining bolts link washers.
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11. Attach the driveshaft rear universal joint.
1. Install a new gasket.
12. Carry out the under body misalignment check.
14. Remove the rear wheel knuckle retaining bolts.
15. Install the left-hand rear halfshaft.
Halfshafts, Removal and Installation). J
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Front Drive Halfshafts -
Wheel hub nut 270 200 -
Tie rod end retaining nut 35 26 -
Lower arm ball joint retaining nut 83 61 -
Front subframe reinforcement plate retaining bolt 35 26 -
Front subframe rear mount retaining bolt 142 105 -
Front subframe front mount retaining bolt 142 105 -
Transfer case Y bracket retaining bolt 25 18 -
Intermediate shaft bearing carrier retaining bolts 25 18 -
Front right-hand halfshaft retaining nuts - Vehicles with 2.0L or diesel engine 25 18 -
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Front Drive Halfshafts - Front Drive Halfshafts
1 Outer constant velocity (CV) joint
2 CV joint boot retaining clip
3 CV joint boot
4 CV joint boot retaining clip
5 Snap ring
6 Barshaft
7 Circlip
8 Tripod star
9 Tripod star housing
The front drive halfshafts are of equal lengths with the inner constant velocity (CV) joint being of the plunger type.
The inner and outer CV joints are linked by a solid barshaft. The inner CV joints are retained in the differential with the aid of a spring clip.
On vehicles with 2.0L or diesel engines there is an addition of an intermediate shaft which connects the right-hand side of the differential
with the right-hand halfshaft. The right-hand halfshaft is retained in the intermedi ate shaft with the aid of a spring circlip. The intermediate
shaft is supported by an additional bearing which is fitted to the outer end of the intermediate shaft and is attached to the right-hand
catalytic converter retaining bracket.
Handling Front Drive Halfshafts
The following points should be observed when handling front drive halfshafts:
Do not pull on the CV joints.
Do not allow the CV joints to exceed 18 degrees of articulation.
Check polished surfaces and splines for damage.
Do not allow the CV joint boots to come into contact with sharp edges, hot vehicle components or the exhaust system.
Do not drop the front drive halfshafts, this may cause damage to the interior of the boots which may not be visible.
Do not support the front drive halfshaft by holding the CV joint alone.
Underbody Protection and Corrosion Prevention
The CV joint boots should be covered during application of underbody protection or corrosion prevention. Foreign matter on the CV boots
may cause premature ageing of the material. Foreign material on the front drive halfshafts may cause imbalance.
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Front Drive Halfshafts - Front Drive Halfshafts
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Front Drive Halfshafts - Front Halfshaft LH
Special Tool(s)
Ball joint splitter
204-192
Wheel hub puller
205-491
Adapter nuts
205-491-01
Forcing screw
204-269
Slide hammer
100-012
100-012-02
Slide hammer shaft
Halfshaft remover fork
204-226
Removal
All vehicles
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2. Remove the front road wheel and tire.
3. Remove the tie rod end retaining nut.
4. Using the special tool detach the tie rod end.
5. Remove the subframe reinforcement plate retaining bolts.
6. Loosen the subframe rear mount retaining bolt.
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7. Loosen the subframe front mount retaining bolt.
1. Remove the lower arm ball joint retaining bolt.
Vehicle with automatic transmission
11. Drain the automatic transmission fluid.
For additional information, refer to: Transmission Fluid Drain and Refill
(307-01B Automatic Transmission/Transaxle - Vehicles With: 6-Speed
Automatic Transaxle - AWF21, General Procedures).
Vehicles with manual transmission
12. Drain the manual transmission fluid.
For additional information, refer to: Transaxle Draining and Filling -
Vehicles With: 6-Speed Manual Transaxle - MMT6 (308-03 Manual
Transmission/Transaxle, General Procedures).
All vehicles
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13. Using the special tools, remove the halfshaft.
14. CAUTION: Use suitable protective covers to protect the barshaft.
Remove the halfshaft snap ring.
Installation
All vehicles
1. Install a new snap ring to the halfshaft.
2. CAUTION: Make sure the CV joint splines are located fully. Do not
use excessive force when engaging the CV joint into the transmission.
Install the halfshaft.
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3. Install the lower arm ball joint retaining bolt.
Tighten to 83 Nm.
4. Tighten the front subframe front mount retaining bolt.
Tighten to 142 Nm.
5. Loosely install the subframe rear mount retaining bolt.
6. Install the subframe reinforcement plate retaining bolts.
Tighten to 35 Nm.
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8. Install the tie rod end.
Tighten to 35 Nm.
9. Loosely install a new wheel hub nut.
10. Install the front road wheel and tire.
Vehicle with automatic transmission
11. Refill the automatic transmission system.
12. Refill the manual transmission system.
Tighten to 270 Nm.
14. Check the subframe alignment.
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Front Drive Halfshafts - Front Halfshaft RH2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L
NA V6 - AJ27
Special Tool(s)
Ball joint splitter
204-192
Wheel hub puller
205-491
Adapter nuts
205-491-01
Forcing screw
204-269
RH halfshaft splitter
307-442
RH halfshaft splitter handle
307-443
Slide hammer shaft
100-012-02
Slide hammer
100-012
204-226
Removal
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All vehicles
3. Remove the tie rod-end retaining nut.
4. Using the special tool, detach the tie-rod end.
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6. Loosen the subframe rear mount bolt.
7. Loosen the subframe front mount bolt.
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11. Remove the exhaust muffler inlet pipe.
For additional information, refer to: Muffler Inlet Pipe - 2.0L NA V6 -
AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27 (309-00 Exhaust System,
12. Remove the halfshaft seal.
13. Remove the transfer case Y bracket retaining bolt.
14. CAUTION: To prevent damage to the transfer box internal seal,
make sure that the link shaft is not retracted further than 200 mm from
the transfer box casing.
Using the special tools, remove the halfshaft.
1. Attach special tools to the halfshaft.
2. Lever the special tools to displace the halfshaft.
3. Install the transfer case Y bracket retaining bolt.
4. Remove the halfshaft.
All vehicles
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Remove and discard the halfshaft snap ring.
Installation
All vehicles
2. Install a new halfshaft seal.
3. Install the halfshaft.
Tighten to 25 Nm.
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1. Remove the transfer case Y bracket retaining bolt.
5. CAUTION: Make sure the CV joint splines are located fully. Do not
use excessive force when engaging the CV joint into the link shaft.
Tighten to 25 Nm.
7. Install the exhaust muffler inlet pipe.
All vehicles
Tighten to 83 Nm.
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9. Tighten the subframe front mount retaining bolt.
Tighten to 142 Nm.
Tighten to 35 Nm.
12. Install the tie-rod end.
Tighten to 35 Nm.
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Tighten to 270 Nm.
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Front Drive Halfshafts - Front Halfshaft RH2.0L Duratorq-TDCi/2.2L Duratorq-TDCi
Special Tool(s)
Ball joint splitter
204-192
Wheel hub puller
205-491
Adapter nuts
205-491-01
Forcing screw
204-269
Removal
3. Remove the tie rod-end retaining nut.
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4. Using the special tool, detach the tie-rod end.
6. Loosen the subframe rear mount bolt.
7. Loosen the subframe front mount bolt.
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Remove and discard the halfshaft snap ring.
Installation
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Tighten to 25 Nm.
Tighten to 83 Nm.
4. Tighten the subframe front mount retaining bolt.
Tighten to 142 Nm.
Tighten to 35 Nm.
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7. Install the tie-rod end.
Tighten to 35 Nm.
Tighten to 270 Nm.
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Front Drive Halfshafts - Inner Constant Velocity (CV) Joint Boot
Removal
1. Remove the front halfshaft. For additional information, refer to
Halfshaft LH. For additional information, refer to Halfshaft RH.
Using a suitable clamp, secure the front halfshaft.
3. Remove the inner constant velocity (CV) joint boot outer retaining clip.
Remove and discard the retaining clip.
4. Remove the tripod star housing.
Remove and discard the grease.
5. Remove the tripod star circlip.
6. CAUTION: Do not damage the roller bearings.
Using a suitable brass drift, remove the tripod star.
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7. Remove the inner CV joint boot retaining clip.
8. Remove the inner CV joint boot.
Installation
1. Install the inner CV joint boot.
2. NOTE: Install a new retaining clip.
Using a suitable tool, install the inner CV joint boot retaining clip.
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3. CAUTION: Do not damage the roller bearings.
Install the tripod star.
4. Install the tripod star circlip.
5. NOTE: Install new grease.
Install the tripod star housing.
6. NOTE: Make sure enough air is present in the CV boot.
NOTE: Install a new retaining clip.
Using a suitable tool, install the inner constant velocity (CV) joint boot
outer retaining clip.
7. Remove the front halfshaft from the clamp.
8. Install the front halfshaft. For additional information, refer to Halfshaft
LH. For additional information, refer to Halfshaft RH.
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Front Drive Halfshafts - Intermediate Shaft
Removal
All vehicles
1. Remove the right-hand halfshaft.
For additional information, refer to Halfshaft RH in this section.
2. Drain the automatic transmission fluid. For additional information, refer
to Section 307-01A Automatic Transmission/Transaxle / 307-01B
Automatic Transmission/Transaxle.
3. Drain the manual transmission fluid.
For additional information, refer to Section 308-03 Manual
All vehicles
4. CAUTION: Before removing the bearing carrier retaining bolts,
identify their correct position. Failure to follow this procedure will result in
damage to the vehicle.
Remove the intermediate shaft bearing carrier retaining bolts.
Remove the branch pipe heat shield.
5. Remove the intermediate shaft.
Installation
All vehicles
1. CAUTION: Make sure the intermediate shaft splines are located
fully. Do not use excessive force when engaging the intermediate shaft
into the transmission.
Install the intermediate shaft.
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2. CAUTION: Before installing the bearing carrier retaining bolts
make sure that the bearing carrier is located in the same position that it
was removed from, failure to follow this procedure will result in damage to
the vehicle.
Install the branch pipe heat shield.
Tighten to 25 Nm.
3. Refill the automatic transmission system. For additional information,
refer to Section 307-01A Automatic Transmission/Transaxle / 307-01B
4. Refill the manual transmission.
For additional information, refer to Section 308-03 Manual
All vehicles
5. Install the right-hand halfshaft.
For additional information, refer to Halfshaft RH in this section.
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Front Drive Halfshafts - Outer Constant Velocity (CV) Joint Boot
Removal
1. Remove the front halfshaft. For additional information, refer to
Halfshaft LH. For additional information, refer to Halfshaft RH.
Using a suitable clamp, secure the front halfshaft
3. Remove the outer constant velocity (CV) joint retaining clips.
Remove and discard the retaining clips.
4. Detach the outer CV joint boot.
Remove and discard the grease.
5. CAUTION: Do not damage the bearing retainer.
NOTE: The outer CV joint is retained to the shaft by a spring clip.
Using a suitable brass drift, remove the outer CV joint.
6. Remove the outer CV joint boot.
Installation
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1. Install the outer CV joint boot.
Install the outer CV joint.
3. Attach the outer CV joint boot.
Install new grease.
4. NOTE: Make sure enough air is present in the CV boot.
NOTE: Install new retaining clips.
Using a suitable tool, install the CV joint retaining clips.
5. Remove the front halfshaft from the clamp.
6. Install the front halfshaft. For additional information, refer to Halfshaft
LH. For additional information, refer to Halfshaft RH.
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Rear Drive Halfshafts -
Lubricants, Fluids, Sealers and Adhesives
Item Specification
Constant velocity (CV) grease Olistamoly LN 584 LO
Fill Capacities
Description Grams
Grease for inner CV joint boot 90
Grease for inner CV joint 90
Grease for outer CV joint boot 90
Grease for outer CV joint 90
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Rear Drive Halfshafts - Rear Drive Halfshafts
1 Outer constant velocity (CV) joint
2 Anti-lock brake system (ABS) ring
3 Outer CV joint boot
4 Inner CV joint boot
5 Seal protector
6 Spring clip
7 Inner CV joint
8 Barshaft
The rear drive halfshafts are of unequal lengths and both the inner CV joint and outer CV joints are of the plunger type.
The outer CV joints are fitted with an ABS ring which is continuously monitored by the wheel speed sensor.
The inner and outer CV joints are linked by a solid barshaft. The inner CV joints are retained in the differential with the aid of a spring clip.
The inner CV joints are fitted with plastic seal protectors to protect the halfshaft oil seals located in the differential from debris.
Due to the unique construction of the rear drive halfshafts they are not a serviceable item. If a problem occurs the halfshaft must be
replaced as a complete unit.
Handling Rear Drive Halfshafts
The following points should be observed when handling rear drive halfshafts:
Do not pull on the CV joints
Do not allow the CV joints to exceed 18 degrees of travel
Check polished surfaces and splines for damage
Do not allow the CV joint boots to come into contact with sharp edges, hot vehicle components or the exhaust system
Do not drop the rear drive halfshafts, this may cause damage to the splined sections of the CV joints, the threaded sections of the
CV joints or the interior of the boots which may not be visible
Do not support the rear drive halfshaft by holding the CV joint alone
Underbody Protection and Corrosion Prevention
The CV joint boots should be covered during application of underbody protection or corrosion prevention. Foreign matter on the CV boots
may cause premature ageing of the material. Foreign material on the rear drive halfshafts may cause imbalance.
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Rear Drive Halfshafts - Rear Drive Halfshafts
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Rear Drive Halfshafts - Rear Halfshaft
Special Tool(s)
Remover, Axle Shaft Oil Seal
308-208
Installer, Oil Seal
204-264
Removal
For additional information, refer to: Wheel Knuckle (204-02 Rear
Suspension, Removal and Installation).
3. Using the special tool, remove and discard the axle shaft oil seal.
Installation
1. Using the special tool, install the axle shaft oil seal.
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2. NOTE: When installing the halfshaft make sure the spring clip is fully
engaged in the differential.
3. Install the wheel knuckle.
For additional information, refer to: Wheel Knuckle (204-02 Rear
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Rear Drive Halfshafts - Outer Constant Velocity (CV) Joint Boot
Removal
NOTE: Outer Constant Velocity (CV) Joint Boot shown, inner Constant Velocity (CV) Joint Boot similar.
2. CAUTION: Use suitable protective covers to protect the halfshaft.
Using a suitable clamp, secure the halfshaft.
3. Remove the outer constant velocity (CV) joint boot retaining clip.
Discard the retaining clip.
Using a suitable brass drift, remove the outer CV joint.
5. Remove the retaining clip.
6. Remove the outer CV joint boot.
Installation
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1. Install the outer CV joint boot.
Install a new retaining clip.
Using a suitable tool, install the retaining clip.
2. Install the new retaining clip.
Install a new retaining clip.
3. CAUTION: Make sure the CV joint ball bearings do not drop out of
the CV joint.
NOTE: Use a CV grease meeting Jaguar specification.
Install the outer CV joint.
Fill the outer CV joint and outer CV gaitor with grease.
4. Install the new retaining clip.
5. Remove the halfshaft from the clamp.
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Brake System - General Information -
CAUTION: Do not use brake fluid ITT Super Dot 4 on 2006my vehicles onwards. Failure to follow this instruction may result in damage
to the vehicle.
NOTE: Brake fluid ITT Super Dot 4 has now been superseded by Shell ESL Super Dot 4 which is the Jaguar recommended brake fluid. Shell
ESL Super Dot 4 can be used on all model years.
Item Specification
Brake fluid ITT Super Dot 4
Brake fluid Shell ESL Super Dot 4
Caliper slide pin grease Klueber GLK1
Brake Lining and Disc Specifications
Item Specification
Brake pad nominal thickness - front 10.4 mm (0.40 in)
Brake pad minimum thickness - front 2 mm (0.08 in)
Brake pad nominal thickness - rear 11.80 mm (0.43 in)
Brake pad minimum thickness - rear 2 mm (0.08 in)
Brake disc diameter - front 300 mm (12 in)
Brake disc diameter - rear 280 mm (11.032 in)
New disc nominal thickness - front 24 mm (0.95 in)
New disc nominal thickness - rear 12 mm (0.47 in)
Worn disc discard thickness - front 22.2 mm (0.87 in)
Worn disc discard thickness - rear 10.2 mm (0.40 in)
Maximum disc runout (installed) - front 0.076 mm ( 0.003 in)
Maximum hub face runout (installed) - front 0.05 mm ( 0.002 in)
Maximum disc runout (installed) - rear 0.076 mm ( 0.003 in)
Maximum hub face runout (installed) - rear 0.05 mm ( 0.002 in)
Maximum thickness variation - new disc - front 0.009 mm ( 0.0004 in) in 360
Maximum thickness variation - new disc - rear 0.009 mm ( 0.0004 in) in 360
Caliper piston diameter -single piston - front 57 mm (2.24 in)
Caliper piston diameter - rear 38 mm (1.49 in)
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Brake System - General Information - Brake System
WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with the eyes. Wash hands thoroughly after handling.
If brake fluid contacts the eyes, flush the eyes for 15 minutes with cold running water. Get medical attention if irritation persists. If taken
internally, drink water and induce vomiting. Get medical attention immediately. Failure to follow these instructions may result in personal
injury.
The braking system is a diagonally split, dual circuit design featuring front and rear disc brakes.
The hydraulic system provides separate circuits for each pair of diagonally opposed wheels (left front, right rear and right front, left rear).
The front calipers, mounted on the front knuckle, are single pistoned floating caliper design which make sure that equal effort is applied
through both brake pads. The rear calipers are a single pistoned floating caliper design. The pads in all cases are asbestos free.
The parking brake control is located between the front seats and operates the rear brakes through a cable system. The cable has a manual
adjust mechanism incorperated into the parking brake control.
The master cylinder is of a tandem design and is linked to a brake booster to reduce the brake pedal effort. On 2.0L variants a vacuum
pump is fitted to ensure assistance in certain circumstances. The tandem design will make sure that in the event of one brake circuit failure
the other will remain fully operational. The booster operating rod is connected directly to the brake pedal.
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Brake System - General Information - Brake System
Principles of Operations
The brake system operates by transferring effort applied to the brake pedal, by the driver, to the brakes at each wheel.
The braking effort is distributed to each wheel, using a hydraulic system. The system is assisted using a vacuum brake booster that reduces
pedal effort for a given hydraulic pressure. The parking brake operates on the rear wheels and is applied using a hand operated control.
NOTE: Prior to carrying out any diagnosis, make sure that the brake system warning indicator is functional.
Visually examine the front and rear tire and wheel assemblies for damage such as uneven wear patterns, tread worn out or sidewall
damage.Verify the tires are the same size, type and, where possible, same manufacture.Replace the damaged wheel or excessively worn
tire. For additional information, refer to
REFER to: Wheel and Tire (204-04 Wheels and Tires, Removal and Installation).
.
Wheels and tires must be cleared of any foreign matter and tire pressures adjusted to the correct specification.
If the tires exhibit uneven wear or feathering, the cause must be corrected. Check the steering and suspension components for damage or
wear, if necessary check and adjust the front wheel alignment. For additional information, refer to
REFER to: Front Toe Adjustment (204-00 Suspension System - General Information, General Procedures).
.
Road Test
Mechanical Electrical
Brake master cylinder Parking brake switch
Brake caliper piston(s) Damaged or corroded wiring harness
Brake discs Brake master cylinder fluid level switch
Wheel bearings Vacuum pump controller
Brake pads Pedal box switches
Power brake booster
Brake pedal linkage
Booster vacuum hose
Tires
Debris
Modulator
Vacuum pump
Carry out a road test to compare actual vehicle braking performance with the performance standards expected by the driver. The ability of
the test driver to make valid comparisons and detect performance deficiencies will depend on experience.
The driver should have a thorough knowledge of brake system operation and accepted general performance guidelines to make good
comparisons and detect performance concerns.
An experienced brake technician will always establish a route that will be used for all brake diagnosis road tests. The roads selected will be
reasonably smooth and level. Gravel or bumpy roads are not suitable because the surface does not allow the tires to grip the road equally.
Crowned roads should be avoided because of the large amount of weight shifted to the low set of wheels on this type of road. Once the
route is established and consistently used, the road surface variable can be eliminated from the test results.
Before a road test, obtain a complete description of the customer concerns or suspected condition. From the description, the technician's
experience will allow the technician to match possible causes with symptoms. Certain components will be tagged as possible suspects while
others will be eliminated by the evidence. More importantly, the customer description can reveal unsafe conditions which should be checked
or corrected before the road test. The description will also help form the basic approach to the road test by narrowing the concern to specific
components, vehicle speed or conditions.
Begin the road test with a general brake performance check. Keeping the description of the concern in mind, test the brakes at different
vehicle speeds using both light and heavy pedal pressure. To determine if the concern is in the front or rear braking system, use the brake
pedal and then use the parking brake control. If the condition (pull, vibration, pulsation) occurs only with the parking brake, the concern is
in the rear brake system.
If the concern becomes evident during this check, verify it fits the description given before the road test. If the concern is not evident,
attempt to duplicate the condition using the information from the description.
If a concern exists, use the Symptom Chart in order to isolate it to a specific sub-system and condition description. From this description, a
list of possible sources can be used to further narrow the cause to a specific component or condition.
Symptom Chart
Brakes noisy Brake pads.
Brake discs.
Vibration when brakes
are applied
Wheels require balancing.
Wheel hub nuts.
Caliper mounting bolts.
Brake pads.
Foreign material/scratches
/corrosion on brake disc contact
surfaces.
Excessive brake disc thickness
variation.
Excessive brake disc runout.
Wheel bearing wear or failure.
Suspension bush wear or failure.
Steering bush wear or failure.
Go to Pinpoint Test B.
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The brakes pull or drift Tire pressures/wear.
Calipers.
Brake pads.
Brake discs.
Wheel alignment adjustment.
Wheel bearing.
Suspension bushes and ball joints.
The pedal feels spongy Air in brake system.
Leak in hydraulic system.
Brake booster/master cylinder.
Brake pads.
The pedal goes down
fast
Air in brake system.
Leak in hydraulic system.
Brake pads.
The pedal goes down
slowly
Air in brake system.
Go to Pinpoint Test F.
Excessive brake pedal
effort
Brake pads.
Brake booster.
Vacuum pump.
GO to Pinpoint Test G.
Brake lockup during light
brake pedal force
Brake pads.
Calipers.
GO to Pinpoint Test H.
Brakes drag Parking brake control
applied/malfunction.
Seized parking brake cables.
Seized caliper slide pins.
Seized caliper.
Brake booster.
Pedal gear.
GO to Pinpoint Test I.
Excessive/Erratic brake
pedal travel
Hydraulic system.
Brake pads.
Brake discs.
Hub and bearing assembly.
GO to Pinpoint Test J.
The red brake warning
indicator is always on
Fluid level. FILL the system to specification. CHECK for leaks.
Brake fluid level sensor. INSTALL a new brake master cylinder fluid reservoir. For additional
information, refer to
REFER to: Brake Master Cylinder (206-06 Hydraulic Brake Actuation,
.
Parking brake control. RELEASE and ADJUST the parking brake. For additional information, refer
to
REFER to: Parking Brake Cable Adjustment - Vehicles With: Manually
Adjusted Parking Brake, VIN Range: D55322->E24053 (206-05 Parking
Brake and Actuation, General Procedures).
.
Electrical circuit. For additional information, refer to the approved Jaguar diagnostic
system for analysis/rectification of the concern.
Slow or incomplete brake
pedal return
Brake pedal binding.
GO to Pinpoint Test K.
PINPOINT TEST A : BRAKES NOISY
A1: INSPECT BRAKE PADS
Inspect the condition of the front and rear brake pads. Check for damage to any anti-squeal shims.
Are the brake pads OK?
Yes
GO to A2.
No
CLEAN the front brake pads or INSTALL new front brake pads if necessary. For additional information, refer to
REFER to: Brake Pads (206-03 Front Disc Brake, Removal and Installation).
. CLEAN the rear brake pads or INSTALL new rear brake pads if necessary. For additional information, refer to
REFER to: Brake Pads (206-04 Rear Disc Brake, Removal and Installation).
.Test vehicle for presence of brake squeal.
A2: INSPECT BRAKE DISCS
Inspect the brake discs for excessive corrosion, wear or disc thickness variation.
Does excessive corrosion, wear or disc thickness variation exist?
Yes
INSTALL new front brake discs and brake pads. For additional information, refer to
REFER to: Brake Disc (206-03 Front Disc Brake, Removal and Installation).
. INSTALL new rear brake discs and brake pads. For additional information, refer to
REFER to: Brake Disc (206-04 Rear Disc Brake, Removal and Installation).
. TEST the system for normal operation.
No
Vehicle is OK.
PINPOINT TEST B : VIBRATION WHEN BRAKES ARE APPLIED
TEST
CONDITIONS
B1: ROAD TEST VEHICLE
Road test the vehicle between 40-80 km/h (25-50 mph) without applying brakes.
Is the vibration present?
Yes
TEST for noise vibration and harshness. For additional information, refer to
REFER to: Noise, Vibration and Harshness (NVH) (100-04 Noise, Vibration and Harshness, Diagnosis and Testing).
. REPEAT road test if necessary.
No
GO to B2.
B2: CHECK FOR BRAKE VIBRATION
Road test the vehicle between 40-80 km/h (25-50 mph) with light and medium application on the brake pedal.
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Is a vibration present?
Yes
CHECK the brake caliper mounting bolts and wheel hub nuts and TIGHTEN as necessary. CHECK the balance of all road
wheels and REPAIR as necessary. CHECK the brake discs for excessive wear, runout, thickness variation or cracks. For
additional information refer to
REFER to: Front Disc Brake (206-03 Front Disc Brake, Diagnosis and Testing).
INSTALL new brake discs and brake pads as necessary. GO to B3.
No
Vehicle is OK.
B3: IS VIBRATION STILL PRESENT UNDER BRAKE APPLICATION?
Road test the vehicle between 40-80 km/h (25-50 mph) with light and medium application on the brake pedal.
Is a vibration present?
Yes
CHECK for wear or failure of steering bushes. For additional information, refer to
REFER to: Power Steering (211-02 Power Steering, Diagnosis and Testing).
. CHECK for wear or failure of steering ball joints. For additional information, refer to
REFER to: Steering Linkage (211-03 Steering Linkage, Diagnosis and Testing).
. CHECK for wear or failure of front wheel bearings, suspension bushes and ball joints. For additional information,
refer to
REFER to: Front Suspension (204-01 Front Suspension, Diagnosis and Testing).
. CHECK for wear or failure of rear wheel bearings, suspension bushes and ball joints. For additional information, refer
to
REFER to: Rear Suspension (204-02 Rear Suspension, Diagnosis and Testing).
.
No
Vehicle is OK.
PINPOINT TEST C : THE BRAKES PULL OR DRIFT
C1: ROAD TEST VEHICLE
Road test the vehicle and apply the brake pedal.
Does the vehicle pull or drift?
Yes
GO to C2.
No
Vehicle is OK.
C2: INSPECT TIRE PRESSURE
Check for excessive tire wear or incorrect pressures.
Are the tires at the correct pressure and in good condition?
Yes
GO to C3.
No
ADJUST the tire pressures or INSTALL new tires if excessively worn. TEST the system for normal operation.
C3: CHECK CALIPERS
Check the front caliper pistons for binding, leaking or sticking. For additional information, refer to
. Check the rear caliper pistons for binding, leaking or sticking. For additional information, refer to
REFER to: Rear Disc Brake (206-04 Rear Disc Brake, Diagnosis and Testing).
.
Do the disc brake caliper pistons and pins bind, leak or stick?
Yes
INSTALL new calipers as necessary. TEST the system for normal operation.
No
GO to C4.
C4: INSPECT BRAKE DISCS
Check the brake discs for excessive damage, thickness variation or runout. For additional information, refer to
.
Does excessive damage or runout exist?
Yes
INSTALL new brake discs and brake pads as necessary.TEST the system for normal operation.
No
GO to C5.
C5: INSPECT THE FRONT HUB AND WHEEL BEARING ASSEMBLY
Check the front hub and wheel bearing assembly. For additional information, refer to
REFER to: Wheel Bearing Inspection (204-00 Suspension System - General Information, General Procedures).
.
Are the wheel bearings OK?
Yes
GO to C6.
No
INSTALL new wheel bearings. For additional information, refer to
REFER to: Front Wheel Bearing and Wheel Hub (204-01 Front Suspension, Removal and Installation).
.TEST the system for normal operation.
C6: CHECK SUSPENSION BUSHES AND BALL JOINTS.
Check all suspension bushes and ball joints.
Are the suspension bushes and ball joints OK?
Yes
GO to C7.
No
INSTALL new front suspension bushes and ball joints as required. For additional information, refer to
REFER to: Front Stabilizer Bar Bushing (204-01 Front Suspension, Removal and Installation).
. INSTALL new rear suspension bushes and ball joints as required. For additional information, refer to
REFER to: Rear Lower Arm (204-02 Rear Suspension, Removal and Installation).
.
C7: CHECK VEHICLE ALIGNMENT
Check the vehicle alignment. For additional information, refer to
REFER to: Underbody Misalignment Check (502-00 Uni-Body, Subframe and Mounting System, General Procedures).
.
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Is the alignment within specification?
Yes
Vehicle is OK.
No
Adjust the alignment as necessary. For additional information, refer to
REFER to: Underbody Misalignment Check (502-00 Uni-Body, Subframe and Mounting System, General Procedures).
.
PINPOINT TEST D : THE PEDAL FEELS SPONGY
TEST
CONDITIONS
D1: CHECK FOR SPONGY PEDAL (IGNITION OFF)
Check for a firm brake pedal.
Is the brake pedal effort and brake pedal travel normal?
Yes
Vehicle is OK.
No
GO to D2.
D2: CHECK BRAKE PEDAL RESERVE (IGNITION OFF)
Pump the brake pedal 10 times and hold on the final application.
Does the brake pedal feel firm on final application?
Yes
GO to D3.
No
BLEED the brake system. For additional information, refer to
REFER to: Brake System Bleeding (206-00 Brake System - General Information, General Procedures).
D3: CHECK BRAKE PEDAL RESERVE (ENGINE ON)
Engine is idle.
Apply the brake pedal lightly three or four times.
Wait 15 seconds for the vacuum to recover.
Push down on the brake pedal until it stops moving downward or an increased resistance to the brake pedal travel
occurs.
Hold the brake pedal in the applied position while increasing the engine speed to 2000 revs/min.
Release the accelerator pedal.
Does the brake pedal move downward as the engine speed returns to idle?
Yes
GO to D4.
No
CHECK the vacuum to brake booster. For additional information, refer to
REFER to: Brake Booster - RHD AWD/RHD FWD (206-07 Power Brake Actuation, Removal and Installation).
.
D4: CHECK BRAKE FLUID LEVEL
Check the brake master cylinder reservoir fluid level.
Is the fluid level OK?
Yes
BLEED the brake system. For additional information, refer to
No
CHECK the brake master cylinder reservoir sealing points. For additional information, refer to Brake Master Cylinder
Component Test in this section. ADD fluid and BLEED the brake system. For additional information, refer to
.TEST the system for normal operation. REPEAT road test if necessary.
PINPOINT TEST E : THE PEDAL GOES DOWN FAST
TEST
CONDITIONS
E1: ROAD TEST VEHICLE
Road test and apply the brake pedal.
Yes
Vehicle is OK.
No
GO to E2.
E2: CHECK BRAKE FLUID LEVEL
Is the fluid level within specification?
Yes
GO to E3.
No
CHECK the brake master cylinder reservoir sealing points. For additional information, refer to Brake Master Cylinder
Component Test in this section. ADD fluid and BLEED the brake system. For additional information, refer to
E3: CHECK BRAKE PEDAL TRAVEL-PRESSURIZE SYSTEM (IGNITION OFF)
Pump the brake pedal rapidly (five times).
Does the brake pedal travel build up and then hold?
Yes
BLEED the brake system. Refer to
. TEST the system for normal operation. REPEAT road test. For additional information, refer to
REFER to: Hydraulic Brake Actuation (206-06 Hydraulic Brake Actuation, Diagnosis and Testing).
.
No
GO to E4.
E4: CHECK FOR BRAKE SYSTEM LEAKS
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Check for external brake system leaks. For additional information, refer to Master Cylinder in this section.
Are leaks found?
Yes
REPAIR as necessary, ADD fluid and BLEED brake system. For additional information, refer to
.TEST the system for normal operation. REPEAT road test.
No
System is OK.
PINPOINT TEST F : THE PEDAL GOES DOWN SLOWLY
TEST
CONDITIONS
F1: ROAD TEST VEHICLE - CHECK BRAKE PEDAL OPERATION
Check if the condition occurs during actual stopping application by applying the brake pedal while the vehicle is
moving.
Does the condition occur when the vehicle is moving?
Yes
GO to F2.
No
GO to F3.
F2: CHECK FOR BRAKE SYSTEM LEAKS
Check for external brake system leaks. For additional information, refer to Master Cylinder in this section.
Are there any external brake system leaks?
Yes
REPAIR as necessary. ADD fluid and BLEED the brake system. For additional information, refer to
No
GO to F3.
F3: CARRY OUT A BRAKE MASTER CYLINDER BYPASS TEST
Test for brake master cylinder bypass condition. Refer to Brake Master Cylinder Component Test in this section.
Are any concerns found?
Yes
INSTALL a new brake master cylinder, ADD fluid and BLEED the brake system. For additional information, refer to
No
System is OK.
PINPOINT TEST G : EXCESSIVE BRAKE PEDAL EFFORT
TEST
CONDITIONS
G1: CHECK BRAKE PADS
Check the brake pads for wear, contamination, correct installation, damage and type.
Yes
INSTALL the front brake pads correctly or INSTALL new front brake pads if necessary. For additional information, refer
to
REFER to: Brake Pads (206-03 Front Disc Brake, Removal and Installation).
.INSTALL the rear brake pads correctly or INSTALL new rear brake pads if necessary. For additional information, refer
to
REFER to: Brake Pads (206-04 Rear Disc Brake, Removal and Installation).
.REPEAT road test.
No
GO to G2.
G2: CHECK VACUUM
Disconnect the vacuum booster hose from the booster.
Connect a vacuum/pressure tester to the vacuum hose.
Run the engine at normal operating temperature.
Record the vacuum reading.
Is the reading 40.5kPa (12 in-Hg) or greater?
Yes
GO to G3.
No
LOCATE and REPAIR the source of low vacuum. TEST the system for normal operation.
G3: INSPECT SYSTEM
Switch the engine off.
Reconnect the vacuum hose.
Inspect the brake booster, rubber grommet and all vacuum plumbing for cracks, holes, damaged connections or
missing clamps.
Pump the brake pedal several times to release the vacuum. Push down on the brake pedal and hold.
Does the brake pedal move down when the engine is started?
Yes
Vacuum system is OK.
No
GO to G4.
G4: CHECK POWER BRAKE BOOSTER VALVE
Check the brake booster and vacuum pump valves. For additional information, refer to Brake Booster in this section.
Is the power brake booster and vacuum pump valve OK?
Yes
CHECK the brake booster. For additional information, refer to Brake Booster in this section. INSTALL a new brake
booster if necessary. TEST the system for normal operation.
No
INSTALL a new brake booster valve and vacuum pump valve. TEST the system for normal operation.
PINPOINT TEST H : BRAKE LOCKUP DURING LIGHT BRAKE PEDAL FORCE
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TEST
CONDITIONS
H1: TEST BRAKE LOCKUP
Road test the vehicle and apply the brake pedal lightly.
Do the brakes lockup?
Yes
GO to H2.
No
Vehicle is OK.
H2: INSPECT BRAKE PADS
Inspect brake pads for contamination, correct installation, damage and type.
Yes
CHECK the front brake pads. For additional information, refer to
REFER to: Front Disc Brake (206-03 Front Disc Brake, Description and Operation).
.CHECK the rear brake pads. For additional information, refer to
REFER to: Rear Disc Brake (206-04 Rear Disc Brake, Description and Operation).
.INSTALL new brake pads as necessary.REPEAT road test.
No
GO to H3.
H3: INSPECT BRAKE CALIPERS
Inspect brake calipers for binding, leaking or sticking.
Yes
CHECK the front brake calipers. For additional information, refer to
.CHECK the rear brake calipers. For additional information, refer to
.INSTALL the brake calipers correctly or INSTALL new brake calipers as necessary. TEST the system for normal
operation. REPEAT road test if necessary.
No
Vehicle is OK.
PINPOINT TEST I : BRAKES DRAG
I1: ROAD TEST VEHICLE
Road test the vehicle and apply the brakes.
Are the brakes functioning correctly?
Yes
Vehicle is OK.
No
GO to I2.
I2: CHECK CALIPERS
Check the front caliper pistons for binding, leaking or sticking. For additional information, refer to
. Check the rear caliper pistons for binding, leaking or sticking. For additional information, refer to
.
Do the disc brake caliper pistons and pins bind, leak or stick?
Yes
INSPECT the brake calipers and parking brake cables. INSTALL new components as necessary. Road test vehicle.
No
GO to I3.
I3: CHECK BRAKE BOOSTER
Check the brake booster connecting rod alignment and travel. For additional information, refer to
REFER to: Power Brake System (206-07 Power Brake Actuation, Diagnosis and Testing).
.
Is the connecting rod OK?
Yes
Vehicle is OK.
No
INSTALL a new brake booster. For additional information, refer to
PINPOINT TEST J : EXCESSIVE/ERRATIC BRAKE PEDAL TRAVEL
TEST
CONDITIONS
J1: TEST ON ROUGH ROAD
Road test the vehicle on rough road conditions.
Apply the brakes slowly.
Yes
Vehicle is OK.
No
GO to J2.
J2: CHECK BRAKE FLUID LEVEL
Is the fluid level OK?
Yes
GO to J3.
No
CHECK brake master cylinder reservoir sealing points. For additional information, refer to Brake Master Cylinder in
this section. ADD brake fluid and BLEED the brake system. For additional information, refer to
J3: CHECK BRAKE PEDAL RESERVE
Engine is idle.
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Apply the brake pedal lightly three or four times.
Wait 15 seconds for the vacuum to replenish.
Push down on the brake pedal until it stops moving downward or an increased resistance to the brake pedal travel
occurs.
Hold the brake pedal in the applied position while increasing the engine speed to 2000 revs/min.
Release the accelerator pedal.
Does the brake pedal move downward as the engine speed returns to idle?
Yes
GO to J4.
No
CHECK the vacuum to the brake booster. For additional information, refer to
REFER to: Power Brake System (206-07 Power Brake Actuation, Diagnosis and Testing).
.
J4: CHECK THE FRONT HUB AND BEARING ASSEMBLY
Check the front hub and bearing assembly. For additional information, refer to
REFER to: Front Suspension (204-01 Front Suspension, Diagnosis and Testing).
.
Are the front wheel bearings loose?
Yes
INSTALL a new front wheel bearing if damaged. For additional information, refer to
REFER to: Front Wheel Bearing and Wheel Hub (204-01 Front Suspension, Removal and Installation).
No
CHECK the front brake discs for thickness variances. For additional information, refer to
REFER to: Brake Disc Runout Check (206-00 Brake System - General Information, General Procedures).
.
PINPOINT TEST K : SLOW OR INCOMPLETE BRAKE PEDAL RETURN
TEST
CONDITIONS
K1: CHECK FOR BRAKE PEDAL RETURN
Run the engine at fast idle while making several brake applications.
Pull the brake pedal rearward with approximately 44 N force.
Release the brake pedal and measure the distance to the toe board.
Make a hard brake application.
Release the brake pedal and measure the brake pedal to toe board distance. The brake pedal should return to its
original position.
Does the brake pedal return to its original position?
Yes
Vehicle is OK.
No
GO to K2.
K2: CHECK FOR BRAKE PEDAL BINDING
Check the brake pedal to make sure it is operating OK.
Is the brake pedal operating OK?
Yes
INSTALL a new brake booster. For additional information, refer to
No
REPAIR or INSTALL new brake pedal. TEST the system for normal operation.
Component Tests
Brake Booster
1. Check all hoses and connections. All unused vacuum connectors should be capped. Hoses and their connections should be correctly
secured and in good condition with no holes and no collapsed areas. Inspect the valve on the brake booster for damage.
1.
2. Check the hydraulic brake system for leaks or low fluid. 2.
3. With the transmission in PARK (automatic transmissions) or in NEUTRAL (manual transmissions), stop the engine and apply the
parking brake. Pump the brake pedal several times to exhaust all vacuum in the system.
3.
4. With the engine switched off and all vacuum in the system exhausted, apply the brake pedal and hold it down. Start the engine.
If the vacuum system is operating, the brake pedal will tend to move downward under constant foot pressure. If no motion is felt,
the vacuum booster system is not functioning.
4.
5. Remove the vacuum hose from the brake booster. Manifold vacuum should be available at the brake booster end of the hose with
the engine at idle speed and the transmission in PARK or NEUTRAL. Make sure that all unused vacuum outlets are correctly
capped, hose connectors are correctly secured and vacuum hoses are in good condition. When it is established that manifold
vacuum is available to the brake booster, connect the vacuum hose to the brake booster and repeat Step 3. If no downward
movement of the brake pedal is felt, install a new brake booster.
5.
6. Operate the engine for a minimum of 10 seconds at a fast idle. Stop the engine and allow the vehicle to stand for 10 minutes.
Then, apply the brake pedal with approximately 89 N of force. The pedal feel (brake application) should be the same as that noted
with the engine running. If the brake pedal feels hard (no power assist), install a new valve and then repeat the test. If the brake
pedal still feels hard, install a new brake booster. If the brake pedal movement feels spongy, bleed the brake system. For
additional information, refer to
in this section.
6.
Brake Master Cylinder
Usually, the first and strongest indicator of anything wrong in the brake system is a feeling through the brake pedal. In diagnosing the
condition of the brake master cylinder, check pedal feel as evidence of a brake concern. Check for brake warning lamp illumination and the
brake fluid level in the brake master cylinder reservoir.
Normal Conditions
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The following conditions are considered normal and are not indications that the brake master cylinder is in need of repair.
New brake systems are designed to produce a pedal effort that is not as hard as in the past. Complaints of light pedal efforts should
be compared to the pedal efforts of another vehicle of the same model and year.
The fluid level will fall with brake pad wear.
Abnormal Conditions
NOTE: Prior to carrying out any diagnosis, make sure the brake system warning indi cator is functional.
Changes in the brake pedal feel or brake pedal travel are indicators that something could be wrong in the brake system. The diagnostic
procedure and techniques use brake pedal feel, warning indicator illumination and low brake fluid level as indicators to diagnosing brake
system concerns. The following conditions are considered abnormal and indicate that the brake master cylinder is in need of repair:
Brake pedal goes down fast. This could be caused by an external or internal leak.
Brake pedal goes down slowly. This could be caused by an internal or external leak.
Brake pedal is low or feels spongy. This condition may be caused by no fluid in the brake master cylinder, reservoir cap vent holes
clogged or air in the hydraulic system.
Brake pedal effort is excessive. This may be caused by a bind or obstruction in the pedal/linkage, a faulty non return valve, booster
or insufficient booster vacuum.
Rear brakes lock up during light pedal force. This may be caused by damaged brake pads, an incorrectly adjusted parking brake, a
partially applied parking brake, a damaged ABS sensor or bearing failure.
Brake pedal effort erratic. This condition could be caused by the brake booster or incorrectly installed brake pads.
Brake warning indicator is on. This may be caused by low fluid level or float assembly damaged.
Non Pressure Leaks
Any reduced fluid volume in the brake master cylinder reservoir condition may be caused by two types of pressure external leaks.
Type 1: An external leak may occur at the master cylinder reservoir cap because of incorrect positioning of gasket and cap. Reposition cap
and gasket.
Type 2: An external leak may occur at the reservoir mounting seals. Repair such a leak by installing new seals and make sure that the
reservoir retaining pin is correctly installed.
Type 3: An external leak may occur in the manual transmission clutch operating system. For additional information, refer to
REFER to: Manual Transmission and Clutch (308-00 Manual Transmission/Transaxle and Clutch - General Information, Diagnosis and
Testing).
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Brake System - General Information - Brake Disc Runout Check
General Procedures
Check
3. Remove the front brake calipers.
For additional information, refer to: Brake Caliper (206-03 Front Disc
Brake, Removal and Installation).
Or remove the rear brake calipers.
For additional information, refer to: Brake Caliper (206-04 Rear Disc
4. Install all wheel nuts and tighten equally to 20 Nm.
Make sure that the disc is fully seated against the hub face.
5. Install a dial test indicator gauge and holding fixture to a suitable
mounting point.
6. NOTE: If the runout is outside specification, check the hub face runout.
Using the dial test indicator with a suitable adaptor, measure the inner
and outer faces of the disc.
1. Position the gauge so that it contacts the disc 10 mm from the
outer edge.
2. Slowly rotate the hub/disc assembly. Note the reading range.
7. If a front hub runout check is required, remove the front brake disc.
For additional information, refer to: Brake Disc (206-03 Front Disc Brake,
If a rear hub runout check is required, remove the rear brake disc. For
additional information, refer to
8. NOTE: The hub surface should be free from dirt and corrosion. Do not
use abrasive cloths to clean hub faces.
Using the dial test indicator, measure the hub face runout.
1. Position the gauge so that it contacts the mounting tube
between the stud and the chamfer.
2. Slowly rotate the hub and note the runout. For additional
information, refer to the specification chart.
If the front hub runout exceeds the specifications, install a new
hub, brake disc and recheck.
For additional information, refer to: Front Wheel Bearing and Wheel
Hub (204-01 Front Suspension, Removal and Installation).
If the rear hub runout exceeds the specifications, install a new hub,
brake disc and recheck.
For additional information, refer to: Wheel Hub (204-02 Rear
9. If the front hub face is within specification, install a new disc.
For additional information, refer to: Brake Disc (206-03 Front Disc Brake,
If the rear hub face is within specification, install a new disc.
10. Install the wheel and tire assembly.
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Brake System - General Information - Brake System Bleeding
General Procedures
WARNING: Brake Fluid contains polyglycol ethers and polyglycols. Avoid contact with the eyes. Wash hands thoroughly after handling.
internally, drink water and induce vomiting. Get medical attention immediately. Failure to follow these instructions can result in personal
injury.
CAUTIONS:
Make sure that the vehicle is standing on a level surface or supported on a wheel free lift.
If brake fluid is spilt on the paintwork, the affected areas must be immediately washed down with cold water.
NOTE: The system consists of separate circuits for each front and diagonally opposite rear wheel.Each front to rear circuit and each wheel
circuit can be bled individually of each other.
NOTE: The service ABS hydraulic control unit is supplied pre-filled with brake fluid. Therefore, a conventional bleed procedure should be
adequate to remove all the air from the brake system.
1. CAUTION: Make sure that the filler cap does not become
contaminated.
Remove the master cylinder reservoir filler cap.
2. NOTE: Always use fluid from a sealed container and dispose of used
fluid safely.
Fill up the master cylinder reservoir to the MAX mark as necessary.
3. Install a bleed tube to the rear right-hand brake caliper bleed nipple.
4. Bleed the circuit.
Make sure the bleed tube is firmly attached to the bleed nipple.
Submerge the end of the bleed tube in a bleed jar containing a
small quantity of approved brake fluid.
Position the bleed jar base at least 300 mm above the bleed nipple
to maintain fluid pressure and prevent air leaking past the bleed
nipple threads.
Open the bleed nipple half a turn.
Slowly apply the brake pedal to its maximum travel (this forces
brake fluid into the bleed jar).
Close the bleed nipple.
Return the brake pedal to the rest position.
Wait 2 seconds to allow the brake fluid to replenish the system.
Fill up the master cylinder reservoir to the MAX mark as necessary.
Continue to bleed the circuit until air-free brake fluid is pumped
into the jar.
Fully tighten the bleed nipple.
5. Repeat the procedure for the rear left, front right and front left-hand
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brake circuits.
6. Fill up the master cylinder reservoir to the MAX mark.
7. Install the master cylinder reservoir cap.
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Front Disc Brake -
to the vehicle.
Item Specification
Brake caliper slide pin grease Klueber GLK1
Brake pipe union 15 11 -
Brake caliper anchor plate retaining bolts 133 98 -
Brake caliper retaining bolts 30 22 -
Brake hose retaining bracket 40 30 -
Brake hose to brake caliper 10 7 -
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Front Disc Brake - Front Disc Brake
1 Brake hose
2 Brake caliper retaining bolts
3 Brake pads
4 Brake caliper anchor plate
5 Brake disc
6 Wheel hub
7 Wheel knuckle
8 Brake hose retaining bracket
9 Brake caliper
internally, drink water and induce vomiting. Get medical attention immediately. Failure to follow these instructions can result in personal
injury.
NOTE: Brake system materials inherently generate heat in order to dissipate energy. As a result, occasional squeal is possible, which may
be compounded by severe environmental conditions, such as cold, heat, rain, snow, salt and mud.
The front disc brake system consists of the following components:
Brake pads.
Single piston, floating brake calipers.
Brake discs.
Brake caliper anchor plates.
Brake hoses.
The brake caliper has two retaining bolts that attach it to the brake caliper anchor plate. The brake caliper anchor plate is attached to the
wheel knuckle with two retaining bolts. The hydraulic system provides separate circuits for each pair of diagonally opposed wheels (i.e. left
front, right rear and right front, left rear).
The brake disc is manufactured from cast iron and is of the vented type. It is retained on the wheel hub studs by the wheel and wheel nuts.
The brake calipers are mounted on the wheel knuckles. These are of single, sliding piston type which ensures that equal effort is applied
through both brake pads.
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Front Disc Brake - Front Disc Brake
For additional information, refer toSection 206-00 Brake System - General Information.
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Front Disc Brake - Brake Caliper
Special Tool(s)
Brake pedal hold-down tool
JDS 9013
Removal
1. Remove the wheel and tire. For additional information, refer toSection
204-04 Wheels and Tires.
2. CAUTION: If brake fluid is spilt on the paintwork, the affected
area must be immediately washed down with cold water.
NOTE: To prevent the loss of brake fluid, apply the brake pedal hold
down tool and adjust to hold the brake pedal down 40mm. Install a
bleeder bottle to the bleed nipple and loosen.
Detach the brake hose.
1. Detach the brake pipe.
3. Detach the brake hose.
3. Detach the brake hose.
4. NOTE: Tighten the bleed nipple and remove the bleeder tube and
bottle.
Remove the brake caliper.
Remove and discard the brake caliper retaining bolts.
Installation
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1. CAUTIONS:
If the pistons are pushed back into the housing, brake fluid will be
forced out of the inlet port of the brake caliper.
Make sure that the brake disc faces are clean before installation.
NOTE: Install new brake caliper retaining bolts.
Install the brake caliper.
Tighten to 30 Nm.
2. Attach the brake hose to the brake caliper.
Tighten to 10 Nm.
3. Attach the brake hose.
1. Attach the brake hose.
2. Install the retaining clip.
3. Attach the brake pipe.
4. Remove the brake pedal hold down tool.
5. Bleed the brake system. For additional information, refer toSection
206-00 Brake System - General Information.
6. Install the wheel and tire. For additional information, refer to Section
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Front Disc Brake - Brake Disc
Removal
1. Remove the brake pads, refer to the procedure in this section :Pads .
2. Remove and discard the brake caliper anchor plate retaining bolts.
3. Detach the brake caliper, brake caliper anchor plate assembly and
secure to one side.
4. NOTE: If the brake disc is being refitted, the tip of a wheel hub stud
must be marked with a corresponding part of the brake disc for correct
re-alignment.
Remove the brake disc.
Installation
1. NOTE: Install new brake caliper anchor plate retaining bolts.
Tighten to 133 Nm.
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Front Disc Brake - Brake Pads
Removal
1. Remove the wheel and tire. For additional information, refer toSection
2. Pivot the brake caliper upwards.
1. Remove and discard the brake caliper lower retaining bolt.
2. Pivot the brake caliper upwards.
3. Remove the brake pads.
Installation
1. CAUTIONS:
If the piston is pushed back into the housing, brake fluid will be
forced into the fluid reservoir.
Push the piston into the housing.
2. Install the brake pads.
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3. Pivot the brake caliper downwards.
4. Install a new brake caliper lower retaining bolt.
Tighten to 30 Nm.
5. Install the wheel. For additional information, refer toSection 204-04
Wheels and Tires.
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Rear Disc Brake -
Lubricants, Fluids, sealers and Adhesives
to the vehicle.
Item Specification
Caliper slide pin grease Dow Corning G807
Brake hose union 38 28 -
Brake caliper anchor plate retaining bolt 70 52 -
Brake caliper retaining bolt 32 24 -
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Rear Disc Brake - Rear Disc Brake
1 Parking brake cable
2 Hub carrier
3 Brake hose
4 Brake disc shield
5 Brake caliper
6 Brake caliper anchor plate
7 Brake pads
8 Wheel hub
9 Brake disc
injury.
NOTE: Brake system materials inherently generate heat in order to dissipate energy. As a result, occasional squeal is possible, which may
be compounded by severe environmental conditions, such as cold, heat, rain, snow, salt and mud.
The rear disc brake system consists of the following components:
Brake pads.
Single piston, floating disc calipers.
Brake discs.
Brake caliper anchor plates.
Brake hoses.
Parking brake cables.
The caliper has two retaining bolts that attach the caliper to the anchor plate. The anchor plate is attached to the hub carrier with two
bolts. The hydraulic system provides separate circuits for each pair of diagonally opposed wheels (i.e.left front, right rear and right front,
left rear).
The brake disc is manufactured from cast iron and is of the solid type. It is retained on the hub by the wheel and the wheel studs.
The rear brake calipers are mounted on the hub carrier. These are of single, sliding piston type which ensures that equal effort is applied
through both brake pads.
The rear brake caliper incorporates the parking brake which is self adjusting according to brake pad wear.
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Rear Disc Brake - Rear Disc Brake
For additional information, refer toSection 206-00 Brake System - General Information.
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Rear Disc Brake - Brake Caliper
Special Tool(s)
JDS 9013
Brake caliper piston retractor tool
206-080
Crankshaft pulley/damper remover
303-588
Removal
2. Detach the parking brake cable.
1. Release the tension.
3. Remove the parking brake cable retaining clip.
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NOTE: To prevent the loss of brake fluid, apply the brake pedal hold
down tool and adjust to hold the brake pedal down 40mm. Install a
bleeder bottle to the bleed nipple and loosen.
NOTE: Remove and discard the brake hose sealing washers.
Detach the brake hose.
5. NOTE: Tighten the bleed nipple and remove the bleeder tube and
bottle.
Remove the brake caliper.
Installation
1. CAUTION: If the piston is pushed back into the housing, brake
fluid will be forced out of the inlet port of the brake caliper.
NOTE: The left-hand brake caliper piston retracts counter clockwise and
the right-hand retracts clockwise.
Using the special tools, fully retract the brake caliper piston.
2. CAUTIONS:
Make sure the piston location mark is in the correct position so that
the locator pin on the brake pad backing plate locates correctly into the
piston.
Install the brake caliper.
Tighten to 32 Nm.
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3. NOTE: Install new brake hose sealing washers.
Attach the brake hose.
Tighten to 38 Nm.
5. Bleed the brake system.
For additional information, refer to: Brake System Bleeding (206-00
Brake System - General Information, General Procedures).
6. Attach the parking brake cable retaining clip.
7. Attach the parking brake cable.
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Rear Disc Brake - Brake Disc
Removal
All vehicles
2. Detach the Anti-lock brake system (ABS) wheel speed sensor.
Remove the ABS wheel speed sensor retaining bolt.
All vehicles
3. Remove the brake caliper anchor plate.
Remove and discard the brake caliper anchor plate retaining bolts.
4. NOTE: If the brake disc is being refitted, the tip of a wheel hub stud
must be marked with a corresponding part of the brake disc for correct
re-alignment.
Remove the brake disc.
Installation
Tighten to 70 Nm.
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Rear Disc Brake - Brake Disc Shield
1. Remove the rear wheel hub. For additional information, refer to Section
204-02 Rear Suspension.
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Rear Disc Brake - Brake Pads
Special Tool(s)
Brake caliper piston retractor tool
206-080
Crankshaft pulley/damper remover
303-588
Removal
3. Remove the parking brake cable retaining clip.
4. Detach the brake caliper and secure to one side.
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Installation
1. CAUTION: If the piston is pushed back into the housing, brake
fluid will be forced back into the fluid reservoir.
NOTE: The left-hand brake caliper piston retracts counter clockwise and
the right-hand retracts clockwise.
Using the special tools, fully retract the brake caliper piston.
2. Install the brake pads.
3. CAUTIONS:
Make sure the piston location mark is in the correct position so that
the locator pin on the brake pad backing plate locates correctly into the
piston.
Attach the brake caliper.
Tighten to 32 Nm.
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4. Attach the parking brake cable retaining clip.
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Parking Brake and Actuation -
Parking brake control retaining nuts 20 15 -
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Parking Brake and Actuation - Parking Brake
1 Front cable
2 Rear cable
3 Brake calipers
The parking brake control system is cable-operated and controlled by an independent hand-operated parking brake control lever. The parking
brake control lever activates the rear brake calipers through a cable and rear caliper lever with a ball in ramp mechanism. The rear caliper
self adjusts to compensate for pad wear through hydraulic operation.
To adjust the cable, operate the parking brake control lever several times.
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*
*
*
*
*
*
1
1
1
1
1
Parking Brake and Actuation - Parking Brake
1. Verify the customer concern by operating the system to duplicate the condition. 1.
2. Visually inspect for obvious signs of mechanical or electrical damage. 2.
Parking brake control Parking brake control warning circuit. For additional information, refer to
REFER to: Instrument Cluster (413-01 Instrument Cluster, Diagnosis and Testing).
.
Cable and conduit
Equalizer
step.
3.
Symptom Chart
The parking brake will not engage Parking brake control.
Cable and conduit.
Go to Pinpoint Test A.
The parking brake will not release Cable and conduit.
Parking brake control.
Pinpoint tests
PINPOINT TEST A : THE PARKING BRAKE WILL NOT ENGAGE
A1: CHECK FOR INCORRECTLY ADJUSTED REAR PARKING BRAKE CABLE
Operate the parking brake control several times to adjust the cable.
Does the parking brake now engage correctly?
Yes
Vehicle OK.
No
GO to A2.
A2: CHECK FOR WORN BRAKE PADS
Inspect the brake pads for excessive wear. For additional information, refer to
REFER to: Brake System (206-00 Brake System - General Information, Diagnosis and Testing).
.
Are brake pads OK?
Yes
GO to A3.
No
INSTALL new brake pads. Test the system for normal operation.
A3: CHECK FOR DAMAGED PARKING BRAKE CABLES
Inspect the parking brake cables and conduit for damage, rust or fraying.
Are the parking brake cables and conduits OK?
Yes
CHECK for other causes such as loose parking brake control or conventional brake system components.
No
REPAIR or INSTALL new cables and conduit as necessary. TEST the system for normal operation.
PINPOINT TEST B : THE PARKING BRAKE WILL NOT RELEASE
TEST
CONDITIONS
B1: CHECK PARKING BRAKE CONTROL
Raise and support the vehicle with the parking brake fully applied. For additional information, refer to
.
Release the parking brake by pulling upwards on the control lever and pushing the release button.
Did the parking button release?
Yes
CHECK for other causes such as conventional brake system components, REPAIR or INSTALL new components as
necessary.
No
GO to B2.
B2: CHECK PARKING BRAKE CABLES
Loosen the parking brake cable tension.
Rotate the wheels by hand.
Did the rear wheels rotate OK?
Yes
INSTALL a new parking brake control; Refer to the procedures in this section. TEST the system for normal operation.
No
GO to B3.
B3: CHECK FRONT PARKING BRAKE CABLE
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1
1
Disconnect the parking brake front cable from the rear brake cable and conduit at the equalizer.
Rotate the wheels by hand.
Did the rear wheels rotate OK?
Yes
INSTALL a new front parking brake cable. For additional information, refer to the procedure in this section:
REFER to: Parking Brake Cable - Vehicles With: Manually Adjusted Parking Brake (206-05 Parking Brake and
Actuation, Removal and Installation).
No
GO to B4.
B4: CHECK REAR PARKING BRAKE CABLES
Disconnect the parking brake rear cable from the rear brake calipers, one at a time.
Rotate the wheel affected by the disconnected parking brake.
Did the rear wheel rotate OK?
Yes
INSTALL a new rear parking brake cable. For additional information, refer to the procedure in this section:
REFER to: Parking Brake Cable - Vehicles With: Manually Adjusted Parking Brake (206-05 Parking Brake and
Actuation, Removal and Installation).
No
For additional information, refer to
REFER to: Brake System (206-00 Brake System - General Information, Description and Operation).
.
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Parking Brake and Actuation - Parking Brake CableVehicles With: Manually Adjusted
Parking Brake
Special Tool(s)
Parking brake cable adjuster socket.
206-087
Removal
1. Release the parking brake.
3. NOTE: 2.5L or 3.0L shown, 2.0L similar.
NOTE: Using special tool 206-087 loosen the rear parking brake cable.
Loosen the rear parking brake cables retaining nut.
Detach the rear parking brake cables.
5. Detach the rear parking brake cable.
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6. Remove the rear parking brake cable retaining clip.
7. Detach the rear parking brake cable and conduit.
10. Remove the rear parking brake cable and conduit.
Installation
2. Carry out the parking brake cable adjustment.
For additional information, refer to Parking Brake Cable Adjustment - in
this section.
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Parking Brake and Actuation - Parking Brake CableVehicles With: Self-Adjusting
Parking Brake
Removal
1. Remove the rear road wheel and tire. For additional information, refer
toSection 204-04 Wheels and Tires.
1. Release the parking brake conduit retaining tangs.
5. Remove the body undertray. For additional information, refer to Section
501-08 Exterior Trim and Ornamentation.
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9. Remove the parking brake rear cable and conduit.
Installation
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Parking Brake and Actuation - Parking Brake ControlVehicles With: Manually Adjusted
Parking Brake
Special Tool(s)
Parking brake cable adjuster socket.
206-087
Removal
All vehicles
1. Remove the center console. For additional information, refer to Section
501-12 Instrument Panel and Console.
2. Disconnect the parking brake warning indicator switch electrical
connector.
3. Detach the park brake grommet.
NOTE: Using special tool 206-087 loosen the rear parking brake cables.
Loosen the rear parking brake cables retaining nut.
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8. Remove the driveshaft. For additional information refer to Section
205-01 Driveshaft.
All vehicles
9. Remove the parking brake.
Installation
Tighten to 25 Nm.
2. Carry out the parking brake cable adjustment.
For additional information, refer to Parking Brake Cable Adjustment - in
this section.
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Parking Brake and Actuation - Parking Brake ControlVehicles With: Self-Adjusting
Parking Brake
Removal
All vehicles
2. Disconnect the parking brake warning indicator switch electrical
connector.
4. Remove the rear road wheels and tires. For additional information, refer
to Section 204-04 Wheels and Tires.
5. Remove the driveshaft. For additional information refer to Section
205-01 Driveshaft.
All vehicles
6. Remove the exhaust front muffler. For additional information, refer to
Section 309-00 Exhaust System.
7. Detach the parking brake rear cables.
8. Remove the exhaust front heat shield.
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9. Remove the exhaust rear heat shield.
10. Remove the parking brake control retaining nuts.
12. Detach the parking brake control.
1. Detach the parking brake cable grommet.
2. Detach the parking brake control.
13. Remove the parking brake control.
1. Align the flat on the nipple to clear the spring.
2. Remove the parking brake control.
Installation
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1. To install, reverse the removal proceedure.
Tighten to 20 Nm.
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Hydraulic Brake Actuation -
to the vehicle.
Item Specification
Brake master cylinder retaining nuts. 20 15 -
Brake tube to brake master cylinder unions. 15 11 -
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Hydraulic Brake Actuation - Hydraulic Brake Actuation
1 Brake master cylinder
2 Brake fluid reservoir
3 Brake booster
4 Rear brake caliper
5 Brake tubes
6 Front brake caliper
7 Hydraulic control unit
injury.
The hydraulic brake system is of a pedal operated, diagonally split dual line brake system that consists of the following components:
a brake booster
a master cylinder and reservoir
front brake calipers
rear brake calipers
brake tubes and hoses
Anti-lock brake system (ABS)
Traction control system (TCS)/Interactive vehicle dynamics (IVD)
Brake Master Cylinder
The brake master cylinder is a dual piston type. The master cylinder operates as fol lows:
when the brake pedal is applied, pressure is applied by mechanical linkage to the primary and secondary systems
brake master cylinder pistons apply hydraulic pressure to the two circuits
The master cylinder consists of the following components:
primary and secondary pistons
brake fluid reservoir with integral fluid level warning indicator
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Hydraulic Brake Actuation - Hydraulic Brake Actuation
For additional information, refer to Section 206-00 Brake System - General Information.
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Hydraulic Brake Actuation - Brake Fluid Reservoir
Removal
All vehicles
NOTE: Make sure the filler cap does not become contaminated.
Remove the brake fluid reservoir filler cap.
2. Using a suitable suction device drain the brake fluid reservoir.
3. Disconnect the brake fluid low level warning indicator electrical
connector.
4. Detach the clutch master cylinder feed hose.
All vehicles
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5. NOTE: Remove and discard the O-ring seals from the brake master
cylinder.
Remove the brake fluid reservoir.
1. Release one leg of the reservoir from the retaining pin.
2. Remove the brake fluid reservoir.
Installation
All vehicles
1. NOTE: Install new O-ring seals to the brake master cylinder.
Install the brake fluid reservoir.
1. Locate the left hand brake fluid reservoir leg to the retaining
pin.
2. Fully seat the brake fluid reservoir to the master cylinder.
3. Fully seat the right hand brake fluid reservoir leg to the
retaining pin.
2. Attach the clutch master cylinder feed hose.
All vehicles
3. Connect the brake fluid low level warning indicator electrical connector.
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4. Fill the brake fluid reservoir.
5. Bleed the brake system. For additional information, refer to Section
6. Install the brake fluid reservoir filler cap.
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Hydraulic Brake Actuation - Brake Master Cylinder
Removal
All vehicles
connector.
4. Detach the brake booster vacuum hose.
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5. Detach the clutch master cylinder feed hose.
All vehicles
6. Reposition the coolant expansion tank.
1. Remove the coolant expansion tank retaining bolt.
2. Turn the coolant expansion tank counter clockwise.
7. Disconnect the coolant low level warning indicator electrical connector.
8. Disconnect the brake fluid supply tubes.
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9. NOTE: Remove and discard the O-ring seal at the rear of the brake
master cylinder.
Remove the brake master cylinder and reservoir.
1. Remove the brake master cylinder retaining nuts.
2. Remove the brake master cylinder and reservoir.
Installation
All vehicles
1. NOTE: Install a new O-ring seal to the rear of the brake master
cylinder.
Install the brake master cylinder and reservoir.
1. Install the brake master cylinder and reservoir.
2. Install the brake master cylinder retaining nuts.
2. Connect the brake fluid supply tubes.
Tighten to 15 Nm.
3. Connect the coolant low level warning indicator electrical connector.
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4. Attach the coolant expansion tank.
2. Turn the coolant expansion tank clockwise.
3. Install the coolant expansion tank retaining bolt.
5. Attach the clutch master cylinder feed hose.
All vehicles
6. Attach the brake booster vacuum hose.
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8. Fill the brake fluid reservoir.
9. Bleed the brake system. For additional information, refer to Section
10. Install the brake fluid reservoir filler cap.
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Hydraulic Brake Actuation - Brake Pedal and Bracket
Removal
1. WARNING: Brake fluid contains polyglycol ethers and polyglycols.
Avoid contact with the eyes. Wash hands thoroughly after handling. If
brake fluid contacts the eyes, flush the eyes for 15 minutes with cold
water. Get medical attention immediately if irritation persists. If taken
internally, drink water and induce vomiting. Get medical attention
immediately. Failure to follow these instructions may result in personal
injury.
CAUTION: If brake fluid is spilt on the paintwork, the affected area
must be immediately washed down with cold water.
Using a suitable suction device, drain the brake fluid reservoir.
3. NOTE: Vehicles with 2.5L or 3.0L engine only.
Detach the engine wiring harness.
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NOTE: Install suitable blanking plugs.
NOTE: Right-hand drive shown, left-hand drive similar.
Disconnect the clutch master cylinder supply line.
NOTE: Install suitable blanking plugs.
Disconnect the clutch slave cylinder supply line from the clutch master
cylinder.
Release the retaining clip to disconnect the line.
Right-hand drive vehicles
6. Remove the brake pedal and bracket retaining nuts.
Vehicles without driver lower air bag
7. Remove the driver side instrument panel lower trim panel.
Vehicles with driver lower air bag
8. Remove the driver lower air bag.
For additional information, refer to: Driver Lower Air Bag Module
(501-20B Supplemental Restraint System, Removal and Installation).
All vehicles
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9. Remove the support panel.
Left-hand drive vehicles
10. Position the front wheels in a straight ahead position and centralize
the steering wheel.
All vehicles
12. Remove the accelerator pedal.
For additional information, refer to: Accelerator Pedal (310-02
Acceleration Control, Removal and Installation).
13. Detach the wiring harness.
14. Remove the anti-collapse bracket clevis pin.
1. Remove the anti-collapse bracket clevis pin retaining clip.
2. Remove the anti-collapse bracket clevis pin.
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15. Reposition the anti-collapse bracket.
16. Remove the brake booster push rod retaining nut.
17. Remove the accelerator pedal mount bracket.
18. Remove the brake booster push rod retaining clip.
1. Release the brake booster push rod retaining clip.
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19. Remove the accelerator pedal mount bracket.
All vehicles
22. NOTE: Right-hand drive shown, left-hand drive similar.
Remove the brake pedal and bracket.
Disconnect the electrical connector.
Installation
All vehicles
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1. NOTE: Right-hand drive shown, left-hand drive similar.
Install the brake pedal and bracket.
Connect the electrical connector.
2. Install the brake pedal and bracket retaining nuts.
Tighten to 25 Nm.
Tighten to 25 Nm.
4. Install the accelerator pedal mount bracket.
Tighten to 25 Nm.
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5. Install the brake booster push rod retaining clip.
6. Install the accelerator pedal mount bracket.
Tighten to 25 Nm.
7. Install the brake booster push rod retaining nut.
Tighten to 3 Nm.
All vehicles
8. Reposition the anti-collapse bracket.
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9. Install the anti-collapse bracket clevis pin retaining clip.
1. Install the anti-collapse bracket clevis pin.
2. Install the anti-collapse bracket clevis pin retaining clip.
10. Attach the wiring harness.
11. Install the accelerator pedal.
For additional information, refer to: Accelerator Pedal (310-02
Acceleration Control, Removal and Installation).
12. Attach the steering column.
Tighten to 25 Nm.
All vehicles
13. Install the support panel.
14. Install the driver lower air bag.
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15. Install the driver side instrument panel lower trim panel.
Tighten to 25 Nm.
NOTE: Remove the blanking plugs.
NOTE: Reposition the retaining clip.
Connect the clutch slave cylinder supply line to the clutch master
cylinder.
Connect the clutch master cylinder supply line.
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19. NOTE: Vehicles with 2.5L or 3.0L engine only.
Attach the engine wiring harness.
Tighten to 10 Nm.
20. Bleed the hydraulic clutch system.
For additional information, refer to: Clutch System Bleeding - Vehicles
With: 6-Speed Manual Transaxle - MMT6 (308-00 Manual
Transmission/Transaxle and Clutch - General Information, General
Procedures).
Install the brake fluid reservoir filler cap.
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Hydraulic Brake Actuation - Brake Pedal Cross-Shaft
Special Tool(s)
Disconnect tool, fuel line.
310-076
310-D005
412-038
5 Point Security Torx Bit.
418-535
Removal
All vehicles
1. Disconnect the battery ground cable.
For additional information, refer to: Battery Disconnect and Connect
(414-01 Battery, Mounting and Cables, General Procedures).
2. Recover the air conditioning (A/C) refrigerant.
For additional information, refer to: Air Conditioning (A/C) System
Recovery, Evacuation and Charging (412-00 Climate Control System -
General Information, General Procedures).
Vehicles with diesel particulate filter
3. Remove the air cleaner outlet pipe.
For additional information, refer to: Air Cleaner Outlet Pipe (303-12B
Intake Air Distribution and Filtering - 2.0L Duratorq-TDCi/2.2L
Duratorq-TDCi (110kW/150PS) - Puma, Removal and Installation).
4. NOTE: Note the orientation of the retaining clip.
Detach the diesel particulate filter (DPF) high-pressure and low-pressure
hoses.
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6. Detach the DPF differential pressure sensor retaining bracket.
7. Disconnect the DPF differential pressure sensor electrical connector.
8. NOTE: Note the orientation of the DPF differential pressure
high-pressure and low-pressure hoses and make sure they are installed in
the same position.
Disconnect the DPF differential pressure sensor high-pressure and
low-pressure hoses.
All vehicles
9. Remove the brake booster.
For additional information, refer to: Brake Booster - RHD AWD/RHD FWD
(206-07 Power Brake Actuation, Removal and Installation).
All except vehicles with diesel engine
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10. Disconnect the upper fuel vapor hose from the evaporative emission
canister purge valve.
11. Detach the oxygen sensor electrical connectors.
12. Disconnect the evaporator solenoid electrical connector.
13. Disconnect the lower fuel vapor hose from the evaporative emission
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14. Detach the wiring harness from the retaining bracket.
15. Remove the evaporative emission canister purge valve retaining
bracket.
16. Remove the intake manifold.
For additional information, refer to: Intake Manifold (303-01A Engine -
2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27, In-vehicle
Repair).
All vehicles
17. Remove the A/C refrigerant line retaining clip.
18. NOTE: Install blanking plugs to the exposed ports.
Using the special tool, disconnect the A/C refrigerant line.
Remove and discard the O-ring seals.
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19. Remove the A/C refrigerant line retaining clip.
21. NOTE: The bolt remains captive in the engine control module (ECM)
electrical connector.
Using special tool 418-535, disconnect the ECM electrical connector.
22. NOTE: Install blanking plugs to the fuel pump fuel supply and return
line male and female connectors.
Disconnect the fuel pump fuel supply and return lines.
For additional information, refer to: Quick Release Coupling - Push
Connect (310-00 Fuel System - General Information, General
Procedures).
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23. Disconnect the engine wiring harness electrical connector.
24. Detach the engine wiring harness retaining clip.
25. Detach the engine wiring harness electrical connector.
26. NOTE: The bolt remains captive in the ECM electrical connector.
Disconnect the ECM harness electrical connector.
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All vehicles
28. Remove the brake pedal cross-shaft support bracket retaining bolt.
29. Rotate the brake pedal cross-shaft clockwise.
30. Remove the brake pedal and bracket.
For additional information, refer to: Brake Pedal and Bracket (206-06
Hydraulic Brake Actuation, Removal and Installation).
31. Remove the sound insulation.
32. Remove the glove compartment hinge retaining screws.
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33. Remove the glove compartment finisher trim.
34. Remove the glove compartment.
Remove the glove compartment retaining screws.
35. Remove the blower motor trim.
36. Remove the central junction box (CJB) retaining nut.
37. Detach the CJB.
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38. Reposition the brake pedal cross-shaft securing bracket.
1. Undo but do not remove the brake pedal cross-shaft securing
bracket retaining nut.
39. Remove the right-hand fender splash shield.
For additional information, refer to: Fender Splash Shield (501-02 Front
End Body Panels, Removal and Installation).
40. Remove the refrigerant lines retaining clips.
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43. Detach the brake lines.
44. Remove the A/C refrigerant line.
Remove the retaining clip.
45. Remove the A/C refrigerant line.
46. NOTE: Note the position of the brake pedal cross-shaft spring.
Detach the brake pedal cross-shaft spring.
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47. Detach the brake pedal cross-shaft left-hand mounting bracket.
48. Detach the brake pedal cross-shaft grommet.
49. NOTE: Remove the brake pedal cross-shaft spring bush.
Remove the brake pedal cross-shaft.
Installation
All vehicles
1. NOTE: Make sure that the brake pedal cross-shaft bush is correctly
positioned.
Install the brake pedal cross-shaft.
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2. Attach the brake pedal cross-shaft grommet.
3. Attach the brake pedal cross-shaft left-hand mounting bracket.
4. NOTE: Make sure the brake pedal cross-shaft spring is located in its
original position.
Attach the brake pedal cross-shaft spring.
5. Install the A/C refrigerant line.
6. Install the A/C refrigerent line.
Install the retaining clip.
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7. Attach the brake lines.
8. NOTE: Remove the blanking plugs.
Connect the A/C refrigerant line.
Install new O-ring seals.
10. Install the A/C refrigerant lines retaining clips.
11. Install the right-hand fender splash shield.
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1. Tighten the brake pedal cross-shaft securing bracket retaining
nut.
13. Attach the CJB.
Tighten to 6 Nm.
14. Install the CJB retaining nut.
Tighten to 6 Nm.
15. Install the blower motor trim.
16. Install the glove compartment.
Install the passenger compartment retaining screws.
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17. Install the glove compartment finisher trim.
18. Install the glove compartment hinge retaining screws.
19. Install the sound insultation.
20. Install the pedal box.
For additional information, refer to: Brake Pedal and Bracket (206-06
Hydraulic Brake Actuation, Removal and Installation).
21. Rotate the brake pedal cross-shaft counter-clockwise.
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22. Install the brake pedal cross-shaft support bracket retaining bolt.
Tighten to 25 Nm.
23. Connect the ECM electrical connector.
Using special tool 418-535, tighten to 5 Nm.
24. Attach the engine wiring harness retaining clip.
25. Connect the ECM electrical connector.
Tighten to 5 Nm.
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26. Attach the engine wiring harness electrical connector.
28. Connect the engine wiring harness electrical connector.
Tighten to 10 Nm.
29. NOTE: Remove the blanking plugs from the fuel pump fuel supply and
return line male and female connectors.
Connect the fuel pump fuel supply and return lines.
Procedures).
All vehicles
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31. Install the A/C refrigerant line retaining clip.
33. Install the refrigerant line retaining clip.
34. Install the intake manifold.
Repair).
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35. Install the evaporative emission canister purge valve retaining
bracket.
Install the retaining nuts.
Tighten to 5 Nm.
36. Attach the wiring harness to the retaining bracket.
37. Connect the lower fuel vapor hose to the evaporative emission
38. Connect the evaporator solenoid electrical connector.
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39. Attach the oxygen sensor electrical connectors.
40. Connect the upper fuel vapor hose to the evaporative emission
All vehicles
41. Install the brake booster.
For additional information, refer to: Brake Booster - RHD AWD/RHD FWD
(206-07 Power Brake Actuation, Removal and Installation).
Vehicles with diesel particulate filter
the same position.
Connect the DPF differential pressure sensor high-pressure and
low-pressure hoses.
43. Connect the DPF differential pressure sensor electrical connector.
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44. Attach the DPF differential pressure sensor retaining bracket.
Install the retaining nuts.
Tighten to 5 Nm.
46. CAUTION: Install the retaining clip to the original position.
Attach the the DPF high-pressure and low-pressure hoses.
47. Install the air cleaner outlet pipe.
All vehicles
48. Recharge the A/C refrigerant.
49. Connect the battery ground cable.
For additional information, refer to: Battery Connect (414-01 Battery,
Mounting and Cables, General Procedures).
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Power Brake Actuation -
Brake booster retaining nuts 25 18 -
Brake master cylinder retaining nuts 25 18 -
Coolant expansion tank retaining bolt 3 - 27
Speed control module retaining bolt - Vehicles with 2.0L engine 4 - 35
Vacuum pump retaining nuts - Vehicles with 2.0L engine 10 - 89
Vacuum pump retaining bolts - Vehicles with diesel engine 23 17 -
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Power Brake Actuation - Brake Booster
WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands after handling. If brake fluid
contacts the eyes, flush the eyes for 15 minutes with cold running water. Get medical attention if irritation persists. If taken internally,
drink water and induce vomiting. Get medical attention immediately. Failure to follow these instructions may result in personal injury.
1 Brake fluid reservoir filler cap
3 Brake fluid low level warning indicator
4 Brake master cylinder
5 Brake booster
6 Brake booster vacuum hose grommet
The diaphragm type power brake booster:
is self contained.
is mounted on the engine side of the bulkhead.
uses engine intake manifold vacuum, vacuum pump and atmospheric pressure for its assistance.
is connected to a manifold vacuum hose with a built in non return valve.
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Power Brake Actuation - Power Brake System
For additional information, refer to Section 206-00 Brake System - General Information.
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Power Brake Actuation - Brake BoosterLHD AWD/LHD FWD
Removal
All vehicles
1. Release the brake booster push rod retaining clip.
connector.
3. Detach the brake fluid low level warning indicator wiring harness from
the coolant expansion tank.
4. NOTE: Install blanking plugs to the cooling system vent hoses and the
coolant expansion tank.
Detach the cooling system vent hoses from the coolant expansion tank.
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1. Detach the coolant expansion tank.
7. Detach the cruise control cable.
8. Detach the throttle cable.
1. Reposition the throttle lever to the fully open position.
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9. Detach the idle air control (IAC) valve wiring harness.
10. Detach the throttle cable retaining bracket.
11. Disconnect the speed control module electrical connector.
12. Remove the speed control module retaining bolt.
13. Reposition the speed control module.
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14. CAUTION: If brake fluid is split on the paintwork, the affected
area must be immediately washed down with cold water. Failure to follow
NOTE: Install blanking plugs to the clutch master cylinder feed hose and
the brake fluid reservoir.
Detach the clutch master cylinder feed hose.
All vehicles
15. Detach the brake fluid supply tubes from the retaining clip.
16. Detach the brake master cylinder assembly from the brake booster.
Remove and discard the O-ring seal at the rear of the brake master
cylinder.
17. Using a suitable cord, reposition the brake master cylinder assembly.
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19. Detach the brake booster.
Remove the brake booster retaining nuts.
20. Remove the brake booster support bracket.
Installation
All vehicles
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1. NOTE: Make sure the brake booster push rod is correctly aligned to the
brake pedal.
NOTE: Do not install the brake booster retaining nuts at this stage.
Install the brake booster.
2. Install the brake booster support bracket.
Loosely install the brake booster support bracket retaining bolt.
3. Attach the brake booster.
Tighten to 25 Nm.
4. Tighten the brake booster support bracket retaining bolt.
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6. NOTE: Install a new brake master cylinder to brake booster O-ring seal.
NOTE: Make sure the brake booster push rod is correctly aligned to the
brake master cylinder assembly.
Attach the brake master cylinder assembly to the brake booster.
Tighten to 25 Nm.
7. Attach the brake fluid supply tubes to the retaining clip.
NOTE: Remove the blanking plugs from the clutch master cylinder feed
hose and the brake fluid reservoir.
Attach the clutch master cylinder feed hose.
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10. Install the speed control module retaining bolt.
Tighten to 4 Nm.
11. Connect the speed control module electrical connector.
12. Attach the throttle cable retaining bracket.
13. Attach the IAC valve wiring harness.
14. Attach the throttle cable.
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15. Attach the cruise control cable.
All vehicles
Tighten to 3 Nm.
18. NOTE: Remove the blanking plugs from the cooling system vent hoses
and the coolant expansion tank.
Attach the cooling system vent hoses to the coolant expansion tank.
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19. Attach the brake fluid low level warning indicator wiring harness to the
21. Install the brake booster push rod retaining clip.
22. Check and top up the cooling system as required.
23. Bleed the clutch system.
Procedures).
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Power Brake Actuation - Brake BoosterRHD AWD/RHD FWD
Special Tool(s)
Brake pedal hold down tool
JDS 9013
Removal
All vehicles
connector.
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8. Detach the idle air control (IAC) valve wiring harness.
10. Disconnect the speed control module electrical connector.
11. Remove the speed control module retaining bolt.
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NOTE: Install blanking plugs to the clutch master cylinder feed hose and
the brake fluid reservoir.
Detach the clutch master cylinder feed hose.
All vehicles
14. Detach the brake fluid supply tubes from the retaining clip.
15. Detach the brake master cylinder assembly from the brake booster.
Remove and discard the O-ring seal at the rear of the brake master
cylinder.
16. Using a suitable cord, reposition the brake master cylinder assembly.
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18. Detach the brake booster.
Remove the brake booster retaining nuts.
19. Remove the brake booster support bracket.
20. Using the brake pedal hold down tool, apply the brake pedal until the
brake booster push rod pin can be removed.
21. Remove the brake booster push rod pin retaining clip.
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22. Remove the brake booster push rod pin.
Installation
All vehicles
1. NOTE: Do not install the brake booster retaining nuts at this stage.
Install the brake booster.
2. Install the brake booster push rod pin.
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3. Install the brake booster push rod pin retaining clip.
5. Install the brake booster support bracket.
Loosely install the brake booster support bracket retaining bolt.
6. Attach the brake booster.
Tighten to 25 Nm.
7. Tighten the brake booster support bracket retaining bolt.
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9. NOTE: Install a new brake master cylinder to brake booster O-ring seal.
NOTE: Make sure the brake booster push rod is correctly aligned to the
brake master cylinder assembly.
Attach the brake master cylinder assembly to the brake booster.
Tighten to 25 Nm.
10. Attach the brake fluid supply tubes to the retaining clip.
NOTE: Remove the blanking plugs from the clutch master cylinder feed
hose and the brake fluid reservoir.
Attach the clutch master cylinder feed hose.
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13. Install the speed control module retaining bolt.
Tighten to 4 Nm.
14. Connect the speed control module electrical connector.
16. Attach the IAC valve wiring harness.
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All vehicles
Tighten to 3 Nm.
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24. Check and top up the cooling system as required.
Procedures).
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Power Brake Actuation - Brake Vacuum Pump2.0L NA V6 - AJV6
Removal
1. Disconnect the vacuum hose.
Release the retaining clip.
2. Disconnect the electrical connector.
3. Remove the vacuum pump.
Installation
Tighten to 25 Nm.
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Power Brake Actuation - Brake Vacuum Pump2.0L Duratorq-TDCi/2.2L Duratorq-TDCi
Special Tool(s)
Remover/Install, Cooling Hose Clamp
303-397
Removal
1. Remove the oil level indicator.
2. Remove the oil filler cap.
3. Remove the engine cover.
4. Drain the cooling system.
For additional information, refer to: Cooling System Draining, Filling and
Bleeding (303-03B Engine Cooling - 2.0L Duratorq-TDCi/2.2L
Duratorq-TDCi (110kW/150PS) - Puma, General Procedures).
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6. Disconnect the brake vacuum hose from the brake vacuum pump.
7. Remove the power steering hose support bracket.
8. Detach the cylinder head temperature (CHT) sensor electrical connector
away from the brake vacuum pump.
9. Using the special tool 303-397, disconnect the coolant hose.
10. Using the special tool 303-397, disconnect the coolant expansion tank
hose from the brake vacuum pump.
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11. Using the special tool 303-397, disconnect the coolant hoses.
12. Remove the brake vacuum pump.
Remove and discard the gasket.
Installation
1. CAUTION: Make sure the drive coupling is aligned with the
camshaft coupling.
NOTE: Install a new brake vacuum pump gasket.
Tighten to 23 Nm.
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Anti-Lock Control - Stability Assist -
to the vehicle.
Item Specification
Brake line connections to brake pressure control valve block 17 13 -
Steering wheel sensor securing screws 1 - 9
Yaw rate sensor securing nut 6 - 53
Front wheel speed sensor securing screw 5 - 44
Rear wheel speed sensor securing screw - Vehicles with 2.5L and 3.0L engine 22 16 -
Rear wheel speed sensor securing screw - Vehicles with 2.0L or diesel engine 7 - 62
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Anti-Lock Control - Stability Assist - Anti-Lock Control - Stability Assist
1 Instrument cluster
2 - Dynamic stability control 'ON/OFF' switch
3 - ABS/Traction control hydraulic unit
4 - Yaw rate sensor
5 - Front wheel speed sensor
6 - Steering wheel angle sensor
7 - Rear wheel speed sensor - Vehicles with 2.5L and 3.0L engines
8 - Rear wheel speed sensor - Vehicles with 2.0L or diesel engines
The anti-lock brake system (ABS) modulates brake pressure on each wheel independently to maintain vehicle stability during braking. The
ABS continually monitors the rotational velocity of each wheel anytime the ignition switch is in the RUN position and determines if a tire is
loosing traction when the brakes are applied. Only then does the ABS intervene to modulate the brake pressure to the necessary wheel. The
modulation continues until the wheel rotates freely. The brake pressure is then restored and the modulate/restore cycle is repeated
whenever loss of traction is detected. This cycle occurs at a rate of several times per second.
The ABS module is capable of detecting the following system conditions:
Hydraulic valve failure
Wheel speed sensor failure
ABS power relay short circuit
Interconnect failures to the ABS sensors, power and ground to the ABS module
Over/under voltage conditions
The ABS provides self-diagnostics and displays failure messages, via the ABS indicator, in the instrument cluster. Failure of the ABS module,
for whatever reason, will not compromise the normal operation of the brake system.
Dynamic stability control (DSC) maximizes vehicle stability under all conditions. The DSC system compares actual vehicle course to that
intended by the driver. If the intended course differs from the actual course due to over steer or under steer conditions, the DSC system will
brake individual wheels and reduce engine torque to bring the vehicle back to the driver's intended direction. By using a combined yaw rate
sensor and lateral accelerometer, the vehicles rotational motion around its vertical axis and centrifugal forces generated while cornering are
calculated to determine the vehicle's actual behavior. Using additional sensors for detecting steering wheel position and road wheel speed
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enables the system to recognize the driver's intentions.
The DSC system also incorporates emergency brake assist (EBA), which measures the rate at which the brake pressure increases during a
braking manoeuvre. If the system detects an emergency braking situation, EBA automatically initiates the full braking effect. This can
reduce the stopping distances in critical situations, therefore allowing an inexperienced driver to stop in the same distance as an
experienced driver.
On vehicles with 2.0L or diesel engines the traction control system (TCS) is incorporated into the anti-lock brake system (ABS). On vehicles
with 2.5L and 3.0L engines the traction control is an additional function added to the DSC system. The vehicles driven wheels are
continually monitored for wheel spin relative to the calculated reference speed and to each other. If wheel spin is detected, the traction
control function intervenes independently of the driver, applying brake pressure to the slipping wheel and reducing the engine drive torque
supply. Meanwhile, brake pressure is modulated by the traction control until traction is re-established. Traction control brake actuation is
diminished above 40 kph (25 mph). Above this speed traction control relies primarily on engine torque reduction.
Dynamic stability control is enabled/disabled via the DSC 'ON/OFF' switch. When the switch is in the 'OFF' position, the amber DSC warning
lamp solidly illuminates within the instrument cluster message center. The DSC is automatically activated when the ignition is switched on.
The DSC provides self-diagnostics also via the instrument cluster message center.
The traction control brake intervention is automatically disabled whenever the brakes exceed a temperature limit. The traction brake
intervention will remain disabled until the brakes have cooled, irrespective of ignition switch position or ignition switch cycling.
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Anti-Lock Control - Stability Assist - Anti-Lock Control - Stability AssistVIN Range:
C00344->J12991
Principle of operation
The anti-lock brake system (ABS) modulates brake pressure on each wheel independently to maintain vehicle stability during braking. The
ABS continually monitors the rotational velocity of each wheel anytime the ignition switch is in the ON position and determines if a tire is
skidding when the brakes are applied. Only then does the ABS intervene to modulate the brake pressure to the skidding wheel. The
modulation continues until the wheel rotates freely. The brake pressure is then restored and the modulate/restore cycle is repeated
whenever skidding is detected. This cycle occurs at a rate of several times per second.
The ABS module is capable of detecting the following system conditions:
hydraulic valve failure
wheel speed sensor failure
ABS power relay short circuit
interconnect failures to the ABS sensors, power and ground to the ABS module
over/under voltage conditions
The ABS provides failure messages, via the ABS indicator, in the instrument cluster. Failure of the ABS module, for whatever reason, will not
compromise the normal operation of the brake system.
Dynamic Stability Control (DSC) equipped vehicles
DSC maximizes vehicle stability under all conditions. The DSC system compares actual vehicle course to that intended by the driver. If the
intended course differs from the actual course due to over steer or under steer conditions, the DSC system will brake individual wheels and
reduce engine torque to bring the vehicle back to the driver's intended direction. By using a combined yaw rate sensor and lateral
accelerometer, the vehicles rotational motion around its vertical axis and centrifugal forces generated while cornering are calculated to
determine the vehicle's actual behavior. Using additional sensors for detecting steering wheel position and road wheel speed enables the
system to recognize the driver's intentions.
DSC/TCS is enabled/disabled via the DSC/TCS ON/OFF switch. When the switch is in the OFF position, the amber DSC/TCS warning lamp
solidly illuminates within the instrument cluster message center. The DSC/TCS is automatically activated when the ignition is switched on.
The DSC/TCS also provides failure messages via the instrument cluster message center.
On 2.0L vehicles the traction control system (TCS) is incorporated into the anti-lock brake system (ABS). Where DSC is fitted, traction
control is a function within the DSC system. The vehicle's driven wheels are continually monitored for wheel spin relative to the calculated
reference speed and to each other. If wheel spin is detected, the traction control function intervenes independently of the driver, applying
brake pressure to the slipping wheel and reducing the engine drive torque supply. Meanwhile, brake pressure is modulated by the traction
control until traction is re-established. Traction control brake actuation is diminished above 40 km/h (25 mph). Above this speed traction
control relies primarily on engine torque reduction.
The traction control brake intervention is automatically disabled whenever the brakes exceed a temperature limit. The traction brake
intervention will remain disabled until the brakes have cooled, irrespective of ignition switch position or ignition switch cycling.
2. Confirm if the ABS warning light was illuminated, or still is. 2.
NOTE: An intermittent fault may allow the warning light to go off. This does not necessarily mean the fault is not present. Some warnings
will appear to clear when the ignition is cycled. This is often because the warning has flagged as a result of one of the vehicle's on-board
diagnostic routines having run to detect the fault. If the same routine is not run when the ignition is switched ON, the warning will not
reflag until the routine does run.
3. In order to confirm the customer concern, it may be necessary to follow a drive cycle which will enable the system to perform it's
diagnostic routine (see below).
3.
Diagnostic Drive Cycles
NOTE: See the DTC index for details of codes and possible sources/actions.
DTC Cycle to detect fault Cycle to clear fault
System response to fault
detection
C1095 Turn the ignition switch to the OFF position. Restart
and drive the vehicle to activate ABS
Drive vehicle at more than 40
km/h (25 mph) for more than 2
minutes
ABS shut-down, ABS light ON,
DSC/TCS shut-down, DSC/TCS
light ON
C1137 Turn the ignition switch to the OFF position, then ON
for more than 8 minutes
Turn the ignition switch to the
ON position
light ON
C1145/C1155
/C1165/C1175
Turn the ignition switch to the OFF position. Restart
and drive the vehicle at more than 20 km/h (12.5 mph)
km/h (12.5 mph)
light ON
C1233/C1234
/C1235/C1236
Turn the ignition switch to the OFF position. Restart
and drive the vehicle at more than 40 km/h (25 mph)
km/h (12.5 mph)
light ON
C1267 Turn the ignition switch to the OFF position. Restart
and drive the vehicle at more than 40 km/h (25 mph)
ON position
light ON
B1342 Turn the ignition switch to the OFF position. Restart
and drive the vehicle at more than 20 km/h (12.5 mph)
ON position
light ON
B1676 Turn the ignition switch to the OFF position, then turn
the ignition switch to the ON position
ON position
System functions between 9 and
19 volts
Visual Inspection
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Check the tire sizes, condition, and inflation
Brake fluid level or leakage
Wheel speed sensor fitment
Wheel speed sensor air gap
Wheel speed sensor toothed wheels (missing teeth/contamination)
Warning light operation
Fuses (see table)
ABS/Traction control control unit
Wheel speed sensors
Wheel speed sensor link leads
Connectors/pins
Harnesses
Grounds
Fuse Identification Table
Location Fuse Number Rating Circuit
Battery junction box 05 30 Amp Vacuum module battery supply (2 ltr only)
Central junction box 67 5 Amp Vacuum module ignition supply (2 ltr only)
Battery junction box 03 60 Amp ABS/DSC/TCS module battery supply
Central junction box 96 7.5 Amp ABS/DSC/TCS module ignition supply
Central junction box 90 7.5 Amp Brake light switch circuit
step.
1.
2. If the cause is not visually evident and the Jaguar approved diagnostic system is not available, use a fault code reader to retrieve
the fault codes before proceeding to the Diagnostic Trouble Code (DTC) Index Chart.
2.
DTC Index
DTC Description Possible Source Action
C1095Pump motor circuit
fault
Pump motor circuit; open circuit,
short circuit, high resistance
Pump motor failure
Pump motor power supply circuit;
open circuit, short circuit to
GROUND
Pump motor GROUND circuit; open
circuit
The pump motor is internal to the control module. For pump circuit
tests, GO to Pinpoint Test I. Please check part is not on any form
of prior authorisation before replacement.
C1137Control module circuit
failure
Control module failure Please check part is not on any form of prior authorisation before
replacement.
C1145Right-hand front wheel
speed sensor (WSS)
circuit failure
Wheel speed sensor circuit(s);
open circuit, short circuit
For right-hand front WSS circuit tests, GO to Pinpoint Test A.
C1155Left-hand front wheel
speed sensor (WSS)
circuit failure
For left-hand front WSS circuit tests, GO to Pinpoint Test B.
C1165Right-hand rear wheel
speed sensor (WSS)
circuit failure
For right-hand rear WSS circuit tests, GO to Pinpoint Test C.
C1175Left-hand rear wheel
speed sensor (WSS)
circuit failure
For left-hand rear WSS circuit tests, GO to Pinpoint Test D.
C1222Wheel speed signal
conflict
Vehicle operating with punctured
tire(s)
Mismatched wheel/tire sizes
Wheel speed sensor reluctor tooth
damage - one or more wheels
Check wheel/tire sizes and conditions, check for sensor/reluctor
damage. Check for associated DTCs. Clear the DTC, check the
system for normal operation.
C1233Left-hand front wheel
speed sensor (WSS)
signal fault
Harness damage/kinks
Incorrect air gap
Contamination of the sensor wheel
Check the air gap at the left-hand front WSS, check the harness for
damage/kinks. For left-hand front WSS circuit tests, GO to Pinpoint
Test B.
C1234Right-hand front wheel
speed sensor (WSS)
signal failure
Incorrect air gap
Check the air gap at the right-hand front WSS, check the harness
for damage/kinks. For right-hand front WSS circuit tests, GO to
Pinpoint Test A.
C1235Right-hand rear wheel
speed sensor (WSS)
signal failure
Incorrect air gap
Wheel speed sensor reluctor
damage (AWD)
Check the air gap at the right-hand rear WSS, check for reluctor
damage (AWD). Check the harness for damage/kinks. For
right-hand rear WSS circuit tests, GO to Pinpoint Test C.
C1236Left-hand rear wheel
speed sensor (WSS)
signal failure
Incorrect air gap
Wheel speed sensor reluctor
damage (AWD)
Check the air gap at the left-hand rear WSS, check for reluctor
damage (AWD). Check the harness for damage/kinks. For left-hand
rear WSS circuit tests, GO to Pinpoint Test D.
C1266Modulator solenoids
power supply circuit
fault
Power supply failure to valve relay
ABS modulator failure
DSC modulator failure
Check the fuses and power circuit. For additional information, refer
to the wiring diagrams. Please check part is not on any form of
prior authorisation before replacement.
C1267Modulator valve fault Modulator valve failure Please check part is not on any form of prior authorisation before
replacement.
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1
2
3
4
1
1
C1278Steering angle sensor
CAN message not
plausible
Steering angle sensor not
calibrated
Steering angle sensor power
supply circuit; open circuit, high
resistance
Steering angle sensor failure
For steering angle sensor power supply circuit tests, GO to Pinpoint
Test E.
C1279Yaw rate sensor circuit
fault
Yaw rate sensor circuit; open
circuit, short circuit, high
resistance
Yaw rate sensor CAN circuit; open
circuit
Yaw rate sensor failure
For yaw rate sensor power supply circuit tests,GO to Pinpoint Test
F. For yaw rate sensor CAN circuit tests,
REFER to: Communications Network - VIN Range: E96603->J28492
(418-00 Module Communications Network, Diagnosis and Testing).
C1280Yaw rate sensor CAN
message not plausible
Yaw rate sensor failure Use the Jaguar approved diagnostic system to measure the yaw
rate offset. For CAN circuit tests,
C1282Lateral acceleration
CAN message not
plausible
Yaw rate sensor installation
Yaw rate sensor failure
Check the power supply to the sensor. For additional information,
refer to the wiring diagrams. Use the Jaguar approved diagnostic
system to measure the lateral accelerator signal. For CAN circuit
tests,
C1288Brake pressure sensor
circuit fault
Brake pressure sensor circuit; open
resistance
Brake pressure sensor failure
For brake pressure sensor circuit tests, GO to Pinpoint Test G.
C1440Brake pressure signal
fault
Brake pressure sensor failure
Control module failure
Use the Jaguar approved diagnostic system to measure the brake
pressure signals.
C1956Steering angle sensor
fault
Steering angle sensor CAN circuit;
open circuit
For CAN circuit tests,
C1975DSC signal conflict Steering angle sensor incorrectly
installed
Steering angle sensor not
calibrated - recalibrate using the
Jaguar approved diagnostic system
Check the installation of the steering angle sensor. Recalibrate as
necessary. INSTALL a new sensor if necessary.
B1676Battery voltage out of
range: 9 - 16 volts
Charging system high/low voltage
Control module failure
For charging system tests, REFER to: (414-00 Battery and Charging
System - General Information)
Charging System - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L
NA V6 - AJ27 (Diagnosis and Testing),
Charging System - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi
(110kW/150PS) - Puma (Diagnosis and Testing).
Please check part is not on any form of prior authorisation before
replacement.
None Brake light switch
circuit fault
Brake light switch power supply
circuit fault
Brake light switch to ABS/DSC
module circuit fault
Brake light switch fault
For brake light switch circuit tests, GO to Pinpoint Test H.
Pinpoint Tests
PINPOINT TEST A : DTC C1145, C1234; RIGHT-HAND FRONT WHEEL SPEED SENSOR (WSS) CIRCUIT FAILURE
CAUTION: To protect against over-voltage and static discharge, the contacts of the wheel speed sensor must not be touched by hand.
NOTE: Where the Jaguar approved diagnostic system is available, use datalogger to monitor the wheel speed sensor values when driving
in the straight-ahead position (all sensors should have the same value).
TEST
CONDITIONS
A1: CHECK THE RIGHT-HAND FRONT WSS SENSOR CIRCUIT FOR HIGH RESISTANCE
Make sure the ignition switch is in the OFF position.
Disconnect the ABS/DSC module electrical connector, JB45/JB185.
Disconnect the wheel speed sensor electrical connector, RF01.
Measure the resistance between RF01, pin 02 (W) and JB45/JB185, pin 16 (WR).
Is the resistance greater than 5 ohms?
Yes
REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC, test
the system for normal operation.
No
GO to A2.
A2: CHECK THE RIGHT-HAND FRONT WSS SENSOR CIRCUIT FOR SHORT CIRCUIT TO BATTERY
Measure the voltage between RF01, pin 02 (W) and GROUND.
Is the voltage greater than 3 volts?
Yes
REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC, test the system
for normal operation.
No
GO to A3.
A3: CHECK THE RIGHT-HAND FRONT WSS SENSOR CIRCUIT FOR SHORT CIRCUIT TO GROUND
Measure the resistance between RF01, pin 02 (W) and GROUND.
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Is the resistance less than 10,000 ohms?
Yes
No
GO to A4.
A4: CHECK THE RIGHT-HAND FRONT WSS POWER CIRCUIT FOR HIGH RESISTANCE
Disconnect the wheel speed sensor.
Measure the resistance between RF01, pin 01 (R) and JB45/JB185, pin 15 (NR).
Yes
No
GO to A5.
A5: CHECK THE RIGHT-HAND FRONT WSS POWER CIRCUIT FOR SHORT CIRCUIT TO BATTERY
Measure the voltage between RF01, pin 01 (R) and GROUND.
Yes
No
GO to A6.
A6: CHECK THE RIGHT-HAND FRONT WSS POWER CIRCUIT FOR SHORT CIRCUIT TO GROUND
Measure the resistance between RF01, pin 01 (R) and GROUND.
Yes
No
INSTALL a new WSS,
REFER to: Front Wheel Speed Sensor (206-09 Anti-Lock Control - Stability Assist, Removal and Installation).
CLEAR the DTC, test the system for normal operation. If the DTC is repeated, please check part is not on any form
PINPOINT TEST B : DTC C1155, C1233; LEFT-HAND FRONT WHEEL SPEED SENSOR (WSS) CIRCUIT FAILURE
TEST
CONDITIONS
B1: CHECK THE LEFT-HAND FRONT WSS SENSOR CIRCUIT FOR HIGH RESISTANCE
Disconnect the wheel speed sensor electrical connector, LF01.
Measure the resistance between LF01, pin 02 (W) and JB45/JB185, pin 12 (W).
Yes
No
GO to B2.
B2: CHECK THE LEFT-HAND FRONT WSS SENSOR CIRCUIT FOR SHORT CIRCUIT TO BATTERY
Measure the voltage between LF01, pin 02 (W) and GROUND.
Yes
No
GO to B3.
B3: CHECK THE LEFT-HAND FRONT WSS SENSOR CIRCUIT FOR SHORT CIRCUIT TO GROUND
Measure the resistance between LF01, pin 02 (W) and GROUND.
Yes
No
GO to B4.
B4: CHECK THE LEFT-HAND FRONT WSS POWER CIRCUIT FOR HIGH RESISTANCE
Measure the resistance between LF01, pin 01 (N) and JB45/JB185, pin 28 (N).
Yes
No
GO to B5.
B5: CHECK THE LEFT-HAND FRONT WSS POWER CIRCUIT FOR SHORT CIRCUIT TO BATTERY
Measure the voltage between LF01, pin 01 (N) and GROUND.
Yes
No
GO to B6.
B6: CHECK THE LEFT-HAND FRONT WSS POWER CIRCUIT FOR SHORT CIRCUIT TO GROUND
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Measure the resistance between LF01, pin 01 (N) and GROUND.
Yes
No
INSTALL a new WSS,
REFER to: Front Wheel Speed Sensor (206-09 Anti-Lock Control - Stability Assist, Removal and Installation).
PINPOINT TEST C : DTC C1165, C1235; RIGHT-HAND REAR WHEEL SPEED SENSOR (WSS) CIRCUIT FAILURE
TEST
CONDITIONS
C1: CHECK THE RIGHT-HAND REAR WSS SENSOR CIRCUIT FOR HIGH RESISTANCE
Disconnect the wheel speed sensor electrical connector, CA60.
Measure the resistance between CA60, pin 02 (WG) and JB45/JB185, pin 31 (WG).
Yes
No
GO to C2.
C2: CHECK THE RIGHT-HAND REAR WSS SENSOR CIRCUIT FOR SHORT CIRCUIT TO BATTERY
Measure the voltage between CA60, pin 02 (WG) and GROUND.
Yes
No
GO to C3.
C3: CHECK THE RIGHT-HAND REAR WSS SENSOR CIRCUIT FOR SHORT CIRCUIT TO GROUND
Measure the resistance between CA60, pin 02 (WG) and GROUND.
Yes
No
GO to C4.
C4: CHECK THE RIGHT-HAND REAR WSS POWER CIRCUIT FOR HIGH RESISTANCE
Measure the resistance between CA60, pin 01 (NG) and JB45/JB185, pin 30 (NG).
Yes
No
GO to C5.
C5: CHECK THE RIGHT-HAND REAR WSS POWER CIRCUIT FOR SHORT CIRCUIT TO BATTERY
Measure the voltage between CA60, pin 01 (NG) and GROUND.
Yes
No
GO to C6.
C6: CHECK THE RIGHT-HAND REAR WSS POWER CIRCUIT FOR SHORT CIRCUIT TO GROUND
Measure the resistance between CA60, pin 01 (NG) and GROUND.
Yes
No
INSTALL a new WSS,
REFER to: Rear Wheel Speed Sensor (206-09 Anti-Lock Control - Stability Assist, Removal and Installation).
PINPOINT TEST D : DTC C1175, C1236; LEFT-HAND REAR WHEEL SPEED SENSOR (WSS) CIRCUIT FAILURE
TEST
CONDITIONS
D1: CHECK THE LEFT-HAND REAR WSS SENSOR CIRCUIT FOR HIGH RESISTANCE
Disconnect the wheel speed sensor electrical connector, CA55.
Measure the resistance between CA55, pin 02 (WU) and JB45/JB185, pin 14 (WU).
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Yes
No
GO to D2.
D2: CHECK THE LEFT-HAND REAR WSS SENSOR CIRCUIT FOR SHORT CIRCUIT TO BATTERY
Measure the voltage between CA55, pin 02 (WU) and GROUND.
Yes
No
GO to D3.
D3: CHECK THE LEFT-HAND REAR WSS SENSOR CIRCUIT FOR SHORT CIRCUIT TO GROUND
Measure the resistance between CA55, pin 02 (WU) and GROUND.
Yes
No
GO to D4.
D4: CHECK THE LEFT-HAND REAR WSS POWER CIRCUIT FOR HIGH RESISTANCE
Measure the resistance between CA55, pin 01 (GB) and JB45/JB185, pin 13 (GB).
Yes
No
GO to D5.
D5: CHECK THE LEFT-HAND REAR WSS POWER CIRCUIT FOR SHORT CIRCUIT TO BATTERY
Measure the voltage between CA55, pin 01 (GB) and GROUND.
Yes
No
GO to D6.
D6: CHECK THE LEFT-HAND REAR WSS POWER CIRCUIT FOR SHORT CIRCUIT TO GROUND
Measure the resistance between CA55, pin 01 (GB) and GROUND.
Yes
No
INSTALL a new WSS,
REFER to: Rear Wheel Speed Sensor (206-09 Anti-Lock Control - Stability Assist, Removal and Installation).
PINPOINT TEST E : C1278; STEERING ANGLE SENSOR PLAUSIBILITY ERROR
NOTE: Calibrate the steering angle sensor, using the Jaguar approved diagnostic system where available. Calibration should be carried
out at each removal of the subframe, steering rack, etc.
NOTE: Where the Jaguar approved diagnostic system is available, use datalogger to monitor the steering angle sensor values when
driving in the straight-ahead position.
TEST
CONDITIONS
E1: CHECK THE POWER SUPPLY TO THE STEERING ANGLE SENSOR
Turn the ignition switch to the OFF position.
Disconnect the steering angle sensor electrical connector, IP19.
Turn the ignition switch to the ON position.
Measure the voltage between IP19, pin 02 (GW) and GROUND.
Is the voltage less than 5 volts?
Yes
GO to E2.
No
GO to E3.
E2: CHECK THE STEERING ANGLE SENSOR POWER SUPPLY CIRCUIT FOR HIGH RESISTANCE
Disconnect the DSC module electrical connector, JB185.
Measure the resistance between IP19, pin 02 (GW) and JB185, pin 39 (GW).
Yes
REPAIR the high resistance circuit. This circuit includes harness splice, IPS6. For additional information, refer to the
wiring diagrams. CLEAR the DTC, test the system for normal operation.
No
REPAIR the circuit between the steering angle sensor and battery. This circuit includes the primary distribution box
(fuse 96), the ignition switch and the DSC control module. For additional information, refer to the wiring diagrams.
Please check part is not on any form of prior authorisation before replacement.
E3: CHECK THE GROUND TO THE STEERING ANGLE SENSOR
Measure the resistance between IP19, pin 01 (B) and GROUND.
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Yes
GO to E4.
No
REFER to: Communications Network - VIN Range: E96603->J28492 (418-00 Module Communications Network,
Diagnosis and Testing).
E4: CHECK THE STEERING ANGLE SENSOR GROUND CIRCUIT FOR HIGH RESISTANCE
Disconnect the DSC control module electrical connector, JB185.
Measure the resistance between IP19, pin 01 (B) and JB185, pin 21 (B).
Yes
wiring diagrams, test the system for normal operation.
No
PINPOINT TEST F : C1279; YAW RATE SENSOR CIRCUIT FAULT
TEST
CONDITIONS
F1: CHECK THE POWER SUPPLY TO THE YAW RATE SENSOR
Disconnect the yaw rate sensor electrical connector, IP20.
Yes
GO to F2.
No
GO to F3.
F2: CHECK THE YAW RATE SENSOR POWER SUPPLY CIRCUIT FOR HIGH RESISTANCE
Yes
wiring diagrams. CLEAR the DTC, test the system for normal operation.
No
REPAIR the circuit between the yaw rate sensor and battery. This circuit includes the primary distribution box (fuse
96), the ignition switch and the DSC control module. For additional information, refer to the wiring diagrams. Please
check part is not on any form of prior authorisation before replacement.
F3: CHECK THE GROUND TO THE YAW RATE SENSOR
Yes
GO to F4.
No
F4: CHECK THE YAW RATE SENSOR GROUND CIRCUIT FOR HIGH RESISTANCE
Measure the resistance between IP20, pin 01 (B) and JB185, pin 21 (B).
Yes
wiring diagrams, test the system for normal operation.
No
PINPOINT TEST G : C1288; BRAKE PRESSURE SENSOR CIRCUIT FAULT
CAUTION: To protect against over-voltage and static discharge, the contacts of the brake pressure sensor must not be touched by
hand.
NOTE: The maximum permitted voltage at the sensor contacts is 5.25 volts.
TEST
CONDITIONS
G1: CHECK THE POWER SUPPLY TO THE BRAKE PRESSURE SENSOR
Disconnect the brake pressure sensor electrical connector, JB89.
Measure the voltage between JB89, pin 03 (GB) and GROUND.
Is the voltage less than 4.5 volts?
Yes
GO to G2.
No
GO to G3.
G2: CHECK THE BRAKE PRESSURE SENSOR POWER SUPPLY CIRCUIT FOR HIGH RESISTANCE
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Measure the resistance between JB89, pin 03 (GB) and JB185, pin 42 (GB).
Yes
REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams, test the system for normal
operation.
No
REPAIR the circuit between the brake pressure sensor and battery. This circuit includes the primary distribution box
(fuse 96), the ignition switch and the DSC control module. For additional information, refer to the wiring diagrams.
G3: CHECK THE GROUND TO THE BRAKE PRESSURE SENSOR
Measure the resistance between JB89, pin 01 (B) and GROUND.
Yes
GO to G4.
No
GO to G5.
G4: CHECK THE BRAKE PRESSURE SENSOR GROUND CIRCUIT FOR HIGH RESISTANCE
Measure the resistance between JB89, pin 01 (B) and JB185, pin 25 (B).
Yes
operation.
No
G5: CHECK THE BRAKE PRESSURE SENSOR SENSOR CIRCUIT FOR HIGH RESISTANCE
Measure the resistance between JB89, pin 02 (WG) and JB185, pin 26 (WG).
Yes
operation.
No
Check the brake light switch circuit. Please check part is not on any form of prior authorisation before replacement.
PINPOINT TEST H : CHECK THE BRAKE LIGHT SWITCH CIRCUIT
TEST
CONDITIONS
H1: CHECK THE POWER SUPPLY TO THE BRAKE LIGHT SWITCH
Disconnect the brake light switch electrical connector, PA03.
Measure the voltage between PA03, pin 03 (NR) and GROUND.
Yes
REPAIR the circuit between the brake light switch and battery. This circuit includes the central junction box (fuse 90),
and the ignition switch. For additional information, refer to the wiring diagrams, test the system for normal operation.
No
GO to H2.
H2: CHECK THE CIRCUIT BETWEEN THE BRAKE LIGHT SWITCH AND THE ABS/DSC MODULE FOR HIGH RESISTANCE
Measure the resistance between PA03, pin 03 (NR) and JB45/JB185, pin 32 (GO).
Yes
REPAIR the high resistance circuit. This circuit includes the central junction box. For additional information, refer to
the wiring diagrams, test the system for normal operation.
No
GO to H3.
H3: CHECK THE CIRCUIT BETWEEN THE BRAKE LIGHT SWITCH AND THE ABS/DSC MODULE FOR SHORT CIRCUIT TO BATTERY
Yes
REPAIR the short circuit. This circuit includes the central junction box. For additional information, refer to the wiring
diagrams, test the system for normal operation.
No
GO to H4.
H4: CHECK THE FUNCTION OF THE BRAKE LIGHT SWITCH
Connect an ohmmeter across pins 01 and 03 of the brake light switch.
Operate the brake pedal.
Measure the resistance across the switch as the pedal is operated up and down.
Does the resistance switch between open and closed circuit as the pedal is operated?
Yes
No
INSTALL a new brake light switch. TEST the system for normal operation.
PINPOINT TEST I : PUMP MOTOR AND SOLENOIDS POWER OR GROUND CIRCUIT FAULT
NOTE: Before beginning this test, check if the pump motor is running constantly. If the pump motor does run constantly, suspect an
ABS/DSC module fault.
TEST
CONDITIONS
I1: CHECK THE POWER SUPPLY TO THE PUMP MOTOR AND SOLENOIDS
Disconnect the ABS/DSC control module electrical connector, JB45/JB185.
Measure the voltage between JB45/JB185, pin 02 (R) and GROUND.
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Measure the voltage between JB45/JB185, pin 06 (R) and GROUND.
Is either voltage less than 10 volts?
Yes
REPAIR the circuit between the ABS/DSC module and battery. This circuit includes the battery junction box (fuse 03)
and harness splice, JBS27. For additional information, refer to the wiring diagrams.
No
GO to I2.
I2: CHECK THE GROUND TO THE ABS/DSC MODULE
Measure the resistance between JB45/JB185, pin 01 (B) and GROUND.
Measure the resistance between JB45/JB185, pin 05 (B) and GROUND.
Is either resistance greater than 5 ohms?
Yes
REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams.
No
RECHECK the DTCs. Please check part is not on any form of prior authorisation before replacement.
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Anti-Lock Control - Stability Assist - Anti-Lock Control - Stability AssistVIN Range:
J12992->V99999
For a detailed description of the Anti-Lock Control - Stability Assist systems, refer to the relevant Description and Operation sections in the
workshop manual. REFER to: Anti-Lock Control - Stability Assist (206-09 Anti-Lock Control - Stability Assist, Description and Operation).
NOTE: An intermittent fault may allow the warning light to go off. This does not necessarily mean the fault is not present. Some warnings
will appear to clear when the ignition is cycled. This is often because the warning has flagged as a result of one of the vehicle's on-board
diagnostic routines having run to detect the fault. If the same routine is not run when the ignition is switched ON, the warning will not
reflag until the routine does run.
Visual inspection
Check the tire sizes, condition, and inflation
Brake fluid level or leakage
Wheel speed sensor fitment
Wheel speed sensor air gap
Wheel speed sensor toothed wheels (missing teeth/contamination)
Wheel bearings
Warning light operation
Fuses
Anti-lock Brake System (ABS)
Traction Control System (TCS)
Dynamic Stability Control (DSC)
Hydraulic Control Unit (HCU)
Steering wheel rotation sensor
Wheel Speed Sensors (WSS)
Wheel speed sensor link leads
Connectors/terminals
Harnesses
Grounds
3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step 3.
DTC index
CAUTION: When probing connectors to take measurements in the course of the pinpoint tests, use the adaptor kit, part number
3548-1358-00.
NOTE: If the control module/HCU is suspect and the vehicle remains under manufacturer warranty, refer to the Warranty Policy and
Procedures manual (section B1.2), or determine if any prior approval programme is in operation, prior to the installation of a new
module/HCU.
NOTE: Generic scan tools may not read the codes listed, or may read only five digit codes. Match the five digits from the scan tool to the
first five digits of the seven digit code listed to identify the fault (the last two digits give additional information read by the manufacturer
approved diagnostic system).
NOTE: When performing electrical voltage or resistance tests, always use a digital multimeter (DMM) accurate to three decimal places,
and with an up-to-date calibration certificate. When testing resistance, always take the resistance of the DMM leads into account.
NOTE: Check and rectify basic faults before beginning diagnostic routines involving pinpoint tests.
NOTE: Inspect connectors for signs of water ingress, and pins for damage and/or corrosion.
NOTE: If DTCs are recorded and, after performing the pinpoint tests, a fault is not present, an intermittent concern may be the cause.
Always check for loose connections and corroded terminals.
DTC Description Possible cause Action
C006308 Yaw Rate Sensor Bus signal / message
failures which cannot
be assigned to a
specific signal or
message
Yaw rate sensor signal
is in a valid range but
is implausible
Yaw rate sensor not
correctly mounted
Yaw rate sensor not
correctly connected
Ignition supply to yaw
rate sensor open
circuit, short to power,
short to ground
Ground line to yaw
rate sensor open
circuit, short to power,
short to ground
Yaw rate sensor
internal failure
Check yaw rate sensor for correct mounting. Check yaw rate sensor connector for
corrosion and correct installation. Refer to the electrical guides and check yaw rate
supply, ground circuits for short to ground, power and open circuit. Install yaw rate
sensor as required. Road test vehicle to ensure DSC lamp is extinguished.
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C007298 Brake
Temperature Too
High
Component or system
over temperature. The
HCU has detected that
the temperature is too
high for the correct
operation of
component or system
Overheating of at
least one hydraulic
braking circuit
Check brake system for binding, dragging brakes.
C110964 Vehicle Dynamics
Control Switch
Signal plausibility
failure. The HCU has
detected a plausibility
failure
Traction switch has
been operated to
frequently, greater
than 15 times within
30 seconds
Traction switch has
been operated for too
long
Traction switch is
stuck closed
Traction off circuit
short to ground
Damage or corrosion
to traction off circuit
wiring or connectors
Verify with customer that switch has not been depressed for greater than 10
seconds or repeatedly pressed. Using the manufacturer approved diagnostic
system check datalogger signal 2B05 electronic traction control / dynamic stability
control input/output, for sticking switch. Refer to the electrical guides and check
traction off circuit for short to ground. Check for damage or corrosion to traction
off circuit wiring and connectors. Install traction switch as required.
C1A0000Control Module Internal failure control
module
Clear DTCs using the manufacturer approved diagnostic system, confirm fault is
still present. Suspect the HCU, check and install a new unit as required, refer to
the new module/component installation note at the top of the DTC Index. After
replacement the new HCU must be configured, by carrying out the following
procedure. Ignition ON for 30 seconds, brake warning lamps will remain
illuminated. Ignition OFF. Ignition ON, brake warning lamps will extinguish after 3
seconds.
C1A0001Electronic Control
Unit
General Electrical
Failure
Implausible HCU valve
actuation
Internal failure
Clear DTCs using the manufacturer approved diagnostic system, confirm fault is
still present. Suspect the HCU, check and install a new unit as required, refer to
the new module/component installation note at the top of the DTC Index. After
seconds.
C1A0016System Voltage
Low
Circuit voltage below
threshold. The HCU
has measured a
voltage below a
specified range but
not necessarily a short
to ground
HCU supply voltage
less than 9.3 volts,
pump running or less
than 9.6 volts, pump
not running
Low or discharged
battery
Ground circuit to
module high
resistance, poor
connection, corroded
terminals
Motor ground circuit to
module high
resistance, poor
terminals
Ignition circuit to
module intermittent
open circuit, poor
terminals
Pump supply circuit to
module intermittent
open circuit, poor
terminals
Solenoid supply circuit
to module intermittent
open circuit, poor
terminals
Check vehicle battery is at correct voltage and is not low or discharged. Check
vehicle charging system is correctly charging the battery. Refer to the electrical
guides and check ground circuit to module for high resistance, poor connection,
corroded terminals. Motor ground circuit to module for high resistance, poor
connection, corroded terminals. Ignition circuit to module intermittent for open
circuit, poor connection, corroded terminals. Pump supply circuit to module for
intermittent open circuit, poor connection, corroded terminals. Solenoid supply
circuit to module for intermittent open circuit, poor connection, corroded terminals.
C1A0017System Voltage
High
Circuit voltage above
threshold. The HCU
has measured a
voltage above a
specified range but
not necessarily a short
Using the manufacturer approved diagnostic system check other control modules
for similar DTCs. Check vehicle battery is at correct voltage and is not above or
overcharged condition. Check vehicle charging system is correctly charging the
battery.
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Module supply voltage
greater than 16.8
volts
Over voltage of the
battery charging
system
Over voltage
measured between
module ignition and
ground
Over voltage
measured between
module pump supply
and motor ground
Over voltage
measured between
module solenoid
supply and motor
ground
C1A001CSystem Voltage
Unstable
Circuit voltage out of
range. The HCU has
measured a voltage
outside the expected
range but not
identified as too high
or too low
Module supply voltage
equal too or less than
8.2 volts for more
than 20ms
Low or discharged
battery
Battery charging
system failure
Ground circuit to
module high
resistance, poor
terminals
Motor ground circuit to
module high
resistance, poor
terminals
Ignition circuit to
module intermittent
open circuit, poor
terminals
Pump supply circuit to
module intermittent
open circuit, poor
terminals
to module intermittent
open circuit, poor
terminals
Check vehicle battery is at correct voltage and is not low or discharged. Check
vehicle charging system is correctly charging the battery. Refer to the electrical
guides and check ground circuit to module for high resistance, poor connection,
corroded terminals. Motor ground circuit to module for high resistance, poor
connection, corroded terminals. Ignition circuit to module intermittent for open
circuit, poor connection, corroded terminals. Pump supply circuit to module for
intermittent open circuit, poor connection, corroded terminals. Solenoid supply
circuit to module for intermittent open circuit, poor connection, corroded terminals.
C1A004AVariant Selection Incorrect component
installed. Mismatch
between the hardware
connected to the HCU/
module and the
hardware expected by
the HCU
Transferred variant
value not released
Transferred variant
value outside
permissible range
EEPROM values with
valid HCU data
implausible
Transferred variant
values from engine
control module are
invalid for this vehicle
Clear DTCs using the manufacturer approved diagnostic system. Cycle ignition and
wait for brake warning lamps to extinguish, allow up to 30 seconds. If the DTC is
still present carry out the following procedure again using the manufacturer
approved diagnostic system vehicle configuration main menu, special applications,
vehicle identification block read. Contact dealer technical support.
C1A0067Control Module Signal incorrect after
event. The HCU has
not seen the correct
change of a parameter
or group of parameters
in response to a
particular event
Incorrect tire pressure
Incorrect size wheel or
tire
Using the manufacturer approved diagnostic system compare the signals for all
the WSS simultaneously. Check for similar values and operation between each
WSS. Check for other WSS DTCs, rectify as required. Clear DTCs road test and
re-check. Contact dealer technical support.
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Poor WSS signal at
higher frequency. At
approximately 50 kph
(31 mph) WSS may
not compare and show
a variance
C1A7614Valve Relay
Circuit
Circuit short to ground
or open
open
short to ground
Internal failure in
HCU, solenoid valve
supply relay
Refer to the electrical guides and check solenoid supply circuit for short to ground
and open circuit. Suspect the HCU, check and install a new unit as required, refer
to the new module/component installation note at the top of the DTC Index. After
seconds.
C1A7804Generic Valve
Fault
System internal
failures
Internal failure in HCU
Suspect the HCU, check and install a new unit as required, refer to the new
module/component installation note at the top of the DTC Index. After
seconds.
C1A9114Front Left Wheel
Speed Sensor
Circuit
or open. The DTC is
logged when the
ignition is on, the
vehicle is stationary
and the fault is
present for greater
than 240 ms
WSS signal front left
circuit short to ground
circuit short to power
open circuit
WSS supply front left
open circuit
WSS internal failure
Check connectors of harness to WSS, intermediate harness connectors and harness
connectors to module for corrosion and correct terminal tension. Refer to the
electrical guides and check WSS signal front left circuit for short to ground, power
and open circuit. Refer to the electrical guides and check WSS supply front left
circuit for short to ground, power and open circuit. Check WSS circuit for damage
to insulation. Install WSS harness as required. Install WSS as required.
C1A9129Front Left Wheel
Speed Sensor
Circuit
Signal invalid. A
failure where the
value of the signal is
not plausible given
the operating
conditions
Excessive free play in
wheel bearings
tire
Excessive air gap
between WSS and
sensor target ring
Incorrect number of
teeth on WSS target
ring
Corrosion of WSS in
sensor mounting
Electrical interference
on the WSS signal
circuit
Damage to WSS circuit
wiring
WSS's crossed over,
monitoring incorrect
wheels
Using the manufacturer approved diagnostic system compare the datalogger
signals for all the WSS simultaneously. Check for similar values and operation
between each WSS. Check wheel rims and tires are to the correct size. Check WSS
target ring air gap is to specification. Check that the WSS target ring is correctly
installed, check wheel bearing is correctly installed. Check correct wheel bearing is
installed. Check that WSS is not corroded in its mounting bracket. Using the
manufacturer approved diagnostic system check that each wheel corresponds
correctly to its signal. Suspect the HCU, check and install a new HCU as required,
refer to the new module/component installation note at the top of the DTC Index.
After replacement the new HCU must be configured, by carrying out the following
seconds.
C1A9214Rear Left Wheel
Speed Sensor
Circuit
or open. The DTC is
logged when the
ignition is on, the
and the fault is
present for greater
than 240 ms
WSS signal rear left
open circuit
WSS supply rear left
electrical guides and check WSS signal rear left circuit for short to ground, power
and open circuit. Refer to the electrical guides and check WSS supply rear left
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open circuit
C1A9229Rear Left Wheel
Speed Sensor
Circuit
Signal invalid. A
failure where the
not plausible given
the operating
conditions
tire
Excessive air gap
between WSS and
sensor target ring
Distortion or
displacement of WSS
target ring
Incorrect number of
teeth on WSS target
ring
Corrosion of WSS in
sensor mounting
WSS target ring dirty
or damaged teeth
WSS's crossed over,
wheels
installed, secure and is not misaligned or has drifted off centre. Check correct
number of teeth are on the WSS target ring. Check that WSS is not corroded in its
mounting bracket. Check WSS target ring is not dirty or damaged. Using the
seconds.
C1A9314Rear Right Wheel
Speed Sensor
Circuit
or open. The DTC is
logged when the
ignition is on, the
and the fault is
present for greater
than 240 ms
WSS signal rear right
open circuit
WSS supply rear right
open circuit
electrical guides and check WSS signal rear right circuit for short to ground, power
and open circuit. Refer to the electrical guides and check WSS supply rear right
C1A9329Rear Right Wheel
Speed Sensor
Circuit
Signal invalid. A
failure where the
not plausible given
the operating
conditions
tire
Excessive air gap
between WSS and
sensor target ring
Distortion or
displacement of WSS
target ring
Incorrect number of
teeth on WSS target
ring
Corrosion of WSS in
sensor mounting
WSS target ring dirty
or damaged teeth
WSS's crossed over,
wheels
installed, secure and is not misaligned or has drifted off centre. Check correct
number of teeth are on the WSS target ring. Check that WSS is not corroded in its
mounting bracket. Check WSS target ring is not dirty or damaged. Using the
seconds.
C1A9414Front Right
Wheel Speed
Sensor Circuit
or open. The DTC is
logged when the
ignition is on, the
and the fault is
present for greater
than 240 ms
WSS signal front right
open circuit
WSS supply front right
electrical guides and check WSS signal front right circuit for short to ground, power
and open circuit. Refer to the electrical guides and check WSS supply front right
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open circuit
C1A9429Front Right
Wheel Speed
Sensor Circuit
Signal invalid. A
failure where the
not plausible given
the operating
conditions
Excessive free play in
wheel bearings
tire
Excessive air gap
between WSS and
sensor target ring
Incorrect number of
teeth on WSS target
ring
Corrosion of WSS in
sensor mounting
Electrical interference
on the WSS signal
circuit
wiring
WSS's crossed over,
wheels
installed, check wheel bearing is correctly installed. Check correct wheel bearing is
installed. Check that WSS is not corroded in its mounting bracket. Using the
seconds.
C1A9529Wheel Speed
Sensor Circuit
Signal invalid. Multiple
WSS have invalid,
poor signals and are
not plausible, the
specific WSS cannot
be identified
Under inflated tire
Wheel tire size
mismatch between
front wheels
WSS transposed on
front axle, incorrectly
assigned at control
module cavity
Number of poles on
wheel bearing is
different between
front wheels
wiring
between each WSS. Check tires are inflated to correct pressures. Check wheel rims
and tires are to the correct size. Refer to the electrical guides and check WSS
supply and signal circuits correspond to the correct cavity on HCU. Check correct
wheel bearing is installed across the front axle. Refer to the electrical guides and
check WSS supply and signal circuits for short to ground, power and open circuit.
Install WSS as required. Suspect the HCU, check and install a new HCU as
required, refer to the new module/component installation note at the top of the
DTC Index. After replacement the new HCU must be configured, by carrying out
the following procedure. Ignition ON for 30 seconds, brake warning lamps will
remain illuminated. Ignition OFF. Ignition ON, brake warning lamps will extinguish
after 3 seconds.
C1A9615Brake Light
Switch Circuit
Circuit short to battery
or open.
Brake switch not
correctly adjusted
Brake switch internal
failure
Brake lamp ip circuit
short to power
open
Using the manufacturer approved diagnostic system check datalogger signal 2B00
brake input switch status for toggling switch. Check brake switch is correctly
adjusted. Refer to the electrical guides and check brake lamp ip circuit for short to
power and open circuit. Install brake lamp switch as required.
C1A9664Brake Light
Switch Circuit
Signal plausibility
failure. The HCU has
detected a plausibility
failure
The brake light switch
signal does not match
brake pressure signal
Brake switch not
correctly adjusted
Brake switch internal
failure
short to power
open
Using the manufacturer approved diagnostic system check datalogger signal 2B00
brake input switch status for toggling switch. Check brake switch is correctly
adjusted. Refer to the electrical guides and check brake lamp ip circuit for short to
power and open circuit. Install brake lamp switch as required. Suspect the HCU,
check and install a new HCU as required, refer to the new module/component
installation note at the top of the DTC Index. After replacement the new HCU
must be configured, by carrying out the following procedure. Ignition ON for 30
seconds, brake warning lamps will remain illuminated. Ignition OFF. Ignition ON,
brake warning lamps will extinguish after 3 seconds.
C1A9800Yaw Rate Sensor
Circuit
General failure. Yaw
rate sensor is off CAN
bus
Ignition supply to yaw
rate sensor open
circuit
Check for YRS CAN related DTCs from DSC module. Refer to the electrical guides
and check CAN circuits between DSC and YRS. Refer to the electrical guides and
check ignition supply to yaw rate sensor for open circuit. Refer to the electrical
guides and check ground line to yaw rate sensor for open circuit. Install new yaw
rate sensor as required.
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Ground line to yaw
rate sensor open
circuit
Yaw rate sensor
sending invalid CAN
message
Yaw rate sensor
sending initialization
status fault
Yaw rate sensor
internal failure
C1A9900Pressure Sensor
Circuit
HCU internal pressure
sensor supply circuit
high resistance
sensor failure
Suspect the HCU, check and install a new HCU as required, refer to the new
seconds.
C1A9913Pressure Sensor
Circuit
Circuit open. The HCU
has determined an
open circuit via lack of
bias voltage, low
current flow, no
change in the state of
an input in response
to an output
sensor supply circuit
high resistance
sensor failure
Suspect the HCU, check and install a new HCU as required, refer to the new
seconds.
C1B0000Steering Angle
Sensor
Steering wheel
rotation sensor
internal failure of
software
Install a new steering wheel rotation sensor. Using the manufacturer approved
diagnostic system select the vehicle configuration main menu, set up and
configuration, steering angle sensor calibration.
Sensor
Bus signal / message
failures which cannot
be assigned to a
specific signal or
message
Ignition supply to
steering wheel
rotation sensor open
circuit
Ground line to
steering wheel
circuit
steering wheel
rotation sensor
incorrectly mounted
steering wheel
rotation sensor
internal software
failure
Park the vehicle on a level surface with the wheels in the straight ahead position,
using the manufacturer approved diagnostic system check datalogger signal 3302
steering wheel angle, value should be less than +/- 15 deg. If outside of this limit
the following should be checked. The steering wheel rotation sensor is mounted in
correct position and is free to rotate. Vehicle steering geometry. Refer to the
electrical guides and check ignition supply to steering wheel rotation sensor for
open circuit. Refer to the electrical guides and check ground line to steering wheel
rotation sensor for open circuit. Install new steering wheel rotation sensor as
required. Using the manufacturer approved diagnostic system select the vehicle
configuration main menu, set up and configuration, steering angle sensor
calibration.
Sensor
Missing calibration.
The steering wheel
rotation sensor has
detected a signal
range failure
Steering wheel
rotation sensor
calibration dataset not
programmed
Steering wheel
rotation sensor
incorrectly mounted
Steering wheel
rotation sensor not
calibrated
Using the manufacturer approved diagnostic system select the vehicle
configuration main menu, set up and configuration, steering angle sensor
calibration. Check the steering wheel rotation sensor is mounted in correct
position and is free to rotate.
C1B0215Return Pump
Circuit
Circuit short to battery
or open
Low or discharged
battery
Vehicle charging
system failure
Pump supply line is
open circuit
Pump supply line short
to power
Pump motor actuation
failure
Pump motor relay
failure
HCU failure
Recharge vehicle battery. Check vehicle charging system. Refer to the electrical
guides and check pump supply line for open circuit. Refer to the electrical guides
and check pump supply line for short to power. Suspect the HCU, check and install
a new HCU as required, refer to the new module/component installation note at
the top of the DTC Index.
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C1B0271Return Pump
Circuit
Actuator stuck.
Low or discharged
battery
Vehicle charging
system failure
Pump supply line is
open circuit
Pump supply line short
to power
Pump motor actuation
failure
Pump motor relay
failure
HCU failure
Recharge vehicle battery. Check vehicle charging system. Refer to the electrical
guides and check pump supply line for open circuit. Refer to the electrical guides
and check pump supply line for short to power. Suspect the HCU, check and install
a new HCU as required, refer to the new module/component installation note at
the top of the DTC Index.
U000188High Speed CAN
Communication
Bus
Bus off.
CAN monitoring has
detected a fault in the
CAN circuit or signal
level
CAN H open circuit
between HCU, PJB and
ECM
CAN L open circuit
between HCU, PJB and
ECM
CAN H circuit, short to
ground between HCU,
PJB and ECM
CAN L circuit, short to
ground between HCU,
PJB and ECM
CAN H circuit, short to
power between HCU,
PJB and ECM
CAN L circuit, short to
power between HCU,
PJB and ECM
Carry out any pinpoint test associated with this DTC using the manufacturer
approved diagnostic system. Refer to the electrical guides, check between HCU
CAN H, PJB CAN H and ECM CAN H for open circuit, short to power, short to
ground. Check between HCU CAN L, PJB CAN L and ECM CAN L for open circuit,
short to power, short to ground.
U010087Lost
Communication
With ECM A
Missing message. The
HCU has not received
one or more expected
messages from the
ECM
CAN H open circuit
between HCU, and
ECM
CAN L open circuit
between HCU, and
ECM
Clear DTCs and re-test for reoccurrence of the DTC after 30s with ignition on. Carry
out any pinpoint test associated with this DTC using the manufacturer approved
diagnostic system. Check ECM for DTCs and refer to the relevant DTC Index. Refer
to the electrical guides, check between HCU CAN H and ECM CAN H for open
circuit. Check between HCU CAN L and ECM CAN L for open circuit.
U012387Lost
Communication
With Yaw Rate
Sensor Module
messages from the
yaw rate sensor
module
Yaw rate sensor not
correctly connected
Ignition supply to Yaw
rate sensor open
circuit
Ground line to Yaw
rate sensor open
circuit
CAN H open circuit
between yaw rate
sensor, steering wheel
rotation sensor and
DSC module
CAN L open circuit
between yaw rate
rotation sensor and
DSC module
Yaw rate sensor
failure
approved diagnostic system. Clear DTCs and check for reoccurrence of the fault
after 30 seconds with ignition on. Check yaw rate sensor is correctly connected.
Refer to the electrical guides and check ignition supply to Yaw rate sensor for
open circuit. Refer to the electrical guides and check ground line to Yaw rate
sensor for open circuit. Refer to the electrical guides and check CAN H for open
circuit between yaw rate sensor and DSC module. Refer to the electrical guides
and check CAN L for open circuit between yaw rate sensor and DSC module. Install
new yaw rate sensor as required.
U012687Lost
Communication
With Steering
Angle Sensor
Module
messages from the
steering angle sensor
module
Steering wheel
rotation sensor not
correctly connected
Ignition supply to
steering wheel
circuit
Ground line to
approved diagnostic system. Clear DTCs and check for reoccurrence of the fault
after 30 seconds with ignition on. Check yaw rate sensor, steering wheel rotation
sensor are correctly connected. Refer to the electrical guides and check ignition
supply to Yaw rate sensor, steering wheel rotation sensor for open circuit. Refer to
the electrical guides and check ground line to Yaw rate sensor, steering wheel
rotation sensor for open circuit. Refer to the electrical guides and check CAN H for
open circuit between yaw rate sensor, steering wheel rotation sensor and module.
Refer to the electrical guides and check CAN L for open circuit between yaw rate
sensor, steering wheel rotation sensor and module. Install new steering wheel
rotation sensor as required.
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steering wheel
circuit
CAN H open circuit
between yaw rate
rotation sensor and
module
CAN L open circuit
between yaw rate
rotation sensor and
module
Steering wheel
rotation sensor failure
U040186Invalid Data
Received From
ECM
Signal invalid. Clear DTCs and re-test for reoccurrence of the DTC after 30s with ignition on.
Check ECM for DTCs and refer to the relevant DTC Index.
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Anti-Lock Control - Stability Assist - Anti-Lock Brake System (ABS) ModuleVIN Range:
C00001->J12991
Removal
1. Disconnect the anti-lock brake system (ABS) module electrical
connector.
2. Detach the hydraulic control unit (HCU).
3. Remove the ABS module.
Installation
1. NOTE: Install new retaining bolts.
Tighten to 3 Nm.
2. Reprogram the ABS module, using the Jaguar approved diagnostic
system.
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Anti-Lock Control - Stability Assist - Front Wheel Speed Sensor
Removal
1. Remove the wheel and tire assembly. For additional information, refer
2. Disconnect the front wheel speed sensor electrical connector.
3. Remove the front wheel speed sensor.
Installation
1. Tighten to 5 Nm
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Anti-Lock Control - Stability Assist - Hydraulic Control Unit (HCU)VIN Range:
C00001->J12991
Removal
All vehicles
3. Connect a bleed pipe bottle to the caliper bleed nipple and loosen the
bleed nipple.
4. Install pedal hold-down tool.
Install the tool between the pedal and the seat frame.
Turn the tool hand-wheel to depress and hold the pedal 60 mm
(2.4 in) from the 'OFF' position
This will prevent loss of fluid from the reservoir through
disconnected brake pipes.
5. Remove the bleed pipe and bottle.
Tighten the caliper bleed nipple.
Disconnect and remove the bleed pipe and bottle.
Install the bleed nipple dust cap.
6. Disconnect the hydraulic control unit electrical connector.
Vehicles with stability assist
7. Disconnect the pressure sensor electrical connector.
All vehicles
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8. CAUTION: If brake fluid is spilt on the paintwork, the effected
Disconnect the hydraulic control unit brake tubes.
9. Remove the hydraulic control unit.
Installation
Tighten to 17 Nm.
2. Bleed the brake system.
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Anti-Lock Control - Stability Assist - Hydraulic Control Unit (HCU)VIN Range:
J12992->V99999
Special Tool(s)
JDS 9013
Removal
3. Connect a bleed pipe bottle to the caliper bleed nipple and loosen the
bleed nipple.
4. Install pedal hold-down tool.
Install the tool between the pedal and the seat frame.
Turn the tool hand-wheel to depress and hold the pedal 60 mm
(2.4 in) from the 'OFF' position.
This will prevent loss of fluid from the reservoir through
disconnected brake pipes.
5. Remove the bleed pipe and bottle.
Tighten the caliper bleed nipple.
Disconnect and remove the bleed pipe and bottle.
Install the bleed nipple dust cap.
6. Disconnect the hydraulic control unit (HCU) electrical connector.
Avoid contact with the eyes. Wash hands thoroughly after handling, as
prolonged contact may cause irritation and dermatitis. If brake fluid
contacts the eyes, flush the eyes with cold water or eyewash solution and
seek medical attention. If taken internally do not induce vomiting, seek
immediate medical attention. Failure to follow these instructions may
result in personal injury.
CAUTIONS:
If brake fluid is spilt on the paintwork, the effected area must be
immediately washed down with cold water.
Cap the exposed brake tubes and ports to prevent loss of fluid and
dirt ingress. Failure to follow this instruction may result in damage to the
vehicle.
Disconnect the HCU brake tubes.
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8. Remove the HCU.
Installation
Tighten to 8 Nm.
2. CAUTION: Make sure the brake tubes are installed to the correct
ports. Failure to follow this instruction may result in damage to the
vehicle.
Tighten to 16 Nm.
3. Bleed the anti-lock brake system (ABS).
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Anti-Lock Control - Stability Assist - Rear Wheel Speed Sensor
Removal
Disassembly and Assembly).
2. Disconnect the rear ABS wheel speed sensor electrical connector.
3. Detach the grommet.
5. Detach the ABS wheel speed sensor wiring harness.
6. Remove the ABS wheel speed sensor.
Vehicles with 2.0L or diesel engine
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7. Disconnect the ABS wheel speed sensor electrical connector.
8. Remove the ABS wheel speed sensor.
Installation
2. To install reverse the removal procudure.
1. Tighten to 7 Nm.
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Anti-Lock Control - Stability Assist - Stability Assist Module
Removal
1. NOTE: Stability assist module is an integral component of the ABS
module and cannot be separated.
Disconnect the anti-lock brake system (ABS) module electrical connector.
2. Detach the hydraulic control unit (HCU).
3. Remove the ABS module.
Installation
Tighten to 3 Nm.
2. Reprogram the ABS module, using the Jaguar approved diagnostic
system.
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Anti-Lock Control - Stability Assist - Steering Wheel Rotation Sensor
Removal
1. Disconnect the steering wheel rotation sensor electrical connector.
2. Remove the upper steering column.
For additional information, refer to: Steering Column.
3. Remove the steering wheel rotation sensor.
Installation
Tighten to 1 Nm.
2. Calibrate the steering wheel angle sensor using the Jaguar approved
diagnostic system.
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Anti-Lock Control - Stability Assist - Yaw Rate Sensor2.0L Duratorq-TDCi/2.0L NA V6 -
AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27
Removal
1. Remove the floor console trim panel.
2. Disconnect the yaw rate sensor electrical connector.
3. WARNING: Note the correct orientation of the yaw rate sensor.
Remove the yaw rate sensor.
Installation
1. WARNING: Make sure the yaw rate sensor is correctly installed.
Tighten to 6 Nm.
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Anti-Lock Control - Stability Assist - Yaw Rate Sensor2.2L Duratorq-TDCi
Removal
1. Detach the J-gate surround.
2. Detach the gear selector surround.
All vehicles
3. Detach the ash tray.
4. Remove the ash tray.
Disconnect the electrical connectors.
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5. CAUTION: Make sure the yaw rate sensor is not subjected to any
form of impact and is not dropped or damaged. Failure to follow this
instruction may result in failure of the sensor.
Detach the yaw rate sensor.
6. Remove the yaw rate sensor.
Installation
1. CAUTION: Make sure the yaw rate sensor is not subjected to any
form of impact and is not dropped or damaged. Failure to follow this
instruction may result in failure of the sensor.
Tighten to 6 Nm.
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Published: 20-Jul-2011
Steering System - General Information -
Steering Linkage Specifications
Steering Linkage Free Play Measurement (mm) Measurement (in)
Free play (measured at the steering wheel rim) 0-6 0-0.24
Power Steering Pump Specifications
Item Specification
Power steering pump relief pressure 106-114 bar
Item Specification
Power steering fluid Dexron 3
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Steering System - General Information - Steering System
1 Fluid cooler
2 Low pressure pipe - fluid cooler to reservoir
3 Fluid reservoir
4 Power steering pump
5 Heat shield
6 Extension shaft
7 Dash panel seal
8 High pressure pipe
9 Steering gear
10 Tie-rod end
11 Low pressure pipe - steering gear to fluid cooler
Vehicles with 2.0L or diesel engines
The power steering system is a rack and pinion design, with an engine-driven pump providing the steering assistance.
Vehicles with 2.5L or 3.0L engines
The power steering system is a rack and pinion design, with an engine-driven pump providing the steering assistance. The system features
variable steering assistance with vehicle speed and a variable ratio steering rack.
Absolute cleanliness must be observed when replenishing the fluid or dismantling any part of the system. New fluid from a sealed container
must be used.
NOTE: If the steering gear, pump or cooler are being replaced for leakage or noise related issues and there is no evidence of fluid
contamination, there is no need to replace the reservoir.
In some cases where the fluid clearly contains particulate matter, and the system continues to function, flush the system with fresh fluid
and replace the reservoir, as there is the possibility that the reservoir internal filter may be damaged or faulty.
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Steering System - General Information - Steering System
1. Verify the customer concern by driving the vehicle. 1.
Mechanical Inspection Chart
Mechanical Checks
Incorrect tire pressure, loose wheel nuts, incorrect wheel alignment
Loose tie-rods
Loose damper and spring assemblies or ball joint
Loose steering column shaft universal joints
Loose pinch bolts on steering column shaft
Loose steering gear assembly
Check for external damage to the steering gear.
- Damaged tie-rods
-
CAUTION: If a steering gear assembly is returned under warranty with leaking seals, but there is also damage to the
steering gear boot/boots the steering gear warranty will be invalid. This is due to the steering gear seals being damaged due to
foreign materials entering the steering gear boot and damaging the steering gear seals thereafter.
Damaged steering gear boot
Damaged accessory drive belt
Binding or misaligned steering column, pump or steering gear
Incorrect fluid level
Hose leaks or line restrictions
Hose fouling bodywork
Electrical Inspection Chart
Electrical Checks/Tests
Make sure all connectors are in place (steering gear Servotronic solenoid and steering control module (SCM) - if applicable)
Make sure all the fuses are in place and not blown
DISCONNECT the steering gear transducer and the steering should become heavy
TEST electrical values:
- Power Supply to the SCM = 12 Volts
- Steering gear transducer resistance 7.0 to 7.5 Ohms is normal (limits: less than 5 Ohms and greater than 9 Ohms would be declared
unacceptable)
- Steering gear transducer voltage = 6 Volts
- Steering gear transducer current = 840 mA at 0 mph reducing to 0 mA at maximum speed
RECONNECT all electrical items disturbed during testing
step.
3.
4. Check the power steering fluid condition. For additional information, REFER to Power Steering Fluid Condition Check in this section. 4.
5. If the concern is not visually evident, verify the symptom and REFER to Steering Fault Diagnosis by Symptom Charts in this
section.
5.
Steering Relay Harness Connector
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Item Description
1 Steering transducer ground
2 Ignition feed
3 Steering transducer feed
4 Ground
5 Speed sensor signal
6 Serial interface
Steering Linkage Inspection and Backlash (Freeplay) Check
CAUTION: Steering gear boots must be handled carefully to avoid damage. Use new clamps when installing steering gear boots.
Inspect the boots for cuts, deterioration, twisting or distortion. Check the steering gear boots to make sure they are tight. Install new boots
or clamps as necessary.
NOTE: The following steps must be carried out with assistance.
1. With the wheels in the straight ahead position, gently turn the steering wheel to the left and the right to check for free play. 1.
2. Free play should be between 0 and 6 mm (0 and 0.24 in) at the steering wheel rim. If the free play exceeds this limit, either the
ball joints are worn, the lower steering column joints are worn or the backlash of the steering gear is excessive.
2.
CAUTION: DO NOT attempt to adjust the steering gear yoke. Failure to follow this instruction will result in the steering gear warranty
to become invalid.
3. The backlash of the steering gear cannot be adjusted, install a new steering gear. For additional information,
REFER to Section 211-02 Power Steering.
3.
4. Grasp the steering wheel firmly and move it up and down and to the left and right without turning the wheel to check for column
bearing wear, steering wheel or steering column. For additional information,
REFER to Section 211-04 Steering Column.
4.
Power Steering Fluid Condition Check
1. Run the engine for 2 minutes. 1.
2. Check the power steering fluid system level. 2.
3. Observe the color and the odor. The color under normal circumstances should be dark reddish, not brown or black. 3.
4. Allow the fluid to drip onto a facial tissue and examine the stain. 4.
5. If evidence of solid material is found, the power steering fluid system should be drained for further inspection. 5.
6. If fluid contamination or steering component failure is confirmed by the sediment in the power steering fluid system, REFER to
Steering Fault Diagnosis by Symptom Charts in this section.
6.
Power Steering Pressure Test
Test Equipment
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Item Special Tool Number Description
1 211-011 Pressure Gauge Hose
2 211-011-08 Pump Return Hose
3 211-011-07 Pump Return Hose Connector
4 211-011-03/2 Test Equipment to High Pressure Hose Adaptor
5 211-011-03/1 Pump High Pressure Outlet to Hose Adaptor
6 211-011-02 Pump Adaptor to Control Valve Hose
7 211-011-01 Control Valve
8 211-011 Pressure Gauge
9 - 'O' Ring Seal
The measurement of the maximum system pressure, (which is governed by the pressure relief valve) is achieved by inserting the Service
Tool (pressure gauge and adaptors) into the fluid circuit of the power steering system. Run the engine at idle speed, turn the steering from
lock to lock and read the maximum pressure recorded on the gauge.
Installing Test Equipment
To install the pressure test equipment:
Place a suitable drain tray below the power steering pump.
Install a hose clamp on the reservoir to pump hose prior to disconnecting any hoses, to avoid unnecessary loss of fluid.
Disconnect the hose from the power steering pump high pressure outlet.
Install the pump outlet to hose adaptor (5). Do not omit the 'O' ring seal (9).
Connect the power steering pump adaptor to control valve hose (6) of the test equipment.
Install the adaptor (4) in the high pressure hose previously removed from the power steering pump outlet.
Connect the connector (3) of the test equipment hose (2) to the adaptor (4).
Remove the hose clamp from the reservoir hose.
Start the engine.
With the control valve (7) OPEN and the engine idling, the following system pressures may be checked:
During turning.
When the steering is held on full lock.
With the steering at rest.
CAUTIONS:
To avoid excessive heating of the power steering pump, do not close the valve for l onger than 5 seconds maximum.
Do not drive the vehicle with the test equipment installed.
With the control valve (7) CLOSED the power steering pump maximum output pressure can be checked.
Removing Test Equipment
To remove the test equipment:
Install a hose clamp on the reservoir to power steering pump hose.
Removing the test equipment is a reversal of the installation instructions.
Install a new 'O' ring seal (9) to the power steering pump high pressure outlet to hose connection.
Install the original hose to the power steering pump.
Remove the clamp from the reservoir to the power steering pump hose.
Top-up the reservoir fluid.
Bleed the power steering system. For additional information,
REFER to Power Steering System Bleeding - in this section.
Steering Fault Diagnosis by Symptom Charts
Leakage
Condition Possible Sources Action
Fluid
leakage
Confirm the position of the fluid
leak.
CLEAN the area of the leak.
Inspect the area and confirm the exact position of leak.
Make sure the fluid is not from another system on the vehicle.
Overfilled system. CORRECT the fluid level as necessary.
Component leak.
NOTE: Record the position of the leak and some indication of the rate of the leak
on the Warranty Return Record Sheet.
LOCATE the suspect component or CHECK hose connections and repair as
necessary.
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Damaged fluid cap. INSTALL a new fluid cap.
Loose or damaged hose
fittings.
TIGHTEN or INSTALL a new hose as necessary.
Leakage at power steering
pump.
INSTALL a new power steering pump as necessary. For additional information,
Fluid
leakage
Leakage at steering hose to
steering gear connection.
CHECK steering hose to steering gear connection for leakage. CHECK and
TIGHTEN the steering hose to steering gear connection retaining bolts/bolts
as necessary.
Power steering fluid leakage
at O-ring seals.
CHECK the power steering system for signs of steering fluid loss from O-ring
seals.
INSTALL new O-ring seals as necessary.
BLEED the power steering system. For additional information,
REFER to Section 211-00 Steering System - General Information.
from transfer pipes.
CHECK the power steering system for signs of steering fluid loss from the
transfer pipes.
CHECK and TIGHTEN the transfer pipes if required, INSTALL new transfer
pipes as necessary.
from the steering gear.
CHECK the power steering gear for signs of fluid loss.
INSTALL a new steering gear as necessary. For additional information,
from steering gear boot.
CHECK the power steering gear for signs of fluid loss.
INSTALL a new steering gear as necessary. For additional information,
Functional
Free play at steering wheel
Excess play in the steering
linkage.
CHECK the steering linkage for excess play. For
additional information, REFER to the Steering Linkage
Inspection and Backlash (Freeplay) Check in this
section.
Steering wheel loose.
CHECK and TIGHTEN the steering wheel retaining
bolt/bolts as necessary. For additional information,
Lower steering column pinch
bolt loose.
CHECK and TIGHTEN the lower steering column pinch
bolts as necessary. For additional information,
Excessive wear in lower
steering column.
CHECK for lower steering column for wear in the
universal joints. If wear is present, INSTALL a new
lower steering column as necessary.
Wear in suspension joints.
CAUTION: DO NOT attempt to adjust the steering gear
yoke. Failure to follow this instruction will result in the
steering gear warranty to become invalid.
CHECK for excess wear in the front suspension joints.
For additional information,
REFER to Section 204-00 Suspension System -
Vehicle wanders from side to
side on the road, when the
vehicle is driven straight ahead
and the steering wheel is held in
a firm position
Incorrect tire pressure or tire
size.
CHECK and ADJUST the tire pressure. For additional
information,
REFER to Section 204-04 Wheels and Tires.
INSTALL a new tire as necessary. For additional
information,
Vehicle is unevenly or
excessively loaded.
ADJUST the load evenly.
Loose/worn tie-rods.
INSTALL a new tie-rod end. For additional information,
REFER to Section 211-03 Steering Linkage.
Steering gear bolts loose or
damaged.
TIGHTEN or INSTALL new bolts.
Loose or worn suspension ball
joint(s).
INSTALL a new suspension ball joint assembly. For
additional information,
REFER to Section 204-01 Front Suspension.
Steering column universal
joint pinch bolt loose.
TIGHTEN the steering column universal joint pinch
bolt. For additional information,
Incorrect toe adjustment.
ADJUST as necessary. For additional information,
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Loose or worn rear
suspension.
TIGHTEN loose, or INSTALL new rear suspension
components. For additional information,
REFER to Section 204-02 Rear Suspension.
Vehicle tends to pull to one side
when driven on a level surface
Incorrect tire pressure.
Incorrect tire size or different
tire/tread type.
Uneven tire wear
information,
information,
Vehicle is unevenly loaded or
overloaded.
Adjust the load.
Damaged front suspension
components.
INSTALL new front suspension components as
necessary. For additional information,
Damaged rear suspension
components.
INSTALL new rear suspension components as
Steering gear valve effort out
of balance.
SHIFT the transmission into NEUTRAL while driving at
no more than 30 miles/hour (50 km/h) and turn the
ignition to position I (engine OFF-coasting). If the
vehicle does not pull with the engine off, INSTALL a
new steering gear. For additional information,
If the vehicle does drift with the engine off, CROSS
SWITCH front wheel assemblies.
If the vehicle pulls to the opposite side, SWITCH
wheels that were on the rear to the same side on the
front.
If the vehicle pull direction is not changed, CHECK the
front suspension components and toe adjustments.
Check the front and rear
brakes for correct operation.
REFER to Section 206-00 Brake System - General
Information.
Check for bent rear
suspension components and
for damaged coil springs in
the front suspension.
INSTALL new rear suspension components as
Check the rear suspension for
loose or worn suspension
components.
TIGHTEN or INSTALL new components as necessary.
Incorrect underbody
alignment.
CHECK underbody alignment. For additional
information,
REFER to Section 502-00 Uni-Body, Subframe and
Mounting System.
Poor returnability of the steering
Lower steering column
interference.
CHECK the steering column is free from interference
from the engine harness, sound proofing or the floor
covering.
Incorrect tire pressure.
information,
Incorrect tire size or type.
information,
Steering column upper shroud
fouling on the steering wheel.
CHECK steering column upper shroud for fouling.
ADJUST as necessary.
joints binding.
INSTALL a new steering column. For additional
information,
Steering column shaft floor
seal binding.
CHECK the steering column shaft floor seal for correct
fitment and REFIT as necessary.
Steering column shaft floor
seal may be torn.
INSTALL a new steering column shaft floor seal as
necessary.
Binding or damaged tie-rods.
CHECK tie-rod end for excessive wear or tightness in
ball joint. INSTALL a new tie-rod end. For additional
information,
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Damaged or worn front
suspension components.
Excessive steering efforts
required during low speed
manoeuvring and/or during
parking manoeuvres
Low power steering fluid.
CHECK steering system for signs of steering fluid loss.
BLEED the power steering system. For additional
information,
REFER to Section 211-00 Steering System - General
Information.
Damaged accessory drive belt
tensioner.
INSTALL a new accessory drive belt tensioner.
Hose or cooler line restriction.
CHECK hose or cooler lines for correct routing.
INSTALL a new hose as necessary.
Fluid aeration.
BLEED the system. For additional information,
REFER to Power Steering System Bleeding in this
section.
Steering transducer not
closed - no feed voltage.
CHECK the steering transducer circuit. For additional
information, REFER to the wiring diagrams.
Carry out the electrical checks and tests. For
additional information, REFER to the Electrical Checks
and Tests in this section.
Steering transducer not
closed - cable fault.
information, REFER to the wiring diagrams.
Steering control module
(SCM) defective.
CHECK the SCM and INSTALL a new SCM as necessary.
Power steering fluid delivery
pressure or flow too low.
CHECK the power steering pressure. For additional
information, REFER to the Power Steering Pressure
Test in this section.
INSTALL a new power steering pump as necessary. For
Internal steering gear
leakage.
INSTALL a new steering gear as necessary. For
Steering operation is very heavy
when driving, but when
stationary manoeuvring is good
Steering transducer open
early.
CHECK steering transducer and INSTALL a new
steering transducer as necessary.
early, steering control module
(SCM) fault.
CHECK SCM and INSTALL a new SCM as necessary.
early, speedo signal error.
CHECK speedo circuit. For additional information,
REFER to the wiring diagrams.
Steering operation is very light
when driving, but when
stationary manoeuvring is good
Steering transducer not open,
(no power steering fluid
flow).
CHECK the power steering fluid condition. For
additional information, REFER to the Power Steering
Fluid condition check in this section.
steering control module (SCM)
fault.
CHECK the SCM and INSTALL a new SCM as necessary.
speedo signal error.
CHECK the speedo circuit. For additional information,
REFER to the wiring diagrams.
CHECK the power steering
fluid low pressure pipe for
restricted flow.
INSTALL a new power steering fluid low pressure pipe.
Steering heavy operation during
rapid manoeuvring
Air in power steering system.
CHECK for an air leak into the power steering system
and repair as necessary.
information,
REFER to Power Steering System Bleeding - in this
section.
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Fluid loss at the power
steering pump shaft seal.
CHECK the power steering pump for signs of steering
fluid loss.
fluid loss.
Steering heavy operation in one
direction
interference.
covering.
Incorrect steering geometry.
CHECK the front wheel alignment. For additional
information,
Faulty rotary valve/seal.
INSTALL a new steering gear as necessary. For
Tire fouling on the wheel arch
liner.
CHECK for clearance between the tire and the wheel
arch liner.
Remove and refit the wheel arch liner or INSTALL a
new wheel arch liner as necessary.
Steering heavy operation in both
directions
information,
REFER to Section 211-00 Steering System - General
Information.
Air in power steering system.
fluid loss.
Fluid loss at the power
steering pump shaft seal.
fluid loss.
fluid loss.
Steering operation varies from
heavy to light when driving at
constant speed
interference.
covering.
Incorrect speedometer signal.
CHECK the speedo circuit. For additional information,
refer to the wiring diagrams.
Steering transducer
cable/connection faulty or
grounded.
information, refer to the wiring diagrams.
Steering wheel varies from light
to heavy two times per
revolution
interference.
covering.
joints binding.
INSTALL a new steering column. For additional
information,
Seized or damaged steering
components.
CHECK for wear or failure of suspension bushes and
ball joints. For additional information,
Noise
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Accessory drive
belt squeal
Incorrect accessory drive belt
tension or accessory drive belt
glazed.
CHECK accessory drive belt condition and INSTALL a new
accessory drive belt as necessary. For additional information,
REFER to Section 303-05 Accessory Drive.
Chirp noise in the
steering pump
Loose or worn accessory drive
belt.
Power steering
pump noisy
Power steering pump worn or
otherwise defective.
CHECK for leaks. REPAIR as necessary.
CHECK the power steering pressure. For additional information,
REFER to the Power Steering Pressure Test in this section.
INSTALL a new power steering pump as necessary. For additional
information,
Whine type noise
Aerated fluid.
REFER to Power Steering System Bleeding - in this section.
Power steering pump.
CHECK for leaks. REPAIR as necessary.
INSTALL a new power steering pump as necessary. For additional
information,
Noise during
steering gear
movement
Water contamination to the
power steering fluid.
DRAIN the power steering system.
Cavitation due to restricted
power steering feed hose.
CHECK and reposition power steering feed hoses and INSTALL
new hoses as necessary.
Continuous noise
Power steering pump drive loose.
CHECK power steering coupling and power steering pump.
INSTALL a new power steering coupling or power steering pump
as necessary. For additional information,
Incorrect accessory drive belt
tension or accessory drive belt
glazed.
Power steering pump drive pulley
loose.
CHECK and TIGHTEN the power steering pump drive pulley
retaining bolts as necessary. For additional information, REFER
to Section 303-03A Engine Cooling / 303-03B Engine Cooling.
Power steering pump retaining
bolts loose.
CHECK the power steering pump retaining bolts and TIGHTEN as
necessary.
Power steering hose/pipe in
contact with the vehicles body.
CHECK and reposition power steering hoses/pipes, INSTALL new
hoses/pipes as necessary.
Power steering hose
restricted/twisted.
CHECK and reposition power steering hose, replace hose as
necessary.
Vibration
Feedback (knocking noises in the steering
gear) - condition where roughness is felt in
the steering wheel by the driver when the
vehicle is driven over rough surfaces
Loose/worn tie-rods.
INSTALL a new tie-rod end. For additional
information,
Steering gear
retaining bolts loose
or damaged.
CAUTION: DO NOT attempt to adjust the steering
gear yoke. Failure to follow this instruction will result in
the steering gear warranty to become invalid.
CHECK and TIGHTEN the steering gear retaining
bolts.
INSTALL new retaining bolts as necessary. For
Loose suspension
bushing, bolts or
ball joints.
TIGHTEN or INSTALL new components as necessary.
Steering column
retaining bolts
loose.
CAUTION: DO NOT attempt to adjust the steering
gear yoke. Failure to follow this instruction will result in
the steering gear warranty to become invalid.
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CHECK and TIGHTEN the steering column retaining
bolts/nuts and pinch bolts if required. For additional
information,
Excessive wear in
steering column
assembly.
CHECK for steering column for wear in the universal
joints and bearings. If wear is present, INSTALL a
new steering column as necessary. For additional
information,
Nibble (Shimmy) Oscillation of the steering
wheel (not vertical which is SHAKE). This is
driven by road wheel imbalance.
Road wheel
imbalance.
CHECK for road wheel imbalance.
CHECK for relevant SERVICE BULLETINS/SERVICE
ACTIONS for the vehicle on Jaguar Communications
Online (JCOL) or in hard copy form.
Steering wheel
replacement.
Rack replacement.
Description of General Steering System Noises
Boom
Rhythmic sound like a drum roll or distant thunder. May cause pressure on the ear drum.
Buzz
Low-pitched sound, like a bee. Usually associated with vibrations.
Chatter
Rapidly repeating metallic sound.
Chuckle
Rapid noise that sounds like a stick against the spokes of a spinning bicycle wheel.
Chirp
High pitched rapidly repeating sound, like chirping birds.
Click
Light sound, like a ball point pen being clicked.
Click/Thump
Heavy metal-to-metal sound, like a hammer striking steel.
Grind
Abrasive sound, like a grinding wheel or sandpaper rubbing against wood.
Groan/Moan
Continuous, low-pitched humming sound.
Groan/Howl
Low, guttural sound, like an angry dog.
Hiss
Continuous sound like air escaping from a tire valve.
Hum
Continuous sound of varying frequencies, like a wire humming in the wind.
Knock
Heavy, loud repeating sound like a knock on a door.
Ping
Similar to knock, except at higher frequency.
Rattle
A sound suggesting looseness, such as marbles rolling around in a can.
Roar
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Deep, long, prolonged sound like an animal, or winds and ocean waves.
Rumble
Low, heavy continuous sound like that made by wagons or thunder.
Scrape
Grating noise like one hard plastic rubbing part rubbing against another.
Squeak
High-pitched sound like rubbing a clean window.
Squeal
Continuous, high-pitched sound like running finger nails across a chalkboard.
Tap
Light, hammering sound like tapping pencil on edge of table. May be rhythmic or intermittent.
Weep
Continuous mid-range sound (lower frequency than squeal, higher frequency than groan).
Whir/Whine
High-pitched buzzing sound, like an electric motor or drill.
Whistle
Sharp, shrill sound, like wind passing a small opening.
Description of Specific Steering System Noise Types
Belt Squeal
Belt squeal is a high frequency air-borne noise generated by slippage of the ribbed Vee belt on the power steering pump pulley. Squeal
increases with system loading and at the end of lock.
Clonk
Clonk is a structure-borne noise heard as a loose-sounding rattle or vibration coming from the steering column. Clonk can be identified by
driving and turning over cobblestones, rough roads, or high frequency bumps such as 25-50 mm tall tar strips. Clonk requires a tie-rod load
impact.
Column Knock
Column knock is a loose-sounding rattle or vibration generated by the steering column shaft contacting other portions of the column
assembly. The noise is both audible and tactile. Column knock is generated by driving over cobblestones or rough pavement. It is not
necessary to turn the steering wheel to create this noise.
Column Rattle
Column rattle is a metallic sounding noise created when applying a highly impulsive force to the steering wheel. Column rattle is often used
to combine the more general group of column noises including clonk and column knock. Column rattle noises can be caused by clonk, knock,
loose column components, bonus parts etc. A series of parked, straight-line driving, and cornering test should be carried out to isolate the
source/sources.
Grinding/Scrape
Grinding is a low frequency noise in the column when the steering wheel is turned. Is generally caused by interference between moving
components such as the steering wheel to steering column shroud.
Grunt (Squawk)
Grunt is a "honking" sound elicited when coming off one of the steering stops. Grunt is generally excited during parking manoeuvres with a
low to medium speed steering input.
Hiss (Swish)
Hiss or Valve Hiss is a high-frequency sound coming from the steering gear when the system is loaded. It is a rushing or "swish" noise that
doesn't change frequency with RPM. Hiss is the general noise generated by the flow of hydraulic fluid through restrictions in the steering
system. Restrictions include the rotary steering valve, power steering tubes, connectors, tuning orifices, etc. Hiss can be air-borne and
structure-borne, but the structure-borne path through the steering intermediate shaft is usually dominant.
Moan (Groan)
Moan is the general structure-borne noise of the steering system. Moan is primarily transmitted to the driver via the body structure through
the pump mount, engine mounts, power steering lines and power steering brackets. On some vehicles, moan is a load humming noise, often
present when the wheel is turned and the system is loaded. It may change frequency with engine RPM and if the system is loaded or
unloaded.
Rack Knock (Rack Slap)
CAUTION: DO NOT attempt to adjust the steering gear yoke. Failure to follow this instruction will result in the steering gear warranty
to become invalid.
Rack Knock is a rattle sound and steering wheel vibration caused by separation of the steering gear and pinion while driving over bumps. It
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is a structure-borne noise transmitted through the intermediate shaft and column. Rack knock can also be heard as a "thump" or impact
noise that occurs with the vehicle stationary when the steering wheel is released from a loaded position and allowed to return to rest. Noise
occurs with the engine on or off.
Rattles
Rattles are noises caused by knocking or hitting with components in the steering system. Steering rattles can occur in the engine
compartment, the suspension, or the passenger compartment . Rattles can be caused by loose parts, movable and flexible parts, and
improper clearances.
Squeaks/Scrapes
Squeaks/Scrapes are noises due to friction or component rubbing anywhere in the steering system. Squeaks/Scrapes have appeared in
steering linkages and joints, in column components and in column and steering wheel trim parts.
Weep
Weep is an air-borne noise, occasionally generated when turning the steering across lock at a constant rate. When present on a vehicle the
noise, once initiated can often be maintained across a large proportion of the available steering movement.
Whistle
Whistle is similar to hiss but is louder and of a higher frequency. It is also more of a pure tone noise than hiss. Whistle is air-borne and is
generated by a high flow rate of hydraulic fluid through a small restriction.
Zip
Zip noise is the air-borne noise generated by power steering pump cavitation when power steering fluid does not flow freely through the
suction hose from the reservoir to the pump. Zip primarily occurs during cold weather at start-up.
Steering System Vibrations and Harshness
Buzz
Buzz is a tactile rotary vibration felt in the steering wheel for slow steering inputs. Buzz can also be called a grinding feel and it is closely
related to grunt and is caused by high system gain with low damping. Buzz is generally excited during parking manoeuvres with low to
medium speed steering input.
Buzz (Electrical)
A different steering buzz can be caused by pulse width modulated (PWM) electric actuators used in variable assist steering systems. This
buzz is felt by turning the ignition key to run without starting the engine and holding onto the steering wheel. In extreme cases, the buzz
can be felt with the engine running also.
Column/Steering Wheel Shake
Column shake is a low frequency vertical vibration excited by primary engine vibrations.
Nibble (Shimmy)
Steering nibble is a rotary oscillation or vibration of the steering wheel, which can be excited at a specific vehicle speed. Nibble is driven by
wheel and tire imbalance exciting a suspension recession mode, which then translates into steering gear travel and finally steering wheel
nibble.
Shudder (Judder)
Shudder is a low frequency oscillation of the entire steering system (tire, wheels, steering gear and linkage, etc.) when the vehicle is
steered during static-park or at low speeds. Shudder is very dependent on road surface.
Torque Ripple
Torque ripple is a concern with Electric Power Steering (EPS) systems. Torque ripple is most evident at static-park steering the wheel very
slowly from lock to lock. Torque ripple is primarily caused by motor commutation.
Torque/Velocity Variation (Phasing/Effort Cycling)
Steering wheel torque variation occurring twice in one revolution is normally as a result of problems with the lower steering column
(intermediate shaft), but foul conditions generally result in either constant stiffness or single point stiffness. Depending upon the
orientation of the joints, the steering can feel asymmetric (torque falling off in one direction and rising in the other) or else it can simply
have pronounced peaks and troughs as the steering moves from lock to lock.
Wheel Fight (Kick Back)
Wheel fight is excess feedback of sudden road forces through the steering system and back to the driver. It is evaluated at all vehicle
speeds over cobblestones, rough roads, and potholes. The tires, wheels, and suspensi on generate forces into the steering systems.
Steering friction, hydraulic damping, hydraulic compliance, mechanical compliance, steering ratio, and assist gain all affect how much is
transmitted to the driver.
Steering Linkage
CAUTION: Steering gear boots must be handled carefully to avoid damage. Use new clamps when installing steering gear boots.
Inspect the boots for cuts, deterioration, twisting or distortion. Check the steering gear boots to make sure they are tight. Install new boots
or clamps as necessary.
NOTE: The following steps must be carried out with assistance.
1. With the wheels in the straight ahead position, gently turn the steering wheel to the left and the right to check for free play. 1.
2. Free play should be between 0 and 6 mm (0 and 0.24 in) at the steering wheel rim. If the free play exceeds this limit, either the 2.
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ball joints are worn, the lower steering column joints are worn or the backlash of the steering gear is excessive.
CAUTION: DO NOT attempt to adjust the steering gear yoke. Failure to follow this instruction will result in the steering gear
warranty to become invalid.
3. The backlash of the steering gear cannot be adjusted, install a new steering gear. For additional information,
3.
4. Grasp the steering wheel firmly and move it up and down and to the left and right without turning the wheel to check for column
bearing wear, steering wheel or steering column. For additional information,
4.
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Steering System - General Information - Power Steering System Filling
General Procedures
1. NOTE: When filling the reservoir, make sure that the fluid is clean and
not agitated prior to use. The fluid should be poured slowly into the
reservoir to minimize the possibility of aeration.
Fill the reservoir.
2. NOTE: Do not start the engine.
Turn the steering from lock to lock.
3. Check the fluid level. Fill the reservoir if necessary.
4. Start the engine and allow to idle. Top up the reservoir as air is vented.
5. With the engine idling turn the steering from lock to lock topping up the
reservoir if necessary.
6. When no further change of fluid level occurs run engine for a further 20
minutes to vent any remaining air.
7. With the engine idling, turn the steering wheel from lock to lock. If
excessive noise is apparent or shudder is evident through the steering
wheel, repeat the filling procedure.
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Steering System - General Information - Power Steering System Flushing
General Procedures
NOTE: If heavy steering or contamination within the power steering system is found, it is necessary to carry out the system flush
procedure as detailed below. If any components have been replaced in the power steering system the procedure below must be carried out
in full.
NOTE: Some variation in the illustrations may occur, but the essential information is always correct.
1. Remove the power steering fluid reservoir cap.
2. Using a suitable syringe, remove the power steering fluid from the
power steering fluid reservoir.
3. CAUTION: Be prepared to collect escaping fluids.
NOTE: Note the orientation of the clip.
Detach the power steering fluid reservoir.
Detach but do not remove the power steering fluid reservoir.
Release the power steering fluid return hose from the power
steering fluid reservoir.
If a quick release coupling is fitted to the power steering return
hose, release the power steering fluid return hose from the
coupling by removing the clip.
NOTE: Make sure that all openings are sealed. Use new blanking caps.
Using a suitable blanking cap, cap the power steering reservoir return
pipe.
NOTE: Make sure the extended pipe is not kinked or twisted and is
correctly secured with hose clips.
Attach a suitable pipe to the power steering return hose to allow the
fluid to drain.
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6. NOTE: The suitable funnel should have the a capacity of 4 litres and
O-ring seal
NOTE: The suitable funnel must be tightly sealed to the power steering
fluid reservoir to avoid fluid leakage.
Install a suitable funnel onto the power steering fluid reservoir.
7. WARNING: Do not work on or under a vehicle supported only by a
jack. Always support the vehicle on safety stands.
Raise and support the vehicle with the wheels just clear of the ground.
8. CAUTIONS:
Steps 8 and 9 must be carried out within 2 - 3 seconds of each
other. Failure to follow this instruction may result in damage to the power
steering system.
Be prepared to collect escaping fluids.
Using the suitable funnel, top up the power steering system with the
specified fluid. Make sure the fluid level is maintained at two thirds full
in the funnel.
9. CAUTIONS:
Be prepared to collect escaping fluids.
Do not allow the power steering fluid level in the power steering
fluid reservoir to fall below the minimum power steering fluid level. Failure
to follow this instruction may result in damage to the power steering
system.
Make sure the engine is switched off as soon as the full 4 litres of
power steering fluid has entered the power steering fluid reservoir.
Flush the power steering system.
Start the engine
With assistance turn the steering slowly lock to lock 3 times at
approximately 1 revolution every 5 seconds.
Continue to flush the power steering system until 4 litres of power
steering fluid has been added to the power steering reservoir. This
should take approximately 30 seconds.
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Remove the suitable funnel.
Remove the suitable pipe to the power steering return hose.
NOTE: Note the orientation of the clip.
If a quick release coupling is fitted to the power steering return hose,
connect the power steering fluid return hose to the coupling by installing
the clip.
13. Install a new power steering fluid reservoir. For additional information,
refer to: (211-02)
Power Steering Fluid Reservoir - 4.2L/3.0L/2.7L Diesel (Removal and
Installation),
Power Steering Fluid Reservoir - 3.0L Diesel (Removal and
Installation).
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Power Steering -
Item Specification
Power assisted steering fluid Dexron 2E
Tie rod end retaining nut 35 26 -
Power steering pump retaining bolts 25 18 -
Extension shaft lower retaining bolt 27 20 -
Power steering gear actuator retaining bolts 3 - 27
Power steering gear retaining bolts 115 85 -
Latch plate to pinion housing retaining bolt 10 7 -
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Power Steering - Power Steering
1 Fluid cooler
2 Low pressure pipe - fluid cooler to reservoir
3 Fluid reservoir
4 Power steering pump suction hose
5 Power steering pump
6 Heat shield
7 Extension shaft
8 Dash panel seal
9 High pressure pipe
10 Steering gear
11 Tie-rod end
12 - Low pressure pipe - steering gear to fluid cooler
Vehicles with 2.0L or diesel engines
The power steering system uses a rack and pinion type, variable ratio steering gear. The power steering pump is belt driven on all model
variants and the power steering oil cooler is of a wire bound tube type and is mounted in front of the radiator.
Vehicles with 2.5L or 3.0L engines
The power steering system uses a rack and pinion type, variable ratio steering gear with servotronic steering assistance. The power steering
pump is belt driven on all model variants and the power steering oil cooler is of a wire bound tube type and is mounted in front of the
radiator.
A variable steering rack ratio reduces the amount of turns from lock to lock to improve parking maneuvers without loosing any steering feel
at higher speeds.
The steering assistance decreases smoothly at a calibrated rate to increase the steering efforts required as vehicle speed increases. The
steering efforts are controlled by the servotronic valve (actuator) position, which in turn is controlled electronically by the servotronic ECU
housed in the instrument cluster.
Absolute cleanliness must be observed when replenishing the fluid or dismantling any part of the system. New fluid from a sealed container
must be used.
NOTE: If the steering gear, pump or cooler are being replaced for leakage or noise related issues and there is no evidence of fluid
In some cases where the fluid clearly contains particulate matter, and the system continues to function, flush the system with fresh fluid
and replace the reservoir, as there is the possibility that the reservoir internal filter may be damaged or faulty.
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Power Steering - Power Steering
For additional information, refer toSection 211-00 Steering System - General Information.
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Power Steering - Start Up Procedure After Power Steering Pump/Gear Overhaul
General Procedures
1. For additional information, refer toSection 211-00 Steering System -
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Power Steering - Power Steering Control Valve Actuator2.5L NA V6 - AJV6/3.0L NA V6
- AJ27
Removal
2. Remove the exhaust front muffler. For additional information, refer to
Section 309-00 Exhaust System.
3. Remove the heat shield.
5. Remove the actuator.
6. Remove and discard the filter.
Installation
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1. Install a new filter
2. CAUTION: Make sure bolts are tightened evenly.
Tighten to 3 Nm.
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Power Steering - Power Steering Fluid Cooler2.0L Duratorq-TDCi
Removal
1. Remove the radiator splash shield. For additional information, refer to
For additional information, refer to: Radiator Splash Shield (501-02 Front
.
2. Disconnect the power assisted steering oil cooler inlet and outlet hoses.
Left-hand side shown, right-hand side similar.
Drain the fluid into a suitable container.
3. Remove the power assisted steering oil cooler.
1. Remove the mounting bolts.
2. Remove the power assisted steering oil cooler.
Installation
Tighten to 7 Nm.
2. NOTE: If the cooler is being replaced for leakage or noise related issues
and there is no evidence of fluid contamination, there is no need to
replace the reservoir.
In some cases where the fluid clearly contains particulate matter, and
the system continues to function, flush the system with fresh fluid and
replace the reservoir, as there is the possibility that the reservoir
internal filter may be damaged or faulty.
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Power Steering - Power Steering Fluid Cooler2.2L Duratorq-TDCi (110kW/150PS) -
Puma
Removal
1. Remove the radiator splash shield.
2. Disconnect the power steering fluid cooler hoses.
3. Remove the power steering fluid cooler retaining bolt.
4. Remove the power steering fluid cooler.
Detach the power steering fluid cooler from the retaining clip.
Installation
Tighten to 7 Nm.
2. NOTE: If the cooler is being replaced for leakage or noise related issues
and there is no evidence of fluid contamination, there is no need to
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Power Steering - Power Steering Fluid Reservoir
Removal
1. CAUTION: If power steering fluid is spilt on the paintwork, the
effected area must be immediately washed down with cold water.
Remove the power steering fluid reservoir.
1. Disconnect the power steering supply and return hoses.
1. Drain the fluid into a suitable container.
2. Remove the power steering reservoir bolts.
3. Remove the power steering reservoir.
Installation
1. CAUTION: Use only Jaguar specification Dexron 2E power assisted
steering oil.
2. Bleed the power steering system. For additional information, refer to
Section 211-00 Steering System - General Information.
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Power Steering - Power Steering Pump2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA
V6 - AJ27
Removal
1. Remove the accessory drive belt.
For additional information, refer to: Accessory Drive Belt - 2.0L NA V6 -
AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27 (303-05 Accessory Drive,
2. CAUTION: Whenever the power steering pump unions are
disconnected the steering gear valve body ports and hoses should be
plugged to prevent dirt ingress.
Disconnect the power steering feed and high pressure hoses.
1. Disconnect the power steering high pressure hose.
1. Drain the fluid into a suitable container.
- Remove and discard the O-ring seal.
2. Disconnect the power steering feed hose.
3. Remove the power steering pump.
1. Remove the power steering pump retaining bolts, power
steering pump heat shield and high pressure pipe securing
bracket.
Installation
Install a new O-ring seal.
2. CAUTION: Make sure the heat shield is fitted correctly and is free
from damage.
Tighten to 25 Nm.
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4. NOTE: If the steering gear, pump or cooler are being replaced for
leakage or noise related issues and there is no evidence of fluid
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Name
Grease
Power Steering - Power Steering Pump2.0L Duratorq-TDCi/2.2L Duratorq-TDCi
Materials
Specification
WSS-M12A4-A2
Removal
3. Remove the air cleaner.
For additional information, refer to: Air Cleaner (303-12B Intake Air
Distribution and Filtering - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi
(110kW/150PS) - Puma, Removal and Installation).
4. Detach the generator and starter motor positive cable from the air
cleaner mount bracket.
5. Remove the air cleaner mount bracket.
6. Detach the power steering pump belt.
Rotate the power steering pump belt tensioner clockwise.
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7. Detach the power steering high-pressure pipe.
8. CAUTION: Whenever the power steering pump feed hose is
disconnected the power steering pump port and hose should be plugged to
prevent dirt ingress. Failure to follow this instruction may result in damage
to the vehicle.
NOTE: Shown with the exhaust gas recirculation (EGR) cooler to EGR
valve tube removed for clarity.
Disconnect the power steering feed hose.
9. CAUTIONS:
Whenever the power steering high-pressure pipe union is
disconnected the power steering pump port and pipe should be plugged to
to the vehicle.
Do not disconnect the quick release connector on the high-pressure
pipe as it will not disconnect. Failure to follow this instruction may result
in damage to the vehicle.
NOTE: Shown with the EGR cooler to EGR valve tube removed for clarity.
Remove the power steering high-pressure pipe union from the power
steering pump boss
Remove and discard the O-ring seal.
10. NOTE: Shown with the EGR cooler to EGR valve tube removed for
clarity.
Remove the power steering pump retaining bolts.
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clarity.
Remove the power steering pump securing bracket.
clarity.
Detach the power steering pump from the coolant pump.
14. Remove and discard the water pump O-ring seal.
Installation
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1. Coat the power steering pump drive splines with grease.
2. Install a new water pump O-ring seal.
3. Install the power steering pump.
4. NOTE: Shown with the EGR cooler to EGR valve tube removed for clarity.
Attach the power steering pump to the coolant pump.
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Install the power steering pump securing bracket.
Tighten to 25 Nm.
Install the power steering pump retaining bolts.
Tighten to 25 Nm.
Install the power steering pump retaining bolt.
Tighten to 10 Nm.
8. NOTE: Remove the plugs from the power steering pump port and the
pipe.
Connect the power steering high-pressure pipe union.
Tighten to 30 Nm.
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9. NOTE: Remove the plugs from the power steering pump port and the
feed hose.
Connect the power steering feed hose.
10. Attach the power steering high-pressure pipe.
11. Attach the power steering pump belt.
12. Install the air cleaner mount bracket.
Tighten to 25 Nm.
13. Attach the generator and starter motor positive cable to the air
cleaner mounting bracket.
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14. Install the air cleaner.
17. NOTE: If the pump is being replaced for leakage or noise related
issues and there is no evidence of fluid contamination, there is no need to
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Power Steering - Steering Gear2.0L Duratorq-TDCi/2.2L Duratorq-TDCi
Removal
2. Remove and discard the extension shaft lower retaining bolt.
Release both tie-rod end ball joints.
1. loosen the locknut.
2. Release both track rods from tie rod ends, note the number of
turns for installation.
5. Disconnect the steering gear fluid lines.
1. Remove the latch plate bolt.
2. Rotate latch plate counter clockwise.
3. Disconnect the steering gear fluid lines.
6. Detach the steering gear cooler pipe.
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7. Detach the steering gear cooler pipe.
8. Detach the right-hand side of the steering gear.
9. Detach the left-hand side of the steering gear.
10. Remove the bulk head panel seal.
1. Reposition the steering gear.
2. Remove the bulk head panel seal.
11. Remove the steering gear.
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Installation
1. Install the steering gear.
1. Install the bulk head panel seal.
3. Attach the left-hand side of the steering gear.
Tighten to 133 Nm.
4. Attach the right-hand side of the steering gear.
Tighten to 133 Nm.
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5. Attach the steering gear cooler pipe.
6. Attach the steering gear cooler pipe.
7. Install new O-ring seals.
8. Attach the steering gear fluid lines.
Tighten to 10 Nm.
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10. NOTE: Right-hand shown, Left hand similar.
Connect tie-rod end ball joints.
1. Attach both tie rods to previously noted positions.
2. Tighten the tie rod locking nut.
11. NOTE: Install a new bolt.
Attach the lower steering column.
Tighten to 25 Nm.
12. Carry out steering system bleed procedure.
For additional information, refer to: Power Steering System Filling
(211-00 Steering System - General Information, General Procedures).
13. NOTE: If the steering gear is being replaced for leakage or noise
related issues and there is no evidence of fluid contamination, there is no
need to replace the reservoir.
14. If a new steering gear has been installed carry out the front toe
adjustment procedure.
For additional information, refer to: Front Toe Adjustment (204-00
Suspension System - General Information, General Procedures).
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Power Steering - Steering Gear2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 -
AJ27
Special Tool(s)
HTJ1200-2
Removal
All vehicles
2. Remove the steering column coupling.
For additional information, refer to: Steering Column Coupling (211-04
Steering Column, Removal and Installation).
3. Remove the right-hand wheel arch liner access cover.
All vehicles
Release both tie-rod end ball joints.
1. Loosen the locknuts.
2. Release both track rods from the tie rod ends, note number of
turns for installation.
5. Disconnect the power steering control valve actuator electrical connector
(if equipped).
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All vehicles
7. Detach the power steering high pressure pipe.
8. Detach the selector lever cable.
All vehicles
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Using the special tool, lower the front subframe to a maximum of 50 mm
(1.97 inches).
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14. Remove the retaining clip from the power steering high and low
pressure pipes.
All vehicles
15. CAUTION: Whenever the power steering pipes are disconnected,
the steering gear valve body ports and power steering pipes should be
plugged to prevent dirt ingress. Failure to follow this instruction may
result in damage to the vehicle.
NOTE: Left-hand drive vehicles shown, right-hand drive vehicles similar.
Disconnect the power steering high and low pressure pipes from the
steering gear.
1. Remove the latch plate retaining bolt.
2. Disconnect the power steering high pressure pipe.
3. Disconnect the power steering low pressure pipe.
16. Remove and discard the O-ring seals.
17. Remove the power steering high pressure pipe bracket retaining bolt.
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18. CAUTION: Whenever the power steering high pressure pipe is
disconnected, the power steering pump port and pipe should be plugged to
to the vehicle.
Disconnect the power steering high pressure pipe from the power
steering pump.
19. Remove and discard the O-ring seal.
All vehicles
20. NOTE: Left-hand drive vehicles shown, right-hand drive vehicles
similar.
Detach the right-hand side of the steering gear.
similar.
Detach the left-hand side of the steering gear.
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similar.
Remove the steering gear bulkhead seal.
similar.
Remove the steering gear.
Rotate the steering gear.
Remove the steering gear through the driver side wheel arch
aperture .
Installation
All vehicles
1. NOTE: Left-hand drive vehicles shown, right-hand drive vehicles similar.
Install the steering gear.
2. CAUTION: Make sure the steering gear bulkhead seal is correctly
aligned. Failure to follow this instruction may result in damage to the
vehicle.
NOTE: Left-hand drive vehicles shown, right-hand drive vehicles similar.
Install the steering gear bulkhead seal.
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Attach the right-hand side of the steering gear.
Loosely install the steering gear retaining bolt.
Attach the left-hand side of the steering gear.
Loosely install the steering gear retaining bolt.
Tighten the right-hand side steering gear retaining bolt.
Tighten to 115 Nm.
Tighten the left-hand side steering gear retaining bolt.
Tighten to 115 Nm.
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7. NOTE: Remove the blanking plug.
8. NOTE: Remove the blanking plug.
Connect the power steering high pressure pipe to the power steering
pump.
Tighten to 30 Nm
9. Install the power steering high pressure pipe bracket retaining bolt.
Tighten to 25 Nm
All vehicles
10. Install new O-ring seals.
similar.
Connect the power steering high and low pressure pipes to the steering
gear.
1. Connect the power steering low pressure pipe.
2. Connect the power steering high pressure pipe.
3. Install the latch plate retaining bolt
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12. Install the retaining clip to the power steering high and low pressure
pipes.
All vehicles
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Tighten to 142 Nm.
M8 to 35 Nm.
M10 to 70 Nm.
19. Attach the selector lever cable.
All vehicles
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20. Attach the power steering high pressure pipe.
All vehicles
22. Connect the power steering control valve actuator electrical connector
(if equipped).
Connect tie-rod end ball joints.
1. Attach both tie rod ends to previously noted positions.
2. Tighten tie rod locking nut.
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All vehicles
25. Carry out steering system bleed procedure.
26. CAUTION: Make sure the steering column coupling is installed
with the vehicle on its wheels. Failure to follow this instruction may result
Install the steering column coupling.
For additional information, refer to: Steering Column Coupling (211-04
Steering Column, Removal and Installation).
27. NOTE: If the steering gear is being replaced for leakage or noise
related issues and there is no evidence of fluid contamination, there is no
need to replace the reservoir.
28. Using the Jaguar approved diagnostic system, configure the steering
angle sensor.
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Steering Linkage -
Tie-rod end retaining nut 35 26 -
Tie-rod end lock nut 40 30 -
Wheel nuts - Vehicles with steel wheels 80 59 -
Wheel nuts - Vehicles with aluminium wheels 103 76 -
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Steering Linkage - Steering Linkage
1 Steering gear
2 Tie-rod end boot
3 Tie-rod
4 Tie-rod end
5 Wheel hub assembly
6 Tie-rod end retaining nut
7 Tie-rod end lock nut
The left and right-hand tie-rod assemblies:
Transmit steering forces from the steering gear to the wheel hubs.
Provide front road wheel toe setting by adjustment of the threaded outer tie-rod ends.
NOTE: Steering geometry adjustments must only be carried out with the vehicle on turn plates to allow the wheels to move during
adjustment.
The left and right-hand steering rack boots:
Are installed between the steering rack and the tie-rod ends.
Are of the concertina type.
Retain lubricant and prevent the ingress of foreign matter.
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Steering Linkage - Steering Linkage
For additional information, refer toSection 211-00 Steering System - General Information.
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Steering Linkage - Steering Gear Boot
Removal
1. Remove the tie-rod end. For additional information, refer to procedure in
this section: Tie Rod End
2. Remove the steering gear boot.
1. Remove and discard the steering gear boot retaining clamp.
2. Detach the steering gear boot retaining clamp.
3. Remove the steering gear boot.
Installation
1. CAUTION: Make sure the steering gear is clean before installing
the boot.
Install the steering gear boot using a new retaining clamp.
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Steering Linkage - Tie Rod End
Special Tool(s)
Seperator, Ball Joint
204-192 (JD-219)
Removal
1. Remove the wheel and tire. For additional information refer to Section
2. Loosen the tie-rod end lock nut.
4. NOTE: When the tie-rod end is seperated from the wheel hub assembly,
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5. NOTE: Make a note of the number of turns required to remove the
tie-rod end.
Remove the tie-rod end.
Installation
1. NOTE: Make sure the tie-rod end is installed on the tie-rod by the same
amount of turns used to remove it.
Tighten to 40 Nm.
3. Check the toe adjustment. For additional information, refer to Section
204-00 Suspension System - General Information.
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Steering Column -
Steering wheel retaining bolt 47 35 -
Steering column lower retaining bolt 25 18 -
Steering column retaining bolts 24 18 -
Steering column flexible coupling retaining bolt. 25 18
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Steering Column - Steering Column
1 Steering column
2 Steering wheel
3 Steering wheel angle sensor
4 Steering column flexible coupling
The steering column lock is secured to the upper casting of the steering column and consists of a locking pin. The steering column is locked
and unlocked by inserting and removing the ignition key respectively.
The steering column has tilt and telescope functions. These allow the driver to manually set the steering column position by using the
tilt/telescope lever, regardless of the ignition switch position. The steering column is capable of being tilted up or tilted down and
telescoped in or out, and is unlocked and locked into position using a single lever located on the underside of the steering column.
The lower part of the steering column consists of two shafts. The lower flexible coupling shaft is attached to both the steering gear and the
upper shaft.
No routine maintenance of the steering wheel is required. Any setting of steering wheel for misalignment must be achieved by adjusting the
tie rods.
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For additional information, refer to Section 211-00 Steering System - General Information.
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Steering Column - Ignition Switch Lock Cylinder
Removal
1. Remove the driver side instrument panel lower trim panel pocket.
2. Remove the drivers side instrument panel lower trim panel.
3. Remove the steering column lower shroud.
4. Remove the ignition switch lock cylinder.
Turn the ignition key to position 1.
Press the locking pin.
Remove the ignition switch lock cylinder.
Installation
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Removal
All vehicles
1. Remove the clockspring.
For additional information, refer to: Clockspring (501-20B Supplemental
Restraint System, Removal and Installation).
Vehicles without Driver Lower Airbag Module
Vehicles with Driver Lower Airbag Module
3. Remove the driver lower airbag module.
All vehicles
4. Disconnect the ignition switch electrical connector.
1. Disconnect the passive anti-theft system transceiver electrical
connector.
2. Disconnect the ignition switch electrical connector.
5. Reposition the steering column wiring harness bracket.
Remove the steering column wiring harness bracket retaining
screw.
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6. Disconnect the steering wheel rotation sensor electrical connector.
7. Remove and discard the steering column lower retaining bolt.
8. Remove the steering column.
1. Remove the steering column retaining bolts.
Installation
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2. Tighten in the sequence shown.
Tighten to 24 Nm.
3. Install a new bolt.
Tighten to 25 Nm.
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Steering Column - Steering Column Coupling
Removal
Installation
Tighten to 25 Nm.
2. Install a new bolt.
Tighten to 25 Nm.
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Steering Column - Steering Wheel
Removal
1. Position the front wheels in a straight ahead position and centralize
steering wheel.
2. Remove the driver airbag module.
For additional information, refer to: Driver Air Bag Module (501-20B
Supplemental Restraint System, Removal and Installation).
4. Remove the steering wheel.
5. Using suitable insulation/masking tape, secure the clockspring to
prevent movement from the centralized position.
Installation
Tighten to 47 Nm.
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Steering Column Switches - Steering Column Switches
Steering Column Multifunction Switch RH
The steering column multifunction switch RH controls the following functions when the ignition switch is in position II:
Flick Wipe
Flick wipe operation:
Is obtained by pulling the switch stalk towards the driver.
Features continuous wipe action at slow speed while the switch stalk position is held.
Intermittent Wipe
In the intermittent wipe position:
The wiper operates intermittently, with a variable time delay between wipes.
The time delay may be varied by rotating the column switch collar. This switch has six positions and varies the delay between 1 and
22 seconds. The collar is turned counter-clockwise to increase the delay.
Slow Speed Wiper
In the slow speed position:
The wiper operates continuously at slow speed.
High Speed Wiper
In the high speed position:
The wiper operates continuously at high speed.
Windscreen Wash/Wipe
The wash/wipe function:
Is operated by the button at the end of the switch stalk.
If the switch stalk is in the off or intermittent position the washers will operate for the duration the button is being pressed. The
wipers will operate at the slow speed while the button is being pressed and provides an additional three sweeps of the wipers after
the button is released.
If the switch stalk is in the flick, slow or high speed position the washers will operate for the duration the button is being pressed.
The wipers will operate at the slow or high speed respectively while the button is being pressed.
Is disabled if the 'Washer Fluid Low' message is displayed but manual operation is still available.
Headlamp Power Wash (if equipped)
The headlamp power wash function:
Operates only when the headlamps are on and the windscreen wash/wipe button is pressed.
Provides one short burst to the headlamps for approximately 0.5 of a second.
After the initial application, the headlamp power wash operates on every fifth operation of the wash/wipe button.
Rain Sensing/Auto Wipe (if equipped)
The rain sensing/auto wipe function:
Operates if the wash/wipe switch is set to the intermittent position and the variabl e delay is adjusted to the minimum position. If
any other position is selected the rain sensing function is disabled and the system reverts to the intermittent function with position
two being the shortest delay.
When rain sensing/auto wipe is selected the area of the windscreen covered by the rain sensor is monitored for moisture. If moisture
is detected the wipers are activated. The speed of the wipers is dependent on the amount of moisture detected on the windscreen.
When the windscreen is dry the wipers are parked until moisture is detected again.
Steering Column Multifunction Switch LH
The steering column multifunction switch LH controls the following functions when the ignition switch is in position II:
Direction Indicators
The direction indicators:
Operate when the ignition switch is in position II.
Are operated by moving the switch stalk up or down until it latches in position to i ndicate a right or left turn respectively.
May be operated while the switch stalk is held against spring pressure before reaching the latched position.
Cancel automatically upon completion of a turn. The multifunction switch LH stalk then returns to the center position.
An audible ticking and a flashing green warning lamp on the instrument cluster indicates that the direction indicators are operating. If an
indicator bulb fails, the warning lamp and ticking operate at twice the normal rate.
Main Beam
The main beam switch has two pull positions. Operating the switch to the first position and then releasing it will cause the main beam to
flashed. The main beam can be flashed with the ignition on or off and will remain activated as long as the switch is held.
Operating the switch to the second position will operate main beam continuously if the headlamps are on.
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Steering Column Switches - Steering Column Switches
2. Visually inspect for obvious signs of electrical damage. 2.
Electrical
Wiring harness for damage or corrosion
Electrical connector(s)
Switch(s)
Relay(s)
Module
step.
3.
4. If the cause is not visually evident, verify the symptom and refer to the Jaguar Approved Diagnostic System. 4.
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Steering Column Switches - Steering Column Multifunction Switch LH
Removal
1. Remove the driver side instrument panel lower trim panel pocket.
4. Remove the steering column upper shroud.
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5. Detach the steering column multifunction switch left-hand.
Release the retaining tang.
6. Remove the steering column multifunction switch left-hand.
Installation
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Steering Column Switches - Steering Column Multifunction Switch RH
Removal
1. Lower the steering column.
3. Detach the steering column multifunction switch right-hand.
Release the retaining tang.
4. Remove the steering column multifunction switch right-hand.
Installation
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Engine System - General Information -
General specifications 2.0 litre diesel.
Item Specification
Code FMBA/FMBB
Firing order 1-3-4-2
Cylinder bore diameter 86 mm
Stroke 86 mm
Displacement 1998 cc
Compression ratio 19:1
Engine weight 195 kg (excluding front end accessory drive)
Power output at 3800 rpm 96 kW (130 PS)
Torque at 1800 rpm 325 Nm
Idle speed 900 rpm
General specifications 2.2 litre diesel.
Item Specification
Code QJBA
Firing order 1-3-4-2
Cylinder bore diameter 86 mm
Stroke 94.6 mm
Displacement 2198 cc
Compression ratio 19:1
Power output at 3800 rpm 114 kW (155 PS)
Torque at 1800 rpm 360 Nm
Idle speed 800 rpm
General specifications 2.0 litre.
Item Specification
Displacement in liters 2.099
Number of cylinders 6
Bore and stroke (mm) 81.6 x 66.84
Firing order 1,4,2,5,3,6
Compression ratio 10.75:1
Item Specification
Item Specification
Cylinder Block Dimensions 2.0 litre and 2.2 litre diesel.
Description mm
Cylinder bore diameter Class 1 86000 - 86010
Main bearing shells 1 to 4 inside diameter (bearings installed) 65003 - 65030
Main bearing shells 5 inside diameter (bearings installed) 70004 - 70033
Main bearings 1 to 4 radial clearance 0033 - 0080
Main bearing 5 radial clearance 0034 - 0083
Main bearings 1 to 4 parent bore diameter vertical measurement 64504 - 64520
Main bearing 5 parent bore diameter vertical measurement 74504 - 74520
Main bearings 1 to 4 parent bore diameter horizontal measurement 69502 - 69525
Main bearing 5 parent bore diameter horizontal measurement 74502 - 74525
Piston Dimensions 2.0 litre and 2.2 litre diesel.
Description mm
Piston cooling code 6
Piston diameter Class A 8594 - 8595
Piston diameter Class B 8595 - 8596
Piston diameter Class C 8596 - 8597
Piston clearance in cylinder 005 - 007
Piston ring gap piston ring installed 2.0 litre and 2.2 litre diesel.
Description mm
Upper compression ring 025 - 050
Lower compression ring 050 - 075
Oil scraper ring 025 - 040
Piston ring gap position: Distribute the piston ring gaps evenly around the circumference of the piston. This also applies to the oil control
scraper ring elements. Position the ring gaps offset at 120 degrees to one another.
Piston Pin Dimensions 2.0 litre and 2.2 litre diesel.
Description mm
Piston pin - length 66700
Piston pin diameter 30000
Piston pin - clearance in piston pin bore 0002 - 0012
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Crankshaft Dimensions 2.0 litre and 2.2 litre diesel.
Description mm
Main bearing journal diameter 69950 - 69970
Main bearing journal end float 0090 - 0305
Big-end bearing journal diameter 52980 - 53000
Main bearing journals 1 to 4 diameter 64950 - 64970
Connecting Rod Dimensions 2.0 litre and 2.2 litre diesel.
Description mm
Big-end bore diameter 55996 - 56016
Small-end bore diameter 30010 - 30018
Bid-end bearing shell inside diameter (bearings installed) - Vehicle with 2.0L diesel engine 56004 - 56032
Bid-end bearing shell inside diameter (bearings installed) - Vehicle with 2.2L diesel engine 53034 - 53080
Big-end bearing radial clearance 0034 - 0100
Big-end bearing end float 0100 - 0320
Camshaft Dimensions 2.0 litre and 2.2 litre diesel.
Description mm
Camshaft bearing journal diameter 26450
Camshaft bearing clearance radial measurement 0065
Camshaft end float 0125
Valves 2.0 litre and 2.2 litre diesel.
Description mm
Valve stem to valve guide clearance intake valve 0045
Valve stem to valve guide clearance exhaust valve 0055
Cylinder Head 2.0 litre and 2.2 litre diesel.
Description mm
Thickness of cylinder head gasket with piston protrusion of 0430 - 0520 mm 110 (1 hole/tooth)
Thickness of cylinder head gasket with piston protrusion of 0521 - 0570 mm 115 (2 holes/teeth)
Thickness of cylinder head gasket with piston protrusion of 0571 - 0620 mm 120 (3 holes/teeth)
Maximum longitudinal/diagonal distortion of cylinder head surface 0100
Peak to valley height of mating surface 0020
Cylinder Head and Valve Train 2.0 litre.
Item Specification
Valve guide inner diameter (mm) 5.514 - 5.544
Intake valve effective length (mm) 91.13 - 90.93
Exhaust valve effective length (mm) 89.88 - 89.68
Valve stem to guide clearance intake - diameter (mm) 0.067 - 0.022
Valve stem to guide clearance exhaust - diameter (mm) 0.080 - 0.035
Valve head diameter intake (mm) 30.15 - 29.85
Valve head diameter exhaust (mm) 26.15 - 25.85
Intake valve face angle degree 45.75
Exhaust valve face angle degree 45.25
Valve stem diameter intake (mm) 5.492 - 5.477
Valve stem diameter exhaust (mm) 5.479 - 5.464
Valve spring free length (mm) 44.2
Valve spring installed height (mm) 33.41
Camshaft lobe lift intake (mm) 8.876
Camshaft lobe lift exhaust (mm) 8.876
Camshaft end play (mm) 0.150 - 0.070
Camshaft journal to cylinder head bearing surface clearance diameter (mm) 0.076 - 0.025
Camshaft journal diameter standard runout limit (mm) 0.040
Camshaft journal diameter standard out of round (mm) 0.013
Item Specification
Item Specification
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Item Specification
Lubrication system 2.0 litre and 2.2 litre diesel.
Item Liters
Oil capacity with filter 6.7
Lubrication system 2.0, 2.5 and 3.0 litre.
Item Liters
Oil capacity with filter 6.5
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Engine System - General Information - Engine
2.0L, 2.5L and 3.0L Engines
The 2.0L, 2.5L and 3.0L engines consists of:
A six cylinder 60 degree 'V' configuration liquid cooled aluminium cylinder block with dry cast iron liners.
Aluminium pistons with cut-outs in the piston crown to clear the valve heads for any available combination of camshaft profile and
valve phasing.
Two aluminium cylinder heads with square squish chambers.
Two cast iron overhead camshafts per bank.
Four valves per cylinder.
Mechanical tappets and top mounted steel shims.
Continuous variable camshaft timing (VCT) of the inlet camshafts.
Two silent timing chains with one hydraulic tensioner per chain.
Magnesium alloy camshaft covers with rubber seals.
A variable intake system containing two electrically controlled intake manifold tuning valves.
Plastic lower intake manifold with integral fuel rail and injectors.
Aluminium timing cover which accommodates the crankshaft front oil seal.
An oil pump mounted around the crankshaft.
An aluminium bed plate.
An aluminium oil pan.
A steel crankshaft (2.5L and 3.0L engines only).
A cast iron crankshaft (2.0L engines only).
Fracture-split connecting rods in sintered-forged steel.
A single, six ribbed vee belt drives the front end accessories.
A water pump belt pulley mounted directly to the exhaust camshaft of the left-hand cylinder head.
A single, three ribbed vee belt which drives the water pump.
A water pump mounted on the rear of the left-hand cylinder head.
An advanced engine management system incorporating electronic throttle control.
The unit meets the requirements of the CARB OBDII USA legislation.
CAUTION: The use of supplementary oil or fuel additives is not approved unless speci fied by Jaguar cars in the form of a service
communication or directive.
The engine code and serial number is located on the left-hand side of the bed plate near the oil cooler assembly.
2.0L and 2.2L common rail diesel engine
The 2.0L and 2.2L common rail diesel engine consists of:
a four cylinder cast iron cylinder block
a aluminium cylinder head
a separate camshaft carrier
a forged steel crankshaft with eight counterweights
lightweight aluminium alloy pistons
fracture split connecting rods
a multi link drive chain which drives the camshafts and the high pressure pump
a single link chain which drives a gear-type oil pump
hydraulically operated timing chain tensioner
fabricated camshafts with sintered lobes
roller rocker valve actuation
two exhaust valves and two inlet valves per cylinder
a plastic composite camshaft cover
a pressed steel timing cover which must be aligned using the special tool
a engine oil cooler is mounted to the left hand side of the engine
a water pump is mounted to the left hand rear of the engine and driven via the rear of the power steering pump
a power steering pump is mounted to the left hand rear of the engine and driven by the rear of the intake camshaft via a multi-vee
belt
a variable vain turbocharger.
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Engine System - General Information - Engine
Since diagnosis and testing actually begins when repairs are taken on, the following procedure is recommended.
1. Verify the customer concern by operating the system. 1.
2. Visually inspect for obvious signs of mechanical damage or electrical damage. If the concern cannot be reproduced, carry out a
road test and/or visual check with the aid of the following table.
Mechanical
Coolant leaks
Oil leaks
Leaks in the fuel system
Visibly damaged or worn parts
Loose or missing nuts or bolts
2.
step.
3.
Symptom Chart
Symptom Chart
Difficult to start during
hot or cold start
Piston ring(s) worn, damaged,
sticking or worn piston/cylinder.
INSTALL a new engine.
Head gasket damaged. INSPECT the head gasket.
Fuel system damaged or
inoperative.
For additional information, refer to Section 303-04A Fuel Charging and
ControlsSection 303-04B Fuel Charging and ControlsSection 303-04C Fuel
Charging and Controls - Turbocharger.
Ignition system inoperative. For additional information, refer to Section 303-04A Fuel Charging and
Poor Idling Restricted exhaust system. INSPECT the exhaust system. For additional information, refer to Section
309-00 Exhaust System.
Vacuum leak. CARRY out the Intake Manifold Vacuum Test in this section. REPAIR and
Burned valve(s). INSPECT the valve(s).
Incorrect valve to valve seat
contact.
INSPECT the valve and valve seat.
inoperative.
Insufficient power Compression leakage from valve
seat.
INSPECT the valve or valve seat.
Valve sticking. INSPECT valve stem to valve guide clearance or carbon accumulation.
Valve spring weak or broken. INSPECT the valve spring.
Cylinder head cracked or
distorted.
INSPECT the cylinder head.
Piston ring(s) worn, damaged or
sticking.
inoperative.
Brakes dragging. For additional information, refer to Section 206-00 Brake System - General
Information.
Restricted exhaust system. INSPECT the exhaust system. For additional information, refer to Section
309-00 Exhaust System.
Excessive or
insufficient
compression.
Valve(s) burnt or sticking. INSPECT the valve(s).
Valve spring(s) weak or broken. INSPECT the valve spring(s).
Carbon accumulation in
combustion chamber.
ELIMINATE carbon build up.
inoperative.
Excessive oil
consumption
Valve stem seal worn or missing. INSPECT the valve or valve stem seal.
Oil leakage. REPAIR oil leakage.
Valve stem or valve guide worn. INSPECT the valve stem or valve guide.
Incorrect oil viscosity. DRAIN and FILL with new oil.
Diluted oil. CHECK oil dilution. DRAIN and FILL as necessary.
Crankcase overfilled. CHECK and adjust the oil level.
Incorrect oil pressure. CHECK the oil pressure. REPAIR as necessary.
Engine noise Excessive crankshaft main
bearing clearance.
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Excessive crankshaft end play. INSTALL a new engine.
Excessive connecting rod bearing
oil clearance.
Piston/cylinder worn. INSTALL a new engine.
Piston ring damaged. INSTALL a new engine.
Connecting rod bent. INSTALL a new engine.
Valve spring(s) broken. INSPECT the valve spring(s).
Excessive valve guide clearance. INSPECT the valve guide or valve.
Cooling system inoperative
(water pump, vibration of
radiator).
For additional information, refer to Section 303-03A Engine CoolingSection
303-03B Engine Cooling.
Fuel system inoperative. For additional information, refer to Section 303-04A Fuel Charging and
Excessive carbon buildup. ELIMINATE carbon buildup.
Exhaust gas leakage. REPAIR leakage. For additional information, refer to Section 309-00 Exhaust
System.
Incorrect drive belt tension. INSPECT the drive belt tension. For additional information, refer to Section
303-05 Accessory Drive.
Generator front bearing worn. For additional information, refer to Section 414-02 Generator and Regulator.
Tappet noise, engine
running
Incorrect tappet clearance. CHECK and ADJUST the tappet clearance as necessary.
Component Tests
Engine Oil Leaks
NOTE: Before installing new gaskets or oil seals, make sure that the fault is clearly established.
If the oil leak cannot be identified clearly by a visual inspection, carry out an UV test:
Fluorescent Oil Additive Method
1. Clean the engine with a suitable cleaning fluid (brake cleaner). 1.
2. Drain the engine oil and refill with recommended oil, premixed with Diesel Engine Oil Dye or equivalent. Use a minimum 14.8 ml
(0.5 ounce) to a maximum 29.6 ml (1 ounce) of fluorescent additive to all engines. If oil is not premixed, fluorescent additive must
first be added to the crankcase.
2.
3. Run engine for 15 minutes. Stop the engine and inspect all seal and gasket areas for leaks using a 12 Volt Master UV Diagnostic
Inspection Kit or equivalent. A clear bright yellow or orange area will identify leak. For extremely small leaks, several hours may be
required for the leak to appear.
3.
4. As necessary, pressurize the main oil gallery system to locate leaks due to incorrectly sealed, loose or cocked plugs. 4.
5. Repair all leaks as necessary. 5.
Compression Test
General Remarks
NOTE: Removing fuses and disconnecting electrical components causes the engine control module (ECM) to log an error message. After
the measurements have been carried out this error message should be cleared from memory by connecting to approved Jaguar diagnostic
system.
NOTE: Only check the compression pressure with the valves set to the prescribed cl earance (if this can be adjusted).
The compression pressure should be checked with the engine at operating temperature.
Check The Compression Pressure
WARNING: On manual transmissions shift the transmission into neutral. On automatic transmission vehicles, select "P". Failure to
1. Remove the fuel pump relay. 1.
2. Start the engine - the engine will start, run for a few seconds then stall. 2.
3. Remove the spark plugs. 3.
4. Install the compression tester. 4.
5. Install an auxiliary starter switch in the starting circuit. With the ignition switch OFF, using the auxiliary starter switch, crank the
engine a minimum of five compression strokes and record the highest reading. Note the approximate number of compression
strokes required to obtain the highest reading.
5.
6. Repeat the test on each cylinder, cranking the engine approximately the same number of compression strokes. 6.
7. Install the components in reverse order, observing the specified tightening torques. 7.
8. Reset the ECM fault memory. 8.
Interpretation of the Results
The indicated compression pressure are considered within specification if the lowest reading cylinder is within 75% of the highest reading.
CAUTION: If engine oil is sprayed into the combustion chamber, after carrying out the measurement run the engine at 2000 rpm for
about 15 minutes, in order to burn the oil and prevent damage to the catalytic converter.
If the measurement on one or more cylinders is much lower than the specified value, spray some engine oil into the combustion chamber
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and repeat the compression measurement.
If the reading greatly improves then the piston rings are damaged.
If the reading stays the same then the cause is either damaged valve seats or valve stem seals.
If the measurements for two cylinders next to each other are both too low then it is very likely that the cylinder head gasket between them
is burnt through. This can also be recognized by traces of engine oil in the coolant and/or coolant in the engine oil.
Excessive Engine Oil Consumption
The amount of oil an engine uses will vary with the way the vehicle is driven in addition to normal engine-to-engine variation. This is
especially true during the first 16,100 km (10,000 miles) when a new engine is being broken in or until certain internal components become
conditioned. Vehicles used in heavy-duty operation may use more oil. The following are examples of heavy-duty operation:
Trailer towing applications.
Severe loading applications.
Sustained high speed operation.
Engines need oil to lubricate the following internal components:
Cylinder block cylinder walls.
Pistons and piston rings.
Intake and exhaust valve stems.
Intake and exhaust valve guides.
All internal engine components.
When the pistons move downward, a thin film of oil is left on the cylinder walls. As the vehicle is operated, some oil is also drawn into the
combustion chambers past the intake and exhaust valve stem seals and burned.
The following is a partial list of conditions that can affect oil consumption rates:
Engine size.
Operator driving habits.
Ambient temperatures.
Quality and viscosity of oil.
Operation under varying conditions can frequently be misleading. A vehicle that has been run for several thousand miles on short trips or in
below-freezing ambient temperatures may have consumed a "normal" amount of oil. However, when checking the engine oil level, it may
measure up to the full mark on the oil level indicator due to dilution (condensation and fuel) in the engine crankcase. The vehicle then
might be driven at high speeds on the highway where the condensation and fuel boil off. The next time the engine oil is checked it may
appear that a liter of oil was used in about 160 km (100 miles) per liter oil consumption rate is about 2,400 km (1,500 miles) per liter.
Make sure the selected engine oil meets Jaguar specification and the recommended API performance category "SG" and SAE viscosity grade
as shown in the vehicle Owner's Guide. It is also important that the engine oil is changed at the intervals specified for the typical operating
conditions.
Oil Consumption Test
The following diagnostic procedure is used to determine the source of excessive oil consumption.
NOTE: Oil use is normally greater during the first 16,100 km (10,000 miles) of service. As mileage increases, oil use decreases. Vehicles in
normal service should get a least 16,000 km (10,000 miles) per liter. High speed driving, towing, high ambient temperature and other
factors may result in greater oil use.
1. Define excessive consumption, such as the number of miles driven per liter of oil used. Also determine customers's driving habits,
such as sustained high speed operation, towing, extended idle and other considerations.
1.
2. Verify that the engine has no external oil leaks as described under Engine Oil Leaks. 2.
3. Verify that the engine has the correct oil level. 3.
4. Verify that the engine is not being run in an overfilled condition. Check the oil level at least five minutes after a hot shutdown
with the vehicle parked on a level surface. In no case should the level be above the top of the cross-hatched area and the letter
"F" in FULL. If significantly overfilled, carry out step 5, sub steps 1 through 4.
4.
5. Carry out an oil consumption test:
1. Drain engine oil and fill with one liter less than the recommended amount.
2. Run the engine for three minutes (10 minutes if cold), and allow oil to drain back for at least five minutes with vehicle
parked on level surface.
3. Remove the oil level indicator and wipe clean. (Do not wipe with anything contaminated with silicone compounds.)
Install the oil level indicator making sure to seat the oil level indicator firmly in the oil level indicator tube. Remove the
oil level indicator and draw a mark on the back (unmarked) surface at the indicated oil level. (This level should be about
the same as the ADD mark on the face of the oil level indicator.)
4. Add one liter of oil. Start the engine and allow to idle for at least two minutes. Shut off the engine and allow the engine
oil to drain back for at least five minutes. Mark the oil level dipstick, using the procedure above. (This level may range
from slightly below the top of the cross-hatched area to slightly below the letter "F" in FULL.
5. Record the vehicles mileage.
6. Instruct the customer to drive the vehicle as usual and:
1. Check the oil level regularly at intervals of 160-240 km (100-150 miles).
2. Return to the service point when the oil level drops below the lower (ADD) mark on the oil level indicator.
3. Add only full liters of the same oil in an emergency. Note the mileage at which the oil is added.
7. Check the oil level under the same conditions and at the same location as in steps 3 and 4.
1. Measure the distance from the oil level to the UPPER mark on the oil level indicator and record.
2. Measure the distance between the two scribe marks and record.
3. Divide the first measurement by the second.
4. Divide the distance driven during the oil test by the result. This quantity is the approximate oil consumption rate in kilometers per
liter or in mile per quart.
5.
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5. If the oil consumption rate is unacceptable go to Step 6.
6. Check the positive crankcase ventilation (PCV) system. Make sure the system is not plugged. 6.
7. Check for plugged oil drain-back holes in the cylinder head and cylinder block. 7.
8. If the condition still exists after carrying out the above tests go to step 9. 8.
9. Carry out a cylinder compression test. Refer to the procedure in this section : Compression Test. This can help determine the
source of oil consumption such as valves, piston rings or other areas.
9.
10. Check valve guides for excessive guide clearance. Install new valve stem seals after verifying valve guide clearance. 10.
11. Worn or damaged internal engine components can cause excessive oil consumption. Small deposits of oil on the tips of the spark
plugs can be a clue to internal oil consumption.
11.
Intake Manifold Vacuum Test
Bring the engine to normal operating temperature. Connect a vacuum gauge or equivalent to the intake manifold. Run the engine at the
specified idle speed.
The vacuum gauge should read between 51-74 kPa (15-22 in-Hg) depending upon the engine condition and the altitude at which the test is
performed. Subtract 4.0193 kPa (1 in-Hg) from the specified reading for every 304.8 m (1,000 feet) of elevation above sea level.
The reading should be steady. As necessary, adjust the gauge damper control (where used) if the needle is fluttering rapidly. Adjust the
damper until the needle moves easily without excessive flutter.
Interpreting Vacuum Gauge Readings
A careful study of the vacuum gauge reading while the engine is idling will help pinpoint trouble areas. Always conduct other appropriate
tests before arriving at a final diagnostic decision. Vacuum gauge readings, although helpful, must be interpreted carefully.
Most vacuum gauges have a normal band indicated on the gauge face.
The following are potential gauge readings. Some are normal; others should be investigated further.
1. NORMAL READING: Needle between 51-74 kPa (15-22 in-Hg) and holding steady. 1.
2. NORMAL READING DURING RAPID ACCELERATION : When the engine is rapidly accelerated (dotted needle), the needle will drop
to a low (not to zero) reading. When the throttle is suddenly released, the needle will snap back up to a higher than normal figure.
2.
3. NORMAL FOR HIGH-LIFT CAMSHAFT WITH LARGE OVERLAP: The needle will register as low as 51 kPa (15 in-Hg) but will be
relatively steady. Some oscillation is normal.
3.
4. WORN RINGS OR DILUTED OIL: When the engine is accelerated (dotted needle), the needl e drops to 0 kPa (0 in-Hg). Upon
deceleration, the needle runs slightly above 74 kPa (22 in-Hg).
4.
5. STICKING VALVES: When the needle (dotted) remains steady at a normal vacuum but occasionally flicks (sharp, fast movement)
down and back about 13 kPa (4 in-Hg), one or more valves may be sticking.
5.
6. BURNED OR BENT VALVES: A regular, evenly-spaced, downscale flicking of the needle indicates one or more burned or damaged
valves. Insufficient hydraulic valve tappet or hydraulic lash adjuster clearance will also cause this reaction.
6.
7. POOR VALVE SEATING: A small but regular downscale flicking can mean one or more valves are not seating correctly. 7.
8. WORN VALVE GUIDES: When the needle oscillates over about a 13 kPa (4 in-Hg) range at idle speed, the valve guides could be
worn. As engine speed increases, the needle will become steady if guides are responsible.
8.
9. WEAK VALVE SPRINGS: When the needle oscillation becomes more violent as engine RPM i s increased, weak valve springs are 9.
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indicated. The reading at idle could be relatively steady.
10. LATE VALVE TIMING: A steady but low reading could be caused by late valve timing. 10.
11. IGNITION TIMING RETARDING: Retarded ignition timing will produce a steady but somewhat low reading. 11.
12. INSUFFICIENT SPARK PLUG GAP: When spark plugs are gapped too close, a regular, small pulsation of the needle can occur. 12.
13. INTAKE LEAK: A low, steady reading can be caused by an intake manifold or throttle body gasket leak. 13.
14. BLOWN HEAD GASKET: A regular drop of fair magnitude can be caused by a blown head gasket or warped cylinder head to
cylinder block surface.
14.
15. RESTRICTED EXHAUST SYSTEM: When the engine is first started and is idled, the reading may be normal, but as the engine rpm
is increased, the back pressure caused by a clogged muffler, kinked tail pipe or other concerns will cause the needle to slowly drop
to 0 kPa (0 in-Hg). The needle then may slowly rise. Excessive exhaust clogging will cause the needle to drop to a low point even
if the engine is only idling.
15.
When vacuum leaks are indicated, search out and correct the cause. Excess air leaking into the system will upset the fuel mixture and cause
concerns such as rough idle, missing on acceleration or burned valves. If the leak exists in an accessory such as the power brake booster,
the unit will not function correctly. Always repair vacuum leaks.
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Engine System - General Information - Bearing Inspection
General Procedures
1. Inspect bearings for the following defects.
1. Cratering - fatigue failure
2. Spot polishing - incorrect seating.
3. Imbedded dirt engine oil.
4. Scratching - dirty engine oil.
5. Base exposed - poor lubrication.
6. Both edges worn - journal damaged.
7. One edge worn - journal tapered or bearing not seated.
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Engine System - General Information - Camshaft Bearing Journal Clearance
General Procedures
1. NOTE: Make sure that the following stages are followed exactly. The
tappets or followers must be removed to carry out this measurement.
NOTE: Make sure that the camshaft is to specification.
NOTE: The bearing caps and journals should be free from engine oil and
dirt.
Position on a length of plastigage on the bearing cap.
Insert the camshaft, without lubrication, into the cylinder head.
Position a plastigage strip, which should be equal to the width of
the bearing cap, on the bearing journal.
2. Install the camshaft bearing caps. For additional information, refer to
Section 303-01A EngineSection 303-01B Engine.
3. NOTE: Do not strike the bearing caps.
Remove the camshaft bearing caps. For additional information, refer to
4. Using the special tool, read off the measurement.
Compare the width of plastigage with the plastigage scale.
The value that is read off is the bearing clearance.
If the values are not to specification install a new camshaft.
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Engine System - General Information - Camshaft Bearing Journal Diameter
General Procedures
1. Determine the diameter of the camshaft journals.
Using a micrometer measure the diameter at 90 degrees intervals
to determine if the journals are out-of-round.
Measure at two different points on the journal to determine if there
is any tapering.
If the measurements are out of the specified range, install a new
camshaft.
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Engine System - General Information - Camshaft End Play
General Procedures
1. NOTE: Make sure that the camshaft is to specification.
Using the special tool, measure the end play.
Slide the camshaft in both directions. Read and note the maximum
and minimum values on the dial indicator gauge.
1. End play = maximum value minus minimum value.
If the measurement is out of specification, install new components.
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Engine System - General Information - Camshaft Lobe Lift
General Procedures
1. Measure the diameter (1) and diameter (2) with a vernier caliper. The
difference in measurements is the lobe lift.
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Engine System - General Information - Camshaft Surface Inspection
General Procedures
1. Inspect camshaft lobes for pitting or damage in the active area. Minor
pitting is acceptable outside the active area.
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Engine System - General Information - Connecting Rod Cleaning
General Procedures
1. CAUTION: Do not use a caustic cleaning solution or damage to
connecting rods may occur.
Mark and separate the parts and clean with solvent. Clean the oil
passages.
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Engine System - General Information - Connecting Rod Large End Bore
General Procedures
1. Measure the bearing bore in two directions. The difference is the
connecting rod bore out-of-round. Verify the out-of-round is within
specification.
2. Measure the bearing bore diameter in two directions. Verify the bearing
bore is within specification.
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Engine System - General Information - Crankshaft End Play
General Procedures
1. Using the Dial Indicator Gauge with Brackets, measure the end play.
Measure the end play by lifting the crankshaft using a lever.
If the value is out of the specification, install new thrust half rings
to take up the end float and repeat the measurement.
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Engine System - General Information - Crankshaft Main Bearing Journal Clearance
General Procedures
1. The main bearing
machine codes
are displayed on
the crankshaft
(1) and the
cylinder block (2)
2. NOTE: Main
bearing number 1
relates to the front
of the engine.
Read the
identification
numbers from the
crankshaft (1).
The first two
numbers
represent
the code for
main bearing
number 1.
The second
pair of
numbers
represents
the code for
main bearing
number 2.
The third
pair of
numbers
represents
the code for
main bearing
number 3.
The last pair
of numbers
represents
the code for
main bearing
number 4.
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3. NOTE: Main
bearing number 1
relates to the front
of the engine.
Read the
identification
numbers on the
cylinder block (2).
The first two
numbers
represent
the code for
main bearing
number 1.
The second
pair of
numbers
represents
the code for
main bearing
number 2.
The third
pair of
numbers
represents
the code for
main bearing
number 3.
The last pair
of numbers
represents
the code for
main bearing
number 4.
4. Using the select fit chart, for each main bearing match the crankshaft
code (1) and the block code (2) with it's corresponding column or row.
By reading across the crankshaft code row (1) and down the block code
column (2) select the correct grade bearing for each main.
1 Crankshaft code.
2 Block code.
5. E.g. if the crankshaft code is *8580*8082* and the Block code is
*0609*0711*, main bearing 1 should be assembled with a grade 1
bearing, as determined by the intersection of the number 06 block
column (2) and the number 85 crankshaft row (1).
Main bearing 2, 3 and 4 would all be assemble with a grade 2.
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Engine System - General Information - Crankshaft Main Bearing Journal Diameter
General Procedures
General Equipment
Micrometer
1. Measure the diameter of the main bearing journals and the big-end
bearing journals.
Repeat the measurement with the micrometer offset by 90, in
order to determine any eccentricity which may be present.
Measure the journal at two different positions to determine any
conicity which may be present.
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Engine System - General Information - Cylinder Block Distortion
General Procedures
1. Using a Straight Edge and a Feeler Gauge, measure the cylinder
block/cylinder head distortion.
Measure the mating face distortion.
If the value is not to specification rework the mating face (if
permitted).
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Engine System - General Information - Cylinder Bore Out-of-Round
General Procedures
1. NOTE: The main bearing caps or lower crankcase must be in place and
tightened to the specified torque; however, the bearing shells should not
be installed.
Measure the cylinder bore with an internal micrometer.
Carry out the measurements in different directions and at different
heights to determine if there is any out-of-roundness or tapering.
If the measurement is out of the specified range, hone out the
cylinder block or install a new block.
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Engine System - General Information - Cylinder Head Distortion
General Procedures
1. Measure the cylinder block/cylinder head distortion.
Using the special tool, measure the mating face distortion.
If the value is not to specification rework the mating face (petrol
only).
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Engine System - General Information - Exhaust Manifold Cleaning and Inspection
General Procedures
1. Inspect the cylinder head joining flanges of the exhaust manifold for
evidence of exhaust gas leaks.
2. Inspect the exhaust manifold for cracks, damaged gasket surfaces, or
other damage that would make it unfit for further use.
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Engine System - General Information - Flywheel Inspection
General Procedures
1. CAUTIONS:
Do not rework the flywheel if it is distorted.
Do not clean the dual mass flywheel with any kind of fluid. Clean
the flywheel with a dry cloth only.
Do not clean the gap between the primary and secondary mass. Only
clean the bolt connection surface and the clutch surface.
Inspect the flywheel for:
1. Any cracks.
2. Worn ring gear teeth.
3. Chipped or cracked ring gear teeth.
2. Check the flywheel for lateral movement
Rotational movement in either one or both directions, or rock on it
axis in relation to the primary mass is acceptable.
If there is any lateral movement, install a new flywheel.
3. CAUTION: Make sure that the three locating dowels are installed.
Check if the locating dowels are touching the primary mass of the
flywheel.
If the locating dowels are touching the primary mass of the
flywheel, install a new flywheel.
4. Inspect for grease along the welding.
If grease is evident, install a new flywheel.
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Engine System - General Information - Piston Diameter
General Procedures
General Equipment
Micrometer
1. NOTE: Mark the piston to make sure the piston is installed correctly.
Using a Micrometer measure the piston diameter.
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Engine System - General Information - Piston Inspection
General Procedures
1. CAUTION: Do not use any aggressive cleaning fluid or a wire brush
to clean the piston.
Carry out a visual inspection.
Clean the piston skirt, pin bush, ring grooves and crown and check
for wear or cracks.
If there are signs of wear on the piston skirt, check whether the
connecting rod is twisted or bent.
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Engine System - General Information - Piston Pin Diameter
General Procedures
1. NOTE: The piston and piston pin are a matched pair. Do not mix up the
components.
Measure the piston pin diameter.
Measure the diameter in two directions.
If the values are not to specification, install a new piston and a
new piston pin.
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Engine System - General Information - Piston Pin to Bore Diameter
General Procedures
1. NOTE: The piston and piston pin form a matched pair. Do not mix up
the components.
Measure the diameter of the piston pin bore.
Measure the diameter in two directions.
If the values are not to specification, install both a new piston and
a new piston pin.
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Engine System - General Information - Piston Ring End Gap
General Procedures
1. CAUTION: Do not mix up the piston rings. Install the piston rings
in the same position and location.
Using the Feeler Gauge, measure the piston ring gap.
The values given in the specification refer to a gauge ring used
during production.
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Engine System - General Information - Piston Ring-to-Groove Clearance
General Procedures
1. NOTE: The piston ring must protrude from the piston groove. To
determine the piston ring clearance, insert the Feeler Gauge right to the
back of the groove, behind the wear ridge.
Using the Feeler Gauge, measure the piston ring clearance.
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Engine System - General Information - Valve Seat Inspection
General Procedures
General Equipment
Valve seat width scale
1. Measure the width of the valve seat.
Measure the valve seat width using the Valve seat width scale.
If the value is not to specification rework the valve seat.
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Engine System - General Information - Valve Spring Free Length
General Procedures
1. Using a vernier gauge, measure the free length of each valve spring.
Verify the length is within specification.
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Engine System - General Information - Valve Stem Diameter
General Procedures
1. Using a micrometer measure the diameter of the valve stems.
If the measurements are not to specification, install a new valve.
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Published: 02-Jun-2011
Engine System - General Information - Leakage Test Using Smoke Test Equipment
General Procedures
CAUTION: The compressed air line supply pressure must be between 3.5 and 12 bar (50 and 175 psi) for the smoke test equipment to
function correctly. Do not exceed this pressure. Failure to follow this instruction may result in damage to the smoke test equipment.
NOTE: The vehicle battery must be in good condition and fully charged before carrying out this procedure.
NOTE: On vehicles with 3.0L TDV6, it will be necessary to insert smoke at both air cleaner outlet pipes independently if the right hand
turbocharger and associated hoses are to be tested.
NOTE: In some cases it may be necessary to remove undertrays, trim or engine covers to obtain access to all potential leak locations.
NOTE: For further information regarding operation of the test equipment refer to the manufacturers operators manual supplied with the
kit.
1. WARNING: Use an additional support to prevent the hood from
falling if the smoke test equipment is secured to the hood. Failure to
follow this instruction may result in personal injury.
Install the smoke test equipment to a suitable location under the hood.
2. Connect a suitable compressed air line to the smoke test equipment.
3. Connect the smoke test equipment positive power cable to the battery
positive terminal.
4. WARNING: Do not connect the smoke test equipment negative
cable to the battery negative terminal.
Connect the smoke test equipment negative cable to a suitable body
ground point.
5. NOTE: A flashing green light indicates low battery voltage. In this case,
place the battery on charge and make sure that the battery is fully
charged before using the smoke test equipment.
Observe the power indicator lamp on the smoke test equipment. Make
sure that a continuous green light is displayed.
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6. NOTE: In some cases it may be necessary to remove the air cleaner(s)
to allow access to the air cleaner outlet pipes.
NOTE: In some cases it will be necessary to cap one of the air cleaner
outlet pipes. Use the blanking caps supplied in the kit to cap the open
orifice.
Disconnect the air cleaner outlet pipe(s).
7. NOTE: Make sure the smoke test equipment adapter is a good fit to the
air cleaner outlet pipe. This must be an air tight seal.
Connect the smoke test equipment supply hose to the air cleaner outlet
pipe.
1. Install the appropriate adapter to the air cleaner outlet pipe.
2. Connect the smoke test equipment supply hose to the adapter
link hose.
8. NOTE: The flow control valve must be in the fully open position.
NOTE: Smoke is produced for 5 minutes. The smoke test equipment will
automatically switch off after this period of time.
Switch the smoke test equipment on.
9. Remove the oil filler cap, and observe until a constant flow of smoke is
visible leaving the oil filler orifice. Install the oil filler cap.
10. NOTE: The longer smoke is allowed to exit from a leak, the more
fluorescent dye will be deposited at a leak location.
Using the torch supplied in the kit set to white light, look for escaping
smoke. Alternatively, use the ultraviolet light to look for fluorescent dye
deposits at the source of a leak.
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Published: 23-Sep-2011
Engine - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27 -
Description Specification
Engine oil 2.0L gasoline, SAE 5W-30 (NAS) API SL and ILSAC GF3
Engine oil 2.0L gasoline, SAE 5W-30 (ROW) API SJ / EC and ACEA A1 or A3 Jaguar WSSM2C913B preferred
Engine oil 2.0L Diesel (EUR) 5W30 meeting Jaguar WSSM2C913B
Engine oil 2.2L Diesel (EUR) 5W30 meeting Jaguar WSSM2C913B
Engine oil 2.5L Gasoline (NAS) API SL and ILSAC GF3
Engine oil 2.5L Gasoline (ROW) API SJ / EC and ACEA A1 or A3 Jaguar WSSM2C913B preferred
Engine oil 3.0L Gasoline (NAS) API SL and ILSAC GF3
Engine oil 3.0L Gasoline (ROW) API SJ / EC and ACEA A1 or A3 Jaguar WSSM2C913B preferred
Engine assembly lubricant SQM-2C9003 AA EP90
Hose assembly surfactant ESE-M99B144-B
Metal surface cleaner WSW-M5B392-A
Sealant WSS-M4G323-A6
Spark plug grease 'Neverseeze' ESE M12 A4A
Capacities
Description Liters
Engine oil, initial fill 6.5
Engine oil, service fill with filter change 5.9
Coolant 8.25
Accessory drive idler pulley (grooved) retaining bolt 25 18 -
Accessory drive idler pulley (smooth) retaining bolt 47 35 -
Accessory drive tensioner retaining bolt 47 35 -
A/C compressor retaining bolts 25 18 -
A/C compressor mounting bracket bolts 25 18 -
A/C compressor supply and return tubes retaining bolt 25 18 -
Air filter retaining bracket retaining bolt 6 - 53
Camshaft bearing caps retaining bolts 10 7 -
Camshaft position sensor retaining bolt 6 - 53
Catalytic converter to exhaust manifold retaining nuts A - -
Catalytic converter retaining studs 9 - 80
Coolant pipe retaining bracket retaining bolt 6 - 53
Coolant by-pass tube to cylinder head retaining bolts. 10 7 -
Crankshaft position sensor retaining bolt 10 7 -
Crankshaft pulley retaining bolt (stage1) A - -
Cylinder head retaining bolts (stage 1) A - -
Engine cover retaining bracket retaining nuts 10 7 -
Engine front cover retaining bolts A - -
Engine ground strap retaining bolt 10 7 -
Engine wiring harness electrical connector retaining bolt 10 7 -
Engine wiring ground strap retaining bolt 10 7 -
Exhaust Manifold retaining nuts. 20 15 -
Exhaust manifold heat shield retaining bolts 10 7 -
Engine mount to body bracket retaining nut 83 61 -
Engine mount bracket to body retaining bolts 80 59 -
Engine support bracket to engine block retaining bolts A - -
Engine support bracket to engine mount retaining bolt 80 59 -
Flexplate retaining bolts 80 59 -
Flywheel retaining bolts 80 59 -
Generator battery positive cable retaining nut 12 9 -
Generator lower retaining bolt 25 18 -
Generator upper retaining bolt 47 35 -
Ignition coil retaining bolt 6 - 53
Intake manifold wiring harness retaining bolts 10 7 -
Knock sensor retaining bolt 25 18 -
Lower intake manifold retaining bolts A - -
Oil cooler retaining bolt 57 42 -
Oil level indicator tube retaining bolt with stud head 10 7 -
Oil pan retaining bolts A - -
Oil pan drain plug 25 18 -
Oil pan to transmission retaining bolts 45 33 -
Oil pressure sensor 14 10 -
Oil pump retaining bolts 10 7 -
Oil pump tube retaining bolts 10 7 -
Oil pump tube retaining nut A - -
Power steering pump retaining bolts 25 18 -
Engine control module (ECM) wiring harness electrical connector retaining bolt 5 - 44
Spark plugs 15 11 -
Timing chain guide retaining bolts A - -
Timing chain tensioner retaining bolts 25 18 -
Upper intake manifold retaining bolts A - -
Upper intake manifold support bracket retaining bolts 10 7 -
Upper intake manifold support bracket retaining nut 6 - 53
Valve cover retaining bolts A - -
Variable Valve Timing (VVT) securing bolts. 40 + 90 degrees 30 + 90 degrees -
Water pump inlet tube retaining bolts 10 7 -
Water pump outlet tube retaining nuts 9 - 80
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Wiring harness to valve cover retaining nuts 6 - 53
Throttle cable retaining bracket bolts 9 - 80
A = refer to the procedure for correct torque sequence - - -
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Engine - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27 - Engine
2.0 Litre
2.5 and 3.0 Litre
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The 2.0, 2.5 and 3.0 litre 24 valve V6 engines have four overhead camshafts and are driven by two timing chains. All three engines
incorporate electronic engine management with distributorless ignition system, sequential electronic fuel injection. All three have two
catalytic converters in the exhaust system which includes two oxygen sensors and two catalytic monitor sensors.
Viewed from the rear of the engine, the right-hand cylinder bank is numbered 5,3,1 and the left-hand cylinder bank is numbered 6,4,2.
The engines include the following:
10.75:1 compression ratio on the 2.0 litre engine.
10.3:1 Compression ratio on the 2.5 litre engine.
10.5:1 Compression ratio on the 3.0 litre engine.
3 Stage variable geometry intake manifold.
Lightweight valve gear.
Unique camshaft lift and duration.
Single knock sensor engine management control.
Continuous variable camshaft timing (VCT) system.
Twin mass flywheel (manual transmission).
Variable Intake System (V.I.S).
The variable intake system consists of a three stage upper intake manifold assembly, two position electronically driven gate valves and an
engine management powertrain control system.
The engine control module (ECM) switches the intake manifold tuning valves between fully open and fully closed at calibrated engine
speeds.
The intake manifold efficiency is therefore increased which will also increase the engine torque and engine performance.
Engine Lubrication System
The engine lubrication system is of the force-feed type in which oil is supplied under pressure (full film) to the:
Crankshaft main bearings.
Crankshaft thrust main bearing.
Connecting rod bearings.
Valve shims.
Camshaft bearings.
Variable camshaft timing.
All other parts are lubricated by thin film lubrication.
Oil Pump
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The rotary oil pump develops the oil pressure:
The oil pump is located at the front of the crankshaft.
The oil pump is driven by the crankshaft.
A full flow oil filter is externally mounted on the oil filter housing.
If the filter element should become blocked a spring-loaded bypass valve will open and allow an uninterrupted flow of oil to the engine.
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For additional information, refer toSection 303-00 Engine System - General Information.
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Engine - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27 - Valve Clearance
Adjustment
General Procedures
1. Remove the camshafts. For additional information, refer toCamshaft
2. Use compressed air to remove the shims that require replacing.
Blow compressed air between the shim edge and bucket to
dislodge the shim.
3. Use the following formula to calculate the required shim thickness.
Original shim thickness + measured clearance - desired clearance =
required shim thickness.
4. Apply a light coat of engine oil to the replacement shim(s) and install.
5. Install the camshafts. For additional information, refer toCamshaft
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Engine - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27 - Valve Clearance
Check
General Procedures
1. Remove the left hand valve cover. For additional information, refer to
Valve CoverLH
2. Remove the right hand valve cover. For additional information, refer to
Valve CoverRH
3. CAUTIONS:
Rotating the crankshaft in a counterclockwise direction may cause
engine damage. Crankshaft journals are directionally machined. Rotating
the crankshaft counterclockwise can raise burrs on bearing surfaces,
reducing engine life.
Camshaft lobes must be 180 degrees away from each valve shim or
valve clearance measurement will be incorrect.
Rotate the engine clockwise to position the camshaft lobe away from
the shim surface.
4. Using the feeler gauge set, measure the clearance between the
camshaft and the shim surface. Record and check the readings. For
additional information, refer to Section 303-00 Engine System - General
Information. Adjust the clearances as necessary. For additional
information, refer to Valve Clearance Adjustment
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Engine - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27 - Camshafts LH
In-vehicle Repair
Removal
1. Remove the timing chains. For additional information, refer to Timing
Drive Components.
2. Remove the camshaft bearing caps evenly.
3. Remove the camshafts.
Installation
1. NOTE: Lubricate the camshafts and the camshaft bearing caps with oil
WSE-M2C908-A or equivalent meeting Jaguar specification prior to
installation.
Install the camshafts.
2. CAUTION: Do not install the cylinder head camshaft journal thrust
caps until the camshaft journal caps are installed or damage to the thrust
caps may occur.
Install the camshaft bearing caps in their original position.
Install the camshaft bearing cap retaining bolts evenly.
Tighten the retaining bolts in the sequence shown to 10 Nm.
3. Carry out a valve clearance check. For additional information, refer
toValve Clearance Check.
4. Install the timing chains. For additional information, refer to Timing
Drive Components.
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Engine - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27 - Crankshaft Front
Seal
In-vehicle Repair
Special Tool(s)
Crankshaft Front Seal Remover
303-700
Crankshaft Front Seal Installer
303-542
Crankshaft Damper Installer
303-102
Removal
1. Remove the crankshaft vibration damper. For additional information,
refer to Crankshaft Pulley.
2. Using the special tool, remove the crankshaft front oil seal.
Installation
1. CAUTION: Make sure the seal and the tool are approximately
parallel to the front of the engine.
NOTE: Lubricate the seal lip with oil WSE-M2C908-A or equivalent
meeting Jaguar specification.
Using the special tool, install the crankshaft front oil seal.
2. Install the crankshaft vibration damper. For additional information, refer
to Crankshaft Pulley.
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Engine - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27 - Crankshaft Pulley
In-vehicle Repair
Special Tool(s)
Wrench strap-universal
303-D055
Crankshaft Damper Remover
303-D121
Thrust Pad
303-D121-01
Crankshaft Damper Installer Draw Bolt
303-102
Crankshaft Damper Installer
303-335/2
Accessory Belt Detensioner
303-703
Removal
1. Remove the wheel and tire. For additional information, refer to Section
2. Remove the splash shield.
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3. Disconnect the crankshaft position sensor (CKP) electrical connector.
4. Remove the CKP sensor.
5. Detach the accessory drivebelt.
1. Using the special tool, rotate the belt tensioner counter
clockwise.
6. Using the special tool, remove the crankshaft vibration damper retaining
bolt.
Remove and discard the crankshaft vibration damper retaining bolt.
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8. Using the special tools, remove the crankshaft vibration damper.
Installation
1. NOTE: Coat the crankshaft damper keyway with silicone gasket sealant
WSE-M4G323-A6 or equivalent meeting Jaguar specification.
Using the special tool, install the crankshaft vibration damper.
2. Using the special tool, tighten the crankshaft vibration damper retaining
bolt.
Install a new crankshaft vibration damper retaining bolt.
1. Complete the tightening sequence.
2. Stage 1: Torque to 120 Nm.
3. Stage 2: Loosen the bolt (minimum 1 turn).
4. Stage 3: Torque to 50 Nm.
5. Stage 4: Angle Torque to 90.
3. Attach the accessory drivebelt.
1. Using the special tool, rotate the belt tensioner counter-
clockwise.
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4. Install the CKP.
Tighten to 10 Nm.
5. Connect the CKP electrical connector.
6. Install the splash shield.
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Engine - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27 - Crankshaft Rear
Seal
In-vehicle Repair
Special Tool(s)
Crankshaft Rear Seal Remover
303-566
Crankshaft Rear Seal Installer
303-178
Crankshaft Rear Seal Installer Adapter Bolts
303-384
Crankshaft Rear Seal Installer Draw Bolts
303-102
Removal
Vehicles With Manual Transmission
1. Remove the flywheel. For additional information, refer to Flywheel
Manual Transmission.
Vehicles With Automatic Transmission
2. Remove the flexplate. For additional information, refer to Flexplate
Automatic Transmission.
All Vehicles
3. CAUTION: Avoid scratching or damaging the oil seal sealing
surfaces on the crankshaft and cylinder block.
Using the special tool, remove the crankshaft rear main oil seal.
Installation
All Vehicles
1. Clean and inspect the crankshaft rear oil seal sealing surfaces.
2. NOTE: Use oil WSE-M2C908-A or equivalent meeting Jaguar
specification.
Lubricate the seal lip with oil.
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3. NOTE: Alternate bolt tightening to correctly seat the crankshaft rear oil
seal until it is flush with the cylinder block.
Using the special tool, install the crankshaft rear oil seal.
4. Install the flywheel. For additional information, refer to Flywheel
Manual Transmission.
5. Install the flexplate. For additional information, refer to Flexplate
Automatic Transmission.
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Engine - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27 - Cylinder Head LH
In-vehicle Repair
Removal
1. Disconnect the engine coolant temperature (ECT) and fuel temperature
sensor (FTS) electrical connectors.
3. Detach fuel sensor vacuum line.
4. Disconnect the coolant temperature (ECT) electrical connector.
All vehicles
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5. Detach the fuel charging wiring harness.
2.5 and 3.0L shown, 2.0L similar.
6. WARNING: Fuel may still be present in the fuel injection supply
manifold, extreme care must be taken as this could cause personal injury.
Detach the fuel injection supply manifold, lower intake manifold and
place to one side.
Remove and discard the lower intake manifold seals.
1. 2.5 and 3.0L shown, 2.0L similar.
7. Remove the fuel injection supply manifold and lower intake manifold.
8. Remove the oil level indicator tube.
Remove and discard the oil level indicator tube O-ring seal.
9. Remove the water pump outlet pipe.
Remove and discard the water pump outlet pipe O-ring seals.
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10. Remove the coolant bypass tube.
Remove and discard the coolant bypass tube O-ring seals.
11. Remove the exhaust manifold.
Remove and discard the exhaust manifold gasket.
12. Remove the left-hand camshafts. For additional information, refer to
Camshaft.
13. NOTE: Remove the bolts in the indicated sequence.
Remove the cylinder head.
Remove and discard the cylinder head gasket.
14. Clean and inspect the cylinder head and cylinder block. For additional
information, refer to Section 303-00 Engine System - General
Information.
Installation
All vehicles
1. NOTE: The head gaskets must be installed over the cylinder block
dowels.
Install a new cylinder head gasket.
2. CAUTION: Use care when installing the cylinder head. Damage to
the cylinder block, cylinder head or the cylinder head gasket may result.
NOTE: Make sure the cylinder head is installed in its original position.
NOTE: Tighten the bolts in the indicated sequence in six stages.
Position the cylinder head and install new cylinder head bolts and
washers.
Stage 3: Loosen 360 degrees (one full turn) in reverse order.
3. Install the left-hand camshafts. For additional information, refer to
Camshaft.
4. Install the exhaust manifold.
Install the new exhaust manifold gasket.
Complete the tightening sequence.
Tighten to 20 Nm.
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5. Install the coolant bypass tube.
Install the new coolant bypass tube O-ring seals.
Tighten to 10 Nm.
6. Install the water pump outlet pipe.
Install the new water pump outlet pipe O-ring seals.
Tighten to 10 Nm.
7. Install the oil level indicator tube.
Tighten to 10 Nm.
8. Attach the fuel injection supply manifold and lower intake manifold.
9. Install the fuel injection supply manifold, lower intake manifold.
Install new lower intake manifold O-ring seals.
Tighten in the sequence shown.
Tighten to 10 Nm.
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10. Attach the fuel charging wiring harness.
11. Connect the coolant temperature (ECT) electrical connector.
12. Attach the fuel sensor vacuum line.
13. Connect the electrical connector.
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14. Connect the engine coolant temperature (ECT) and fuel temperature
sensor (FTS) electrical connectors.
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Engine - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27 - Engine Front Cover
In-vehicle Repair
Removal
CAUTION: It is necessary to remove the engine in order to remove the engine front cover.
All vehicles
1. Using a suitable container drain the engine oil.
2. Remove the automatic or manual transmission. For additional
information, refer to Section 307-01A Automatic
Transmission/TransaxleSection 307-01B Automatic
Transmission/Transaxle or Section 308-03 Manual
3. Detach the positive crank case ventilation hose.
5. Disconnect the idle actuator control valve electrical connector.
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6. Disconnect the throttle position sensor electrical connector.
10. Detach the coolant hoses.
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11. Disconnect the electrical connectors.
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16. Detach the vacuum hose.
All vehicles
17. NOTE: 2.5L and 3.0L shown, 2.0L similar.
Remove the intake manifold support bracket.
Remove the intake manifold.
Remove and discard the intake manifold gaskets.
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20. Disconnect the left-hand ignition coil electrical connectors.
21. Remove the left-hand ignition coils.
22. Disconnect the variable camshaft timing (VCT) solenoid electrical
connector.
Disconnect the camshaft position sensor electrical connectors.
Remove the (CMP) sensors.
25. Reposition the left-hand wiring harness for access to the valve cover.
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26. Detach the heated positive crankcase ventilation valve coolant hoses.
All vehicles
Detach the coolant hose.
28. Remove the left-hand valve cover.
Remove and discard the valve cover gaskets.
29. Disconnect the right-hand ignition coil electrical connectors.
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30. Remove the right-hand ignition coils.
32. Disconnect and reposition the variable camshaft timing (VCT) solenoid
33. Remove the engine cover retaining bracket.
34. Reposition the right-hand wiring harness for access to the valve cover.
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35. Remove the right-hand valve cover.
clockwise.
37. Remove the accessory drive belt tensioner.
39. Detach the generator positive cable protective cover.
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40. Disconnect the generator positive cable electrical connector.
41. Disconnect the generator electrical connector.
42. Remove the generator.
43. Using the special tool, remove the crankshaft vibration damper
retaining bolt.
Remove and discard the crankshaft vibration damper retaining bolt.
44. Disconnect the crankshaft position (CKP) sensor electrical connector.
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45. Remove the CKP.
47. Using the special tools, remove the crankshaft vibration damper.
48. Remove the air conditioning compressor.
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50. Remove the oil pan.
Remove and discard the oil pan gasket.
51. Remove the idler pulley.
53. Remove the engine front cover.
Remove and discard the engine front cover gaskets.
Installation
All vehicles
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1. Install the new front timing cover gaskets.
2. NOTE: Prior to applying sealer clean the front timing cover to engine
block and cylinder head sealing surfaces with metal surface cleaner.
NOTE: Apply a 6 mm diameter dot of silicone sealant WSE-M4G323-A6 or
equivalent meeting Jaguar specification to the indicated locations.
Apply silicone sealant to the indicated locations.
3. NOTE: The front timing cover retaining bolts numbered 3, 4, 10 and 11
are longer than the retaining bolts numbered 1, 2, 5, 6, 7, 8, 9, 12, 13, 15
and 16. The retaining bolt in number 14 is a retaining bolt with a stud
head.
Stage 1: Bolts 1 and 2, 25 Nm.
Stage 2: Bolts 3 and 4, 30 Nm + 45.
Stage 3: Bolts 5 through 9, 25 Nm.
Stage 4: Bolts 10 and 11, 30 Nm + 45.
Stage 6: Bolt 14, 25 Nm.
4. Install the idler pulley.
Tighten to 47 Nm.
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Tighten to 25 Nm.
6. NOTE: Apply a 10 mm diameter dot of silicone sealant WSE-M4G323-A6
or equivalent meeting Jaguar specification to the engine front cover to the
cylinder block mating joints.
NOTE: Loosely install the oil pan to transmission housing bolts.
NOTE: The oil pan retaining bolts numbered 1 and 2 are longer than the
retaining bolts numbered 3 through 15.
NOTE: Tighten the oil pan bolts within six minutes of applying sealer.
Install the oil pan.
Install the new oil pan gasket.
Tighten to 25 Nm.
Tighten to 25 Nm.
8. Install the air conditioning compressor.
Tighten to 25 Nm.
9. Using the special tool, install the crankshaft vibration damper.
Coat the crankshaft damper keyway with silicone gasket sealant
WSE-M4G323-A6 or equivalent meeting Jaguar specification.
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10. Using the special tool, tighten the crankshaft vibration damper
retaining bolt.
Install a new crankshaft vibration retaining bolt.
Stage 1: Torque to 120 Nm.
Stage 2: Loosen the bolt (minimum 1 turn).
Stage 3: Torque to 50 Nm.
Stage 4: Angle Torque to 90.
11. Install the CKP sensor.
Tighten to 10 Nm.
13. Install the generator retaining bolts.
Tighten bolt 1 to 47 Nm.
Tighten bolt 2 to 25 Nm.
14. Connect the generator electrical connector.
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15. Connect the generator positive cable.
Tighten to 12 Nm.
16. Attach the generator positive cable protective cover.
17. Attach the accessory drive belt.
18. Install the accessory drive belt tensioner.
Tighten to 47 Nm.
clockwise.
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20. NOTE: Apply a 5 mm diameter bead of silicone gasket sealant
WSE-M4G323-A6 or equivalent meeting Jaguar specification on the half
round gaskets and apply an 8 mm diameter bead of silicone gasket
sealant on the two places where the cylinder head and front timing cover
join.
NOTE: Make sure that the valve cover isolator mounts are correctly
installed to the new valve cover gaskets.
Install the new valve cover gaskets.
Tighten to 10 Nm.
21. Install the right-hand ignition coils.
Tighten to 6 Nm.
22. Connect the right-hand ignition coils electrical connectors.
join.
Tighten to 10 Nm.
24. Install the coolant hose.
Tighten to 6 Nm.
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25. Install the heated positive crank case ventilation valve coolant hoses.
All vehicles
Install the (CMP) semsors.
Tighten to 7 Nm.
27. NOTE: Right-hand shown, left hand similar.
Connect the camshaft position sensor electrical connector.
28. Connect the variable camshaft timing (VCT) solenoid electrical
connector.
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29. Install the left-hand ignition coils.
Tighten to 6 Nm.
30. Connect the left-hand ignition coils electrical connectors.
NOTE: The intake manifold retaining bolts numbered 1, 2 and 3 are
longer than the retaining bolts numbered 4, 5 and 6.
Install the new intake manifold gaskets.
Tighten to 10 Nm.
Install the intake manifold support bracket.
Tighten to 10 Nm.
Tighten to 10 Nm.
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Tighten to 6 Nm.
35. Connect the vacuum hose.
Tighten to 10 Nm.
37. Connect the electrical connectors.
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41. Install the coolant hoses.
42. Attach the throttle cable bracket.
Tighten to 9 Nm.
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45. Connect the throttle position sensor electrical connector.
46. Connect the idle actuator control valve electrical connector.
47. Attach the positive crank case venilation hose.
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48. Attach the positive crank case ventilation hose.
All vehicles
49. Install the automatic or manual transmission. For additional
information, refer to Section 307-01A Automatic
Transmission/TransaxleSection 307-01B Automatic
Transmission/Transaxle or Section 308-03 Manual
specification.
Refill the engine with oil.
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Engine - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27 - Engine Front
Mount
In-vehicle Repair
Special Tool(s)
HTJ1200-02
Removal
1. Drain the cooling system. For additional information, refer to .
Bleeding (303-03A Engine Cooling - 2.0L NA V6 - AJV6/2.5L NA V6 -
AJV6/3.0L NA V6 - AJ27, General Procedures).
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Position and adjust the special tool front height adjuster.
5. Position and adjust the special tool engine height adjusters.
6. Detach the coolant pipe.
7. Remove the engine support bracket.
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8. Remove the engine mount.
9. Remove the hydromount.
Installation
Tighten to 83 Nm.
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4. Tighten fixings to 40 Nm or 48 Nm as outlined below.
NOTE:
If reusing existing fixings, on vehicles built prior to VIN J24252, tighten to 48 Nm.
If new fixings are used on any vehicle tighten to 40 Nm.
5. Tighten to 9 Nm.
6. Fill and bleed the cooling system.
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Engine - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27 - Exhaust Manifold
LH
In-vehicle Repair
Removal
1. Drain the cooling system. For additional information, refer to Section
303-03A Engine CoolingSection 303-03B Engine Cooling.
2. Remove the cooling fan motor and shroud. For additional information,
refer to Section 303-03A Engine CoolingSection 303-03B Engine Cooling.
4. Remove the air filter intake pipe.
5. Detach the generator wiring harness.
6. Remove the air filter retaining bracket.
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8. Detach the coolant hose.
9. Raise the vehicle.
10. Remove the coolant hose.
11. Disconnect the heated oxygen sensor (HO2S) electrical connector.
12. Remove the exhaust manifold heat shield retaining bolt.
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14. Remove the exhaust manifold heat shield.
15. Detach the catalytic converter.
Discard the retaining nuts.
Remove and discard the retaining studs.
16. Using a suitable tool remove the HO2S.
Installation
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Tighten to 20 Nm.
2. Install the H02S.
Tighten to 40 Nm.
3. NOTE: Make sure that the retaining nuts are tightened twice in the
sequence shown.
Attach the catalytic converter.
Install new retaining nuts and studs.
Tighten to 9 Nm.
Tighten in the sequence shown to 25 Nm.
4. Install the exhaust manifold heat shield.
Tighten to 11 Nm.
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7. Connect the heated oxygen sensor (HO2S) electrical connector.
10. Attach the coolant hose.
11. Install the coolant pipe retaining bracket.
Tighten to 10 Nm.
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12. Attach the coolant pipe.
14. Install the air filter retaining bracket.
15. Attach the generator wiring harness.
16. Install the air filter intake pipe.
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17. Install the cooling fan motor and shroud. For additional information,
refer to Section 303-03A Engine CoolingSection 303-03B Engine Cooling.
18. Fill and bleed the cooling system. For additional information, refer to
Section 303-03A Engine CoolingSection 303-03B Engine Cooling.
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Engine - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27 - Flexplate
In-vehicle Repair
Removal
1. Remove the automatic transmission. For additional information, refer
toSection 307-01A Automatic Transmission/TransaxleSection 307-01B
2. NOTE: Prevent the flexplate from rotating.
Remove the flexplate.
Installation
1. NOTE: Make sure the crankshaft and flexplate mating faces are clean
before installation.
NOTE: The flexplate will only locate in one position.
NOTE: Tighten the retaining bolts working diagonally.
Install the flexplate.
Prevent the flexplate from rotating.
Tighten to 80 Nm.
2. Install the automatic transmission. For additional information, refer
toSection 307-01A Automatic Transmission/TransaxleSection 307-01B
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Engine - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27 - Exhaust Manifold
RH
In-vehicle Repair
Removal
1. Remove the three way catalytic converter (TWC). For additional
information, refer to Section 309-00 Exhaust System.
3. Using a suitable tool remove the HO2S.
Installation
Tighten to 20 Nm.
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3. Install the three way catalytic converter (TWC). For additional
information, refer to Section 309-00 Exhaust System.
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Engine - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27 - Flywheel
In-vehicle Repair
Removal
1. Remove the clutch disc and pressure plate. For additional information,
refer to Section 308-01 Clutch.
2. NOTE: Prevent the flywheel from rotating.
Remove the flywheel.
Installation
1. NOTE: Make sure the crankshaft and flywheel mating faces are clean
NOTE: The flywheel will only locate in one position.
NOTE: Tighten the retaining bolts working diagonally.
Install the flywheel.
Prevent the flywheel from rotating.
Tighten to 80 Nm.
2. Install the clutch disc and pressure plate. For additional information,
refer to Section 308-01 Clutch.
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Engine - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27 - Intake Manifold
In-vehicle Repair
Removal
All vehicles
1. Remove the engine cover (if equipped).
2. Remove the air filter outlet pipe.
For additional information, refer to: Air Cleaner Outlet Pipe (303-12A
Intake Air Distribution and Filtering - 2.0L NA V6 - AJV6/2.5L NA V6 -
AJV6/3.0L NA V6 - AJ27, Removal and Installation).
3. Remove the positive crankcase ventilation hose.
4. Remove the air cleaner resonator.
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9. Disconnect the throttle body electrical connector.
10. Disconnect the throttle body electrical connector.
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12. Disconnect the throttle body electrical connectors.
All vehicles
Detach the vacuum hoses.
1. Press the retaining ring.
2. Detach the vacuum hose.
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15. Detach the coolant hose from the retaining clips.
All vehicles
17. Detach the injector harness electrical connector from the intake
manifold support bracket.
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19. NOTE: 2.0L shown, 2.5L and 3.0L similar.
Detach the engine wiring harness bracket.
Detach the intake manifold support bracket.
21. WARNINGS:
Never remove the coolant expansion tank pressure cap under any
circumstances while the engine is operating. Failure to follow this
To avoid hot coolant or steam blowing out of the cooling system,
use extreme care when removing the coolant expansion tank pressure cap.
Wait until the engine has cooled down, then insulate the coolant pressure
cap with a suitable cloth and slowly loosen the coolant expansion tank
pressure cap until the cooling system pressure is released. Do not remove
the coolant expansion tank pressure cap. Step back while the pressure is
released from the system. When all of the pressure has been released
slowly remove the coolant expansion tank pressure cap (still with the
suitable cloth in position) from the coolant expansion tank. Failure to
Release the cooling system pressure.
Remove the coolant expansion tank pressure cap.
22. NOTE: Cap the coolant hoses to minimize coolant loss.
Detach the intake manifold coolant hoses.
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23. NOTE: Remove and discard the O-ring seal.
Detach the throttle body.
All vehicles
Installation
All vehicles
1. NOTE: Install new intake manifold gaskets.
NOTE: The intake manifold retaining bolts in position 1, 4 and 5 are
longer than the retaining bolts in position 2, 3 and 6.
NOTE: Do not fully tighten the retaining bolts.
Install the intake manifold.
Attach the intake manifold support bracket.
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4. NOTE: The intake manifold retaining bolts in position 1, 4 and 5 are
longer than the retaining bolts in position 2, 3 and 6.
NOTE: 2.5L and 3.0L shown, 2.0L similar.
Tighten to 10 Nm.
Tighten to 10 Nm.
7. Attach the injector harness electrical connector to the intake manifold
support bracket.
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8. NOTE: Install a new O-ring seal.
Attach the throttle body.
Install the retaining bolts.
All vehicles
Tighten to 10 Nm.
Attach the vacuum hoses.
1. Press the retaining ring.
2. Attach the vacuum hose.
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12. NOTE: Remove the coolant hose caps.
Attach the intake manifold coolant hoses.
13. Attach the coolant hose to the retaining clips.
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16. Connect the throttle body electrical connectors.
17. Connect the throttle body electrical connector.
18. Connect the throttle body electrical connector.
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22. Attach the positive crank case ventilation hose.
23. Fill the cooling system up to the MAX mark on the coolant expansion
tank using a fifty percent mixture of Jaguar Premium Cooling System
Fluid or equivalent, meeting Jaguar specification WSS M97B44-D and
fifty percent water.
24. Install the air cleaner resonator.
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25. Install the positive crankcase ventilation hose.
All vehicles
26. Install the air filter outlet pipe.
For additional information, refer to: Air Cleaner Outlet Pipe (303-12A
Intake Air Distribution and Filtering - 2.0L NA V6 - AJV6/2.5L NA V6 -
27. Install the engine cover (if equipped).
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Engine - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27 - Lower Intake
Manifold
In-vehicle Repair
Removal
All vehicles
Repair).
2. Disconnect the spring lock coupling.
For additional information, refer to: Spring Lock Couplings (310-00 Fuel
System - General Information, General Procedures).
sensor electrical connectors.
4. Disconnect the fuel pressure sensor electrical connector.
5. Disconnect the engine coolant temperature (ECT) electrical connector.
Detach the harness.
All vehicles
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6. Remove the engine cover retaining bracket (if equipped).
7. Disconnect the fuel injector harness electrical connector.
8. WARNING: Fuel may still be present in the fuel injection supply
manifold.
NOTE: Remove and discard the lower intake manifold O-ring seals.
Remove the lower intake manifold.
Installation
All vehicles
1. NOTE: Install new O-ring seals.
Install the lower intake manifold.
Tighten the retaining bolts in the sequence shown.
Tighten to 10 Nm.
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2. Connect the fuel injector harness electrical connector.
3. Install the engine cover retaining bracket (if equipped).
4. Connect the engine coolant temperature (ECT) electrical connector.
Attach the harness.
5. Connect the fuel pressure sensor electrical connector.
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6. Connect the engine coolant temperature (ECT) and fuel temperature
7. Connect the spring lock coupling.
Repair).
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Engine - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27 - Oil Cooler
In-vehicle Repair
Removal
2. Drain the engine oil.
3. Remove and discard the engine oil filter.
4. Detach the inlet and outlet coolant hoses.
5. Remove the oil cooler.
Remove the oil cooler retaining bolt.
Remove and discard the oil cooler O-ring seal.
Installation
1. To install reverse the removal procedure.
2. NOTE: Make sure the oil cooler locating tag is correctly located.
Install the oil cooler.
Install a new oil cooler O-ring seal.
Install the oil cooler retaining bolt.
Tighten to 57 Nm.
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Engine - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27 - Oil Pan
In-vehicle Repair
Special Tool(s)
Accessory Belt Detensioner
303-703
Removal
All vehicles
2. Remove the transfer case. For additional information, refer to Section
308-07 Transfer Case.
3. Detach the exhaust link pipe rear retaining clamp.
4. Remove the link pipe.
5. Remove the catalytic converter retaining bracket.
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6. Remove the sump to transmission securing bolt.
7. Slacken but not remove the upper catalyst retaining bracket support
securing bolt.
8. Reposition the catalyst retaining bracket support.
All vehicles
1. Using the special tool rotate the belt tensioner counter-
clockwise.
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10. NOTE: Do not remove the A/C compressor upper retaining bolts.
Reposition the air conditioning (A/C) compressor.
1. Remove the A/C compressor lower retaining bolts.
2. Loosen the A/C compressor upper retaining bolts.
11. Remove the access cover.
12. Remove the retaining bolt.
13. Remove the retaining bolts.
All vehicles
www.JagDocs.com
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Clean and inspect the oil pan and the cylinder block sealing
surfaces using metal surface cleaner or equivalent meeting Jaguar
specification WSE-M5B392-A.
Installation
All vehicles
1. NOTE: Apply a 10 mm diameter dot of silicone sealant WSE-M4G323-A6
or equivalent meeting Jaguar specification to the engine front cover to the
cylinder block mating joints.
NOTE: The oil pan retaining bolts numbered 1 and 2 are longer than the
retaining bolts numbered 3 through 15.
NOTE: Tighten the oil pan bolts within six minutes of applying sealer.
Install the new oil pan gasket.
Tighten to 25 Nm.
All vehicles
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8. Tighten to 25 Nm,
11. Install the transfer case. For additional information, refer to Section
308-07 Transfer Case.
All vehicles
specification.
Refill the engine with oil.
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Engine - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27 - Oil Pressure
Sender
In-vehicle Repair
Removal
2. Remove and discard the oil filter.
3. Disconnect the oil pressure sender electrical connector.
4. Remove the oil pressure sender.
Installation
1. NOTE: Apply a small bead of sealant WSK-M4G328-A3 or equivalent
sealant meeting Jaguar specification on the first three threads of the oil
pressure sender.
Tighten to 15 Nm.
2. Install a new oil filter.
specification.
Check and top up the engine with oil.
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Engine - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27 - Oil Pump
In-vehicle Repair
Removal
1. Remove the timing chains. For additional information, refer to Timing
Drive Components.
2. Remove and discard the engine oil filter.
3. Remove the oil pump tube.
4. Remove the oil pump.
Inspect the oil pump for damage and wear.
Installation
1. CAUTIONS:
Install the oil pump flush to the cylinder block for correct sealing.
Rotate the inner rotor of the oil pump to align with the flats on the
crankshaft before installation.
Install the oil pump.
Tighten to 10 Nm.
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2. Install the oil pump tube.
Tighten to 10 Nm.
3. Tighten to 5 Nm + 45.
4. Install a new engine oil filter.
5. Install the timing chains. For additional information, refer to Timing
Drive Components.
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Engine - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27 - Timing Drive
Components
In-vehicle Repair
Removal
For additional information, refer to: Engine Front Cover (303-01A Engine
- 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27, In-vehicle
Repair).
2. Remove the spark plugs.
3. NOTE: Note the position of the crankshaft position (CKP) sensor pulse
wheel during removal. It must be returned to its original position during
installation.
Remove the crankshaft position (CKP) sensor pulse wheel.
4. CAUTION: Do not rotate the crankshaft counterclockwise. The
timing chains may bind causing engine damage.
Install the crankshaft pulley retaining bolt and washer.
Rotate the crankshaft clockwise until the crankshaft keyway is at the 7
O'clock position, the alignment mark on the right-hand intake camshaft
sprocket is at the 1 O'clock position and the alignment mark on the
right-hand exhaust camshaft sprocket is at the 8 O'clock position.
6. Release the timing chain tensioner ratchet.
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7. NOTE: Keep the timing chain tensioner ratchet released.
Reposition the timing chain tensioner plunger.
8. Retain the timing chain tensioner plunger.
9. Remove the right-hand timing chain tensioner.
10. Remove the right-hand timing chain outer guide.
11. Remove the right-hand timing chain.
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12. CAUTION: Inspect and replace the O-ring seal if necessary.
Remove the right-hand timing chain inner guide.
O'clock position, the alignment mark on the left-hand intake camshaft
left-hand exhaust camshaft sprocket is at the 2 O'clock position.
14. NOTE: Right-hand bank shown, left-hand bank similar.
Release the timing chain tensioner ratchet.
NOTE: Keep the timing chain tensioner ratchet released.
Reposition the timing chain tensioner plunger.
Retain the timing chain tensioner plunger.
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17. Remove the left-hand timing chain tensioner.
18. Remove the left-hand timing chain inner guide.
19. Remove the left-hand timing chain.
20. CAUTION: Inspect and replace the O-ring seal if necessary.
Remove the left-hand timing chain outer guide.
21. CAUTION: Make sure the crankshaft keyway is at the 9 O'clock
position before any further engine repairs are carried out.
Remove the crankshaft pulley retaining bolt and washer.
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22. Remove the crankshaft sprocket.
Installation
1. NOTE: Make sure the crankshaft sprocket timing marks are facing
outwards.
Install the crankshaft sprocket.
2. CAUTION: Make sure the crankshaft keyway is at the 9 O'clock
position before the camshaft positions are aligned.
3. Rotate the left-hand intake camshaft clockwise until the camshaft
sprocket alignment mark is at the 9 O'clock position and rotate the
left-hand exhaust camshaft sprocket clockwise until the camshaft
sprocket alignment mark is at the 2 O'clock position.
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4. Rotate the right-hand intake camshaft clockwise until the camshaft
right-hand exhaust camshaft sprocket clockwise until the camshaft
5. Rotate the crankshaft clockwise until the keyway is at the 11 O'clock
position.
6. CAUTIONS:
Inspect and replace the O-ring seal if necessary.
Make sure the O-ring seal is correctly installed.
Install the left-hand timing chain outer guide.
Tighten the retaining bolts in the sequence shown in two stages.
Stage 1: Tighten bolt 1 to 25 Nm.
Stage 2: Tighten bolts 2 to 25 Nm.
7. CAUTIONS:
Make sure the crankshaft keyway is at the 11 O'clock position, the
alignment mark on the left-hand intake camshaft sprocket is at the 9
O'clock position and the alignment mark on the left-hand exhaust
camshaft sprocket is at the 2 O'clock position.
Make sure the timing chain alignment marks are correctly positioned
to the crankshaft sprocket and camshaft sprocket alignment marks.
Make sure the timing chain slack is on the tensioned side of the
timing chain.
Install the left-hand timing chain.
8. Install the left-hand timing chain inner guide.
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9. CAUTION: Do not manually adjust the timing chain tensioner.
Install the left-hand timing chain tensioner.
Tighten to 25 Nm.
Make sure the left-hand timing chain alignment marks have remained
correctly positioned to the camshaft sprocket and crankshaft sprocket
alignment marks.
Remove the timing chain tensioner retaining pin.
O'clock position.
13. CAUTIONS:
Inspect and replace the O-ring seal if necessary.
Make sure the O-ring seal is correctly installed.
Install the right-hand timing chain inner guide.
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14. CAUTIONS:
alignment mark on the right-hand intake camshaft sprocket is at the 5
O'clock position and the alignment mark on the right-hand exhaust
timing chain.
Install the right-hand timing chain.
15. Install the right-hand timing chain outer guide.
Install the right-hand timing chain tensioner.
Tighten to 25 Nm.
Remove the timing chain tensioner retaining pin.
18. CAUTIONS:
Make sure the right-hand timing chain alignment marks have
remained correctly positioned to the camshaft sprocket and crankshaft
sprocket alignment marks.
Do not manually adjust the timing chain tensioner.
Make sure all the timing chain alignment marks are in the positions
shown.
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NOTE: Rotate the crankshaft using hand tools only
Rotate the crankshaft two complete turns clockwise to make sure the
valves and pistons do not clash.
21. CAUTIONS:
Make sure the CKP sensor pulse wheel is correctly installed with the
missing tooth aligned to the crankshaft keyway.
Make sure the CKP sensor pulse wheel is correctly installed with the
teeth pointing outwards.
Install the CKP sensor pulse wheel.
22. Install the spark plugs.
Tighten to 15 Nm.
23. Install the engine front cover.
For additional information, refer to: Engine Front Cover (303-01A Engine
- 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27, In-vehicle
Repair).
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Engine - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27 - Valve Cover LH
In-vehicle Repair
Removal
All vehicles
1. Remove the ignition coils. For additional information, refer to Section
303-07A Engine IgnitionSection 303-07B Glow Plug System.
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7. Detach the heated positive crankcase ventilation valve coolant pipes.
All vehicles
connector.
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10. Remove the valve cover.
Installation
round gaskets, apply an 8 mm diameter bead of silicone gasket sealant on
the two places where the cylinder head and front timing cover join and the
twe places wherethe cylindar head and the water pump join.
Tighten to 10 Nm.
2. Tighten to 6 Nm.
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Engine - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27 - Valve Cover RH
In-vehicle Repair
Removal
1. Remove the ignition coils. For additional information, refer toSection
303-07A Engine IgnitionSection 303-07B Glow Plug System.
connector.
4. Remove the engine cover retaining bracket.
5. Remove the intake manifold support bracket.
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Installation
join.
Tighten to 10 Nm.
2. Tighten to 6 Nm.
3. Tighten to 6 Nm.
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Engine - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27 - EngineVehicles
With: 5-Speed Manual Transmission - MT75/6-Speed Manual Transaxle - MMT6
Removal
Special Tool(s)
HTJ1200-2
5 Point Security Torx Bit
418-535
Ball joint splitter
204-192
Wheel hub puller
205-491
Adaptor nuts
205-491-01
Forcing screw
204-269
Slide hammer
100-012
Slide hammer shaft
100-012-02
204-226
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Right-hand halfshaft splitter
307-442
Right-hand halfshaft splitter handle
307-443
Pinion oil seal remover
308-208
Link shaft limiting tool
307-446
Engine lifting kit
303-707
Removal
All vehicles
Loosen the front hub retaining nuts.
2. Drain the transaxle.
4. Remove the battery tray.
For additional information, refer to: Battery Tray (414-01 Battery,
Mounting and Cables, Removal and Installation).
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8. CAUTION: To prevent the vehicle becoming unstable when the
engine and transmission assembly are removed, install the vehicle tie
down straps.
Install the front vehicle tie down strap.
down straps.
Install the rear vehicle tie down strap.
Remove the splash shield.
Detach the brake caliper assembly.
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Detach the brake pipe.
13. NOTE: Support the brake caliper assembly using tie straps.
Reposition and secure the brake caliper assembly.
Detach the anti-lock braking system (ABS) wheel speed sensor.
Disconnect the ABS wheel speed sensor.
16. NOTE: Secure the ABS wheel speed sensor using tie straps.
Reposition and secure the ABS wheel speed sensor.
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17. Remove the cooling fan motor and shroud.
For additional information, refer to: Cooling Fan Motor and Shroud
(303-03A Engine Cooling - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA
V6 - AJ27, Removal and Installation).
All vehicles
19. Remove the front muffler.
For additional information, refer to: Front Muffler - 2.0L NA V6 -
20. NOTE: Using a suitable blanking plug, seal the tube and the A/C
compressor.
NOTE: Secure the A/C compressor supply and return tubes using tie
straps.
Detach the A/C compressor supply and return tubes.
For additional information, refer to: Air Cleaner (303-12A Intake Air
Distribution and Filtering - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA
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29. Detach the accelerator cable.
1. Reposition the accelerator lever to the fully open position.
30. Detach the accelerator cable retaining bracket.
All vehicles
32. Detach the battery cables.
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33. NOTE: Upper selector cable shown, lower selector cable similar.
Detach the selector cables.
1. Press the button.
2. Detach the selector cables.
34. NOTE: Secure the selector cables using tie straps.
NOTE: Drain the fluid into a suitable container.
NOTE: Using a suitable blanking plug, seal the pipe and the slave
cylinder.
NOTE: Secure the clutch slave cylinder pipe using tie straps.
Disconnect the clutch slave cylinder pipe and secure to one side.
1. Detach the clutch slave cylinder pipe from the slave cylinder.
2. Detach the clutch cylinder from the retaining bracket.
36. Disconnect the reverse light switch electrical connector.
37. Disconnect the engine harness electrical connector.
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38. Using special tool 418-535, disconnect the engine control module
(ECM) electrical connector.
39. Disconnect the ground cable.
40. NOTE: Drain the fluid into a suitable container.
NOTE: Use a suitable blanking plug to seal the hose.
Detach the power steering hose.
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Detach the strut and spring assembly.
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50. Remove the transaxle mount bracket securing nut.
51. Remove the clutch master cylinder to clutch slave cylinder
high-pressure pipe support bracket.
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Remove the front subframe reinforcement plate.
Detach the front subframe.
Remove the engine and transaxle assembly.
Rotate the special tool height adjustment valve counter clockwise.
56. Remove the coolant system top hose.
57. Remove the transaxle mount.
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59. Remove the left-hand exhaust manifold heat shield.
61. Remove the upper exhaust heat shield.
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62. Remove the center exhaust heat shield retaining bolts.
63. Remove the center exhaust heat shield.
Remove the front wheel hub retaining nuts.
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Using the special tools, detach the halfshafts.
Remove the tie rod end retaining nuts.
Using the special tool, detach the tie rod ends.
Detach the stabilizer bar link arms.
Detach the wheel knuckles.
3. Detach the wheel knuckles.
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71. Using the special tools, remove the left-hand halfshaft.
72. Remove and discard the halfshaft snap ring.
73. Remove the power steering high-pressure pipe retaining bolt.
74. Disconnect the power steering high-pressure pipe.
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76. Remove the engine roll restrictor retaining bolt.
77. Remove the engine roll restrictor.
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78. CAUTION: Make sure the right-hand drive halfshaft is supported,
failure to follow this instruction may result in damage to the component.
Using the special tool, remove the engine and transaxle from the
subframe.
79. Remove the halfshaft and intermediate shaft assembly.
80. Remove the transfer case Y bracket retaining bolts. J
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81. Remove the transfer case Y bracket.
83. CAUTION: To prevent damage to the transfer case internal seal,
make sure the link shaft is not retracted further that 200 mm (7.87 inches)
from the transfer case.
1. Attach the special tools to the halfshaft.
2. Lever the special tools, to detach the halfshaft.
85. Disconnect the right-hand catalyst monitor sensor electrical connector.
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86. Disconnect the right-hand heated oxygen sensor (HO2S) electrical
connector.
87. Remove the right-hand catalytic converter retaining bolts.
88. Remove the right-hand catalytic converter.
Remove and discard the retaining nuts.
89. Remove and discard the catalytic converter retaining studs.
90. Remove and discard the catalytic converter sealing ring.
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91. Using the special tool, detach the transfer case link shaft.
Using the special tool, partially remove transfer case link shaft.
93. Remove the catalytic converter mounting bracket.
94. Remove the transfer case mounting bracket.
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95. Remove the transfer case.
96. Remove and discard the transfer case O-ring seal.
97. Remove and discard the link shaft snap ring.
98. Remove the link shaft limiting tool.
99. Remove the link shaft.
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100. Using the special tool, remove and discard the link shaft oil seal.
All vehicles
101. Remove the starter motor.
102. Remove the dust cover.
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104. Remove the transaxle retaining bolts.
106. Remove the transaxle.
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With: 5-Speed Automatic Transaxle - JATCO/6-Speed Automatic Transaxle - AWF21
Removal
Special Tool(s)
HTJ1200-2
418-535
Ball joint splitter
204-192
Wheel hub puller
205-491
Adaptor nuts
205-491-01
Forcing screw
204-269
Slide hammer
100-012
Slide hammer shaft
100-012-02
204-226
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307-442
307-443
308-208
307-446
Engine lifting kit
303-707
Removal
All vehicles
Loosen the front hub retaining nuts.
2. Drain the transaxle.
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down straps.
Install the front vehicle tie down strap.
down straps.
Install the rear vehicle tie down strap.
Remove the splash shield.
Detach the brake caliper assembly.
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13. NOTE: Support the brake caliper assembly using tie straps.
Reposition and secure the brake caliper assembly.
16. NOTE: Secure the ABS wheel speed sensor using tie straps.
Reposition and secure the ABS wheel speed sensor.
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All vehicles
20. NOTE: Using a suitable blanking plug, seal the tube and the A/C
compressor.
NOTE: Secure the A/C compressor supply and return tubes using tie
straps.
22. Remove the selector cable shield.
23. Detach the selector cable.
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24. NOTE: Secure the selector cable using tie straps
Disconnect the selector cable.
25. Disconnect the automatic transaxle electrical connectors.
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All vehicles
36. Detach the battery cables.
37. Disconnect the engine harness electrical connector.
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38. Using special tool 418-535 disconnect the engine control module (ECM)
39. Disconnect the ground cable.
NOTE: Use a suitable blanking plug to seal the hose.
Detach the power steering hose.
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50. Detach the support bar.
51. Remove the support bar.
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Remove the engine and transaxle assembly.
57. Remove the coolant system top hose.
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58. Remove the transaxle mount.
60. Remove the left-hand exhaust manifold heat shield.
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62. Remove the upper exhaust heat shield.
63. Remove the center exhaust heat shield retaining bolts.
64. Remove the center exhaust heat shield.
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Remove the front wheel hub retaining nuts.
Using the special tools, detach the halfshafts.
Remove the tie rod end retaining nuts.
Using the special tool, detach the tie rod ends.
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Detach the wheel knuckles.
3. Detach the wheel knuckles.
72. Using the special tools, remove the left-hand halfshaft.
74. Remove the power steering high-pressure pipe retaining bolt.
75. Disconnect the power steering high-pressure pipe.
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77. Remove the engine roll restrictor retaining bolt.
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Using the special tool, remove the engine and transaxle from the
subframe.
80. Remove the halfshaft and intermediate shaft assembly.
81. Remove the transfer case Y bracket retaining bolts. J
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82. Remove the transfer case Y bracket.
1. Attach the special tools to the halfshaft.
2. Lever the special tools, to detach the halfshaft.
86. Disconnect the right-hand catalyst monitor sensor electrical connector.
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87. Disconnect the right-hand heated oxygen sensor (HO2S) electrical
connector.
88. Remove the right-hand catalytic converter retaining bolts.
89. Remove the right-hand catalytic converter.
91. Remove and discard the catalytic converter sealing ring.
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92. Using the special tool, detach the transfer case link shaft.
Using the special tool, partially remove transfer case link shaft.
94. Remove the catalytic converter mounting bracket.
95. Remove the transfer case mounting bracket.
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97. Remove and discard the transfer case O-ring seal.
98. Remove and discard the link shaft snap ring.
100. Remove the link shaft.
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101. Using the special tool, remove and discard the link shaft oil seal.
All vehicles
103. Remove the dust cover.
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105. NOTE: Rotate the torque converter to gain access to the remaining
retaining bolts.
Remove the torque converter retaining bolts.
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110. WARNING: Do not let the torque converter drop out of the
transaxle. Failure to follow this instruction may result in personal injury.
Remove the transaxle.
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Disassembly
Special Tool(s)
303-D055
Crankshaft Pulley Remover
303-D121
Crankshaft Pulley Installer
303-102
Trust Pad
303-D121-01
Crankshaft pulley installer
303-335/2
Disassembly
1. Disconnect the throttle motor electrical connector.
2. Disconnect the throttle position sensor.
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3. Disconnect the positive crankcase ventilation (PCV) hose.
5. Disconnect the fuel pressure regulator vacuum hose.
6. Remove the fuel pressure regulator bracket.
7. Detach the intake manifold front retaining bracket.
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8. Detach the engine wiring harness from the intake manifold rear
retaining bracket.
9. Detach the intake manifold rear retaining bracket.
10. NOTE: The evaporative emission canister purge valve transfer pipe is
attached to the induction manifold by a quick release coupling.
Disconnect the evaporative emission canister purge valve transfer pipe.
12. Remove and discard the intake manifold gaskets.
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13. Remove the engine breather hose.
14. Remove the evaporative emission purge valve hose.
15. Disconnect the oil cooler coolant hoses.
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19. Detach the engine harness.
20. Detach engine harness.
21. Remove the rear knock sensor.
1. Detach the knock sensor wiring harness.
2. Remove the rear knock sensor.
22. Disconnect the right-hand camshaft position sensor.
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23. Detach the engine harness retaining bracket.
25. Disconnect the right-hand ignition coils.
27. Disconnect the left-hand camshaft position sensor.
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28. Disconnect the left-hand ignition coils.
29. Disconnect the engine wiring harness electrical connectors.
30. Remove the engine wiring harness.
31. Remove the ignition coils.
32. Remove the lower intake manifold and injector supply manifold.
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33. Remove and discard the lower intake manifold gaskets.
34. Remove the left-hand knock sensor.
1. Use a 3/8 inch drive bar to release the accessory drive belt
tensioner.
36. Remove the right-hand idler pulley.
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39. Remove the air conditioning (A/C) compressor.
40. Remove the A/C compressor mounting bracket.
41. Remove the oil level indicator tube.
1. Remove and discard the O-ring seal.
42. NOTE: Right-hand shown, Left-hand similar.
Remove the exhaust manifold heat shields.
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Remove the exhaust manifolds.
44. Remove the flywheel.
Prevent the engine from rotating.
45. Remove the engine rear backing plate.
46. Remove the oil filter housing assembly.
47. Remove the engine oil pressure and oil temperature sensors.
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48. Remove the coolant crossover tube.
49. Remove the water pump and coolant hose assembly.
1. Detach the hose.
2. Remove the water pump and coolant hose assembly.
51. Install the special tool, loosen the crankshaft pulley retaining bolt.
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53. Using the special tool, remove the crankshaft vibration damper.
54. Remove the left-hand idler pulley.
Remove and discard the oil pan gasket.
Clean and inspect the oil pan and cylinder block sealing surfaces
using Metal surface cleaner or equivalent meeting Jaguar
specification.
Remove the valve covers.
57. Remove the engine front cover
Remove and discard the engine front cover gaskets.
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58. Remove the crankshaft position (CKP) sensor pulse wheel.
O'clock position, the alignment mark on the right-hand intake camshaft
right-hand exhaust camshaft sprocket is at the 8 O'clock position.
62. Remove the right-hand timing chain tensioner.
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63. Remove the right-hand timing chain outer guide.
64. Remove the right-hand timing chain.
65. Remove the right-hand timing chain inner guide.
66. Remove the crankshaft outer sprocket.
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O'clock position, the alignment mark on the left-hand intake camshaft
left-hand exhaust camshaft sprocket is at the 2 O'clock position.
70. Remove the left-hand timing chain tensioner.
71. Remove the left-hand timing chain inner guide.
72. Remove the left-hand timing chain.
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73. Remove the left-hand timing chain outer guide.
74. Remove the crankshaft inner sprocket.
75. Remove the RH exhaust camshaft bearing cap bolts evenly.
Remove the exhaust camshaft bearing caps.
76. Remove the RH exhaust camshaft.
77. Remove the RH inlet camshaft bearing cap bolts evenly.
Remove the inlet camshaft bearing caps.
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78. Remove the RH inlet camshaft.
79. Remove the LH exhaust camshaft bearing cap bolts evenly.
Remove the exhaust camshaft bearing caps.
80. Remove the LH exhaust camshaft.
81. Remove the LH inlet camshaft bearing cap bolts evenly.
Remove the inlet camshaft bearing caps.
82. Remove the LH inlet camshaft.
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Remove the RH cylinder head.
Discard the gasket.
Remove the LH cylinder head.
Discard the gasket.
85. Remove the engine coolant housing.
Discard the 'O' ring seals.
86. NOTE: Engine inverted for clarity.
Remove the oil pump tube.
87. Remove the oil pan baffle.
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Inspect the oil pump for damage and wear.
89. CAUTION: Pistons, connecting rods and connecting rod bearings
should be numbered to make sure they are reassembled in the same
position.
NOTE: Mark the position of the connecting rod caps to the connecting
rods to make sure correct insulation.
NOTE: Discard the connecting rod bolts after removal.
Remove the connecting rod bolts, the connecting rod caps and the lower
connecting rod bearings.
90. Inspect the tops of the cylinder bores. As necessary remove ridge and
carbon build up from each cylinder.
91. CAUTION: Use appropriate protection to prevent damage to the
crankshaft bearing journals and cylinder bore surfaces.
Install special tools to the connecting rods.
92. CAUTION: Care should be taken not to damage the connecting
rod and cap joint face surfaces or possible engine damage may occur.
Avoid contaminating the fracture joint surfaces with dirt or grease.
NOTE: Reattach the connecting rods and caps after removal to avoid
mismatch.
Remove the pistons.
Rotate the crankshaft to locate pistons at the bottom of travel.
Push the piston, connecting rod and upper bearing through the top
of the cylinder.
93. NOTE: Remove the lower cylinder block bolts in the indicated
sequence.
Remove the lower cylinder block.
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94. NOTE: Mark the position of the upper and lower crankshaft main
bearing and the crankshaft thrust bearing for reassembly.
Remove the lower crankshaft bearings.
1. Remove the lower crankshaft thrust main bearing.
2. Remove the lower crankshaft main bearings.
95. CAUTION: Avoid damage to any crankshaft bearing surfaces.
NOTE: Never remove any pipe plugs or dowels unless they are to be
newly installed or the cylinder block is to be washed.
Remove the crankshaft.
Discard the crankshaft rear main oil seal.
96. Remove the upper crankshaft main bearings.
97. Clean the cylinder block with a soap and water solution. Dry the
cylinder block completely with compressed air.
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Engine - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27 - Cylinder Head
Special Tool(s)
Valve Spring Compressor
303-252
Disassembly
1. CAUTION: If the cylinder head valve components are to be reused,
mark position of the valve components to make sure they are reassembled
in the same position.
Remove the bucket tappet and shim assemblies.
2. Using the special tool, compress the valve springs.
Remove the valve collets.
3. Remove the valve spring retainers and valve springs.
1. Remove the valve spring retainers.
2. Remove the valve springs.
3. Remove the valve stem oil seals.
4. Remove the valves from the cylinder heads.
1. Remove the intake valves.
2. Remove the exhaust valves.
5. Inspect the cylinder heads and the related components.
For additional information, refer to Section 303-00 Engine System -
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6. Remove the pipe plugs and alignment dowels as necessary to clean the
cylinder heads.
Assembly
1. WARNING: Eye protection is required during use of compressed
air. Failure to follow these instructions may result in personal injury.
CAUTION: The cylinder head surface finish is measured in microns.
For correct head gasket sealing, avoid any contact of finish with metallic
objects.
Clean gasket material, dirt and foreign material from cylinder heads.
Wash with a suitable soap and water solution and dry completely using
compressed air if pipe plugs have been removed.
2. Install the pipe plugs and alignment dowels to cylinder heads.
Apply pipe sealant to plugs prior to installation.
3. NOTE: Lubricate the valve stems before assembly.
Install the valves into the cylinder heads.
1. Install the intake valves.
2. Install the exhaust valves.
4. Install the valve spring retainers and valve springs.
1. Install the valve stem oil seals.
2. Install the valve springs.
3. Install the valve spring retainers.
5. Using the special tool, compress the valve springs.
Install the valve collets.
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6. Install the bucket tappet and shim assemblies.
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Engine - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27 - Piston
Disassembly
1. NOTE: Mark the pistons to the original connecting rods to make sure
correct installation in the same cylinders from which they were removed.
Remove the top compression ring.
2. Remove the second compression ring.
3. Remove the first oil control ring.
4. Remove the oil control spacer ring.
5. Remove the second oil control ring.
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6. WARNING: The retaining rings have a tendency to spring out
during removal. Cover the end of the pin bore with a hand or a rag when
removing the retaining ring. Eye protection should be worn. Failure to
Remove the retaining clips.
7. Remove the piston pin and the connecting rod from the piston.
8. Clean and inspect the connecting rod and the piston. For additional
information, refer to Section 303-00 Engine System - General
Information.
Assembly
1. Install the piston pin.
Lubricate the piston pin and piston bore.
2. Install the retaining clips.
3. Check the piston ring end gap. For additional information, refer to
Section 303-00 Engine System - General Information.
4. Lubricate the piston and piston rings.
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5. Install the second oil control ring.
6. Install the oil control spacer ring.
7. Install the first oil control ring.
8. Install the second compression ring.
The top of the second compression ring has a "0" marked on it.
Position this side of the ring towards the top of the piston.
9. Install the top compression ring.
The top compression ring can be installed with either side up.
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Assembly
Special Tool(s)
Wrench Strap-Universal
303-D055
Crankshaft Rear Seal Installer
303-178
Crankshaft Rear Seal Installer Adapter Bolts
303-384
Piston Ring Compressor
303-372
Cylinder Bore Protector
303-535
Assembly
1. CAUTION: Use only plastic scraper when removing old gasket
material.
Clean all the mating faces and reusable parts thoroughly and check for
damage.
If gasket material remains on the cylinder head after cleaning, use
a plastic tipped scraper to remove remaining material.
2. NOTE: Never remove pipe plugs or alignment dowels unless they are to
be serviced.
Reseal oil passage blanking plugs, as necessary.
3. NOTE: The main bearings are precision selective fit. For additional
information, refer to Section 303-00 Engine System - General Information.
Install the upper crankshaft thrust washer.
Align assembly tab on thrust bearing to machining spot face on
cylinder block.
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4. Install the upper crankshaft main bearings.
Lubricate the bearings and thrust washer.
5. CAUTION: Avoid damage to any crankshaft journal bearing
surfaces.
Install the crankshaft.
6. NOTE: Push the crankshaft rearward prior to installation of upper thrust
bearings.
NOTE: Visually inspect the bearings to verify that the bearing oiling
holes align with cylinder block oil feed holes.
Install the lower crankshaft bearings into the cylinder block.
1. Install the lower crankshaft thrust main bearing into lower
cylinder block.
2. Install the lower crankshaft main bearings into lower cylinder
block.
Lubricate the bearings and thrust washer.
7. NOTE: Sealant application must stop 6 mm from the rear crankshaft
bore on each side.
NOTE: Install lower cylinder block and tighten all bolts to specification
within four minutes of applying sealer.
Apply a bead of sealant to the cylinder block housing.
Use Silicone gasket and sealant.
8. CAUTION: Make sure all dowels are fully seated into lower cylinder
block prior to tightening the bolts.
NOTE: Before installing the bolts lightly seat the crankshaft forward.
NOTE: Do not lubricate the lower cylinder block bolts.
NOTE: Loosely install the lower cylinder block bolts.
NOTE: Do not rotate crankshaft until all bolts are tightened to
specification.
NOTE: Bolts must be tightened within 4 minutes of applying sealant.
Install the lower cylinder block on the cylinder block.
Push crankshaft rearward to seat the crankshaft thrust washer.
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9. CAUTION: Bolts 1 through 16 are tighten-to-yield and must be
replaced.
NOTE: Tighten the bolts in the indicated sequence in four stages.
Stage 1: Bolts 1-8, 25 Nm
Stage 3: Bolts 1-16, 90
Verify the crankshaft rotates freely.
10. Remove excess sealant which may squeeze out at the front cover
sealing surface.
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11. NOTE: Alternate bolt tightening to correctly seat the crankshaft rear
oil seal until it is flush with the cylinder block.
Using the special tools, install the crankshaft rear oil seal.
12. CAUTION: Use appropriate protection to prevent damage to the
crankshaft bearing journals and cylinder bore surfaces.
Install special tools to the connecting rods.
Position the crankshaft journal at the bottom of the stroke.
13. NOTE: Make sure the piston ring gaps are positioned at different
locations opposite the thrust side of the piston before installation.
NOTE: Install pistons with arrow to front of engine.
Using the special tool compress the rings and install the piston and
connecting rod.
Lubricate all piston components.
14. CAUTIONS:
When assembling the connecting rods and connecting rod caps, it is
imperative that bearing slots and tangs be located on the same side of
the connecting rods.
Connecting rod bolts are torqued to yield and must be replaced.
NOTE: Remove the special tools from the connecting rods.
NOTE: Tighten the bolts in the indicated sequence in three stages.
Position the connecting rod cap on the appropriate connecting rod.
Stage 1: 23 Nm
Stage 2: 43 Nm
Stage 3: 105
15. Rotate the crankshaft to check correct operation.
16. CAUTIONS:
Install the oil pump flush to the cylinder block for correct sealing.
Rotate the inner rotor of the oil pump to align with the flats on the
crankshaft before installation.
Install the oil pump.
Tighten to 10 Nm.
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17. CAUTION: Oil pan baffle nuts are tightened to yield and must not
be reused.
NOTE: Tighten the bolts in the indicated sequence in two stages.
Install the oil pan baffle.
Stage 1: 5 Nm
Stage 2: 45
Install the oil pump tube.
Tighten to 10 Nm.
Tighten to 5 Nm + 45.
20. Install the engine coolant housing.
Install new 'O' ring seals.
Tighten to 25 Nm.
21. Position the crankshaft.
Turn the crankshaft until the key is in the 11 o'clock position.
Remove the crankshaft pulley bolt and washer.
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22. Install a new cylinder head gasket (LH shown - RH similar).
1. Make sure the cylinder head dowels are correctly located.
2. Install a new cylinder head gasket.
23. NOTE: Install the bolts in the indicated sequence.
Install the LH cylinder head.
Tighten to 30 Nm.
Tighten 90.
Loosen 360.
Tighten to 30 Nm.
Tighten 90.
Tighten 90.
24. NOTE: Install the bolts in the indicated sequence.
Install the RH cylinder head.
Tighten to 30 Nm.
Tighten 90.
Loosen 360.
Tighten to 30 Nm.
Tighten 90.
Tighten 90.
25. Install the LH inlet camshaft.
26. CAUTION: Do not install the cylinder head camshaft journal
thrust caps until the camshaft journal caps are installed or damage to the
thrust caps may occur.
NOTE: Lubricate the camshafts and the camshaft bearing caps with oil
installation.
Install the LH inlet camshaft bearing cap bolts evenly.
Install the inlet camshaft bearing caps.
Tighten to 10 Nm.
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27. Install the LH exhaust camshaft.
28. CAUTION: Do not install the cylinder head camshaft journal
thrust caps until the camshaft journal caps are installed or damage to the
thrust caps may occur.
NOTE: Lubricate the camshafts and the camshaft bearing caps with oil
installation.
Install the LH exhaust camshaft bearing cap bolts evenly.
Install the exhaust camshaft bearing caps.
29. Install the RH inlet camshaft.
30. Install the RH inlet camshaft bearing cap bolts evenly.
Install the inlet camshaft bearing caps.
31. Install the RH exhaust camshaft.
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32. Install the RH exhaust camshaft bearing cap bolts evenly.
Install the exhaust camshaft bearing caps.
33. Rotate the right-hand intake camshaft clockwise until the camshaft
right-hand exhaust camshaft sprocket clockwise until the camshaft
34. Install the crankshaft inner sprocket.
35. Install the left-hand timing chain outer guide.
36. CAUTIONS:
alignment mark on the left-hand intake camshaft sprocket is at the 9
O'clock position and the alignment mark on the left-hand exhaust
timing chain.
Install the left-hand timing chain.
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37. Install the left-hand timing chain inner guide.
38. CAUTION: Use suitable protective covers on the vice jaws to
protect the timing chain tensioner.
Secure the left-hand timing chain tensioner in the vice jaws.
39. CAUTION: During timing chain tensioner compression, do not
release the ratchet stem until the timing chain tensioner piston is fully
bottomed in its bore or damage to the ratchet stem will result.
Using a suitable tool, hold the left-hand timing chain tensioner ratchet
lock mechanism away from the ratchet stem.
40. NOTE: The timing chain tensioner piston should retract with minimal
force. If binding occurs, reposition the timing chain tensioner to eliminate
side loading.
Slowly compress the left-hand timing chain tensioner.
41. NOTE: The retaining tool must remain in the timing chain tensioner
until the timing chain tensioner is installed to the engine with the piston
bottomed in the bore.
Using a suitable tool, retain the left-hand timing chain tensioner piston.
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42. Install the left-hand timing chain tensioner.
Tighten to 25 Nm.
43. Release the tension in the left-hand timing chain tensioner.
Remove the retaining tool.
44. Make sure the left-hand timing chain alignment marks have remained
correctly positioned to the camshaft sprocket and crankshaft sprocket
alignment marks.
O'clock position.
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48. Install the crankshaft outer sprocket.
49. Install the right-hand timing chain inner guide.
50. CAUTIONS:
alignment mark on the right-hand intake camshaft sprocket is at the 5
O'clock position and the alignment mark on the right-hand exhaust
timing chain.
Install the right-hand timing chain.
51. Install the right-hand timing chain outer guide.
52. CAUTION: Use suitable protective covers on the vice jaws to
protect the timing chain tensioner.
Secure the right-hand timing chain tensioner in the vice jaws.
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53. CAUTION: During timing chain tensioner compression, do not
release the ratchet stem until the timing chain tensioner piston is fully
bottomed in its bore or damage to the ratchet stem will result.
Using a suitable tool, hold the right-hand timing chain tensioner ratchet
lock mechanism away from the ratchet stem.
54. NOTE: The timing chain tensioner piston should retract with minimal
force. If binding occurs, reposition the timing chain tensioner to eliminate
side loading.
Slowly compress the right-hand timing chain tensioner.
55. NOTE: The retaining tool must remain in the timing chain tensioner
until the timing chain tensioner is installed to the engine with the piston
bottomed in the bore.
Using a suitable tool, retain the right-hand timing chain tensioner
piston.
56. Install the right-hand timing chain tensioner.
Tighten to 25 Nm.
57. Release the tension in the right-hand timing chain tensioner.
Remove the retaining tool.
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58. CAUTION: Make sure the right-hand timing chain alignment
marks have remained correctly positioned to the camshaft sprocket and
crankshaft sprocket alignment marks.
Make sure all the timing chain alignment marks are in the positions
shown.
Check the engine valve timing is correctly set.
Rotate the crankshaft two complete turns clockwise. Make sure the
alignment marks on the camshaft sprockets are in the positions
shown when the crankshaft keyway is at the 11 O'clock position.
62. NOTE: Make sure the CKP sensor pulse wheel is correctly installed with
the teeth pointing outwards.
Install the CKP sensor pulse wheel.
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63. Carry out a valve clearance check.
For additional information, refer to Valve Clearance Check in this
section.
64. Install new front timing cover gaskets.
65. NOTE: Prior to applying sealer clean the front cover to engine block
and cylinder head sealing surfaces with metal surface cleaner.
Apply a 6 mm diameter dot of silicone sealant meeting Jaguar
specification to the indicated locations.
66. NOTE: The engine front cover retaining bolts numbered 3,4,10 and 11
are longer than the retaining bolts numbered 1,2,5,6,7,8,9,12,13,15 and
16. The retaining bolt numbered 14 is a retaining bolt with a stud head.
Install the engine front cover, completing the tightening sequence .
Tighten to 25 Nm.
67. NOTE: Apply an 10 mm dot of silicone gasket and sealant meeting
Jaguar specification to the engine block and front cover mating surface.
NOTE: Tighten all oil pan retaining bolts with in six minutes of applying
the sealer.
Install the oil pan rear retaining bolts.
Tighten to 25 Nm.
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Install the valve covers.
Tighten to 10 Nm.
69. Install the left-hand idler pulley.
Tighten to 25 Nm.
70. Using the special tools, install the crankshaft pulley.
Coat the crankshaft pulley keyway with silicone gasket sealant
Coat the sealing surfaces of the crankshaft pulley with silicone
gasket sealant meeting Jaguar specification.
71. Install the crankshaft pulley retaining bolt.
Torque to 120 Nm.
Loosen the bolt (minimum 1 turn).
Torque to 50 Nm.
Angle Torque to 90.
Tighten 45 Nm.
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73. Install the water pump and coolant hose assembly.
1. Attach the hose.
2. Install the water pump and coolant hose assembly.
Tighten to 25 Nm.
74. NOTE: Install new coolant crossover O-ring seals.
Install the coolant crossover tube.
Tighten to 10 Nm,
75. Install the engine oil pressure and oil temperature sensors.
Tighten to 14Nm.
Install the oil filter housing assembly.
Tighten all oil filter housing retaining bolts to 25 Nm.
77. Tighten the oil filter housing assembly retaining bolts in sequence.
2. Tighten to 40 Nm + 90 degrees.
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78. Install the engine rear backing plate.
79. Install the flywheel.
Prevent the engine from rotating.
Tighten to 80 Nm.
Install the exhaust manifolds.
Tighten to 25 Nm.
Install the exhaust manifold heat shields.
Tighten to 10 Nm.
Install the oil level indicator tube.
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83. Install the A/C compressor mounting bracket.
Tighten to 25 Nm.
84. Install the air conditioning (A/C) compressor.
Tighten to 25 Nm.
Tighten to 25 Nm.
86. Install the generator.
Tighten to 48 Nm.
87. Install the right-hand idler pulley.
Tighten to 25 Nm.
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88. Install the accessory drive belt.
1. Use a 3/8 inch drive bar to release the accessory drive belt
tensioner.
89. Install the left-hand knock sensor.
Tighten to 25 Nm.
90. Install new lower intake manifold gaskets.
91. Install the lower intake manifold and injector supply manifold.
Tighten to 10 Nm.
92. Install the ignition coils.
Tighten to 10 Nm.
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93. Install the engine wiring harness.
Tighten to 10 Nm.
94. Connect the engine wiring harness electrical connectors.
95. Connect the left-hand ignition coils.
96. Connect the left-hand camshaft position sensor.
97. Attach the engine harness.
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98. Connect the right-hand ignition coils.
100. Attach the engine harness retaining bracket.
101. Disconnect the right-hand camshaft position sensor.
102. Install the rear knock sensor.
1. Attach the knock sensor wiring harness.
2. Install the rear knock sensor.
Tighten to 25 Nm.
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103. Attach engine harness.
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108. Connect the oil cooler coolant hoses.
109. Install the evaporative emission purge valve hose.
110. Install the engine breather hose.
111. Install new intake manifold gaskets.
112. NOTE: The intake manifold retaining bolts in position 1,2,3 and are
longer than the retaining bolts in position 4,5 and 6.
Install new intake manifold gaskets.
Tighten to 10 Nm.
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113. Connect the evaporative emission canister purge valve transfer pipe.
114. Attach the intake manifold rear retaining bracket.
Tighten to 10 Nm.
115. Attach the engine wiring harness from the intake manifold rear
retaining bracket.
116. Attach the intake manifold front retaining bracket.
Tighten to 10 Nm.
117. Install the fuel pressure regulator bracket.
Tighten to 10 Nm.
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119. Connect the fuel pressure regulator vacuum hose.
121. Connect the positive crankcase ventilation (PCV) hose.
122. Connect the throttle position sensor.
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123. Connect the throttle motor electrical connector.
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With: 5-Speed Manual Transmission - MT75/6-Speed Manual Transaxle - MMT6
Installation
Special Tool(s)
Halfshaft oil seal installer
205-115
307-446
Engine lifting kit
303-707
HTJ12000-2
418-535
Installation
All vehicles
1. Install the transaxle.
Tighten to 47 Nm.
2. Install the transaxle retaining bolts.
Tighten to 47 Nm.
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Tighten to 47 Nm.
4. Install the access cover.
Tighten to 10 Nm.
5. Install the dust cover.
Tighten to 10 Nm.
6. Install the starter motor.
Tighten to 35 Nm.
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7. NOTE: Using a suitable surface cleaner, WSE-M5B392-A or equivalent,
meeting the Jaguar specification. Clean the seal face on the transfer case
before installing the new link shaft oil seal.
Using the special tool, install a new link shaft oil seal.
8. Install the link shaft.
9. Install a new link shaft snap ring.
10. Install a new transfer case O-ring seal.
11. NOTE: Engage the link shaft into the transaxle.
Install the transfer case.
Tighten to 90 Nm.
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12. NOTE: Do not tighten the engine roll restrictor bracket top retaining
bolts at this stage at this stage.
Install the engine roll restrictor bracket.
Install the engine roll restrictor bracket top retaining bolts.
13. NOTE: Do not tighten the engine roll restrictor bracket retaining nuts
at this stage.
14. Install the engine roll restrictor bracket side retaining bolts.
Tighten to 35 Nm.
15. Tighten the engine roll restrictor bracket retaining nuts.
Tighten to 35 Nm.
16. Tighten the engine roll restrictor bracket top retaining bolts.
Tighten to 55 Nm.
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17. NOTE: Do not tighten the catalytic converter retaining bolts at this
stage.
Install the catalytic converter mount bracket.
18. Install the catalytic converter mount bracket retaining bolt.
Tighten to 25 Nm.
19. Tighten the catalytic converter mount bracket retaining bolts.
Tighten to 55 Nm.
20. Install a new catalytic converter sealing ring.
21. Install new catalytic converter retaining studs.
Tighten to 9 Nm.
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22. CAUTION: Never use jointing compound forward of the catalytic
converter. Failure to follow this instruction may result in damage to the
component.
NOTE: Make sure the retaining nuts are tightened twice in the sequence
shown.
Install the right-hand catalytic converter.
Install new retaining nuts.
23. Install the right-hand catalytic converter retaining bolts.
Tighten to 25 Nm.
24. Connect the right-hand heated oxygen sensor (HO2S) electrical
connector.
25. Connect the right-hand heated catalyst monitor sensor electrical
connector.
26. Install a new halfshaft snap ring.
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28. CAUTION: Do not use excessive force when engaging the
halfshaft to the link shaft. Failure to follow this instruction may result in
damage to the component.
NOTE: Make sure the halfshaft is fully located to the link shaft.
29. Install the transfer case Y bracket.
Tighten to 55 Nm.
30. Install the transfer case Y bracket retaining bolts.
Tighten to 25 Nm.
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31. Install the halfshaft and intermediate shaft assembly.
Tighten to 20 Nm.
All vehicles
Using the special tool, install the engine and transaxle to the subframe.
33. Install the engine roll restrictor.
Tighten to 80 Nm.
34. Install the engine roll restrictor retaining bolt.
Tighten to 80 Nm.
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36. Connect the power steering high-pressure pipe.
Tighten to 30 Nm.
37. Install the power steering high-pressure pipe retaining bolt.
Tighten to 25 Nm.
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39. Install the left-hand halfshaft.
NOTE: Make sure the halfshaft is aligned to the front wheel hub.
Attach the wheel knuckles.
2. Attach the wheel knuckles.
Attach the stabilizer bar link arms.
Tighten to 48 Nm.
Attach the tie rod ends.
Tighten to 35 Nm.
NOTE: Do not tighten the front wheel hub retaining nuts at this stage.
Install the front wheel hub retaining nuts.
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45. Install the center exhaust heat shield.
Tighten to 10 Nm.
46. Install the center exhaust heat shield retaining bolts.
Tighten to 10 Nm.
47. Install the upper exhaust heat shield.
Tighten to 6 Nm.
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49. Install the left-hand exhaust manifold heat shield.
Tighten to 10 Nm.
51. Install the transaxle mount.
Tighten to 80 Nm.
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52. Install the coolant system top hose.
Install a new gasket.
Tighten to 9 Nm.
53. WARNING: Raise the special tool platform slowly. Failure to
follow this instruction can result in personal injury.
Install the engine and transaxle assembly.
Raise the special tool platform.
Make sure the special tool rear height adjuster aligns into the locating
hole in the vehicle floor pan.
Loosely install the front subframe retaining bolt.
Install the front subframe reinforcement plate.
Loosely install the front subframe rear retaining bolt.
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M8 to 35 Nm.
M10 to 70 Nm.
Tighten the front subframe retaining bolt.
Tighten to 142 Nm.
Tighten the front subframe rear retaining bolt.
Tighten to 142 Nm.
60. Install the transaxle mount bracket securing nut.
Tighten to 133 Nm.
61. Install the engine support bracket.
Tighten to 80 Nm.
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62. Tighten the engine support bracket retaining bolts.
Tighten to 40 Nm.
NOTE: If fixings can be re-used on vehicles built prior to VIN J24254, then the ol d torque must be used (48 Nm). If new fixings are used
on any vehicle use the new torque.
Attach the strut and spring assembly.
Tighten to 30 Nm.
Tighten to 9 Nm.
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68. NOTE: Remove the blanking plug from the hose.
Attach the power steering hose.
69. Connect the ground cable.
Tighten to 10 Nm.
70. Connect the engine control module (ECM) electrical connector.
Tighten to 10 Nm.
72. Connect the reverse light switch electrical connector.
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73. Install the clutch master cylinder to clutch slave cylinder high pressure
pipe support bracket.
NOTE: Remove the tie straps.
NOTE: Remove the blanking plugs from the pipe and slave cylinder.
Connect the clutch slave cylinder pipe.
1. Attach the clutch slave cylinder pipe to the slave cylinder.
2. Attach the clutch cylinder to the retaining bracket.
75. NOTE: Remove the tie straps.
Attach the selector cables.
Tighten to 25 Nm.
76. NOTE: Upper selector cable shown, lower selector cable similar.
77. Attach the battery cables.
Tighten to 10 Nm.
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78. Attach the coolant hoses.
79. Attach the accelerator cable retaining bracket.
Tighten to 9 Nm.
80. Attach the accelerator cable.
All vehicles
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NOTE: Remove the blanking plugs from the tube and the A/C
compressor.
Attach the A/C compressor supply and return tubes.
Tighten to 25 Nm.
90. Install the front muffler.
All vehicles
92. Install the cooling fan motor and shroud.
Detach and reposition the anti-lock brake system (ABS) wheel speed
sensor.
Connect the ABS wheel speed sensor.
Tighten to 5 Nm.
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Attach the ABS wheel speed sensor.
Detach and reposition the brake caliper assembly.
Attach the brake pipe.
NOTE: Install new brake caliper anchor plate retaining bolts.
Attach the brake caliper assembly.
Tighten to 133 Nm.
Install the splash shield.
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Remove the rear vehicle tie down strap.
Remove the front vehicle tie down strap.
103. Install the battery tray.
105. Bleed the power steering system.
107. Install the steering column lower retaining bolt.
Tighten to 25 Nm.
108. Fill the transaxle.
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Tighten the front hub retaining nuts.
Tighten to 290 Nm.
110. Carry out the underbody misalignment check.
111. Check the engine oil level and correct as necessary.
112. NOTE: When the battery has been disconnected and reconnected,
some abnormal drive symptoms may occur while the vehicle relearns its
adaptive strategy.
Finishing operations.
Check the routing of the vacuum hoses and wiring and secure them
with cable ties.
Check the fluid levels after the road test and correct as necessary.
Check the engine and cooling system for leaks (visual inspection).
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With: 5-Speed Automatic Transaxle - JATCO/6-Speed Automatic Transaxle - AWF21
Installation
Special Tool(s)
205-115
307-446
Engine lifting kit
303-707
HTJ12000-2
418-535
Installation
All vehicles
1. NOTE: Use high temperature grease ESD-M1C220-A or equivalent
meeting the Jaguar specification.
Apply a thin layer of grease to the centering spigot bore on the torque
converter.
2. CAUTION: The torque converter must remain at the correct
installation depth throughout the whole installation procedure.
NOTE: The torque converter must engage fully in the oil pump drive
gear.
Check the installation depth between the transmission flange and the
torque converter is at least 0.04 mm (0.015 in).
Install the transaxle.
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Tighten to 48 Nm.
Tighten to 48 Nm.
Tighten to 48 Nm.
Tighten to 48 Nm.
8. NOTE: Rotate the torque converter to gain access to the remaining
retaining bolts.
Install the torque converter retaining bolts.
Tighten to 55 Nm.
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9. Install the access cover.
Tighten to 10 Nm.
10. Install the dust cover.
Tighten to 10 Nm.
Tighten to 35 Nm.
12. NOTE: Using a suitable surface cleaner, WSE-M5B392-A or equivalent,
meeting the Jaguar specification. Clean the seal face on the transfer case
before installing the new link shaft oil seal.
Using the special tool, install a new link shaft oil seal.
13. Install the link shaft.
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14. Install a new link shaft snap ring.
15. Install a new transfer case O-ring seal.
16. NOTE: Engage the link shaft into the transaxle.
Install the transfer case.
Tighten to 90 Nm.
17. NOTE: Do not tighten the engine roll restrictor bracket top retaining
bolts at this stage at this stage.
Install the engine roll restrictor bracket top retaining bolts.
18. NOTE: Do not tighten the engine roll restrictor bracket retaining nuts
at this stage.
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19. Install the engine roll restrictor bracket side retaining bolts.
Tighten to 35 Nm.
20. Tighten the engine roll restrictor bracket retaining nuts.
Tighten to 35 Nm.
21. Tighten the engine roll restrictor bracket top retaining bolts.
Tighten to 55 Nm.
22. NOTE: Do not tighten the catalytic converter retaining bolts at this
stage.
23. Install the catalytic converter mount bracket retaining bolt.
Tighten to 25 Nm.
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Tighten to 55 Nm.
25. Install a new catalytic converter sealing ring.
Tighten to 9 Nm.
converter. Failure to follow this instruction may result in damage to the
component.
NOTE: Make sure the retaining nuts are tightened twice in the sequence
shown.
Install the right-hand catalytic converter.
28. Connect the right-hand heated oxygen sensor (HO2S) electrical
connector.
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29. Connect the right-hand catalyst monitor sensor electrical connector.
30. Install the right-hand catalytic converter retaining bolts.
Tighten to 25 Nm.
33. CAUTION: Do not use excessive force when engaging the
halfshaft to the link shaft. Failure to follow this instruction may result in
NOTE: Make sure the halfshaft is fully located to the link shaft.
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34. Install the transfer case Y bracket.
Tighten to 55 Nm.
35. Install the transfer case Y bracket retaining bolts.
Tighten to 25 Nm.
36. Install the halfshaft and intermediate shaft assembly.
Tighten to 20 Nm.
All vehicles
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Using the special tool, install the engine and transaxle to the subframe.
Tighten to 80 Nm.
39. Install the engine roll restrictor retaining bolt.
Tighten to 80 Nm.
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41. Connect the power steering high-pressure pipe.
Tighten to 30 Nm.
42. Install the power steering high-pressure pipe retaining bolt.
Tighten to 25 Nm.
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NOTE: Make sure the halfshaft is aligned to the front wheel hub.
Attach the wheel knuckles.
2. Attach the wheel knuckles.
Tighten to 48 Nm.
Attach the tie rod ends.
Tighten to 35 Nm.
NOTE: Do not tighten the front wheel hub retaining nuts at this stage.
Install the front wheel hub retaining nuts.
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50. Install the center exhaust heat shield.
Tighten to 10 Nm.
51. Install the center exhaust heat shield retaining bolts.
Tighten to 10 Nm.
52. Install the upper exhaust heat shield.
Tighten to 6 Nm.
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54. Install the left-hand exhaust manifold heat shield.
Tighten to 10 Nm.
56. Install the transaxle mount.
Tighten to 80 Nm.
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57. Install the coolant system top hose.
Tighten to 9 Nm.
Install the engine and transaxle assembly.
Loosely install the front subframe retaining bolt.
Loosely install the front subframe rear retaining bolt.
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M8 to 35 Nm.
M10 to 70 Nm.
Tighten the front subframe retaining bolt.
Tighten to 142 Nm.
Tighten the front subframe rear retaining bolt.
Tighten to 142 Nm.
65. Install the spacer.
66. Install the support bar.
Tighten to 133 Nm.
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67. Tighten to the support bar retaining bolts.
Tighten to 25 Nm.
Tighten to 80 Nm.
69. Tighten the support bar retaining bolts.
Tighten to 25 Nm.
Attach the strut and spring assembly.
Tighten to 30 Nm.
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Tighten to 9 Nm.
75. NOTE: Remove the blanking plug from the hose.
Attach the power steering hose.
76. Connect the ground cable.
Tighten to 10 Nm.
77. Connect the engine control module (ECM) electrical connector.
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78. Connect the engine harness electrical connector.
Tighten to 10 Nm.
79. Attach the battery cables.
Tighten to 10 Nm.
81. Attach the accelerator cable retaining bracket.
Tighten to 9 Nm.
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NOTE: Remove the blanking plugs from the tube and the air conditioning
(A/C) compressor.
Attach the air conditioning (A/C) compressor supply and return tubes.
Tighten to 25 Nm.
All vehicles
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94. Install the cooling fan motor and shroud.
Detach and reposition the anti-lock brake system (ABS) wheel speed
sensor.
Tighten to 5 Nm.
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Attach the brake caliper assembly.
Tighten to 133 Nm.
Install the splash shield.
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109. Install the steering column lower retaining bolt.
Tighten to 25 Nm.
110. Fill the transaxle.
Tighten the front hub retaining nuts.
Tighten to 290 Nm.
113. Check the engine oil level and correct as necessary.
114. NOTE: When the battery has been disconnected and reconnected,
some abnormal drive symptoms may occur while the vehicle relearns its
adaptive strategy.
Finishing operations.
Check the routing of the vacuum hoses and wiring and secure them
with cable ties.
Check the fluid levels after the road test and correct as necessary.
Check the engine and cooling system for leaks (visual inspection).
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Engine - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) - Puma -
Engine Oil Capacity
Description Liters
Initial fill including oil filter 67
Service fill including oil filter 60
Service fill without oil filter 58
Lubricants, Sealers and Adhesives
Item Specification
SAE 5W-30 engine oil WSS-M2C913-B
Sealant Loctite 5910 WSE-M4G323-A4
Oil Pressure Specifications
Description Bar
Maximum oil pressure at idle speed 12
Maximum oil pressure at 2000 rpm 20
Tightening Torques
Engine to transmission retaining bolts 40 30 -
Rear engine mount retaining stud 133 98 -
Front engine mounting 80 59 -
Engine roll restrictor to transmission 80 59 -
Front subframe rear bolts 142 105 -
Front subframe rear bracket bolts 70 52 -
Steering gear to subframe 133 98 -
Engine roll restrictor to subframe 80 59 -
Lower suspension arm ball joint 83 61 -
Axle driveshaft center bearing 25 18 -
Engine ground cable 13 10 -
Thermostat housing 23 17 -
Thermostat cover 10 - 89
Crankshaft pulley a - -
Crankshaft rear oil seal carrier 10 - 89
Flywheel a - -
Crankshaft bearing caps a - -
Big-end bearing caps a - -
Fuel injectors 47 35 -
Injection pump sprocket 33 24 -
Injector tubes 38 28 -
Lower crankcase a - -
Camshaft carrier (M8) a - -
Camshaft carrier (M6) a - -
Rocker shafts a - -
Timing chain guides 15 11 -
Timing chain tensioner 15 11 -
Oil pump chain tensioner 16 12 -
Camshaft sprocket 33 24 -
Auxiliary unit drive belt tensioner 23 17 -
Exhaust gas recirculation valve (EGR valve) 10 - 89
Line for EGR valve 23 17 -
Coolant pump 25 18 -
Dip stick tube (M8 x 14) 23 17 -
Oil intake pipe. 10 - 89
Oil filter cooler 23 17 -
Oil pump 10 - 89
Oil pan drain plug 23 17 -
Oil pan a - -
Cylinder head bolts (M10 x 160) a - -
Cylinder head bolts (M8 x 120) a - -
Engine front cover a - -
Glow plugs 13 10 -
Glow plug wires (M4 x 14) 3 - 27
Power steering pump 18 13 -
Power steering pump bracket 23 17 -
Intake manifold 16 12 -
Exhaust manifold and turbocharger 40 30 -
Turbocharger oil return line 10 - 89
Turbocharger oil feed line 14 10 -
Front engine lifting eye (M8 x 20) 23 17 -
Common rail studs 23 17 -
Knock sensor (KS) 20 15 -
Crankshaft position sensor (CKP sensor) (M6 x 16) 7 - 62
Camshaft position sensor (CMP sensor) 10 - 89
Cylinder head temperature sensor (CHT sensor) 11 8 -
a = Refer to the procedure in this section.
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Engine - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) - Puma - Engine
General View
1 - Intake manifold
2 - Fuel injection supply manifold
3 - Fuel injector
4 - Valve cover
5 - Turbocharger
6 - Brake vacuum pump
7 - Thermostat housing
8 - Rear accessory drive belt tensioner
9 - Flywheel
10 - Power steering pump
11 - Waterpump
12 - Oil cooler
13 - Oil filter housing
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14 - Oil pressure switch
15 - Fuel injection pump
16 - Oil level indicator and tube
17 - Exhaust gas recirculation (EGR) valve
Engine Identification Code
Engine code and engine serial number
The engine code (4-digit) and the engine serial number (consisting of two letters for the year and month and five numbers, which constitute
the serial number) are located on the cylinder block, adjacent to the injection pump.
When replacing the engine or the cylinder block, the vehicle identification number must be stamped at the location indicated.
1 - Engine serial number
2 - Vehicle identification number
3 - Engine code
General
The 2.0L and 2.2L diesel engines are both 4-cylinder, 16-valve, common rail direct injection turbo charged diesel engines.
This diesel engine design incorporates twin rocker shafts with 16 valves operated by hydraulically adjusted rocker arm. The intake ports are
designed to ensure optimum charging and swirl of the mixture charge of air and fuel at all engine speeds.
The two overhead camshafts and the fuel injection pump are driven by means of multil ink chain with automatic hydraulic adjustment.
The new design of cylinder head and high fuel pressures produces an optimum torque curve. Continuous torque is maintained even at low
engine speed.
The engine features smooth running characteristics, achieved through the use of a modern engine management system and an advanced
fuel injection system.
Low fuel consumption of the engine is the result of efficient combustion and high injection pressures which has also led to reduced
emissions of carbon dioxide CO2.
Fuel metering is controlled electronically by a mapped engine management system (EMS) with driver input with fly by wire accelerator.
These characteristics, including electronically controlled EGR system coupled with an oxidation catalyst, meet current exhaust emission
standards. In addition, the engine has the potential to meet future exhaust emission limits.
European Stage 4 Diesel Emissions - Vehicles built from VIN:E25782
In order to meet European stage 4 diesel emission legislation, the 2.0L diesel engine has the following changes:-
A revised piston crown design to improve combustion swirl.
An electronically controlled turbocharger.
For additional information, refer to: Turbocharger (303-04C Fuel Charging and Controls - Turbocharger, Description and Operation).
An electronically controlled EGR system.
These changes have therefore been utilized on the 2.2L diesel engine.
Cylinder Head
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1 - Cylinder head
2 - Cylinder head bolts
3 - Intake valves
4 - Cylinder head gasket
5 - Exhaust valves
6 - Exhaust camshaft
7 - Intake camshaft
8 - Camshaft carrier
9 - Camshaft carrier bearing brackets (5 off)
10 - Sealing surface
11 - Rocker shaft with rocker arms (exhaust)
12 - Rocker shaft with rocker arms (intake)
Cylinders head
The cylinder head is of aluminium construction and CANNOT be reworked. The cylinder head is secured to the engine block by two sizes of
bolts the inner bolts being the larger. THE CYLINDER HEAD BOLTS BOLTS MUST ALWAYS BE RENEWED.
Rocker Arms
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1 - Rocker shaft, exhaust rocker arm
2 - Rocker shaft, intake rocker arm
3 - Stud on rocker arm
The valves are operated by lightweight aluminium rocker arms, which are mounted on two rocker shafts. The rocker arms are of different
lengths to match the offset valve configuration. Therefore, the distances between the inlet valves and exhaust valves differ. It will be noted
that the inlet rocker shaft has helical springs fitted between the rocker arms; this is to keep the arms equally spaced. The rocker shafts are
marked for assembly purpose and care must be taken to follow correct installation.
The rocker shafts are supplied with engine oil through oil bores. When installing the rocker shafts make sure that the oil bores face
downwards. The rocker shafts are marked for assembly purpose and care must be taken to follow correct installation.
Front Cover
1 - Sealing bead
2 - Engine front cover
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3 - Engine front cover gasket
Front Cover
The timing cover is of steel construction and is fitted using sealing compound. Prior to fitting, the mating faces on the timing case and
cover must be cleaned thoroughly. A special tool is used to align the cover to the engine in relation to the crankshaft.
Camshaft cover
The camshaft cover is made from plastic composite material and is secured to the camshaft carrier. It also incorporates the crankcase
ventilation and location for the fuel injector seals. The cover is sealed to the carrier by means of rubber gasket. The head incorporates four
valves per cylinder to ensure improved cylinder charging. A vertical centrally placed fuel injector guarantees maximum distribution of fuel
into the combustion chamber. The valve stem oil seals also form the lower guide for the valve spring.
Pistons and connecting rods
Connecting rod dimensions
The connecting rods of the diesel engine are divided into the following length categories:
K
L
M
NOTE: For tolerances refer to the specifications table.
1 - Piston pin
2 - Length category
Piston
The piston crown incorporates a pronounced bowl that forms the combustion chamber. This promotes swirl and turbulence which is
necessary for good combustion and improved emission. In addition, the piston skirt, which comes into contact with the cylinder bore, has
molybdenum-coated surfaces. These counteract scoring of the cylinder and piston therefore helping to increase engine life.
When installing the pistons, it must be ensured that the arrow on the piston points to the timing chain side.
1 - Mark on piston skirt
2 - Engine cooling code
3 - Piston skirt diameter code
Oil Spray Nozzles
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1 - Oil spray nozzle
2 - Tab
The piston also incorporates an oil gallery for cooling purposes. This is supplied by oil spray nozzles which are located in engine block oil
gallery. Optimum piston cooling is ensured, which is necessary due to high power output and high combustion temperatures.
Oil pump
The oil pump is a gear-type pump and is bolted to the underside of the bedplate. It is driven from the crankshaft by means of a chain, and
is fitted with its own hydraulic tensioner. Care must be taken when the oil pump is installed. The sprocket on the oil pump must be aligned
precisely with the sprocket on the crankshaft, to prevent noise and premature chain failure.
Oil cooler and filter
The oil cooler forms a unit with the oil filter and is mounted on the side of the cylinder block. The oil is cooled using the engine cooling
system. This eliminates an additional oil cooler remotely mounted. The engine is lubricated by a forced-feed oil circulation system with full
flow oil filter. The oil filter and cooler is designed to incorporate the oil filter.
Crankshaft
The crankshaft has induction-hardened journals which run in five bearings with clamped two-layer bearing shells. The bearing shells are
made of steel and roll-bounded aluminium-tin alloy. The upper shell of main bearing No 3 is flanged which limits the end float of the
crankshaft. All main bearing caps are numbered and are marked with an arrow which must point towards the timing chain.
Cylinder Block
The cylinder block is made of grey cast iron with the cylinder bores machined directly into the block. Three different bore diameters are in
production to ensure precise clearance between pistons and cylinders. Once the bore diameter has been established the optimum piston is
fitted.
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Engine - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) - Puma - Crankshaft
Front Seal
In-vehicle Repair
Special Tool(s)
Release tool, belt tensioner
303-676
303-D055
Remover/Installer, Front Oil Seal
303-679 (21-238)
Removal
2. Remove the right-hand wheel arch liner access panel.
3. Using the special tool, detach the accessory drive belt.
4. Using the special tool, remove the crankshaft pulley.
Remove and discard the crankshaft pulley bolts.
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5. Using the special tool, remove the crankshaft front oil seal.
Discard the oil seal.
Installation
1. NOTE: Install a new crankshaft front oil seal.
NOTE: A new crankshaft front oil seal is supplied with an alignment
sleeve that will be pushed out during installation.
Using the special tool, install the crankshaft front oil seal.
Tighten to 19 Nm.
2. CAUTIONS:
Install new crankshaft pulley retaining bolts. Failure to follow this
instruction many result in damage to the vehicle.
Tighten the new crankshaft pulley bolts in 2 stages. Failure to follow
this instruction many result in damage to the vehicle.
Install the crankshaft pulley.
Using the special tool, retain the crankshaft pulley.
Stage 1: 45 Nm.
Stage 2: 120 degrees.
3. Using the special tool, install the accessory drive belt.
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4. Install the right-hand wheel arch liner access panel.
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Engine - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) - Puma - Crankshaft
Rear Seal
In-vehicle Repair
Removal
For additional information, refer to: Flywheel (303-01B Engine - 2.0L
Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) - Puma, In-vehicle
Repair).
2. Remove the crankshaft rear seal.
Discard the crankshaft rear seal and the bolts.
Installation
CAUTION: A new crankshaft rear seal is supplied with an alignment sleeve that must not be removed until the crankshaft rear seal is
fully installed. Failure to follow this instruction may result in damage to the vehi cle.
NOTE: Clean area on engine before installing a new crankshaft rear seal carrier.
1. Check the two foam pads are located as shown on the ladder frame
gasket.
If the ladder frame gasket tabs are present, trim using a suitable
tool flush to the engine block and ladder frame.
NOTE: Make sure the sealant sits between the joints between
the engine block and the ladder frame.
Apply a thin layer of sealant to the areas shown.
2. CAUTIONS:
Install the new crankshaft rear seal within five minutes of applying
the recommended sealant. Failure to follow this instruction may result in
Do not add any more than the specified quantity of sealant or add
the sealant anywhere other than the area shown.
Using the recommended sealant completely fill the square areas shown.
For additional information, refer to: Specifications (303-01B Engine -
2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) - Puma,
Specifications).
3. NOTE: Do not fully tighten the crankshaft rear oil seal retaining bolts at
this stage.
Install the crankshaft rear oil seal.
Install the new retaining bolts.
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4. Tighten the crankshaft rear oil seal carrier retaining bolts.
Tighten the bolts in the sequence shown.
Tighten to 10 Nm.
5. Remove the crankshaft rear oil seal alignment sleeve.
6. Install the flywheel.
For additional information, refer to: Flywheel (303-01B Engine - 2.0L
Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) - Puma, In-vehicle
Repair).
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Front Cover
In-vehicle Repair
Special Tool(s)
Aligner, Front Cover
303-682 (21-241)
Removal
1. Remove the engine front mount.
For additional information, refer to: Engine Front Mount (303-01B Engine
- 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) - Puma,
In-vehicle Repair).
2. Detach the engine wiring harness.
4. Remove the retaining bracket.
1. Remove the retaining nuts.
2. Remove the retaining bracket.
5. Remove the crankshaft front seal.
For additional information, refer to: Crankshaft Front Seal (303-01B
Engine - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) - Puma,
In-vehicle Repair).
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6. Detach the generator positive cable.
8. Remove the generator upper retaining bolt.
9. Detach the generator.
Slide the generator rearwards as far away from the accessory drive
belt tensioner assembly as possible.
10. Detach the accessory drive belt tensioner assembly.
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11. Detach the accessory drive belt.
13. Remove the engine front cover lower retaining nuts and bolts.
15. NOTE: Engine shown removed for clarity.
NOTE: The idler pulley can not be removed until the engine mount
bracket is removed.
Remove the idler pulley retaining nut.
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Remove the front engine mount bracket and idler pulley.
Remove the engine front cover upper retaining bolts.
18. CAUTION: Avoid damage to the engine front cover mating face
on the engine. Failure to follow this instruction may result in damage to
the vehicle.
NOTE: Lubricate the suitable tool with clean engine oil.
Using a suitable tool, remove and discard the engine front cover.
Insert the suitable tool between the front cover and the engine,
slide the suitable tool in between the engine and engine front
cover.
Installation
1. Clean the engine front cover mating faces.
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2. CAUTIONS:
A new engine front cover must be installed. Failure to follow this
Install the engine front cover within five minutes of applying the
sealer. Failure to follow this instruction may result in damage to the
vehicle.
Apply a 3 mm (0.118 inch) bead of sealer to the four T-joints.
3. Apply a 3 mm (0.118 inch) bead of selaer to the engine front cover.
4. WARNING: Make sure that the engine front cover does not come
into contact with the engine until correct position is obtained.
With the aid of a second technician, position the engine front cover.
Using the special tool, align the engine front cover.
Intall and tighten 2 engine front cover bolts to 6 Nm.
Install and tighten the remaining 16 engine front cover bolts and 2
nuts to 6 Nm.
Slacken the engine front cover bolts and nuts 360 degrees.
Install the special tool.
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7. Tighten the engine front cover lower retaining nuts and bolts.
Tighten the engine front cover nuts and bolts to 3 Nm.
Tighten the engine front cover nuts and bolts in the following
sequence:
Tighten the 2 bolts indicated to 11 Nm.
Tighten the remaining nuts and bolts to 10 Nm.
Remove the special tool.
NOTE: Install the engine front mount bracket, the idler pulley and bolts
as one item.
Install the front engine mount bracket and idler pulley.
Tighten to 80 Nm.
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Install the idler pulley retaining nut.
Tighten to 43 Nm.
13. Attach the accessory drive belt tensioner assembly.
Tighten to 47 Nm.
14. NOTE: Do not tighten the generator retaining nuts at this stage.
Attach the generator.
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15. Install the generator upper retaining bolt.
Tighten to 47 Nm.
18. Attach the generator positive cable.
Tighten to 8 Nm.
19. Install the crankshaft front seal.
For additional information, refer to: Crankshaft Front Seal (303-01B
Engine - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) - Puma,
In-vehicle Repair).
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20. Install the retaining nuts.
1. Install the retaining bracket.
2. Install the retaining nuts.
21. Attach the engine wiring harness.
23. Install the engine front mount.
For additional information, refer to: Engine Front Mount (303-01B Engine
In-vehicle Repair).
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Front Mount
In-vehicle Repair
Special Tool(s)
Engine support bracket
303-021
Engine lifting eye
303-1067
Removal
All vehicles
3. NOTE: Install the oil filler cap and oil level indicator to prevent foreign
material entering the valve cover.
Remove the engine cover.
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4. Detach the wiring harness from the engine cover mounting bracket.
5. Detach the electrical connector from the engine cover mounting bracket.
6. Remove the engine cover mounting bracket.
Tighten to 23 Nm.
8. Using the special tool, support the engine and transmission assembly.
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Vehicles built up to VIN:E43868
9. Disconnect the fuel pump fuel supply and return lines.
Procedures).
Install blanking plugs to the fuel pump fuel supply and return line
male and female connectors.
10. Detach the power steering fluid hose from the fuel return line.
11. Remove the power steering fluid reservoir retaining nuts.
12. Detach the power steering fluid reservoir.
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13. Secure the power steering fluid reservoir to one side.
14. Remove the engine mount damper.
15. NOTE: Mark the position of the engine mount before removal.
Remove the engine mount and bracket assembly.
Vehicles built from VIN:E43869
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17. Disconnect the fuel pump fuel supply and return lines.
Procedures).
Install blanking plugs to the fuel pump fuel supply and return line
male and female connectors.
20. Detach the power steering reservoir away from the power steering
reservoir retaining bracket.
21. NOTE: Mark the position of the engine mount before removal.
Remove the engine mount and bracket assembly.
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Installation
1. NOTE: Clean the front engine mount mating faces.
Tighten to 80 Nm.
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4. NOTE: Clean the front engine mount mating faces.
Tighten to 80 Nm.
All vehicles
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Engine - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) - Puma - Flexplate
In-vehicle Repair
Removal
3. Remove the transmission.
For additional information, refer to: Transmission (307-01B Automatic
Transmission/Transaxle - Vehicles With: 6-Speed Automatic Transaxle -
AWF21, Removal).
4. CAUTION: Discard the bolts.
NOTE: Some variation in the illustrations may occur, but the essential
information is always correct.
Remove the flexplate.
Remove the 8 bolts.
Installation
1. CAUTION: Make sure that new bolts are installed.
Install the flexplate.
Stage 1: Tighten bolts in the sequence shown to 25 Nm.
Stage 2: Tighten bolts in the sequence shown to 40 Nm.
Stage 3: Tighten bolts in the sequence shown a further 48 degrees.
2. Install the transmission.
AWF21, Removal).
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Engine - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) - Puma - Flywheel
In-vehicle Repair
Removal
1. Remove the clutch disc and pressure plate. For additional information,
refer to: Clutch Disc and Pressure Plate (308-01 Clutch, Removal and
Installation).
Discard the bolts.
Installation
1. NOTE: Install new flywheel bolts.
Tighten the bolts in the sequence shown in three stages.
Stage 1: Tighten bolts 1 through 8 to 15 Nm.
Stage 4: Tighten bolts 1 through 8 to 45 degrees.
2. Install the clutch disc and pressure plate. For additional information,
refer to: Clutch Disc and Pressure Plate (308-01 Clutch, Removal and
Installation).
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Engine - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) - Puma - Intake
Manifold
In-vehicle Repair
Removal
1. Remove the air cleaner assembly.
4. Detach the exhaust gas recirculation (EGR) valve from the intake
manifold.
Remove and discard the EGR valve gasket.
5. Detach the engine wiring harness from the intake manifold.
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Installation
Tighten to 15 Nm.
2. NOTE: Install a new EGR valve gasket.
Tighten to 10 Nm.
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Engine - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) - Puma - Oil Pan
In-vehicle Repair
Removal
All vehicles
For additional information, refer to: Air Deflector - 2.2L Diesel/2.0L
Diesel (501-02 Front End Body Panels, Removal and Installation).
3. NOTE: Install a new drain plug seal.
Install the drain plug.
Tighten to 23 Nm.
Vehicles with 2.2L diesel engine
4. Remove the charge air cooler intake pipe retaining bolts.
Reposition the charge air cooler intake pipe for access.
All vehicles
5. Remove the oil pan retaining bolts.
6. CAUTIONS:
A new oil pan must be installed. Failure to follow this instruction
may cause damage to the vehicle.
Avoid damage to the oil pan mating face of the engine. Failure to
follow this instruction may cause damage to the vehicle.
NOTE: Lubricate the suitable tool with clean engine oil.
Using a suitable tool remove and discard the oil pan.
Insert the suitable tool between the oil pan and the engine, slide
the suitable tool in between the engine and oil pan.
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Installation
All vehicles
1. CAUTION: Avoid damage to the oil pan mating face of the cylinder
block. Failure to follow this instruction may cause damage to the vehicle.
Clean the cylinder block mating faces.
2. CAUTIONS:
A new oil pan must be installed. Failure to follow this instruction
may cause damage to the vehicle.
Install the oil pan within five minutes of applying the sealer. Failure
to follow this instruction may cause damage to the vehicle.
Apply a 3 mm bead of sealer WSE-M4G323-A4 to the oil pan.
3. NOTE: Do not fully tighten the oil pan retaining bolts at this stage.
4. Tighten the oil pan retaining bolts.
Tighten the bolts in the sequence shown in two stages.
5. Reposition the charge air cooler pipe.
Install the charge air cooler pipe retaining bolts.
Tighten to 35 Nm.
All vehicles
For additional information, refer to: Air Deflector - 2.2L Diesel/2.0L
Diesel (501-02 Front End Body Panels, Removal and Installation).
8. Fill the engine with engine oil.
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Engine - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) - Puma - Timing
Chain
In-vehicle Repair
Special Tool(s)
Timing Tool, Crankshaft
303-698 (21-251)
Removal
For additional information, refer to: Engine Front Cover (303-01B Engine
In-vehicle Repair).
3. Remove the crankshaft position (CKP) sensor.
For additional information, refer to: Crankshaft Position (CKP) Sensor
(303-14B Electronic Engine Controls - 2.0L Duratorq-TDCi/2.2L
4. CAUTION: Do not turn the crankshaft when the special tool is fully
located into the flywheel. Failure to follow this instruction will cause
damage to the CKP sensor hole.
NOTE: Make sure the crankshaft is only rotated in the normal direction of
rotation.
Turn the crankshaft to 50 degrees before top dead center (BTDC) and
insert the special tool through the CKP sensor hole.
5. Loosen the camshaft sprocket retaining bolts.
6. Loosen the fuel injection pump sprocket retaining bolts.
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7. Using suitable 6 mm bar, lock the timing drive sprockets.
8. Detension and lock the timing chain tensioner.
1. Retract the pawl.
2. Push the lock in.
3. Insert a pin.
9. NOTE: Engine removed for clarity.
Remove the timing chain tensioner and guides.
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10. Remove the timing chain.
Installation
1. CAUTION: Make sure the colored links align to the timing marks.
Install the timing chain.
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2. CAUTION: Make sure the timing chain tensioner is fully retracted
before installation. Failure to follow this instruction may result in damage
to the vehicle.
NOTE: Engine removed for clarity.
Install the timing chain tensioner and guides.
Tighten to 15 Nm.
3. NOTE: Make sure the timing chain tensioner is completely released.
Unlock the timing chain tensioner.
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6. Remove the suitable 6 mm bar.
7. Remove the special tool from the crankshaft position (CKP) sensor hole.
8. NOTE: Only turn the engine in the normal direction of rotation.
Using a suitable screwdriver, turn the engine clockwise two revolutions.
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9. Check the camshaft timing by inserting a suitable 6 mm bar through the
holes in the camshaft and fuel injection pump sprockets.
10. Check the timing by inserting the special tool in the CKP sensor hole.
11. Remove the special tool and the suitable 6 mm bar.
For additional information, refer to: Crankshaft Position (CKP) Sensor
(303-14B Electronic Engine Controls - 2.0L Duratorq-TDCi/2.2L
13. Install the air intake pipe.
14. Install the engine front cover.
For additional information, refer to: Engine Front Cover (303-01B Engine
In-vehicle Repair).
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Name
High pressure fuel supply line union
lubricant
TBD
Engine - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) - Puma - Valve
Cover
In-vehicle Repair
Special Tool(s)
Aligner, Fuel Injector
303-711 (21-258)
General Equipment
Pneumatic vacuum gun
Materials
Specification
TBD
Removal
WARNINGS:
Wait at least 15 minutes after the engine stops before commencing any repair to the high pressure fuel injection system.
Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related components. Highly
flammable mixtures are always present and may ignite. Failure to follow these instructions may result in personal injury.
This procedure involves fuel handling. Be prepared for fuel spillage at all times and always observe fuel handling precautions. Failure
to follow these instructions may result in personal injury.
Do not carry out any repairs to the fuel injection system with the engine running. The fuel pressure within the system can be as high
as 1600 bar. Failure to follow this instruction may result in personal injury.
CAUTIONS:
Make sure the workshop area in which the vehicle is being worked on is as clean and as dust free as possible. Foreign matter from
work on clutches, brakes or from machining or welding operations can contaminate the fuel system and may result in later malfunction.
Always carry out the cleaning process before carrying out any repairs to the fuel injection system components. Failure to follow this
instruction may result in foreign matter ingress to the fuel injection system.
Fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is therefore essential that absolute
cleanliness is observed when working with these components. Always install blanking plugs to any open orifices or lines.
Do not disassemble the fuel injectors or clean the nozzles, even with an ultrasonic cleaner. Always install new fuel injectors when
required.
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3. NOTE: Install the engine oil filler cap to prevent foreign material
entering the valve cover.
4. CAUTION: Protect the fuel injector electrical connectors with
lint-free material to prevent contamination from the cleaning fluid.
Clean the fuel injector, high-pressure fuel supply line and surrounding
areas.
For additional information, refer to: Fuel Injection Component Cleaning
(303-04B Fuel Charging and Controls - 2.0L Duratorq-TDCi/2.2L
5. CAUTIONS:
Make sure that the high-pressure fuel supply line remains in contact
with both the fuel injector and the fuel injection supply manifold until both
unions have been detached and cleaned. Failure to follow this instruction
may result in foreign matter ingress to the fuel injection system.
Make sure the tool used to loosen the high-pressure fuel supply line
unions is used at the top of the unions as this is where there is most
material. Failure to follow this instruction may result in damage to the
unions.
Make sure that the fuel injector does not move when loosening the
high-pressure fuel supply lines. Failure to follow this instruction will result
in damage to the fuel injector and the fuel injector sealing washer.
NOTE: One pipe shown other pipes are similar.
Loosen the high-pressure fuel supply line from the fuel injector and fuel
injection supply manifold.
6. CAUTION: Make sure that the high-pressure fuel supply line
remains in contact with both the fuel injector and the fuel injection supply
manifold until both unions have been detached and cleaned. Failure to
follow this instruction may result in foreign matter ingress to the fuel
injection system.
Using the pneumatic vacuum gun, vacuum foreign material from the
high-pressure fuel supply line, the fuel injector and the fuel injection
supply manifold.
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7. NOTE: One pipe shown other pipes are similar.
Remove and discard the high-pressure fuel supply line.
8. Using the pneumatic vacuum gun, vacuum foreign material from the fuel
injector and the fuel injection supply manifold.
9. Install blanking caps to the open threaded ports on the fuel injector and
the fuel injection supply manifold.
10. NOTE: One fuel return line shown other fuel return lines are similar.
Disconnect the fuel return line from the fuel injector.
Discard the fuel return line O-ring seal.
11. NOTE: One fuel injector electrical connector shown other fuel injector
electrical connectors are similar.
Disconnect the fuel injector electrical connector.
12. NOTE: One fuel injector shown other fuel injectors are similar.
Remove the valve cover fuel injector seal.
Discard the valve cover fuel injector seal.
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13. Disconnect the mass air flow (MAF) sensor electrical connector.
14. Detach the starter motor wiring harness.
15. Detach the cylinder head temperature (CHT) sensor electrical
connector.
16. Disconnect the CHT sensor electrical connector.
17. Disconnect the positive crankcase ventilation (PCV) hose from the
valve cover.
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18. Detach the starter motor and injector wiring harness.
Reposition and tie the wiring harness aside.
19. NOTE: Right-hand shown left-hand similar.
Detach the mass air flow (MAF) sensor wiring harness.
Reposition and tie the wiring harness aside.
20. Remove the fuel injection supply manifold retaining bolts.
21. Remove the fuel injection supply manifold support brackets.
22. Remove the sound proof padding.
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Remove and discard the valve cover gasket.
Installation
WARNINGS:
CAUTIONS:
Diesel fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is therefore essential that absolute
required.
NOTE: Install new high-pressure fuel supply lines.
NOTE: Install a new valve cover fuel injector seal.
NOTE: Install a new injector nut O-ring seal (if equipped).
NOTE: Install new fuel return line O-ring seals.
1. NOTE: Install a new valve cover gasket.
Install the valve cover.
Tighten to 10 Nm.
2. Install the sound proof padding.
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3. NOTE: Do not tighten the retaining bolts at this stage.
Install the fuel rail brackets.
Install the fuel injection supply manifold retaining bolts.
5. Loosen the fuel injection supply manifold retaining bolt.
6. NOTE: Remove the tie strap.
Attach the starter motor and injector wiring harness.
Attach the MAF sensor wiring harness.
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8. Connect the positive crankcase ventilation (PCV) hose to the valve
cover.
9. Connect the CHT sensor electrical connector.
10. Attach the (CHT) sensor electrical connector.
11. Attach the starter motor wiring harness.
12. Connect the MAF sensor electrical connector.
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13. NOTE: One fuel injector shown other fuel injectors are similar.
Install a new valve cover fuel injector seal.
14. Lubricate the high-pressure fuel supply line union threads with clean
lubricant.
15. CAUTION: Do not allow the unions to hit the olive ends of the
high-pressure fuel supply line as this may damage the ends of the line and
allow foreign matter to enter the fuel injection system.
NOTE: The yellow colored collar is fitted at the fuel injector end and the
blue colored collar is fitted at the fuel supply manifold end of the
high-pressure fuel supply line.
NOTE: To aid identification of the high-pressure fuel supply line, the
union at the fuel injector end is etched with the cylinder number.
Position the high-pressure fuel supply line as near to the final
installation position as possible and then remove and discard the
blanking plugs from the high-pressure fuel supply line.
16. Remove the blanking plug from the fuel injector and the fuel injection
supply manifold threaded port.
17. CAUTION: Maintain pressure on the high-pressure fuel supply line
to keep the olives in contact with the fuel injectors and the fuel injection
supply manifold cones while installing the unions.
NOTE: Install the high-pressure fuel supply lines to the fuel injection
supply manifold end first followed by the fuel injector end.
NOTE: Do not tighten the high-pressure fuel supply line unions at this
stage.
Install new high-pressure fuel supply lines.
18. NOTE: High pressure fuel supply lines shown removed for clarity.
Tighten the fuel injection supply manifold support brackets retaining
bolts.
Tighten to 14 Nm.
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Tighten the fuel injection supply manifold retaining bolts.
Tighten to 23 Nm.
Tighten the fuel injection supply manifold retaining bolt.
Tighten to 23 Nm.
21. CAUTIONS:
Make sure the special tool is clamped around the fuel injector which
is being tightened and is resting up against the adjacent fuel injector.
Make sure the tool used to tighten the high-pressure fuel supply line
unions is used at the top of the union as this is where there is most
union.
Make sure that the fuel injector does not move when tightening the
NOTE: One fuel injector shown other fuel injectors are similar.
Install the special tool and tighten the high-pressure fuel supply line
union at the fuel injector.
Tighten to 40 Nm.
23. CAUTION: Make sure the tool used to tighten the high-pressure
fuel supply line unions is used at the top of the union as this is where
there is most material. Failure to follow this instruction may result in
damage to the union.
Tighten the high-pressure fuel supply line union at the fuel injection
supply manifold.
Tighten to 40 Nm.
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24. Connect the fuel injector electrical connectors.
25. Connect the fuel return lines to the fuel injectors.
26. Install the engine cover.
27. Install the oil filler cap.
28. Install the oil level indicator.
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Engine2.0L Duratorq-TDCi
Removal
Special Tool(s)
Remover/Installer, Cooling Hose Clamp
303-397 (24-003)
Ball joint splitter
204-192
Wheel hub puller
205-491
Adaptor nuts
205-491-01
Forcing screw
204-269
Slide hammer
100-012
Slide hammer shaft
100-012-02
204-226
HTJ1200-02
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Engine lifting eye
303-1067
418-535
Removal
1. Detach the lower steering column shaft.
3. Recover the air conditioning refrigerant.
5. Remove the exhaust flexible pipe.
For additional information, refer to: Exhaust Flexible Pipe - 2.0L
Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) - Puma (309-00
Exhaust System, Removal and Installation).
6. Disconnect the heater hoses from the heater core.
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7. Disconnect the radiator lower coolant hose.
engine and transmission assembly are removed, install the vehicle
tie-down straps. Failure to follow this instruction may result in damage to
the vehicle.
Install the front vehicle tie down straps.
the vehicle.
Install the rear vehicle tie down straps.
10. Lower the vehicle to a suitable working height.
12. Remove the front brake pads.
For additional information, refer to: Brake Pads (206-03 Front Disc
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Detach the brake caliper and brake caliper anchor plate assembly.
16. CAUTION: Support the brake caliper assembly using tie straps.
Reposition and attach the brake caliper assembly.
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19. CAUTION: Secure the ABS wheel speed sensor using tie straps.
Reposition and attach the ABS wheel speed sensor.
NOTE: Cap the exposed ports.
Disconnect the suction accumulator pipe.
21. Disconnect the air temperature sensor electrical connector.
22. Disconnect the high intensity discharge (H.I.D) sensor drop arm.
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1. Press the retaining clip.
25. Remove the front bumper splitter vain.
Remove the front bumper splitter vain finisher trims.
Disconnect the power assisted steering hose.
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29. Disconnect the brake vacuum pump vacuum hose.
30. Disconnect the exhaust gas recirculation (E.G.R) valve module vacuum
hose.
31. Disconnect the expansion tank vent hose.
32. Detach the cooling system hose.
33. Disconnect the expansion tank outlet hose.
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34. NOTE: The retaining bolt remains captive in the electrical connector.
Disconnect the engine harness electrical connector.
35. Disconnect the glow plug harness electrical connector.
36. Disconnect the battery cables.
37. Detach the wiring harness from the battery tray mount.
38. Disconnect the charge air cooler hose.
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39. CAUTION: If fluid is spilt on the paintwork, the affected area
must be immediately washed down with cold water. Failure to follow this
NOTE: Secure the clutch slave cylinder pipe using tie strap.
Disconnect the clutch slave cylinder pipe and secure to one side.
1. Detach the clutch slave cylinder pipe from the slave cylinder.
2. Disconnect the clutch slave cylinder pipe and secure to one
side.
40. Disconnect the radiator upper coolant hose.
42. Remove the exhaust manifold to E.G.R valve tube.
For additional information, refer to: Exhaust Gas Recirculation (EGR)
Cooler to EGR Valve Tube (303-08 Engine Emission Control - 2.0L
Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) - Puma, Removal and
Installation).
43. NOTE: Place suitable absorbent material below the fluid reservoir to
absorb fluid spillage.
www.JagDocs.com
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44. Detach the power assisted steering hose.
45. NOTE: Cap the exposed ports.
46. NOTE: Cap the exposed ports.
Disconnect the E.G.R valve vacuum pipe.
47. Loosen the air conditioning compressor line retaining bolt.
48. NOTE: Remove and discard the O-ring seals.
Disconnect the air conditioning compressor lines.
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49. Disconnect the fuel lines.
Procedures).
Install blanking plugs to the fuel pump fuel supply and fuel return
50. Disconnect the engine wiring harness electrical connector.
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53. NOTE: Bolt remains captive in the engine control module (ECM)
Using the special tool, disconnect the ECM harness electrical connector.
55. Detach the engine wiring harness earth lead.
58. CAUTION: Do not support the engine and transaxle assembly
directly on the oil pan.
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62. Remove the engine rear mount retaining nut.
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63. NOTE: Discard the retaining nuts.
Remove the engine front mount retaining nuts.
Remove the engine, suspension and transmission assembly.
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directly on the oil pan. Failure to follow this instruction may cause damage
to the component.
Place the engine, suspension and transmission assembly to a suitable
working area.
70. Detach the electrical connector.
71. Remove the engine cover rear mount bracket.
72. Install the engine rear lifting eye.
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Remove and discard the wheel hub nuts.
74. CAUTION: When the tie-rod end is separated from the wheel hub
assembly, the ball joint seal should be protected to prevent damage.
Remove and discard the tie rod-end retaining nuts.
Using the special tools, detach the drive halfshaft.
Remove the anti-roll bar link retaining nut.
Remove the wheel knuckle and strut.
1. Remove and discard the lower arm ball joint retaining nut and
bolt.
2. Reposition the lower arms.
3. Remove the wheel knuckle and strut.
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78. Using the special tools, remove the drive halfshaft.
79. Remove and discard the drive halfshaft snap ring.
80. Remove the drive halfshaft.
81. NOTE: Discard the O-ring seals.
Disconnect the power steering lines.
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to the component.
Using a suitable hydraulic lift, remove the engine and transmission from
the subframe and place to a suitable working area.
85. Remove the charge air cooler pipe retaining nut.
86. Detach the reverse lamp switch wiring harness retaining clip.
87. Remove the charge air cooler pipe.
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88. Disconnect the reverse lamp switch electrical connector.
89. Remove the vacuum regulator solenoid valve.
2. Detach the vacuum hoses.
3. Remove the vacuum regulator solenoid valve.
91. Remove the starter motor wiring harness retaining bracket.
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92. Disconnect the starter motor wiring harness electrical connector.
1. Disconnect the starter motor electrical connector.
2. Disconnect the starter motor solenoid electrical connector.
95. Disconnect the crankshaft sensor electrical connector.
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96. Remove the transmission upper retaining bolts.
97. Remove the transmission right-hand retaining bolts.
to the component.
Remove the engine assembly from the transmission assembly.
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Engine2.2L Duratorq-TDCi (110kW/150PS) - Puma
Removal
Special Tool(s)
303-397 (24-003)
Ball joint splitter
204-192
Wheel hub puller
205-491
Adaptor nuts
205-491-01
Forcing screw
204-269
HTJ1200-02
Engine lifting eye
303-1067
418-535
Removal
All vehicles
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4. Recover the air conditioning refrigerant.
Vehicles without auxiliary heating
7. Disconnect the heater hoses from the heater core.
Vehicles with electric booster heater
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8. Detach the electric booster heater electrical connector from the
subframe retaining tang.
9. Detach the coolant hoses from the retaining clips.
Disconnect the coolant hose.
Vehicles with fuel fired booster heater
11. Disconnect the fuel fired booster heater electrical connector from the
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13. Disconnect the coolant hose.
All vehicles
the vehicle.
Install the front vehicle tie down straps.
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the vehicle.
Install the rear vehicle tie down straps.
18. Remove the front brake pads.
Detach the brake caliper and brake caliper anchor plate assembly.
Remove the wheel arch liner access cover.
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23. CAUTION: Support the brake caliper assembly using tie straps.
Reposition and attach the brake caliper assembly.
26. CAUTION: Secure the ABS wheel speed sensor using tie straps.
Reposition and attach the ABS wheel speed sensor.
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Disconnect the suction accumulator pipe.
28. Disconnect the air temperature sensor electrical connector.
30. Detach the charge air cooler outlet hose from the charge air cooler.
31. Detach the battery breather hose.
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NOTE: Use care when repositioning power assisted steering hose.
Remove the power assisted steering hose retaining clip.
Reposition the power assisted hose through the radiator side seal.
34. Disconnect the brake vacuum pump vacuum hose.
35. Disconnect the exhaust gas recirculation (EGR) valve module vacuum
hose.
36. Disconnect the expansion tank vent hose.
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37. Detach the cooling system hose.
38. Disconnect the expansion tank outlet hose.
39. NOTE: The retaining bolt remains captive in the electrical connector.
Disconnect the engine harness electrical connector.
40. Disconnect the glow plug harness electrical connector.
41. Disconnect the battery cables.
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42. Detach the wiring harness from the battery tray mount.
43. CAUTION: If fluid is spilt on the paintwork, the affected area
must be immediately washed down with cold water. Failure to follow this
NOTE: Secure the clutch slave cylinder hose using a tie strap.
Detach the clutch slave cylinder hose from the clutch slave cylinder pipe.
Release the clutch slave cylinder hose retaining clip.
Disconnect the clutch slave cylinder hose and secure to one side.
44. Disconnect the radiator upper coolant hose.
46. NOTE: Place suitable absorbent material below the fluid reservoir to
absorb fluid spillage.
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47. Loosen the air conditioning (A/C) compressor line retaining bolt.
48. NOTE: Remove and discard the O-ring seals.
Disconnect the A/C compressor lines.
Procedures).
Install blanking plugs to the fuel pump fuel supply and fuel return
51. Remove the engine wiring harness trim panel.
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53. NOTE: Bolt remains captive in the engine control module (ECM)
Using the special tool, disconnect the ECM harness electrical connector.
55. Detach the engine wiring harness earth lead.
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directly on the oil pan.
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64. Remove the engine rear mount retaining nut.
65. NOTE: Discard the retaining nuts.
Remove the engine front mount retaining nuts.
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69. Lower the engine, suspension and transmission assembly to gain
access to the A/C pipe.
70. NOTE: Secure the A/C pipe using tie straps.
Reposition the AC pipe clear of the engine, suspension and transmission
assembly.
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71. Remove the engine, suspension and transmission assembly.
to the component.
Place the engine, suspension and transmission assembly to a suitable
working area.
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76. Install the engine rear lifting eye.
77. Remove and discard the right-hand wheel hub nut.
78. CAUTION: When the tie-rod end is separated from the wheel hub
assembly, the ball joint seal should be protected to prevent damage.
Remove and discard the right-hand tie rod-end retaining nut.
79. Using the special tools, detach the right-hand drive halfshaft.
80. Remove the right-hand anti-roll bar link retaining nut.
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81. Remove the right-hand wheel knuckle and strut.
1. Remove and discard the lower arm ball joint retaining nut and
bolt.
2. Reposition the lower arms.
3. Remove the wheel knuckle and strut.
82. Remove the right-hand drive halfshaft.
83. Remove and discard the drive halfshaft snap ring.
84. NOTE: Discard the O-ring seals.
Disconnect the power steering lines.
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to the component.
Using a suitable hydraulic lift, raise the engine and transmission from
the subframe.
89. Remove the charge air cooler pipe retaining bolt.
90. Remove the charge air cooler pipe.
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92. Disconnect the emission control solenoid electrical connector.
93. Disconnect the emission control solenoid hose.
94. Remove the emission control solenoid assembly.
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96. Remove the starter motor wiring harness retaining bracket.
97. Disconnect the starter motor wiring harness electrical connector.
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101. Remove the transmission upper retaining bolts.
102. Remove the transmission right-hand retaining bolts.
to the component.
Remove the engine assembly from the transmission assembly.
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Disassembly
Special Tool(s)
Engine stand
303-011
Universal Flange Holding Wrench
205-053
Adapter for 205-053-02
205-053-02
303-698
Remover, Fuel Injector
303-711
303-397
Disassembly
All vehicles
1. Using the special tool, mount the engine to the engine stand.
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2. Detach the glow plug wiring harness.
Remove the glow plug wiring harness securing nut.
3. Detach the wiring harness from the intake manifold.
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4. Detach the wiring harness from the air conditioning (AC) compressor.
5. Disconnect the AC compressor electrical connector.
6. Detach the wiring harness from the retaining stud.
7. Detach the mass air flow (MAF) sensor wiring harness.
8. Detach the generator wiring harness electrical connector.
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9. Remove the wiring harness.
1. Reposition the accessory drive belt tensioner.
12. Remove the AC compressor.
13. Detach the generator electrical connector.
Remove the generator electrical connector securing nut.
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Remove the wiring harness support bracket from the generator
upper retaining bolt.
16. Remove the accessory drive belt tensioner bracket.
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18. Remove the turbo outlet pipe retaining bolt.
19. Remove the turbo outlet pipe and charge air cooler intake pipe
assembly.
All vehicles
20. Remove the turbocharger heat shield.
21. Remove the catalytic converter retaining bolts.
Remove the catalytic converter securing bracket.
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22. Remove the catalytic converter.
23. Remove the catalytic converter retaining bracket.
24. Remove the halfshaft retaining bracket.
25. Remove the exhaust gas recirculation (EGR) cooler coolant hose.
26. Using the special tool, remove the water pump hoses.
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27. Disconnect the turbocharger vacuum hose.
28. Remove the air filter outlet tube retaining clip.
29. Remove the air filter outlet tube.
30. Remove the power assisted steering high-pressure pipe.
Discard the O-ring seal.
31. Disconnect the coolant hose.
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34. Remove the starter motor to generator wiring harness.
36. Remove the glow plug wire retaining nuts.
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37. Remove the glow plug wiring harness.
38. Remove the glow plugs.
39. Remove the oil level indicator and tube.
40. Remove the brake vacuum pump retaining bolts.
Remove the power steering pump belt cover.
41. Remove the power steering pump belt.
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42. Remove the power assisted steering pump bracket retaining bolts.
43. Disconnect the coolant hose from the water pump.
44. Remove the water pump and power assisted steering pump assembly.
45. Disconnect the oil pressure switch electrical connector.
46. Remove the oil filter housing.
Remove and discard the oil filter.
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47. Disconnect the knock sensor (KS) electrical connector.
49. NOTE: Protect the fuel metering valve and fuel temperature sensor
electrical connectors with lint free cloth to prevent contamination from the
cleaning fluid.
Disconnect the fuel metering valve and fuel temperature sensor
electrical connectors.
50. CAUTION: Loosen the clutch pressure plate retaining bolts by
two turns at a time in the sequence shown.
Remove the clutch disc and pressure plate.
Remove and discard the retaining bolts.
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53. Remove the engine front mount bracket.
54. Disconnect the oil supply tube from the turbocharger.
Remove and discard the sealing washers.
55. Detach the oil supply tube.
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56. Remove the oil supply tube.
57. Disconnect the oil return tube from the turbocharger.
58. Remove the oil return tube.
59. Remove the EGR cooler mount bracket retaining bolt.
60. Remove the EGR cooler mount bracket.
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Remove and discard the retaining bolts and nuts.
62. Detach the cylinder head temperature (CHT) sensor electrical
connector.
64. Disconnect the camshaft position (CMP) sensor electrical connector.
65. CAUTIONS:
unions.
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NOTE: Injector number 4 shown, injector numbers 1, 2 and 3 similar.
injection system.
supply manifold.
67. NOTE: Injector number 4 shown, injector numbers 1, 2 and 3 similar.
Remove and discard the high-pressure fuel supply line.
68. Using the pneumatic vacuum gun, vacuum foreign material from the
fuel injector and the fuel injection supply manifold.
69. Install blanking caps to the open threaded ports on the fuel injector
and the fuel injection supply manifold.
Disconnect the fuel return lines from the fuel injectors.
Discard the fuel return line O-ring seals.
Disconnect the fuel injector electrical connector.
Remove the valve cover fuel injector seal.
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73. CAUTION: Make sure that the fuel injector does not move when
loosening the fuel injector locking collar. Failure to follow this instruction
will result in damage to the fuel injector and the fuel injector sealing
washer.
NOTE: Injector number 4 shown, injector numbers 1, 2 and 3 similar.
Using the special tool, remove the fuel injector.
74. Detach the starter motor and injector wiring harness.
75. Remove the wiring harness.
Disconnect the fuel pressure sensor electrical connector.
76. CAUTION: Make sure that the high pressure fuel supply line
remains in contact with both the fuel pump and the fuel injection supply
injection system.
Using the pneumatic vacuum gun, vacuum foreign material from the high
pressure fuel supply line and the fuel pump.
77. Disconnect the fuel injector to fuel pump fuel return line and detach
the line from the retaining clip.
Install blanking plugs to the fuel injector to fuel pump fuel return
78. Clean the fuel injectors and high pressure fuel supply lines and
surrounding areas.
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injection system.
supply manifold.
80. CAUTIONS:
union is used at the top of the union as this is where there is most
union.
Maintain pressure on the high-pressure fuel supply line to keep the
olive in contact with the fuel pump cone while unscrewing the union.
Failure to follow this instruction may result in foreign matter ingress to the
Loosen the high-pressure fuel supply line at the fuel pump.
81. Remove the fuel pump to fuel injection supply manifold high pressure
pipe retaining bracket.
82. CAUTIONS:
union.
olive in contact with the fuel injection supply manifold cone while
unscrewing the union. Failure to follow this instruction may result in
foreign matter ingress to the fuel injection system.
While maintaining the pressure on the high-pressure fuel supply
line, clean and vacuum foreign material from the line and union.
Loosen the high-pressure fuel supply line at the fuel injection supply
manifold.
83. Remove and discard the high pressure fuel supply line.
84. Install blanking caps to the open threaded ports on the fuel pump and
85. Clean the fuel injection supply manifold and surrounding areas.
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87. Loosen the fuel injection supply manifold support brackets.
88. Remove the sound proof padding.
89. Remove the fuel injection supply manifold.
Remove and discard the valve cover gasket.
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91. Using the special tools, remove the crankshaft damper.
92. Remove and discard the engine front cover.
Remove the engine front cover retaining nuts and bolts.
93. Turn the crankshaft to 50 degrees before top dead center (BTDC) and
insert the special tool 303-698, through the crankshaft position (CKP)
sensor hole.
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95. Loosen the camshaft sprocket retaining bolts.
96. Loosen the fuel injection pump sprocket retaining bolts.
97. Using a suitable tool, retain the timing chain tensioner piston.
1. Retract the pawl.
2. Push the lock in.
3. Insert a pin.
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98. Remove the timing chain tensioner and guides.
99. Remove the timing chain.
100. Remove the high-pressure fuel pump retaining bolts.
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101. Remove the timing chain oil feed pipe.
102. Remove the high-pressure fuel pump.
2. Remove the high-pressure fuel pump.
103. Remove the KS.
104. Remove the rocker shafts.
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105. CAUTION: Remove the camshaft carrier bolts in the sequence
shown.
Remove the camshaft carrier.
Remove and discard the intake camshaft rear oil seal.
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107. CAUTION: Remove the cylinder head bolts in the sequence
shown.
Remove the cylinder head.
Remove and discard the cylinder head gasket and the bolts.
109. Remove the CKP sensor bracket.
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110. NOTE: Do not discard the crankshaft rear oil seal carrier.
Remove the crankshaft rear oil seal carrier.
111. Remove and discard the oil pan.
Remove the oil pan retaining nuts and bolts.
112. Remove the oil pump pickup tube.
Remove the chain from the crankshaft sprocket.
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114. CAUTION: Remove the ladder frame bolts in the sequence
shown.
Remove the ladder frame.
Remove and discard the ladder frame gasket.
115. NOTE: One piston oil cooler jet shown, other piston oil cooler jets
similar.
Remove the piston oil cooler jets.
116. CAUTION: Keep the connecting rod bearing caps in order for
installation.
Remove the connecting rod bearing caps.
117. CAUTION: Match the piston and connecting rods to the
connecting rod caps.
Remove the pistons.
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118. CAUTION: Keep the crankshaft main bearing caps in order for
installation.
Remove the crankshaft main bearing caps.
119. Remove the crankshaft.
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Assembly
Special Tool(s)
Piston ring compressor
303-372
Universal Flange Holding Wrench
205-053
Adapter for 205-053
205-053-02
Bedplate alignment plate
303-1095
Remover/Installer Crankshaft Front Oil Seal
303-679
Aligner, Engine Front Cover
303-682
303-698
303-711
Oil seal installer
308-417
Pointer, top dead center (TDC)
303-1094
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303-397
Engine stand
303-011
Assembly
All vehicles
WARNINGS:
CAUTIONS:
Do not disassemble or clean inside the fuel injection supply manifold, even with an ultrasonic cleaner. Always install a new fuel
injection supply manifold and fuel lines when required.
1. Clean the mating faces of the cylinder head and cylinder block with
suitable metal surface cleaner.
2. NOTE: Lubricate the crankshaft main bearing shells with clean engine
oil.
Install the crankshaft main bearing shells.
3. NOTE: Lubricate the crankshaft and the crankshaft main bearing shells
with clean engine oil.
Install the crankshaft.
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4. CAUTIONS:
Assemble caps with arrows pointing forward. Caps are identified
from front to rear, F, 2, 3, 4, R.
Crankshaft main bearing cap bolts must only be used four times.
Tighten the bolts in three stages in the sequence shown.
NOTE: Lubricate the crankshaft and the crankshaft main bearing shells
with clean engine oil.
NOTE: Stamp the bolt heads with a center punch to indicate usage.
Install the crankshaft main bearing caps.
Stage 1: 45 Nm.
Stage 2: 80 Nm.
5. Lubricate the cylinder bores and pistons with clean engine oil.
6. CAUTION: Make sure the connecting rod does not damage the
crankshaft big end bearing surface.
NOTE: The piston ring gaps must be distributed evenly around the
circumference of the piston. This also applies to the oil control ring
elements. Align the piston ring gaps at 120 degrees to each other.
NOTE: The arrow on the piston must point to the front to the engine.
Using the special tool 303-372, install the pistons.
7. Lubricate the connecting rod bearing shells with clean engine oil.
8. CAUTIONS:
Connecting rod bearing cap bolts must only be used four times.
Make sure that the fracture split connecting rod bearing cap is
installed correctly.
NOTE: Stamp the bolt heads with a center punch to indicate usage.
NOTE: The identification marks on the big-end bearing caps must point
to the front of the engine.
Install the connecting rod bearing caps.
Tighten the bolts in two stages.
Stage 1: 30 Nm.
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9. Install the piston oil cooler jets.
10. CAUTION: Do not trim or damage protruding foam pads.
NOTE: Install new ladder frame gaskets.
NOTE: Do not fully tighten the ladder frame retaining nuts and bolts at
this stage.
Install the ladder frame.
11. CAUTION: The ladder frame and the cylinder block must be
aligned so that the side clearance does not exceed 0.05 mm overlap to
0.05 mm gap.
Using the special tool 303-1095 align the ladder frame to the cylinder
block.
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12. Install the old crankshaft rear seal and carrier.
13. CAUTION: The ladder frame and the cylinder block must be
aligned so that the rear clearance does not exceed 0.01 mm overlap to 0.2
mm gap.
Using a suitable straight edge, align the ladder frame to the cylinder
block.
14. NOTE: Tighten the nuts and bolts in the sequence shown.
Tighten the ladder frame nuts and bolts.
Tighten to 23 Nm.
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15. Remove the old crankshaft rear seal and carrier.
Remove and discard the crankshaft rear oil seal.
16. NOTE: Install a new crankshaft rear oil seal carrier and crankshaft rear
oil seal carrier retaining bolts.
NOTE: A new crankshaft rear oil seal carrier is supplied with an
alignment sleeve that must be removed following installation.
NOTE: Tighten the nuts and bolts in the sequence shown.
Install the crankshaft rear oil seal carrier.
Tighten to 10 Nm.
18. NOTE: Do not fully tighten the oil pump retaining bolts at this stage.
Install the oil pump and oil pump chain.
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19. Using a suitable dial indicator gauge take a reference measurement
from the front face of the crankshaft sprocket.
1. Position the dial gauge holding fixture on the cylinder block.
2. Position the dial indicator gauge plunger on the crankshaft
sprocket and set the dial to zero.
20. NOTE: Take measurements at two different points on the oil pump
sprocket.
Using the dial indicator gauge align the oil pump sprocket and tighten
the oil pump retaining bolts.
21. Check the alignment of the oil pump sprocket with the crankshaft
sprocket. Repeat the alignment procedure if necessary.
23. Check the alignment of the oil pump sprocket with the crankshaft
sprocket. Repeat the alignment procedure if necessary.
24. Install the oil pump tensioner.
Install the oil pump pickup tube.
Tighten to 10 Nm.
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26. CAUTIONS:
A new oil pan must be installed
Install the oil pan within five minutes of applying the sealer.
Apply a 3 mm bead of sealer WSE-M4G323-A4 to the oil pan.
27. NOTE: Do not fully tighten the oil pan retaining bolts at this stage.
28. NOTE: Tighten the bolts in the sequence shown in two stages.
Tighten the oil pan retaining bolts in the sequence shown.
29. NOTE: Install new flywheel retaining bolts.
NOTE: Tighten the retaining bolts in the sequence shown in three
stages.
Stage 1: 25 Nm.
Stage 2: 40 Nm.
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30. NOTE: Tighten the retaining bolts in the sequence shown.
Install the clutch disc and pressure plate.
Tighten to 29 Nm.
31. NOTE: Do not fully tighten the crankshaft position sensor bracket
retaining bolts at this stage.
Install the crankshaft position (CKP) sensor bracket.
32. NOTE: After installation do not move the special tool.
33. Rotate the crankshaft until piston number one is approximately 10 mm
before top dead center (TDC).
34. Zero the dial indicator gauge.
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35. Mark the position on the flywheel primary mass.
36. NOTE: Rotate the crankshaft counterclockwise.
Rotate the crankshaft until the piston number one achieves zero on the
dial indicator gauge.
Mark the position on the flywheel primary mass.
37. Repeat the previous steps to make sure that the marking is correct.
38. NOTE: The middle of the markings is TDC.
Measure the distance between the two marks.
39. Divide the amount by two and mark the TDC position on the flywheel
primary mass.
40. Measure the circumference of the flywheel primary mass.
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41. NOTE: Mark the calculated amount on the flywheel primary mass by
measuring from TDC counterclockwise.
Multiply the circumference by 0.1388.
1. First mark.
2. Second mark.
3. Determined TDC.
4. Determined 50 degrees before top dead center (BTDC).
42. NOTE: Rotate the crankshaft in the normal direction of rotation to the
mark of the calculated 50 degrees BTDC.
Install the special tool 303-698.
43. Tighten the CKP sensor bracket retaining bolts.
Tighten to 23 Nm.
44. Clean the cylinder block mating face and the piston.
45. NOTE: Measure the piston protrusion of each cylinder at top dead
center (TDC).
Measure the distance between the piston crown and the cylinder block at
the points indicated.
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46. NOTE: The largest measurement determines the choice of the cylinder
head gasket.
Using a suitable tool, measure the piston protrusion.
47. Determine the cylinder head gasket thickness.
For additional information, refer to: Specifications (303-01B Engine -
Specifications).
48. CAUTION: The thickness of the new cylinder head gasket
depends on the piston protrusion (hole/tooth marked).
Install a new cylinder head gasket.
49. CAUTION: Install new cylinder head bolts.
Install the cylinder head.
Tighten the bolts in the sequence shown in six stages.
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50. Apply a 2.5 mm diameter bead of sealer WSE-M4G323-A4 to the
mating face of the cylinder head.
Remove and discard the intake camshaft rear oil seal.
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52. NOTE: Tighten the bolts in the sequence shown in two stages.
Install the camshaft carrier.
53. Using special tool 308-417, install a new camshaft rear seal.
54. NOTE: Do not fully tighten at this stage.
Install the camshaft sprocket retaining bolts.
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55. NOTE: Install new rocker shaft retaining bolts.
NOTE: Lubricate the rocker shafts with clean engine oil.
NOTE: The oil supply holes in the rocker shafts must point down.
NOTE: Tighten the bolts in two stages.
Install the rocker shafts.
Stage 1: 13 Nm.
56. Install the knock sensor (KS).
Tighten to 20 Nm.
57. Install the high-pressure fuel pump.
1. Install the high-pressure fuel pump.
2. Tighten to 33 Nm..
58. Install the timing chain oil feed pipe.
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59. Install the high-pressure fuel pump retaining bolts.
Tighten to 22 Nm.
60. CAUTIONS:
Do not tighten the high-pressure fuel supply line union at this
stage.
olive in contact with the fuel pump cone while hand installing the union.
Install a new high-pressure fuel supply line to the fuel pump.
61. NOTE: Do not tighten the retaining nut at this stage.
Install the high-pressure fuel pump pipe retaining bracket.
Install the fuel injection pump sprocket.
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64. CAUTION: Make sure the colored links align to the timing marks.
Install the timing chain.
65. CAUTION: Make sure the timing chain tensioner is fully retracted
before installation. Failure to follow this instruction may result in damage
to the vehicle.
Install the timing chain tensioner and guides.
Tighten to 14 Nm.
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66. Unlock the timing chain tensioner.
69. Remove the locking pins from the timing drive sprockets.
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70. Remove the special tool 303-698.
71. Rotate the crankshaft two revolutions.
72. Using special tool 303-698, check the timing by inserting the special
tool in the CKP sensor hole.
73. Check the camshaft timing by inserting a suitable 6 mm bar through
the holes in the camshaft and fuel injection pump sprockets.
74. Remove the locking pins from the timing drive sprockets.
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77. CAUTION: Install the engine front cover within five minutes of
applying the sealer.
NOTE: Install a new engine front cover.
Apply a 3 mm diameter bead of sealer WSE-M4G323-A4 to the engine
front cover.
78. Using the special tool 303-682, install the engine front cover.
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79. Install the front cover retaining nuts and bolts.
Tighten the bolts to 14 Nm.
Tighten the nuts to 10 Nm.
80. Remove special tool.
81. NOTE: Install a new crankshaft front oil seal.
NOTE: A new crankshaft front oil seal is supplied with an alignment
sleeve that will be pushed out during installation.
Using the special tool 303-679, install the crankshaft front seal.
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82. NOTE: New crankshaft pulley bolts must be installed.
Using the special tools 205-053 and 205-053-02, install the crankshaft
damper.
Stage 1: 45 Nm.
83. NOTE: Install a new valve cover gasket.
Install the valve cover.
Tighten to 10 Nm.
84. NOTE: One valve cover fuel injector seal shown, other valve cover fuel
injector seals similar.
Install new valve cover fuel injector seals.
85. NOTE: Do not fully tighten the fuel injection supply manifold retaining
bolt at this stage.
Install the fuel injection supply manifold.
86. Connector the fuel pressure sensor electrical connector.
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87. Attach the starter motor and injector wiring harness.
88. Install the sound proof padding.
89. NOTE: Do not fully tighten the fuel injection supply manifold support
bracket bolts at this stage.
Install the fuel injection supply manifold support brackets.
90. NOTE: Do not fully tighten the fuel injection supply manifold retaining
bolts at this stage.
91. Using a suitable multipurpose lubricant spray, lubricate the new
high-pressure fuel supply line union threads.
high pressure fuel supply line as this may damage the ends of the line and
NOTE: The yellow colored collar is fitted at the fuel pump end and the
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blue colored collar is fitted at the fuel injection supply manifold end of the
high pressure fuel supply line.
NOTE: To aid identification of the high pressure fuel supply lines, the
union at the fuel pump end is etched with the word Pump.
93. Remove the blanking plugs from the fuel injection supply manifold
threaded ports.
94. CAUTIONS:
stage.
olive in contact with the fuel injection supply manifold cone while hand
installing the union. Failure to follow this instruction may result in foreign
matter ingress to the fuel injection system.
Attach the high-pressure fuel supply line to the fuel injection supply
manifold.
95. Using a suitable multipurpose lubricant spray, lubricate the new
97. Remove the blanking plugs from the fuel injector and the fuel injection
supply manifold threaded ports.
supply manifold cones while hand installing the unions.
stage.
Install new high-pressure fuel supply lines.
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99. NOTE: High-pressure fuel supply lines shown removed for clarity.
Tighten the fuel injection supply manifold support brackets.
Tighten to 14 Nm.
Tighten to 23 Nm.
Tighten to 23 Nm.
102. CAUTIONS:
union.
Install the special tool and tighten the high pressure fuel supply line
Tighten to 40 Nm.
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supply manifold.
Tighten to 40 Nm.
105. Repeat steps 97, 98 and 99 for tightening the three remaining
high-pressure fuel supply line unions.
106. NOTE: Cylinders three and four fuel injectors shown, cylinders one
and two fuel injectors similar.
NOTE: Install new O-ring seals.
Install the wiring harness.
Connect the fuel injector electrical connectors.
107. NOTE: Cylinders three and four fuel injectors shown, cylinders one
and two fuel injectors similar.
Connect the fuel return lines to the fuel injectors.
108. Tighten the high pressure fuel supply line union at the fuel injection
supply manifold.
Tighten to 40 Nm.
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109. CAUTION: Make sure the tool used to tighten the high pressure
fuel supply line union is used at the top of the union as this is where
Tighten the high pressure fuel supply line union at the fuel injection
supply manifold.
Tighten to 40 Nm.
111. NOTE: Remove the blanking plugs from the fuel injector to fuel pump
fuel return line male and female connectors.
Connect the fuel injector to fuel pump fuel return line and attach the
line to the retaining clip.
112. Connect the fuel metering valve and fuel temperature sensor
113. Attach the mass air flow (MAF) sensor wiring harness.
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114. Connect the camshaft position (CMP) sensor electrical connector.
115. Connect the cylinder head temperature (CHT) sensor electrical
connector.
116. Attach the CHT sensor electrical connector.
Tighten to 40 Nm.
118. Install the exhaust gas recirculation (EGR) cooler mount bracket.
Tighten to 10 Nm.
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119. Install the EGR cooler mount bracket retaining bolt.
Tighten to 10 Nm.
Install the oil return tube.
Tighten to 10 Nm.
121. NOTE: Install a new gasket.
Connect the oil return tube to the turbocharger.
Tighten to 10 Nm.
122. Install the oil supply tube.
Tighten to 14 Nm.
123. Attach the oil supply tube.
Tighten to 23 Nm.
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124. NOTE: Install new sealing washers.
Connect the oil supply tube to the turbocharger.
Tighten to 14 Nm.
125. Install the engine front mount bracket.
Tighten to 80 Nm.
Tighten to 43 Nm.
Install the oil filter housing.
Tighten to 22 Nm.
128. Connect the oil pressure switch electrical connector.
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129. NOTE: Install a new water pump gasket.
Install the water pump and power assisted steering pump assembly.
Tighten to 22 Nm.
130. Connect the coolant hose to the water pump.
131. Install the power assisted steering pump bracket retaining bolts.
Tighten to 22 Nm.
132. Install the power assisted steering pump belt.
Rotate the tensioner clockwise.
133. Install the brake vacuum pump retaining bolts.
Tighten to 10 Nm.
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134. Install the oil level indicator and tube.
135. Install the glow plugs.
Tighten to 13 Nm.
136. Install the glow plug wire.
Tighten to 2 Nm.
137. NOTE: Install new manifold gaskets.
Tighten to 15 Nm.
138. Install the starter motor to generator wiring harness.
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139. Install the coolant hoses.
140. Install the air filter outlet tube.
141. NOTE: Install a new air filter outlet tube retaining clip.
Install the air filter outlet tube.
142. Connect the turbocharger vacuum hose.
143. Connect the coolant hoses.
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144. Connect the coolant hose.
145. NOTE: Install a new power assisted steering high-pressure O-ring
seal.
Install the power assisted steering high pressure pipe.
146. Using the special tool, install the water pump hoses.
147. Install the EGR cooler coolant hose.
148. Install the halfshaft bracket.
Tighten to 25 Nm.
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149. Install the catalytic converter bracket.
Tighten to 46 Nm.
150. NOTE: Install new retaining nuts.
Install the catalytic converter.
Tighten to 46 Nm.
151. Install the catalytic converter retaining bolts.
Install the catalytic converter securing bracket.
Tighten to 46 Nm.
152. Install the turbocharger heat shield.
Tighten to 8 Nm.
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153. NOTE: Do not tighten the retaining clip.
Align the turbo outlet pipe and charge air cooler intake pipe assembly.
154. Install the turbo outlet pipe retaining bolt.
155. Install the charge air cooler intake pipe retaining bolts.
156. Tighten the retaining clip.
Tighten to 4 Nm.
All vehicles
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157. Install the accessory drive belt tensioner bracket.
Tighten to 25 Nm.
158. NOTE: Install the wiring harness support bracket to the generator
upper retaining bolt.
Install the generator.
Tighten to 47 Nm.
160. Attach the generator electrical connector.
Tighten to 8 Nm.
161. Install the air conditioning (AC) compressor.
Tighten to 25 Nm.
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1. Reposition the accessory drive belt tensioner.
164. Install the wiring harness.
165. Connect the generator wiring harness electrical connector.
166. Attach the mass air flow (MAF) sensor wiring harness.
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167. Attach the wiring harness to the retaining stud.
168. Connect the AC compressor electrical connector.
169. Attach the wiring harness to the AC compressor.
170. Attach the glow plug wiring harness.
Tighten to 5 Nm.
171. Attach the wiring harness to the intake manifold.
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172. Remove the engine from the engine stand.
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Engine2.0L Duratorq-TDCi
Installation
Special Tool(s)
303-397 (24-003)
HTJ1200-02
Engine lifting eye
303-1067
418-535
Installation
to the component.
Install the engine assembly to the transmission assembly.
Tighten to 40 Nm.
2. Install the transmission right-hand retaining bolts.
Tighten to 40 Nm.
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3. Install the transmission upper retaining bolts.
Tighten to 40 Nm.
4. Connect the crankshaft sensor electrical connector.
Tighten to 25 Nm.
2. Tighten to 6 Nm.
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7. Connect the starter motor wiring harness electrical connector.
8. Install the starter motor wiring harness retaining bracket.
Tighten to 20 Nm.
10. Install the vacuum regulator solenoid valve.
2. Attach the vacuum hoses.
3. Install the vacuum regulator solenoid valve.
Tighten to 23 Nm.
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11. Connect the reverse lamp switch electrical connector.
12. Install the charge air cooler pipe.
Tighten to 4 Nm.
13. Attach the reverse lamp switch wiring harness retaining clip.
14. Install the charge air cooler pipe retaining nut.
Tighten to 23 Nm.
to the component.
Using a suitable hydraulic lift install the engine and transmission to the
subframe.
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Tighten to 80 Nm.
18. NOTE: Un-Cap the exposed ports.
Connect the the power steering lines.
Tighten to 10 Nm.
19. Install a new drive halfshaft snap ring.
20. CAUTIONS:
Make sure the CV joint splines are located fully. Do not use
excessive force when engaging the CV joint into the transmission.
Do not damage the oil seal.
Install the drive halfshaft.
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3. Install a new lower arm ball joint retaining nut and bolt.
Tighten to 83 Nm.
Install a new anti-roll bar link retaining nut.
Tighten to 48 Nm.
Install a new tie rod-end retaining nut.
Tighten to 35 Nm.
Loosely install a new wheel hub nut.
25. Remove the engine rear lifting eye.
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26. Install the engine cover rear mount bracket.
Tighten to 23 Nm.
27. Attach the electrical connector.
Install the engine.
Raise the special tool.
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Loosely install the front subframe retaining bolts.
Loosely install the front subframe rear retaining bolts.
Install the front subframe reinforcement plate retaining bolts.
Tighten to 70 Nm.
Fully tighten the front subframe retaining bolts.
Tighten to 142 Nm.
Tighten to 142 Nm.
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Install the engine front mount retaining nuts.
Tighten to 80 Nm.
Install the engine rear mount retaining nut.
Tighten to 133 Nm.
40. Attach the strut and spring assembly.
Tighten to 30 Nm.
41. Attach the engine wiring harness earth lead.
Tighten to 10 Nm.
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43. CAUTION: Make sure that the electrical connector locates
correctly in the ECM. Do not force or overtighten the electrical connector.
Failure to follow this instruction may result in damage to the components.
NOTE: Bolt remains captive in the ECM electrical connector.
Using the special tool, connect the ECM harness electrical connector.
Tighten to 10 Nm.
46. Connect the engine wiring harness electrical connector.
Tighten to 10 Nm.
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47. Connect the fuel lines.
Procedures).
Remove the blanking plugs.
NOTE: Un-cap the exposed ports.
Connect the air conditioning compressor lines.
49. Fully tighten the air conditioning compressor line retaining bolt.
Tighten to 20 Nm.
50. NOTE: Un-cap the exposed ports.
Connect the exhaust gas recirculation (EGR) valve vacuum pipe.
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Install the power assisted steering hose.
52. Attach the power assisted steering hose.
53. Connect the power assisted steering hose.
54. Install the exhaust manifold to EGR valve tube.
Installation).
55. Connect the charge air cooler hose.
Tighten to 4 Nm.
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56. Connect the radiator upper coolant hose.
NOTE: Remove the tie strap.
Attach the clutch slave cylinder pipe.
1. Connect and fully seat the clutch slave cylinder pipe and
retaining clip.
2. Attach the clutch slave cylinder pipe.
Tighten to 4 Nm.
59. Attach the wiring harness to the battery tray mount.
60. Connect the battery cables.
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61. Connect the glow plug harness electrical connector.
Tighten to 10 Nm.
63. Attach the the expansion tank outlet hose.
64. Connect the expansion tank outlet hose.
65. Connect the exhaust gas recirculation (EGR) valve module vacuum
hose.
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66. Connect the brake vacuum pump vacuum hose.
Connect the power assisted steering hose.
Install the front bumper splitter vain finisher trims.
70. Install the front bumper splitter vain.
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71. NOTE: Remove the selector cables tie straps.
72. Attach the selector cables.
73. Connect the high intensity discharge (HID) sensor drop arm.
74. Connect the air temperature sensor electrical connector.
Connect the suction accumulator pipe.
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76. NOTE: Remove the anti-lock braking system (ABS) wheel speed sensor
tie straps.
Detach and reposition the ABS wheel speed sensor.
79. NOTE: Remove the brake caliper assembly tie straps.
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Attach the brake caliper and brake caliper anchor plate assembly.
Tighten to 133 Nm.
82. Install the front brake pads.
86. Connect the radiator lower coolant hose.
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87. Connect the heater hoses to the heater core.
88. Install the exhaust flexible pipe.
90. Check and top up the transmission fluid level.
91. Carry out the clutch bleeding system procedure.
Procedures).
93. Recharge the air conditioning refrigerant.
94. Attach the lower steering column shaft.
Tighten to 25 Nm.
96. Carry out the gear shift cable adjustment procedure.
For additional information, refer to: Gearshift Cable Adjustment (308-00
Manual Transmission/Transaxle and Clutch - General Information,
General Procedures).
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Engine2.2L Duratorq-TDCi (110kW/150PS) - Puma
Installation
Special Tool(s)
303-397 (24-003)
HTJ1200-02
Engine lifting eye
303-1067
418-535
Installation
All vehicles
to the component.
Using a suitable hydraulic lift, install the engine assembly to the
transmission assembly.
Tighten to 40 Nm.
2. Install the transmission right-hand retaining bolts.
Tighten to 40 Nm.
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3. Install the transmission upper retaining bolts.
Tighten to 40 Nm.
4. Connect the crankshaft position (CKP) sensor electrical connector.
Tighten to 25 Nm.
2. Tighten to 6 Nm.
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7. Connect the starter motor wiring harness electrical connector.
8. Install the starter motor wiring harness retaining bracket.
Tighten to 20 Nm.
10. Install the emission control solenoid assembly.
Tighten to 23 Nm.
11. Connect the emission control solenoid hose.
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12. Connect the emission control solenoid electrical connector.
14. Install the charge air cooler pipe.
Tighten to 4 Nm.
15. Install the charge air cooler pipe retaining bolt.
Tighten to 10 Nm.
Tighten to 35 Nm.
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to the component.
Using a suitable hydraulic lift, lower the engine and transmission from
the subframe.
18. Attach the reverse lamp switch wiring harness retaining clip.
Tighten to 23 Nm.
to the component.
Using a suitable hydraulic lift install the engine and transmission to the
subframe.
Tighten to 80 Nm.
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23. NOTE: Un-Cap the exposed ports.
Connect the the power steering lines.
Tighten to 10 Nm.
24. Install a new drive halfshaft snap ring.
25. CAUTIONS:
Make sure the CV joint splines are located fully. Do not use
excessive force when engaging the CV joint into the transmission.
Do not damage the oil seal.
Install the right-hand drive halfshaft.
Tighten to 25 Nm.
26. Attach the right-hand wheel knuckle.
3. Install a new lower arm ball joint retaining nut and bolt.
Tighten to 83 Nm.
27. Install a new right-hand anti-roll bar link retaining nut.
Tighten to 48 Nm.
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28. Install a new right-hand tie rod-end retaining nut.
Tighten to 35 Nm.
29. Loosely install a new wheel right-hand hub nut.
30. Remove the engine rear lifting eye.
Tighten to 23 Nm.
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34. Raise the engine, suspension and transmission assembly to a suitable
height.
Reposition the air conditioning (A/C) pipe to the engine, suspension and
transmission assembly.
Install the engine.
Raise the special tool.
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Loosely install the front subframe retaining bolts.
Loosely install the front subframe rear retaining bolts.
Install the front subframe reinforcement plate retaining bolts.
Tighten to 70 Nm.
Tighten to 142 Nm.
Tighten to 142 Nm.
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Install the engine front mount retaining nuts.
Tighten to 80 Nm.
Install the engine rear mount retaining nut.
Tighten to 133 Nm.
47. Attach the strut and spring assembly.
Tighten to 30 Nm.
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50. Attach the engine wiring harness earth lead.
Tighten to 10 Nm.
52. CAUTION: Make sure that the electrical connector locates
correctly in the ECM. Do not force or overtighten the electrical connector.
Failure to follow this instruction may result in damage to the components.
NOTE: Bolt remains captive in the ECM electrical connector.
Using the special tool, connect the ECM harness electrical connector.
Tighten to 10 Nm.
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54. Install the engine wiring harness trim panel.
56. Connect the fuel lines.
Procedures).
Connect the air conditioning (A/C) compressor lines.
58. Fully tighten the A/C compressor line retaining bolt.
Tighten to 20 Nm.
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59. Connect the power assisted steering hose.
Tighten to 4 Nm.
Attach the clutch slave cylinder pipe.
Connect and fully seat the clutch slave cylinder pipe and retaining
clip.
63. Attach the wiring harness to the battery tray mount.
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64. Connect the battery cables.
65. Connect the glow plug harness electrical connector.
Tighten to 10 Nm.
67. Attach the the expansion tank outlet hose.
68. Connect the expansion tank outlet hose.
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69. Connect the exhaust gas recirculation (EGR) valve module vacuum
hose.
70. Connect the brake vacuum pump vacuum hose.
NOTE: Use care when repositioning power assisted steering hose.
Connect the power assisted steering hose.
Reposition the power assisted hose through the radiator side seal.
Install the power assisted steering hose retaining clip.
73. Attach the battery breather hose.
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74. Attach the charge air cooler outlet hose to the charge air cooler.
75. Connect the high intensity discharge (HID) sensor drop arm.
76. Connect the air temperature sensor electrical connector.
Connect the suction accumulator pipe.
78. NOTE: Remove the anti-lock braking system (ABS) wheel speed sensor
tie straps.
Detach and reposition the ABS wheel speed sensor.
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81. NOTE: Remove the brake caliper assembly tie straps.
Install the wheel arch liner access cover.
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Attach the brake caliper and brake caliper anchor plate assembly.
Tighten to 133 Nm.
85. Install the front brake pads.
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91. Connect the fuel fired booster heater electrical connector to the
Vehicles without electric booster heater
Connect the coolant hose.
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93. Attach the coolant hoses to the retaining clips.
94. Attach the electric booster heater electrical connector to the subframe
retaining tang.
Vehicles without auxiliary heating
95. Connect the heater hoses to the heater core.
All vehicles
98. Check and top up the transmission fluid level.
Vehicles With: 5-Speed Manual Transmission - MT75 (308-03 Manual
99. Carry out the clutch bleeding system procedure.
With: 5-Speed Manual Transmission - MT75 (308-00 Manual
Procedures).
101. Recharge the air conditioning refrigerant.
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102. Install the steering column coupling.
103. Attach the lower steering column shaft.
Install a new retaining bolt.
Tighten to 25 Nm.
105. Carry out the gear shift cable adjustment procedure.
For additional information, refer to: Gearshift Cable Adjustment (308-00
Manual Transmission/Transaxle and Clutch - General Information,
General Procedures).
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Engine Cooling - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27 -
Fluids and Lubricants
Jaguar Premium Cooling System Fluid ESE-M97B44-A
Premium Cooling System Flush EGR-M14P7-A
O-Ring Lubricant ESE-M99B176-A
Cooling System Refill Capacities
Engine Capacity
2.5/3.0L 8.25L
Air conditioning condenser retaining bolts 7 - 62
Block heater 40 30 -
Coolant expansion tank retaining bolt 3 - 27
Cooling fan motor control module retaining screws 2 - 18
Cooling fan motor retaining nuts 6 - 53
Engine block drain plug 40 30 -
Radiator drain plug 1 - 9
Radiator support beam retaining bolts 25 18 -
Thermostat housing retaining bolts 10 - 89
Water pump housing retaining bolts 10 - 89
Water pump to water pump housing retaining bolts 10 - 89
Water pump drive pulley retaining bolts 11 8 -
Water pump housing inlet pipe retaining nuts 9 - 80
Water pump housing inlet pipe retaining studs 12 9 -
Water pump housing outlet pipe retaining bolts 10 - 89
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Engine Cooling - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27 - Engine
Cooling
Cooling Module Components
1 Cooling fan motor control module
2 Cooling fan shroud
3 Cooling fan, R/H
4 Radiator upper isolator mounting
5 Radiator side seal
6 Radiator lower isolator mounting
7 Radiator lower seal
8 Radiator support beam
9 Radiator lower isolator mounting
10 Radiator side seal
11 Radiator
12 Radiator upper isolator mounting
13 Radiator upper seal
14 Cooling fan, L/H
Engine Cooling System Components
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1 Upper coolant hose
2 Water pump
3 Coolant expansion tank
4 Coolant pressure cap
5 Thermostat
6 Engine oil cooler
7 Engine block heater (cold climate market vehicles only)
8 Engine block drain plug
WARNINGS:
Never remove the coolant pressure cap under any circumstances while the engine is operating. Failure to follow this instruction may
To avoid having scalding hot coolant or steam blow out of the cooling system, use extreme care when removing the coolant pressure cap
from a hot cooling system. Wait until the engine has cooled, then wrap a thick cloth around the coolant pressure cap and turn it slowly until
the pressure begins to release. Step back while the pressure is released from the system. When certain all the pressure has been released
(still with a cloth) turn and remove the coolant pressure cap from the coolant expansion tank. Failure to follow these instructions may result
in personal injury.
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To avoid the possibility of personal injury, do not operate the engine with the hood open until the fan blades have been examined for
cracks and separation. Failure to follow this instruction may result in personal injury.
Remove fuse 37 from the engine compartment fuse box prior to performing any under hood service in the area of the cooling fans
when the engine is hot, since the cooling fan motors could operate if the engine has been switched OFF. Failure to follow this instruction
may result in personal injury.
CAUTIONS:
The engine cooling system must be maintained with the correct concentration and type of anti-freeze solution to prevent corrosion
and frost damage.
result in damage to the engine.
The cooling system consists of the following:
Water pump.
Thermostat.
Radiator.
Coolant expansion tank.
Coolant pressure cap.
Two electric cooling fans.
Cooling fan motor control module.
Engine oil cooler.
Water Pump
The water pump is of a conventional design and is located at the rear of the engine. It is driven by the L/H exhaust camshaft through the
water pump drive pulley and belt. The water pump belt tension is maintained by an automatic drive belt tensioner. For additional
information, refer to Section 303-05 Accessory Drive.
Thermostat
The thermostat is located in a housing in the upper coolant hose and allows rapid engine warm-up by restricting coolant flow through the
radiator below 82C (180F). The thermostat also assists in keeping the engine operating temperature within predetermined limits. The
thermostat begins to open at 82C (180F) and is fully open at 93C (199F).
When the engine is cold and the thermostat is closed, coolant flows from the water pump through the engine. It then returns to the water
pump through the upper coolant hose.
When the engine is warm and the thermostat is open, coolant flows into the radiator through the upper coolant hose. It then returns to the
water pump from the radiator through the lower coolant hose and engine oil cooler.
The heater core is on a parallel circuit and is unaffected by the position of the thermostat.
Radiator
The radiator is of aluminium construction with plastic end tanks. Foam seals are fitted to the radiator to prevent the cooling air from by
passing the radiator core. The radiator is located by four isolator mountings and supported by the radiator support beam. A coolant drain
plug is provided in the lower coolant hose for the draining of the coolant. The Cooling fan shroud is attached to the radiator.
Cooling Fans
Two variable speed electric cooling fans are housed in the cooling fan shroud for the cooling of the radiator. The speed of the electric
cooling fans are adjusted by the cooling fan motor control module, which is controlled by the engine control module (ECM).
The ECM determines the cooling fan speed by receiving inputs from the engine coolant temperature (ECT) sensor and the dual automatic
temperature control module (DATC). The ECM sends a variable pulse width modulated (PWM) signal to the fan motor control module to
operate the cooling fans at the required speed. The cooling fans are operated at slow speed when the engine coolant temperature is at
95C (203F) and are operated at full speed when the engine coolant temperature is at 105C (221F). A coolant temperature between
these temperatures will cause the cooling fans to be operated at a speed which is proportional to the engine coolant temperature.
When the engine is running with the ECT above 100C (212F), if the ignition switch is turned to the OFF position the cooling fans will
continue to operate for a time which is determined by the ECM.
If the PWM signal from the ECM to the cooling fan control module is between 7% and 95% the cooling fan control module will operate the
cooling fans at the required speed. If the PWM signal from the ECM to the cooling fan control module is below 3% and above 95% the
cooling fan control module will operate the cooling fans at maximum speed. If the PWM signal from the ECM to the cooling fan control
module is between 3% and 7% the cooling fans will not be operated.
Engine Block Heater
For vehicle markets subject to very cold climate conditions, an engine block heater for connection to an external mains power supply, is
fitted in place of the engine block drain plug.
Coolant Recovery System
A pressurized coolant expansion tank system is used which continuously separates the air from the cooling system and replenishes the
system through the coolant expansion tank outlet hose, attached to the heater return hose.
A continuous vent from the engine and radiator to the coolant expansion tank prevents air locks from forming in the cooling system.
No manual bleed points are provided on the system.
The coolant expansion tank serves as the location for:
Service fill.
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Coolant expansion during warm-up.
Air separation during operation.
System pressurization by the coolant pressure cap.
The coolant expansion tank is designed to have approximately 0.5 to 1 liter of air when cold to allow for coolant expansion.
Engine Oil Cooler
The engine oil cooler is a Modine oil to water type. The oil cooler is fitted between the oil filter housing and the oil filter and is a full flow
system.
The coolant supply for the engine oil cooler is through the radiator bottom hose.
Coolant Flow Diagram (Thermostat open)
1 Engine
2 Throttle body
3 Expansion tank
4 Heater core
5 Water pump
6 Thermostat
7 Engine oil cooler
8 Radiator
Engine Coolant
The long life engine coolant is formulated to last for five years or 240,000 km (150,000 miles). The coolant is silicate free and orange in
color. The long life engine coolant must not be mixed with conventional engine coolant.
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1
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Engine Cooling - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27 - Engine
Cooling
step.
2.
4. If the concern is not an electrical fault and is not visually evident, verify the concern and refer to the symptom chart. 4.
5. If the concern is an electrical fault and is not visually evident, use a fault code reader to retrieve the fault codes before
proceeding to the symptom chart.
5.
Leaks Fuse
Coolant expansion tank Wiring harness
Coolant pressure cap Loose or corroded connector(s)
Cooling fan motor(s) Cooling fan motor(s)
Radiator Engine coolant temperature (ECT) sensor
Water pump Cooling fan motor control module
- Block heater
Symptom chart
DTC P0480; High/low signal from the cooling fan motor control module to the
engine control module (ECM)
Fuse F40 (80A), power distribution
fuse box.
Circuit.
Cooling fan motor.
ECM.
Loss of coolant Hoses.
Hose connections.
Radiator.
Water pump.
Heater core.
Gaskets.
Coolant expansion tank.
Coolant pressure cap.
Engine casting cracks.
Engine core plugs.
Engine overheats Engine coolant.
Thermostat.
Fuse F40 (80A), power distribution
fuse box.
Circuit.
Cooling fan motor(s).
Radiator.
Water pump.
Water pump drive belt.
Engine coolant temperature (ECT)
sensor.
ECM.
Go to Pinpoint Test C.
Engine block heater does not operate properly Block heater power cable.
Block heater.
Go to Pinpoint Test D.
The engine does not reach normal operating temperature Thermostat. INSTALL a new
thermostat.
PINPOINT TEST A : DTC P0480; HIGH/LOW SIGNAL FROM THE COOLING FAN MOTOR CONTROL MODULE TO THE
ECM
TEST
CONDITIONS
A1: CHECK THE OPERATION OF THE COOLING FANS
Disconnect the engine coolant temperature sensor electrical connector.
Connect a 100 ohm resistor to the engine coolant temperature sensor electrical connector.
START and RUN the engine.
Are the cooling fans operating?
Yes
GO to A2. .
No
GO to A7. .
A2: CHECK THE OPERATION OF THE TWO COOLING FANS
Inspect the operation of the two cooling fans.
Are both the cooling fans operating?
Yes
Connect the engine coolant temperature sensor electrical connector.GO to A4. .
No
GO to A3. .
A3: RUN THE TWO COOLING FANS AT MAXIMUM SPEED.
Turn the ignition switch to the OFF position and disconnect the cooling fan control module electrical connector JB187
(to VIN E71957) and connector JB190 (from VIN 71958).
Remove the PWM signal wire from the cooling fan control module electrical connector JB187-1 (WU) (to VIN E71957)
and connector JB190-4 (WU) (from VIN 71958).
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3
4
5
6
7
1
2
3
1
1
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1
2
Connect the cooling fan control module electrical connector JB187 (to VIN E71957) and connector JB190 (from VIN
71958) and turn the ignition switch to the RUN position. The cooling fans will run at maximum speed.
Allow the cooling fans to run for 5 minutes. Turn the ignition switch to the OFF position and disconnect the cooling
fan control module electrical connector JB187 (to VIN E71957) and connector JB190 (from VIN 71958).
Install the PWM signal wire to the cooling fan control module electrical connector JB187-1 (WU) (to VIN E71957) and
connector JB190-4 (WU) (from VIN 71958).
Connect the cooling fan control module electrical connector JB187 (to VIN E71957) and connector JB190 (from VIN
71958) to the cooling fan control module.
Turn the ignition switch to the RUN position.
Are both the cooling fans operating?
Yes
Connect the engine coolant temperature sensor electrical connector.GO to A4. .
No
INSTALL a new cooling fan motor as necessary. For additional information, refer to
REFER to: Cooling Fan Motor (303-03A Engine Cooling - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27,
. CLEAR the DTC. TEST the system for normal operation.
A4: CHECK CONTINUITY OF THE COOLING FAN MOTOR CONTROL MODULE SIGNAL WIRE FROM THE ECM
Disconnect the ECM electrical connector EN16 and the cooling fan motor control module electrical connector JB187 (to
VIN E71957) and connector JB190 (from VIN 71958).
Measure the resistance between electrical connector (JB187-1 to VIN E71957) or connector (JB190-4 from VIN
71958) and EN16-51.
Is the resistance less than 5 ohms?
Yes
GO to A5. .
No
REPAIR the circuit from the ECM to the cooling fan motor control module. CLEAR the DTC. TEST the system for normal
operation.
A5: CHECK THE COOLING FAN MOTOR CONTROL MODULE SIGNAL WIRE FROM THE ECM FOR A SHORT TO GROUND
Measure the resistance between connector (JB187-1 to VIN E71957) or connector (JB190-4 from VIN 71958)
and ground.
Yes
GO to A6. .
No
operation.
A6: CHECK THE COOLING FAN MOTOR CONTROL MODULE SIGNAL WIRE FROM THE ECM FOR A SHORT TO BATTERY POSITIVE
Measure the resistance between JB187-1 and JB187-2 (to VIN E71957) or JB190-4 and JB190-3 (from VIN 71958).
Yes
INSTALL a new cooling fan motor control module. For additional information, refer to
REFER to: Cooling Fan Module (303-03A Engine Cooling - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27,
. CLEAR the DTC. TEST the system for normal operation. If the DTC is repeated, INSTALL a new ECM. For additional
REFER to: Electronic Engine Controls (303-14A Electronic Engine Controls - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L
NA V6 - AJ27, Description and Operation).
.
No
operation.
A7: CHECK FUSE F40 IN THE POWER DISTRIBUTION FUSE BOX
Check the fuse.
Is the fuse OK?
Yes
GO to A9. .
No
GO to A8. .
A8: CHECK FUSE F40 OF THE POWER DISTRIBUTION FUSE BOX FOR A SHORT TO GROUND
Measure the resistance between electrical connector JB212-1 of the power distribution fuse box and ground.
Yes
REPAIR short to ground between the engine compartment fuse box and the cooling fan motor control module.
INSTALL a new fuse. CLEAR the DTC. TEST the system for normal operation.
No
A9: CHECK THE POWER SUPPLY TO THE COOLING FAN MOTOR CONTROL MODULE
Measure the voltage between the cooling fan motor control module electrical connector JB212-1 and ground.
Yes
GO to A10. .
No
GO to A11. .
A10: CHECK FOR BATTERY VOLTAGE AT FUSE F40 OF THE ENGINE COMPARTMENT FUSE BOX
Measure the voltage between the engine compartment fuse box electrical connector JB212-1 and ground
Yes
Repair the circuit between engine compartment fuse box and the battery. CLEAR the DTC. TEST the system for normal
operation.
No
REPAIR the circuit between the engine compartment fuse box and the cooling fan motor control module. CLEAR the
DTC. TEST the system for normal operation.
A11: CHECK THE IGNITION SUPPLY TO THE COOLING FAN MOTOR CONTROL MODULE
Measure the voltage between the cooling fan motor control module electrical connector ( JB187-2 to VIN E71957) or
connector (JB190-3 from VIN 71958) and ground.
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2
Yes
REPAIR the circuit between the engine compartment fuse box and the cooling fan motor control module. CLEAR the
No
GO to A12. .
A12: CHECK THE COOLING FAN MOTOR CONTROL MODULE GROUND CIRCUIT
Measure the resistance between the cooling fan motor control module electrical connector (JB188-2 to VIN E71957) or
connector (JB190-2 from VIN 71958) and ground.
Yes
INSTALL a new cooling fan motor control module. For additional information, refer to
REFER to: Cooling Fan Module (303-03A Engine Cooling - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27,
. CLEAR the DTC. TEST the system for normal operation. If the DTC is repeated, INSTALL a new ECM. For additional
REFER to: Electronic Engine Controls (303-14A Electronic Engine Controls - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L
NA V6 - AJ27, Description and Operation).
.
No
REPAIR the ground circuit to the cooling fan motor control module. CLEAR the DTC. TEST the system for normal
operation.
PINPOINT TEST B : LOSS OF COOLANT
TEST
CONDITIONS
B1: VISUAL INSPECTION
Visually inspect for loss of coolant.
Is the engine cooling system leaking?
Yes
INSTALL a new component as required. For additional information, refer to the appropriate section. TEST the cooling
No
Carry out the Cooling System Pressure TEST. For additional information, refer to the component test in this section.
PINPOINT TEST C : THE ENGINE OVERHEATS
C1: CHECK COOLANT
WARNING: Never remove the coolant pressure cap under any circumstances while the engine is operating. Failure to follow this
(still with a cloth) turn and remove the coolant pressure cap from the coolant expansion tank. Failure to follow these instructions may
CAUTION: Never remove the coolant pressure cap under any circumstances while the engine is operating. Failure to follow this
instruction may result in personal damage to the engine.
Inspect the coolant level.
Is the coolant level OK?
Yes
GO to C2. .
No
DIAGNOSE and REPAIR the coolant leaks. REFILL the cooling system. For additional information, refer to
REFER to: Cooling System Draining, Filling and Bleeding (303-03A Engine Cooling - 2.0L NA V6 - AJV6/2.5L NA V6 -
. TEST the cooling system for normal operation.
C2: CHECK THE CONDITION OF THE WATER PUMP DRIVE BELT
Inspect the water pump drive belt. For additional information, refer to
REFER to: Water Pump Belt - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27 (303-05 Accessory Drive,
.
Is the water pump drive belt OK?
Yes
GO to C3. .
No
INSTALL a new water pump drive belt. For additional information, refer to
. TEST the cooling system for normal operation.
C3: CHECK THE WATER PUMP DRIVE
Remove the water pump drive belt. For additional information, refer to
.
Attempt to turn the water pump drive pulley by hand.
Does the water pump drive pulley turn?
Yes
GO to C4. .
No
GO to C5. .
C4: CHECK THE LEFT HAND EXHAUST CAMSHAFT
Remove the water pump. For additional information, refer to
REFER to: Water Pump (303-03A Engine Cooling - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27,
.
Inspect the water pump drive shaft splines of the exhaust camshaft.
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Are the drive splines OK?
Yes
Install a new water pump. For additional information, refer to
No
INSTALL a new camshaft. For additional information, refer to
REFER to: Camshafts LH (303-01A Engine - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27, In-vehicle
Repair).
. Install a new water pump. For additional information, refer to
C5: CHECK THE OPERATION OF THE COOLING FANS
Disconnect the engine coolant temperature (ECT) sensor electrical connector.
Connect a 100 ohm resistor to the engine coolant temperature sensor electrical connector.
Yes
Turn the ignition switch to the OFF position. Connect the ECT sensor. GO to C7. .
No
Turn the ignition switch to the OFF position. Connect the ECT sensor. GO to A1. .
C6: CHECK THE AIR CONDITIONING CONDENSER AND RADIATOR CORE FOR OBSTRUCTION.
INSPECT the air conditioning condenser and radiator core for obstruction.
Is the air conditioning condenser or radiator core obstructed?
Yes
Remove the obstruction and clean the air conditioning condenser and radiator core. TEST the system for normal
operation.
No
GO to C8. .
C7: CHECK THE OPERATION OF THE COOLING FANS WITH THE ENGINE RUNNING AT NORMAL OPERATING TEMPERATURE
START and RUN the engine until the ECT is between 95C (203F) and 105C (221F).
Yes
Turn the ignition switch to the OFF position. GO to C8. .
No
DIAGNOSE the electronic engine controls. For additional information, refer to
REFER to: Electronic Engine Controls - 2.5L NA V6 - AJV6/3.0L NA V6 - AJ27, VIN Range: E96603->J28492
(303-14A Electronic Engine Controls - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27, Diagnosis and
Testing).
.
C8: CHECK THE TEMPERATURE OF THE RADIATOR
Check the radiator core temperature.
Is the radiator core hot?
Yes
GO to C9. .
No
GO to C10. .
C9: CHECK THE RADIATOR CORE FOR COLD SPOTS
Check the radiator core for cold spots.
Does the radiator core have any cold spots?
Yes
Backflush the radiator. For additional information, refer to
REFER to: Cooling System Backflushing (303-03A Engine Cooling - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA
V6 - AJ27, General Procedures).
. TEST the system for normal operation. If the fault is still present, INSTALL a new radiator. For additional
REFER to: Radiator (303-03A Engine Cooling - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27, Removal
and Installation).
.
No
GO to C10. .
C10: CHECK THE THERMOSTAT
TEST the thermostat. For additional information, refer to the component TEST in this section.
Is the thermostat OK?
Yes
GO to C11. .
No
INSTALL a new thermostat. For additional information, refer to
REFER to: Thermostat (303-03A Engine Cooling - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27, Removal
and Installation).
C11: CHECK THE ENGINE OIL COOLER FOR A BLOCKAGE
Remove the engine oil cooler. For additional information, refer to
REFER to: Oil Cooler (303-01A Engine - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27, In-vehicle
Repair).
.
Check the engine oil cooler for a coolant blockage.
Is the engine oil cooler blocked?
Yes
Install a new engine oil cooler. For additional information, refer to
REFER to: Oil Cooler (303-01A Engine - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27, In-vehicle
Repair).
No
INSTALL a new water pump. For additional information, refer to
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PINPOINT TEST D : THE ENGINE BLOCK HEATER DOES NOT OPERATE
TEST
CONDITIONS
D1: CHECK CONTINUITY OF THE BLOCK HEATER POWER SUPPLY CABLE AND THE BLOCK HEATER
Measure the resistance between the live supply terminal and the negative terminal of the block heater power
supply connector.
Yes
Repair the mains power supply to the vehicle block heater cable. TEST the system for normal operation.
No
GO to D2. .
D2: CHECK THE CONTINUITY OF THE BLOCK HEATER
Disconnect the block heater electrical connector from the block heater.
Measure the resistance between the live supply terminal and the negative terminal of the block heater.
Yes
GO to D3. .
No
INSTALL a new block heater. For additional information, refer to
REFER to: Block Heater (303-03A Engine Cooling - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27, Removal
and Installation).
D3: CHECK THE BLOCK HEATER FOR A SHORT TO GROUND
Measure the resistance between the live supply terminal and the earth terminal of the block heater.
Yes
Install a new block heater. For additional information, refer to
REFER to: Block Heater (303-03A Engine Cooling - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27, Removal
and Installation).
No
GO to D4. .
D4: CHECK THE CONTINUITY OF THE BLOCK HEATER POWER SUPPLY CABLE
Measure the resistance of the live supply wire of the block heater cable.
Measure the resistance of the neutral supply wire of the block heater cable.
Measure the resistance of the ground supply wire of the block heater cable.
Yes
GO to D5. .
No
Install a new block heater power supply cable. TEST the system for normal operation.
D5: CHECK THE BLOCK HEATER POWER SUPPLY CABLE FOR A SHORT CIRCUIT
Measure the resistance between the live supply wire and the neutral supply wire of the block heater cable.
Measure the resistance between the live supply wire and the ground wire of the block heater cable.
Yes
Install a new block heater power supply cable. TEST the system for normal operation.
No
Repair the mains power supply to the vehicle block heater cable. TEST the system for normal operation.
Component Tests
Pressure Test
WARNING: Never remove the coolant pressure cap under any circumstances while the engine is operating. Failure to follow this
in personal injury.
1. Switch the engine OFF. 1.
2. Open the hood and install protective fender covers. 2.
3. Carefully remove the coolant pressure cap from the coolant expansion tank to relieve pressure from the cooling system. Add
coolant to the coolant expansion tank as necessary.
3.
4. Install the cooling system Pressure Tester adaptor tightly to the coolant expansion tank. 4.
5. Attach the pressure pump and gauge to the adapter fitting and pressurize the cooling system to 100 kPa (14.5 psi). 5.
6. Observe the gauge reading for approximately two minutes. The pressure should not drop during this time.
If system holds pressure, proceed to step 8.
If the pressure drops check for leaks in the cooling system. Correct any leaks found and recheck the system.
6.
7. Release the system pressure by slowly loosening the cooling system Pressure Tester adaptor. Check the coolant level and
replenish as necessary with the correct coolant solution.
7.
8. Conduct the pressure cap Pressure Test in this section. 8.
Coolant Expansion Tank Pressure Cap Pressure Test
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WARNING: Never remove the coolant expansion tank cap under any circumstances while the engine is operating. Failure to follow
these instructions may result in damage to the cooling system or engine and/or personal injury. To avoid having scalding hot coolant or
steam blow out of the cooling system, use extreme care when removing the coolant expansion tank cap from a hot cooling system. Wait
until the engine has cooled, then wrap a thick cloth around the coolant expansion tank cap and turn it slowly until the pressure begins to
release, step back while the pressure is released from the system. When certain that all pressure has been released, (still with a cloth) turn
and remove the coolant expansion tank cap. Failure to follow these instructions may result in personal injury.
1. Remove the coolant pressure cap from the coolant expansion tank. 1.
2. Install the coolant pressure cap to the coolant system Pressure Tester. 2.
3. Operate the cooling system pressure tester. Pressurize the coolant pressure cap until the pressure relief valve in the coolant
pressure cap opens and observe the gauge reading.
NOTE: If the plunger of the pump is operated too quickly, an erroneous pressure reading will result.
3. Compare the gauge reading with the maximum opening pressure of the coolant pressure cap: 100 KPa (14.5 psi).
3.
4. Release the pressure. Repeat Step 3 at least twice to make sure that the pressure test reading is repeatable and within
acceptable gauge reading limits of the expansion tank cap.
4.
5. If the pressure test gauge readings are not within acceptable gauge reading limits, install a new coolant pressure cap. 5.
6. Pressurize the coolant pressure cap until the pressure is just below the opening pressure of the coolant pressure cap. 6.
7. Observe the reading of the pressure gauge for one minute. The pressure should not fall within this time. 7.
8. If the pressure falls below 10 KPa (1.5 psi) of the recorded pressure, install a new coolant pressure cap. 8.
Thermostat Test, Mechanical
NOTE: Fully open means the thermostat valve lifts a distance of 9.0 mm (0.35 inch) or more off the valve seat.
1. Remove the thermostat. For additional information, refer to
REFER to: Thermostat (303-03A Engine Cooling - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27, Removal and
Installation).
.
1.
2. Immerse the thermostat in water. 2.
3. Increase the temperature of the water. 3.
4. Observe the state of the thermostat and the temperature of the water. 4.
5. The thermostat should begin to open at 82C (179F) and is fully open at 93C (199F). 5.
6. If the thermostat fails to open within acceptable limits, install a new thermostat. 6.
Radiator Leak Test, Removed From the Vehicle
CAUTION: Do not leak test an aluminium radiator in the same water that is used to leak test copper/brass radiators. Flux and caustic
cleaners may be present in the test water which will corrode aluminum.
Clean the radiator before leak testing to prevent contamination of the test tank. Leak test the radiator in clean water with 138 kPa (20 psi)
air pressure.
A separate clean test tank is recommended for aluminium radiators. If a separate tank is not available for aluminium radiator testing, rinse
the test tank each time before testing an aluminium radiator.
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Engine Cooling - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27 - Cooling
System Backflushing
General Procedures
CAUTIONS:
The heater core must be backflushed separately from the engine cooling system to prevent the engine cooling system particles from
clogging the heater core tubes and reducing (or eliminating) coolant flow through the heater core.
All engine cooling system flushing and backflushing procedures must include a separate backflushing of the heater core after the flushing or
backflushing of the engine cooling system.
Heater core internal pressure must not exceed 100 kPa (14.5 psi). Failure to follow this instruction may cause damage to the heater
core.
NOTE: Cooling system backflushing should be carried out before the cooling system components are installed after the cooling system
flushing procedure.
1. Disconnect the heater outlet coolant hose from the engine and connect
the heater hose to a suitable hose pipe.
2. Disconnect the heater inlet coolant hose from the engine and allow the
coolant to drain into a suitable container.
3. Turn the water supply valve to the hose ON and allow water pressure to
flow through the heater core.
4. Allow water pressure to flow through the heater core for approximately
five minutes.
5. Turn the water supply valve to the hose OFF and disconnect the hose
pipe from the heater hose.
6. Connect the heater inlet coolant hose to the engine.
7. Connect the heater outlet coolant hose to the engine.
8. Fill the cooling system as described using a 50% mixture of Jaguar
Premium Cooling System Fluid, or equivalent meeting Jaguar
specification ESE-M97B44-A and 50% distilled water.
9. Test the system for correct heater performance with the specified
engine cooling system conditions.
Radiator Backflushing
1. Remove the radiator. For additional information, refer to Radiator.
2. Invert the radiator.
3. Connect a suitable hose pipe to the lower coolant hose connection of
the radiator.
flow through the radiator.
5. Allow water pressure to flow through the radiator for approximately five
minutes.
pipe from the radiator.
7. Allow the coolant to drain from the radiator.
8. Install the radiator. For additional information, refer to Radiator.
Engine Backflushing
NOTE: Make sure that the thermostat is removed before backflushing the engine.
1. Position the high-pressure water hose into the engine through the
engine return and backflush the engine.
2. Connect a suitable hose pipe to the upper coolant hose connection of
the engine.
flow through the engine.
4. Allow water pressure to flow through the engine for approximately five
minutes.
pipe from the upper coolant hose connection of the engine.
6. Connect the upper coolant hose to the engine.
7. Fill the cooling system as described using a 50% mixture of Jaguar
Premium Cooling System Fluid or equivalent, meeting Jaguar
specification ESE-M97B44-A and 50% distilled water.
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System Draining, Filling and Bleeding
General Procedures
WARNINGS:
in personal injury.
To avoid the possibility of personal injury, do not operate the engine with the hood open until the fan blades have been examined for
cracks and separation. Failure to follow this instruction may result in personal injury.
CAUTIONS:
Do not run the engine without first making sure the engine cooling fans operate. Start the engine, set air conditioning (A/C) to
maximum cold, set the blower motor to maximum and observe that the engine cooling fan operates. Failure to follow this instruction may
cause damage to the engine.
and frost damage.
Do not RUN the engine with the coolant pressure cap removed. Failure to follow this instruction may cause damage to the engine.
Do not RUN the engine without the correct level of coolant. Failure to follow this instruction may cause damage to the engine.
1. WARNING: Relieve the cooling system pressure by unscrewing the
coolant pressure cap.
2. Remove the undertray. For additional information, refer to Section
501-02 Front End Body Panels.
3. Remove the coolant drain plug.
Drain the coolant into a suitable container.
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4. CAUTION: Do not over tighten the drain plug. Failure to follow this
instruction may cause damage to the vehicle.
Install the drain plug when all coolant has drained.
Tighten to 1 Nm.
Remove the drain tray.
5. Install the undertray. For additional information, refer to Section 501-02
Front End Body Panels.
8. Fill the cooling system up to the MAX mark on the coolant expansion
tank using a 50% mixture of Jaguar Premium Cooling System Fluid or
equivalent, meeting Jaguar specification ESE-M97B44-A and 50%
distilled water.
9. Install the coolant expansion tank pressure cap.
10. NOTE: During this procedure the thermostat should open.
START and RUN the engine at 2000 rpm until the cooling fan operates.
11. Stop the engine and allow to cool for two minutes.
12. Loosely install a pipe clamp to the heater inlet hose.
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13. Loosely install a pipe clamp to the heater return hose.
14. START and RUN the engine at 2000 rpm.
15. With the engine at 2000 rpm, fully clamp the heater outlet hose and
then fully clamp the heater inlet hose.
16. Continue to run the engine for a further two minutes.
17. Switch the engine off.
18. Remove the heater hose clamps.
19. Fit the engine cover.
20. Allow the vehicle to cool to room temperature.
21. Remove the coolant expansion tank pressure cap, top up the coolant
level to the MAX mark on the coolant expansion tank.
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System Flushing
General Procedures
NOTE: To remove rust, sludge and other foreign material from the cooling system, use Premium Cooling System flush, meeting Jaguar
specification EGR-M14P7-A, which is safe for use with aluminium cooling systems. This cleaning restores cooling system efficiency and helps
prevent overheating.
NOTE: In severe cases where cleaning solvents will not properly clean the cooling system, it will be necessary to use the pressure flushing
method using Cooling System Flusher, 164-R3670 to restore efficient operation.
NOTE: A pulsating or reversed direction of flushing water will loosen sediment more quickly than a steady flow in the normal coolant flow
direction.
NOTE: Dispose of old coolant and flushing water contaminated with coolant and cleaning chemicals in accordance with local, state and
federal laws.
1. Remove the air cleaner. For additional information, refer to Section
303-12A Intake Air Distribution and FilteringSection 303-12B Intake Air
Distribution and Filtering.
2. Remove the thermostat. For additional information, refer to Thermostat.
3. Detach the lower coolant hose from the radiator and position to one
side.
5. Detach the upper coolant hose from the radiator.
6. Connect a hose pipe to the radiator upper coolant hose connection
using a suitable connector.
7. CAUTION: Radiator internal pressure must not exceed 100 kPa
(14.5 psi). Failure to follow this instruction may cause damage to the
radiator.
Flush the radiator using the hose pipe until the coolant flowing from the
radiator lower coolant hose connection is clear.
8. Remove the hose pipe from the radiator upper coolant hose connection.
9. Connect a hose pipe to the upper coolant hose using a suitable
connector.
10. Flush the engine using the hose pipe until the coolant flowing from the
radiator lower coolant hose is clear.
11. Remove the hose pipe from the upper coolant hose connection.
12. Connect the upper coolant hose to the radiator.
13. Install the thermostat. For additional information, refer to Thermostat.
14. Fill the cooling system. For additional information, refer to Cooling
System Draining, Filling and Bleeding.
15. Install the undertray. For additional information, refer to Section
16. Install the air cleaner. For additional information, refer to Section
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Engine Cooling - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27 - Block
Heater
Removal
1. Drain the cooling system. For additional information, refer to Cooling
2. Disconnect the block heater electrical connector.
3. Remove the block heater.
Installation
Tighten to 40 Nm.
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Engine Cooling - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27 - Coolant
Expansion Tank
Removal
1. NOTE: Clamp the hose to minimize coolant loss.
Detach the coolant expansion tank outlet hose from the coolant
expansion tank.
2. NOTE: Clamp the hoses to minimize coolant loss.
4. Remove the coolant expansion tank.
Installation
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Tighten to 3 Nm.
2. Check and top up the cooling system.
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Fan Module
Removal
1. Remove the air cleaner. For additional information, refer to:
Air Cleaner (303-12A Intake Air Distribution and Filtering - 2.0L NA
V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27, Removal and
Installation),
Air Cleaner (303-12B Intake Air Distribution and Filtering - 2.0L
Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) - Puma, Removal
and Installation).
3. NOTE: Left hand shown, right hand similar.
Disconnect the cooling fan motor electrical connectors.
4. Disconnect the cooling fan module electrical connectors.
5. Detach the cooling fan module electrical connectors from the cooling fan
shroud.
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6. Detach the cooling fan module wiring harness from the cooling fan
shroud.
7. Remove the cooling fan module.
Installation
Tighten to 3 Nm.
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Fan Motor
Removal
refer to Cooling Fan Motor and Shroud.
2. Disconnect the cooling fan motor electrical connector.
3. Remove the cooling fan motor assembly.
4. Remove the cooling fan from the cooling fan motor.
Installation
Tighten to 6 Nm.
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Fan Motor and Shroud
Removal
All vehicles
2. CAUTION: Make sure that the air conditioning (A/C) condenser is
not damaged when installing the retaining straps. Failure to follow this
NOTE: To allow the cooling module to be partially lowered and supported
when the radiator support beam is removed, suitable retaining straps must
be installed to the radiator.
Loosely attach suitable retaining straps to the radiator.
5. Disconnect the cooling fan motor control module electrical connectors.
6. Disconnect the cooling fan motor control module electrical connector.
All vehicles
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8. Reposition the coolant hose from the engine oil cooler to the
thermostat housing and secure it to the front cross member using a
suitable retaining strap.
9. Remove the radiator support beam.
Allow the cooling module to be partially lowered and supported by
the retaining straps.
side.
11. CAUTION: Make sure that the retaining lugs of the radiator are
not damaged when displacing the cooling fan motor and shroud. Failure to
Displace the cooling fan motor and shroud from the retaining lugs of the
radiator.
12. CAUTION: Make sure that the radiator is not damaged when
removing the cooling fan motor and shroud. Failure to follow this
Remove the cooling fan motor and shroud.
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Installation
1. CAUTIONS:
Make sure that the radiator is not damaged when installing the
cooling fan motor and shroud. Failure to follow this instruction may result
Make sure that the retaining lugs of the radiator are not damaged
when installing the cooling fan motor and shroud. Failure to follow this
Tighten to 25 Nm.
2. Fill the cooling system.
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Module
Removal
All Vehicles
2. Remove the air cleaner intake duct.
3. CAUTION: Make sure that the air conditioning (A/C) condenser is
not damaged when installing the retaining straps. Failure to follow this
NOTE: To allow the cooling module to be partially lowered and supported
when the radiator support beam is removed, suitable retaining straps must
be installed to the A/C condenser.
Loosely attach suitable retaining straps to the A/C condenser.
side.
6. Reposition the coolant hose from the engine oil cooler to the
thermostat housing and secure it to the front cross member using a
suitable retaining strap.
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8. Detach the radiator vent hose from the radiator.
10. Disconnect the cooling fan motor control module electrical connectors.
11. Detach the radiator vent hose from the radiator.
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13. Disconnect the cooling fan motor control module electrical connector.
All vehicles
15. Remove the air splitter grille.
16. Remove the front towing eye trims.
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17. NOTE: Left-hand side shown, right-hand side similar.
Detach the power assisted steering oil cooler inlet and return pipes.
Allow the power assisted steering fluid to drain into a suitable
container.
Using suitable blanking plugs, blank the exposed ports.
18. Detach the power assisted steering oil cooler inlet pipe.
Allow the power assisted steering fluid to drain into a suitable
container.
Using suitable blanking plugs, blank the exposed ports.
All Vehicles
19. Remove the radiator support beam.
20. CAUTION: Apply suitable tape to the right-hand side lower
section of the front bumper to prevent damage to the paintwork from the
A/C pipe when the cooling module is lowered. Failure to follow this
procedure may cause damage to the vehicle.
Remove the right-hand side A/C condenser retaining bolt from the
radiator.
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21. Lower the cooling module and the A/C condenser to a position where
the air conditioning pipe is forward of the front bumper.
22. Remove the left-hand side A/C condenser retaining bolt from the
radiator.
NOTE: The power assisted steering oil cooler remains captive to the
automatic transmission oil cooler.
Detach the automatic transmission oil cooler from the radiator.
24. CAUTION: Do not allow the power assisted steering oil cooler
and automatic transmission oil cooler to hang on the automatic
transmission oil cooler pipes. Failure to follow this instruction may cause
Position the power assisted steering oil cooler and the automatic
transmission oil cooler to one side and secure with suitable retaining
straps.
All vehicles
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Detach the cooling module from the A/C condenser.
26. CAUTION: Make sure that the radiator and the A/C condenser are
not damaged during the removal of the cooling module. Failure to follow
this instruction may cause damage to the vehicle.
Remove the cooling module.
Installation
All vehicles
1. CAUTION: Make sure that the radiator and the A/C condenser are
not damaged whilst installing the cooling module. Failure to follow this
instruction may cause damage to the vehicle.
Install the cooling module.
Attach the cooling module to the A/C condenser.
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Install the automatic transmission oil cooler to the radiator.
All Vehicles
4. Install the left-hand side A/C condenser retaining bolt.
Tighten to 7 Nm.
5. Install the right-hand side A/C condenser retaining bolt.
Tighten to 7 Nm.
7. CAUTION: Do not over tighten the retaining straps. Failure to
NOTE: To allow installation of the radiator support beam, install
retaining straps to the radiator to hold the cooling module in position.
Install suitable retaining straps to the radiator. Align the cooling module
to the upper isolator mounting points.
Carefully tension the retaining straps to hold the cooling module in
position.
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9. Install the radiator support beam.
Tighten to 25 Nm.
Connect the power assisted steering oil cooler inlet and return pipes.
11. Connect the power assisted steering oil cooler inlet pipe.
All Vehicles
12. Connect the lower coolant hose to the radiator.
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13. Remove the retaining strap from the engine oil cooler coolant hose.
14. Install the front towing eye trims.
15. Install the air splitter grille.
Remove the protective tape from the front bumper.
17. Remove the retaining straps from the A/C condenser and radiator.
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18. Connect the cooling fan motor control module electrical connector.
19. Connect the upper coolant hose onto the radiator.
20. Connect the radiator vent hose onto the radiator.
21. Connect the cooling fan motor control module electrical connectors.
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22. Connect the upper coolant hose onto the radiator.
23. Connect the radiator vent hose onto the radiator.
All vehicles
24. Install the air cleaner intake duct.
26. Fill the cooling system.
27. Check and adjust the power assisted steering fluid level.
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Engine Cooling - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27 - Radiator
Removal
1. Remove the cooling module. For additional information, refer to Cooling
Module.
2. CAUTION: Make sure that the retaining lugs of the radiator are not
damaged when removing the cooling fan motor and shroud from the
radiator.
Remove the cooling fan motor and shroud.
Installation
1. CAUTIONS:
Make sure that the retaining lugs of the radiator are not damaged
when installing the cooling fan motor and shroud to the radiator.
The radiator isolator mountings are constructed from a special
material. Use only the correct specification radiator isolator mountings.
Inspect the radiator isolator mountings for damage and fatigue.
Install new radiator isolator mountings if required.
Inspect the radiator seals for damage and security. Install new
radiator seals if required.
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Engine Cooling - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27 -
Thermostat
Removal
1. Drain the cooling system. For additional information, refer to
.
2. Detach the oil cooler coolant hose from the thermostat housing and
position to one side.
3. NOTE: The thermostat remains captive in the thermostat housing.
Remove the thermostat.
Installation
2. Fill the cooling system. For additional information, refer to
.
3. NOTE: For NAS vehicles only.
If required, carry out a long drive cycle.
For additional information, refer to: Powertrain Control Module (PCM)
Long Drive Cycle Self-Test (303-14A Electronic Engine Controls - 2.0L NA
V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27, General Procedures).
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Engine Cooling - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27 - Water
Pump
Removal
3. Remove the water pump belt. For additional information, refer to
Section 303-05 Accessory Drive.
4. Remove the water pump drive pulley.
5. Remove the water pump.
Installation
Tighten to 10 Nm.
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Engine Cooling - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27 - Water
Pump Housing
Removal
3. Remove the water pump belt tensioner. For additional information, refer
to Section 303-05 Accessory Drive.
4. Remove the left-hand valve cover. For additional information, refer to
5. Remove the water pump drive pulley.
6. Detach the coolant expansion tank outlet hose from the water pump
housing.
7. Remove the water pump coolant outlet pipe.
Remove and discard the seals.
8. Detach the coolant inlet pipe from the water pump housing.
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9. Remove the water pump housing.
10. Remove the water pump from the water pump housing.
Remove and discard the gasket from the water pump.
Installation
Tighten to 10 Nm.
2. CAUTION: Make sure that the water pump housing is tightened in
the sequence shown. Failure to follow this instruction may result in
damage to the water pump drive pulley bearings.
NOTE: Install a new gasket.
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Tighten to 9 Nm.
4. NOTE: Install new O-ring seals to the water pump coolant outlet pipe.
NOTE: Prior to installation of the water pump outlet pipe, lubricate the
O-ring seal of the water pump outlet pipe at the joint with the engine
coolant inlet tube with lubricant ESE-M99B176-A.
Tighten to 12 Nm.
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Engine Cooling - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) - Puma -
Fluids and Lubricants
Jaguar Premium Cooling System Fluid ESE-M97B44-A
Premium Cooling System Flush EGR-M14P7-A
O-Ring Lubricant ESE-M99B176-A
Cooling System Capacities
Engine Capacity
2.0L & 2.2 Diesel 10.0L (initial fill)
Antifreeze
Specific Gravity (providing no other additive is in
coolant)
Approximate percentage of Anti-Freeze (by
volume)
Remains Fluid
to Solidifies at
1.061 at +15C 50% 25C (13F) 30C
(22F)
Cooling System Pressure Specification
Description Pressure kpa (psi)
Radiator pressure test 138 kpa (20 PSI)
Coolant expansion tank cap release pressure 130 to 150kpa (18 to 21)
Radiator support bracket retaining bolts 25 18
Thermostat housing retaining bolt x 1 23 17 -
Thermostat housing retaining bolts x 3 10 - 89
Water pump retaining bolts 23 17 -
Water pump cover 10 - 89
Water pump bleed screw 10 - 89
Engine oil temperature control thermostat retaining bolt 10 - 89
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Engine Cooling
WARNINGS:
result in personal injury. To avoid having scalding hot coolant or steam blow out of the cooling system, use extreme care when removing
the coolant pressure cap from a hot cooling system. Wait until the engine has cooled, then wrap a thick cloth around the coolant pressure
cap and turn it slowly until the pressure begins to release. Step back while the pressure is released from the system. When certain all the
pressure has been released (still with a cloth) turn and remove the coolant pressure cap from the coolant expansion tank. Failure to follow
these instructions may result in personal injury.
Remove fuses 40 and 16 from the engine compartment fuse box prior to performing any under hood service in the area of the cooling
fans when the engine is hot, since the cooling fan motors could operate if the engine has been switched off. Failure to follow this
CAUTION: The engine cooling system must be maintained with the correct concentration and type of anti-freeze solution to prevent
corrosion and frost damage. Failure to follow this instruction may result in damage to the engine.
1 - Coolant expansion tank
2 - Thermostat
3 - Water pump
4 - Radiator
5 - Cooling fan motor and shroud
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1 - Cooling module
2 - Cooling fan motor and shroud
3 - Cooling fan
4 - Radiator upper isolator mounting
5 - Radiator side seal
6 - Radiator lower isolator mounting
7 - Radiator lower seal
8 - Radiator support beam
9 - Radiator lower isolator mounting
10 - Radiator side seal
11 - Radiator
12 - Radiator upper isolator mounting
13 - Radiator upper seal
14 - Cooling fan
The cooling system consists of a:
water pump.
thermostat.
radiator.
coolant pressure cap.
two electric cooling fans.
cooling module.
engine oil cooler.
engine oil temperature control thermostat.
Water Pump
The water pump is mounted directly to the cylinder block at the transmission-end of the engine. The water pump is directly driven by the
power steering pump.
Thermostat
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The thermostat is located in the thermostat housing which is bolted to the cylinder head and allows rapid engine warm-up by restricting
coolant flow through the radiator below 88C (190F). The thermostat also assists in keeping the engine operating temperature within
predetermined limits. The thermostat begins to open at 88C (190F) and is fully open at 102C (216F).
When the engine is cold and the thermostat is closed, coolant flows from the water pump through the engine. It then returns to the water
pump through the upper coolant hose.
When the engine is warm and the thermostat is open, coolant flows into the radiator through the upper coolant hose. It then returns to the
water pump from the radiator through the lower coolant hose and engine oil cooler.
The heater core is on a parallel circuit and is unaffected by the position of the thermostat.
Radiator
The radiator is of aluminium construction with plastic end tanks. Foam seals are fitted to the radiator to prevent the cooling air from by
passing the radiator core. The radiator is located by four isolator mountings and supported by the radiator support beam. A coolant drain
plug is provided in the lower coolant hose for the draining of the cooling system. The cooling fan motor and shroud is attached to the
radiator via retaining clips.
Electric Cooling Fans
Two variable speed electric cooling fans are housed in the cooling fan shroud for the cooling of the radiator. The speed of the electric
cooling fans is adjusted by the cooling fan control module, which is controlled by the engine control module (ECM).
The ECM determines the cooling fan speed by receiving inputs from the cylinder head temperature (CHT) sensor. The ECM sends a variable
pulse width modulated (PWM) signal to the cooling fan control module to operate the cooling fans at the required speed. The cooling fans
are operated at slow speed when the engine coolant temperature is at 95C (203F) and are operated at full speed when the engine coolant
temperature is at 105C (221F). A coolant temperature between these temperatures will cause the cooling fans to be operated at a speed
which is proportional to the engine coolant temperature.
When the engine is running with the CHT above 100C (212F), if the ignition switch is turned to the OFF position the cooling fans will
continue to operate for a time which is determined by the ECM.
If the PWM signal from the ECM to the cooling fan control module is between 7% and 95% the cooling fan control module will operate the
cooling fans at the required speed. If the PWM signal from the ECM to the cooling fan control module is below 3% and above 95% the
cooling fan control module will operate the cooling fans at maximum speed. If the PWM signal from the ECM to the cooling fan control
module is between 3% and 7% the cooling fans will not operate.
Coolant Recovery System
A pressurized coolant expansion tank system is used which continuously separates the air from the cooling system and replenishes the
system through the coolant expansion tank outlet hose, attached to the heater return hose.
A continuous vent from the engine and radiator to the coolant expansion tank prevents air locks from forming in the cooling system.
The coolant expansion tank serves as the location for:
service filling.
coolant expansion during warm-up.
air separation during operation.
system pressurization by the coolant pressure cap.
Engine Oil Cooler
The engine oil cooler is a oil to water type. The oil cooler is mounted to the oil filler housing an sealed with two O-ring seals.
The coolant supply for the engine oil cooler is through the radiator bottom hose.
Engine oil cooler thermostat
The engine oil cooler thermostat is located in the water pump housing and helps to reduce the warm-up time by limiting the coolant flow
through the lubrication system until the engine reaches it's optimum operating temperature. The engine oil cooler thermostat starts to open
at 75C (167F) and is fully open at 89C (192F).
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General Procedures
1. WARNING: When releasing the cooling system pressure, cover the
expansion tank cap with a thick cloth to prevent the possibility of scalding.
NOTE: Release the cooling system pressure by slowly turning the coolant
expansion tank cap a quarter of a turn.
Remove the coolant expansion tank cap.
Allow the coolant to drain into a suitable container.
4. Install the radiator drain plug.
5. Install the radiator splash shield.
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9. Loosen the cooling system air bleed screw.
10. Fill the coolant expansion tank until coolant emerges from the cooling
system air bleed screw.
11. Tighten the cooling system air bleed screw.
Tighten to 10 Nm.
12. CAUTION: The engine cooling system must be maintained with
the correct concentration and type of anti-freeze solution to prevent
corrosion and frost damage.
Fill the coolant expansion tank to the Max mark.
Tighten the retaining bolts.
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15. Install the air cleaner assembly.
16. Start the engine and maintain an engine speed of 1500 revolutions per
minute (RPM) for 20 seconds.
17. Switch the engine off.
18. Fill the coolant expansion tank to 15mm above the MAX mark.
19. Install the coolant expansion tank cap.
20. Start the engine, allow the engine to idle for a two minutes.
21. CAUTION: Observe the engine temperature gauge. If the engine
starts to over-heat switch off immediately and allow to cool. Failure to
Raise the engine speed to 3000 RPM and maintain at 3000 RPM until the
engine cooling fan operates, while observing the engine temperature
gauge.
22. CAUTION: Observe the engine temperature gauge. If the engine
starts to over-heat switch off immediately and allow to cool. Failure to
Allow the engine to idle for a further five minutes.
23. Switch off the engine.
24. Allow the engine to cool.
25. Remove the coolant expansion tank cap.
26. CAUTION: The engine cooling system must be maintained with
the correct concentration and type of anti-freeze solution to prevent
corrosion and frost damage.
Fill the coolant expansion tank to the Max mark.
27. Install the coolant expansion tank cap.
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Cooling System Draining and Vacuum Filling
General Procedures
WARNING: To avoid having scalding hot coolant or steam blowing out of the cooling system, use extreme care when removing the
coolant pressure cap from a hot cooling system. Wait until the engine has cooled, then wrap a thick cloth around the coolant pressure cap
and turn it slowly until the pressure begins to release. Step back while the pressure is released from the system. When certain all the
pressure has been released (still with a cloth) turn and remove the coolant pressure cap from the coolant expansion tank. Failure to follow
CAUTIONS:
and frost damage. Failure to follow this instruction may result in damage to the vehicle.
Engine coolant will damage the paint finished surfaces. If spilt, immediately remove the coolant and clean the area with water.
Do not run the engine without first making sure the engine cooling fans operate. Start the engine, set air conditioning (A/C) to
maximum cold, set the blower motor to maximum and observe that the engine cooling fan operates. Failure to follow this instruction may
cause damage to the engine.
1. Set the heater controls to maximum HOT.
2. WARNING: Relieve the cooling system pressure by unscrewing the
coolant pressure cap. Failure to follow this instruction may result in
personal injury.
CAUTION: Do not RUN the engine with the coolant pressure cap
removed. Failure to follow this instruction may cause damage to the
engine.
4. NOTE: Remove and discard the radiator drain plug O-ring seal.
Remove the coolant drain plug.
Drain the coolant into a suitable container.
5. CAUTION: Do not over tighten the drain plug. Failure to follow this
NOTE: Install a new O-ring seal.
Install the coolant drain plug.
Tighten to 1 Nm.
Remove the drain tray.
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7. Install the cooling system vacuum refill adaptor to the expansion tank.
8. Install the vacuum filler gauge to the cooling system vacuum refill
adaptor.
9. Install the venturi tube assembly to the vacuum filler gauge.
10. NOTE: Make sure that both valves are in the closed position on the
vacuum filler gauge assembly.
NOTE: The coolant vacuum fill tool needs an air pressure of 6 to 8 bar
(87 to 116 psi) to operate correctly.
NOTE: Small diameter or long airlines may restrict airflow to the coolant
vacuum fill tool.
Connect a regulated compressed air supply to the venturi tube
assembly.
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11. Open the air supply valve.
12. NOTE: Make sure the coolant supply hose is positioned into a
container of fifty percent mixture of Jaguar Premium Cooling System Fluid
or equivalent, meeting Jaguar specification WSS M97B44-D and fifty
percent water. Make sure no air can enter the coolant supply hose.
Open the coolant supply valve for 2 seconds to prime the coolant supply
hose.
13. Apply air pressure progressively until the arrow on the vacuum filler
gauge reaches the green segment.
14. Close the air supply valve.
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15. Allow one minute to check the vacuum is held.
Disconnect the air supply.
16. NOTE: Close the coolant supply valve when the coolant expansion tank
MAX mark is reached or coolant movement has ceased.
Open the coolant supply valve and allow the coolant to be drawn into
the system.
17. Remove the vacuum filler gauge and cooling system vacuum refill
adaptor assembly.
19. Set the heating system to the COLD position.
20. Start the engine, allow the engine to idle for a two minutes.
21. NOTE: During this procedure the thermostat should open.
Raise the engine speed to 3000 RPM and maintain until the engine
cooling fan operates.
22. Allow the engine to idle for a further five minutes.
23. Switch the engine OFF and allow to cool.
24. WARNING: To avoid having scalding hot coolant or steam blow
out of the cooling system, use extreme care when removing the coolant
pressure cap from a hot cooling system. Wait until the engine has cooled,
then wrap a thick cloth around the coolant pressure cap and turn it slowly
until the pressure begins to release. Step back while the pressure is
released from the system. When certain all the pressure has been
released (still with a cloth) turn and remove the coolant pressure cap from
the coolant expansion tank. Failure to follow these instructions may result
in personal injury.
After two minutes, release the cooling system pressure.
25. Check and top-up the coolant if required.
27. Check for coolant leaks.
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Cooling Fan Motor and Shroud
Removal
1. Remove the cooling module.
For additional information, refer to: Cooling Module (303-03B Engine
Cooling - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) -
Puma, Removal and Installation).
2. Remove the cooling fan motor and shroud assembly.
1. Release the retaining tangs.
2. Remove the cooling fan motor and shroud assembly.
Installation
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Cooling Module
Special Tool(s)
Remover/installer, cooling hose clamp.
303-397
Removal
2. Carry out the air conditioning (A/C) system recovery procedure.
3. Carry out the cooling system drain procedure.
5. Detach the radiator vent hose.
6. Detach the radiator upper coolant hose.
8. Remove the charge air cooler.
For additional information, refer to: Charge Air Cooler - 2.0L
Duratorq-TDCi (303-12B Intake Air Distribution and Filtering - 2.0L
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Installation) /
Charge Air Cooler - 2.2L Duratorq-TDCi (110kW/150PS) - Puma (303-12B
Disconnect the A/C lines.
11. WARNING: Using an assistant support the cooling module.
Using an assistant, remove the radiator support beam.
12. WARNING: Using an assistant, remove the cooling module.
CAUTION: Make sure that the radiator and the air conditioning
condenser are not damaged during the removal of the cooling module.
Using an assistant, remove the cooling module.
Installation
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1. WARNING: Using an assistant, install the cooling module. Failure
to follow this instruction may result in personal injury.
CAUTION: Make sure that the radiator and the air conditioning
condenser are not damaged during the installation of the cooling module.
Using an assistant, install the cooling module.
2. WARNING: Using an assistant support the cooling module. Failure
Using an assistant, install the radiator support beam.
Tighten to 25 Nm.
3. NOTE:
Connect the A/C lines.
Tighten to 25 Nm.
5. Install the charge air cooler.
For additional information, refer to: Charge Air Cooler - 2.0L
Duratorq-TDCi (303-12B Intake Air Distribution and Filtering - 2.0L
Installation) /
Charge Air Cooler - 2.2L Duratorq-TDCi (110kW/150PS) - Puma (303-12B
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8. Connect the radiator vent hose.
10. Carry out the cooling system filling and bleeding procedure.
11. Carry out the A/C system evacuation and charging procedure.
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Radiator
Removal
(303-03B Engine Cooling - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi
2. Remove the radiator.
Installation
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Name
Grease
Water Pump
Special Tool(s)
303-397 (24-003)
Materials
Specification
WSS-M12A4-A2
Removal
1. Remove the exhaust gas recirculation (EGR) tube.
Installation).
All vehicles
3. Detach the power steering fluid pipe.
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5. NOTE: Shown with the exhaust gas recirculation (EGR) cooler to EGR
valve tube removed for clarity.
Remove the power steering pump retaining bolts.
Remove the power steering pump securing bracket.
Detach the power steering pump from the water pump.
8. Using the special tool, disconnect the coolant hoses from the water
pump.
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Detach the wiring harness.
clarity.
Detach the water pump.
Detach the wiring harness from the water pump lower retaining
bolts.
11. Remove the water pump.
12. Remove and discard the water pump O-ring seal.
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13. Remove the engine oil temperature control thermostat.
Installation
All vehicles
1. NOTE: Install a new engine oil temperature control thermostat O-ring
seal.
Install the engine oil temperature control thermostat.
2. Install a new water pump O-ring seal.
3. NOTE: Install a new water pump gasket.
Install the water pump.
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Attach the water pump.
Tighten the water pump retaining bolts to 24 Nm.
Attach the wiring harness to the water pump lower retaining bolts.
Attach the wiring harness.
6. Using the special tool, connect the coolant hoses to the water pump.
7. Coat the power steering pump drive shaft splines with grease.
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Attach the power steering pump to the water pump.
Install the power steering pump securing bracket.
Tighten to 25 Nm.
clarity.
Tighten to 25 Nm.
clarity.
Tighten to 10 Nm.
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12. Attach the power steering pump belt.
13. Attach the power steering fluid pipe.
15. Install the exhaust gas recirculation (EGR) tube.
Installation).
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Fuel Charging and Controls - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27
-
Lower intake manifold retaining bolts 10 - 89
Fuel injection supply manifold retaining bolts 10 - 89
Fuel pressure sensor retaining bolts 10 - 89
Throttle body retaining bolts 10 - 89
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- Fuel Charging and Controls
1 Fuel charging wiring harness
2 Fuel injector
3 Fuel pressure sensor
4 Throttle body
5 Fuel injection supply manifold
6 - Fuel temperature sensor
The electronic returnless fuel system utilized has the advantages of reduced fuel tank vapor, requires less electrical power and does not
require a fuel return line.
Fuel is supplied at high pressure to the injectors via a fuel rail which incorporates six fuel injectors, a fuel pressure regulator and a fuel
temperature sensor. The engine control module (ECM) maintains 380 kPa across the injectors, by increasing the pulse width modulation
signal to the fuel pump controller. This in turn controls the voltage output to the fuel pump.
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CAUTION: The use of supplementary oil or fuel additives is not approved unless speci fied by Jaguar Cars in the form of a service
A fuel pressure relief valve is fitted to the fuel rail at the front of the camshaft cover. This valve allows the fuel system to be depressurized
during servicing and troubleshooting.
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- Fuel Charging and Controls2.0L NA V6 - AJV6
3. Make sure there is sufficient fuel in the vehicle. 3.
step.
4.
5. The DTC summaries are generated to support the Jaguar approved diagnostic system, but also provide the basis for diagnosis of
OBD related concerns using a suitable generic scan tool, in conjunction with the electrical guides. Until the DTC summaries and
electrical guides are available, the fuel charging and controls system can only be diagnosed using the Jaguar approved diagnostic
system. For additional information, refer to Dealer technical support.
5.
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Published: 24-Nov-2011
- Fuel Charging and Controls2.5L NA V6 - AJV6/3.0L NA V6 - AJ27, VIN Range:
E96603->J28492
step.
3.
4. If the concern is not visually evident, use a fault code reader to retrieve fault codes before proceeding to the Symptom Chart. 4.
Symptom Chart
DTC Condition Possible Causes Action
P0171 Right-Hand bank
combustion too
lean
Engine misfire
Air intake leak between
MAF sensor and throttle
Fuel injector restriction
Fuel filter/system
restriction
Fuel pressure sensor
failure (low fuel pressure)
Low fuel pump output
HO2S (1/1; 1/2) harness
wiring condition fault
Exhaust leak (before
catalyst)
engine control module
(ECM) receiving incorrect
signal from one or more
of the following
components; ECT sensor,
MAF sensor, IAT sensor,
IP sensor, EFT sensor, TP
sensor
REFER to: Engine Ignition - 2.5L NA V6 - AJV6/3.0L NA V6 - AJ27 (303-07A
Engine Ignition - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27,
Diagnosis and Testing) / Engine (303-01A Engine - 2.0L NA V6 - AJV6/2.5L NA
V6 - AJV6/3.0L NA V6 - AJ27, Diagnosis and Testing) / Fuel Charging and
Controls - 2.5L NA V6 - AJV6/3.0L NA V6 - AJ27, VIN Range: E96603->J28492
(303-04A Fuel Charging and Controls - 2.0L NA V6 - AJV6/2.5L NA V6 -
AJV6/3.0L NA V6 - AJ27, Diagnosis and Testing) / Fuel Injectors (303-04A Fuel
Charging and Controls - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 -
AJ27, Removal and Installation) / Exhaust System (309-00 Exhaust System,
Diagnosis and Testing) / Electronic Engine Controls - 2.5L NA V6 - AJV6/3.0L
NA V6 - AJ27, VIN Range: E96603->J28492 (303-14A Electronic Engine Controls
- 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27, Diagnosis and
Testing).
P0172 Right-hand bank
combustion too
rich
Restricted air filter
Leaking fuel injector(s)
failure (high fuel
pressure)
ECM receiving incorrect
of the following
sensor
REFER to: Intake Air Distribution and Filtering (303-12A Intake Air Distribution
and Filtering - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27,
Diagnosis and Testing) / Fuel Injectors (303-04A Fuel Charging and Controls -
2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27, Removal and
Installation) / Electronic Engine Controls - 2.5L NA V6 - AJV6/3.0L NA V6 -
AJ27, VIN Range: E96603->J28492 (303-14A Electronic Engine Controls - 2.0L
NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27, Diagnosis and Testing).
P0174 Left-hand bank
combustion too
lean
Engine misfire
Air intake leak between
MAF sensor and throttle
Fuel filter/system
restriction
failure (low fuel pressure)
HO2S (2/1; 2/2) harness
wiring condition fault
Exhaust leak (before
catalyst)
of the following
sensor
Diagnosis and Testing) / Engine (303-01A Engine - 2.0L NA V6 - AJV6/2.5L NA
V6 - AJV6/3.0L NA V6 - AJ27, Diagnosis and Testing) / Fuel Charging and
Controls - 2.5L NA V6 - AJV6/3.0L NA V6 - AJ27, VIN Range: E96603->J28492
(303-04A Fuel Charging and Controls - 2.0L NA V6 - AJV6/2.5L NA V6 -
AJV6/3.0L NA V6 - AJ27, Diagnosis and Testing) / Fuel Injectors (303-04A Fuel
Charging and Controls - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 -
AJ27, Removal and Installation) / Exhaust System (309-00 Exhaust System,
Diagnosis and Testing) / Electronic Engine Controls - 2.5L NA V6 - AJV6/3.0L
NA V6 - AJ27, VIN Range: E96603->J28492 (303-14A Electronic Engine Controls
- 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27, Diagnosis and
Testing).
combustion too
rich
failure (high fuel
pressure)
of the following
sensor
REFER to: Intake Air Distribution and Filtering (303-12A Intake Air Distribution
and Filtering - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27,
Diagnosis and Testing) / Fuel Injectors (303-04A Fuel Charging and Controls -
2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27, Removal and
Installation) / Electronic Engine Controls - 2.5L NA V6 - AJV6/3.0L NA V6 -
AJ27, VIN Range: E96603->J28492 (303-14A Electronic Engine Controls - 2.0L
P1251,
P1631,
P1657,
P1658
Concern with
throttle motor
relay
Throttle motor relay
circuit
REFER to: Electronic Engine Controls - 2.5L NA V6 - AJV6/3.0L NA V6 - AJ27,
VIN Range: E96603->J28492 (303-14A Electronic Engine Controls - 2.0L NA V6
- AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27, Diagnosis and Testing).
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P0112,
P0113
Concern with IAT
sensor
Engine faulty leading to
overheating
Intake air temperature
(IAT) sensor fault
Harness fault
ECM failure
REFER to: Acceleration Control (310-02 Acceleration Control, Diagnosis and
Testing) / Electronic Engine Controls - 2.5L NA V6 - AJV6/3.0L NA V6 - AJ27,
P0121,
P0122,
P0123,
P0222,
P0223
Concern with
throttle position
(TP) sensor
TP sensor fault
Harness fault
ECM failure
P0116,
P0117,
P0118,
P0125
Concern with
engine coolant
temperature
Engine coolant
temperature sensor
Harness fault
ECM failure
P0201,
P0202,
P0203,
P0204,
P0205,
P0206
Concern with fuel
injectors
Faulty injector(s)
Harness fault
ECM failure
REFER to: Fuel Injectors (303-04A Fuel Charging and Controls - 2.0L NA V6 -
AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27, Removal and Installation) / Fuel
Charging Wiring Harness (303-04A Fuel Charging and Controls - 2.0L NA V6 -
AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27, Removal and Installation) /
E96603->J28492 (303-14A Electronic Engine Controls - 2.0L NA V6 - AJV6/2.5L
NA V6 - AJV6/3.0L NA V6 - AJ27, Diagnosis and Testing).
P0191 Concern with
injection
pressure (IP)
sensor
Fuel rail pressure sensor
Harness fault
Fuel filter/system
restriction
Fuel system leak
Incorrect fuel pump
output
IP sensor to ECM sensing
circuit; high resistance,
to high voltage
IP sensor to splice in
sensor supply circuit;
high resistance, open
circuit
sensor ground circuit;
circuit
circuit, short circuit to
ground, short circuit to
high voltage
IP sensor failure
GO to Pinpoint Test B.
P0192 Concern with
injection
pressure (IP)
sensor (low
voltage/low
pressure)
IP sensor disconnected
IP sensor to ECM sensing
circuit; open circuit or
short circuit to ground
sensor supply circuit;
circuit
IP sensor failure
P0193 Concern with
injection
pressure (IP)
sensor (high
voltage/high
pressure)
IP sensor to ECM wiring
(supply/sense) short
circuit to each other
IP sensor to ECM sense
circuit; short circuit to
high voltage
open circuit
IP sensor failure
P0460 Concern with fuel
level sensors
Fuel level sensor to
instrument cluster
circuit(s); intermittent
short circuit, open circuit,
high resistance
Fuel level sensor failure
Instrument cluster fault
P1234,
P1236
Concern with fuel
pump commands
(no commands
received by ECM)
ECM to fuel pump control
module control and/or
feedback circuits; open
resistance
Fuel pump control module
failure
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pump commands
(fuel pump not
activated when
requested by
ECM)
ECM to fuel pump control
module control and/or
feedback circuits; open
resistance
failure
P1229 Concern with
throttle motor
control circuit
Throttle motor
disconnected
Throttle motor to ECM
drive circuits; short
circuit or open circuit
Throttle motor failure
GO to Pinpoint Test F.
P1224 Concern with
throttle control
position
Throttle adaptions not
performed after battery
disconnect
TP sensor disconnected
TP sensor to ECM sense
circuits; open circuit, high
resistance
failure
Throttle motor relay to
ECM circuit fault
power supply open circuit
ECM ground circuit fault
(relay coil drive)
Throttle motor to ECM
drive circuits; open
resistance
Throttle body failure
GO to Pinpoint Test F. REFER to: Electronic Engine Controls - 2.5L NA V6 -
AJV6/3.0L NA V6 - AJ27, VIN Range: E96603->J28492 (303-14A Electronic
Engine Controls - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27,
Diagnosis and Testing). Individual Pinpoint tests for components and circuits
listed
P1250,
P1254
Concern with
throttle valve
return spring and
"limp-home"
spring
Throttle body These DTCs can only be accurately diagnosed using the Jaguar approved
diagnostic system. If this is not available, INSTALL a new throttle body.
REFER to: Throttle Body (303-04, Removal and Installation).
CLEAR the DTC, TEST the system for normal operation.
P1656 Concern with TP
sensor amplifier
circuit
ECM REFER to: Electronic Engine Controls - 2.5L NA V6 - AJV6/3.0L NA V6 - AJ27,
PINPOINT TEST A : FUEL INJECTORS, P0201, P0202, P0203, P0204, P0205, P0206.
NOTE: The DTC set will indicate which cylinder injector or circuit is faulty. Only in the event of multiple cylinder misfires will it be
necessary to check more than one injector or circuit, in which case, multiple DTCs will be set.
TEST
CONDITIONS
A1: CHECK THE INJECTOR COIL RESISTANCE
Disconnect the relevant injector electrical connector (IJ1 to 6).
Measure the resistance between the injector pins.
Is the resistance between 12 and 16 ohms?
Yes
GO to A2.
No
INSTALL a new injector.
REFER to: Fuel Injectors (303-04A Fuel Charging and Controls - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 -
AJ27, Removal and Installation).
CLEAR the DTC. TEST the system for normal operation.
A2: CHECK THE INJECTOR COIL INSULATION
Measure the resistance between the injector pin 1 and the injector body.
Are both resistances greater than 10 Mohms?
Yes
GO to A3.
No
A3: CHECK THE INJECTOR SUPPLY VOLTAGE
Disconnect the relevant injector harness electrical connector (IJ1 to 6).
Measure the voltage between the relevant injector harness electrical connector (IJ1 to 6) pin 2 and GROUND.
Is the voltage greater than 12 Volts?
Yes
GO to A4.
No
REPAIR the circuit between the relevant injector harness electrical connector, (IJ1 to 6) pin 2 and battery. This circuit
includes the power distribution fuse box, fuse 41, and the EMS control relay. For additional information, refer to wiring
diagrams. CLEAR DTC. TEST the system for normal operation.
A4: CHECK THE INJECTOR GROUND CIRCUIT
Disconnect the ECM electrical connector EN16.
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Measure the resistance between the relevant injector harness electrical connector (IJ1 to 6) pin 1 and EN16 pins as
follows -
Injector 1 pin 1 (NW) and ECM pin 115.
Injector Cyl 3 pin 1 (N) and ECM pin 114.
Injector Cyl 5 pin 1 (NR) and ECM pin 113.
Injector Cyl 2 pin 1 (NU) and ECM pin 120.
Injector Cyl 4 pin 1 (NG) and ECM pin 119.
Injector Cyl 6 pin 1 (NY) and ECM pin 118.
Yes
GO to A5.
No
REPAIR the circuit between the relevant injector harness electrical connector pin 1 and the ECM electrical connector.
For additional information, refer to wiring diagrams. CLEAR the DTC. TEST the system for normal operation.
A5: CHECK THE INJECTOR GROUND CIRCUIT FOR SHORT CIRCUIT TO BATTERY
Measure the voltage between the relevant injector harness electrical connector (IJ1 to 6) pin 1 and GROUND.
Is the voltage greater than 1 volt?
Yes
REPAIR the short circuit. For additional information, refer to wiring diagrams. CLEAR the DTC. TEST the system for
normal operation.
No
GO to A6.
A6: CHECK THE INJECTOR GROUND CIRCUIT FOR SHORT CIRCUIT TO GROUND
Measure the resistance between the relevant injector harness electrical connector (IJ1 to 6) pin 1 and GROUND.
Yes
normal operation.
No
INSTALL a new ECM.
REFER to: Electronic Engine Controls - 2.5L NA V6 - AJV6/3.0L NA V6 - AJ27, VIN Range: E96603->J28492 (303-14A
Electronic Engine Controls - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27, Diagnosis and Testing).
Before replacing a ECM, contact Dealer technical support.
PINPOINT TEST B : FUEL RAIL PRESSURE SENSOR. P0190, P0192, P0193
TEST
CONDITIONS
B1: CHECK THE FUEL RAIL PRESSURE SENSOR SUPPLY VOLTAGE
Disconnect the fuel rail pressure sensor electrical connector IJ007.
Measure the supply voltage to the fuel rail pressure sensor electrical connector IJ007 pin 1 (YG) and GROUND.
Is the supply voltage between 4.5 and 5.5 volts?
Yes
GO to B2.
No
REPAIR the circuit between IJ007 pin 1, (YG) and ENS07. For additional information, refer to wiring diagrams. CLEAR
the DTC. TEST the system for normal operation. If the DTC is repeated, INSTALL a new ECM.
(The fault could be in any of the components or sensors in the 5 volt supply circuit, or the ECM)
B2: CHECK THE FUEL RAIL PRESSURE SENSOR GROUND CIRCUIT FOR OPEN CIRCUIT
Measure the resistance between the fuel rail pressure sensor electrical connector IJ007 pin 2, (WG) and GROUND.
Is the resistance greater than 10,000 ohms?
Yes
REPAIR the circuit between IJ007 pin 2 (WG) and ground at IJS02. For additional information, refer to wiring
diagrams. CLEAR the DTC. TEST the system for normal operation.
No
GO to B3.
B3: CHECK THE FUEL RAIL PRESSURE SENSOR SIGNAL CIRCUIT FOR OPEN CIRCUIT
Measure the resistance between the fuel rail pressure sensor electrical connector IJ007 pin 3 (WG) and EN16 pin 73.
Yes
REPAIR the circuit between IJ007 pin 3 (WG) and EN016 pin 73 (WG). For additional information, refer to wiring
No
GO to B4.
B4: CHECK THE FUEL RAIL PRESSURE SENSOR SIGNAL CIRCUIT FOR SHORT TO GROUND
Measure the resistance between the fuel rail pressure sensor electrical connector IJ007 pin 3 (WG) and GROUND.
Yes
REPAIR the circuit between IJ007 pin 3 (WG) and EN016 pin 73 (WG). For additional information, refer to wiring
No
GO to B5.
B5: CHECK THE FUEL RAIL PRESSURE SENSOR CIRCUIT RESISTANCE
Disconnect the fuel rail pressure sensor electrical connector IJ007.
Measure the resistance between the fuel rail pressure sensor pins 1 and 2.
Is the resistance between 10,000 and 12,000 ohms?
Yes
GO to B6.
No
Install a new fuel rail pressure sensor.
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REFER to: Fuel Pulse Damper - 2.5L NA V6 - AJV6/3.0L NA V6 - AJ27 (303-04A Fuel Charging and Controls - 2.0L NA
V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27, Removal and Installation).
Yes
GO to B7.
No
Yes
Install a new ECM.
No
PINPOINT TEST C : FUEL LEVEL SENSORS. P0460
TEST
CONDITIONS
C1: CHECK THE FUEL LEVEL SENSOR (1) GROUND CIRCUIT
Disconnect the fuel level sensor electrical connector FT2.
Measure the resistance between electrical connector FT2 pin 3 (B) and GROUND.
Yes
GO to C2.
No
REPAIR the circuit between electrical connector FT2 pin 3 (B) and GROUND. For additional information, refer to wiring
diagrams.CLEAR the DTC. TEST the system for normal operation.
C2: CHECK THE FUEL LEVEL SENSOR (1) SIGNAL CIRCUIT
Disconnect the Instrument cluster electrical connector IP10.
Measure the resistance between electrical connector FT2 pin 1 (WU) and electrical connector IP10 pin 7 (WU)
Yes
GO to C3.
No
REPAIR the circuit between FT2 pin 1 (WU) and IP10 pin 7 (WU). For additional information, refer to wiring diagrams.
C3: CHECK THE FUEL LEVEL SENSOR (1) RHEOSTAT (EMPTY)
Empty the fuel tank.
Measure the resistance between pins 1 and 3 of the fuel level sensor.
Is the resistance 20 ohms?
Yes
GO to C4.
No
INSTALL a new fuel level sensor.
REFER to: Fuel Tank and Lines (310-01 Fuel Tank and Lines, Diagnosis and Testing).
C4: CHECK THE FUEL LEVEL SENSOR (1) RHEOSTAT (FULL)
Fill the fuel tank.
Yes
INSTALL a new instrument cluster.
No
Disconnect the fuel level sensor electrical connector, FT3.
Measure the resistance between electrical connector FT3, pin 3 (B) and GROUND.
Yes
GO to C6.
No
REPAIR the circuit between FT3 pin 3 (B) and ground. For additional information, refer to wiring diagrams. CLEAR the
Disconnect the instrument cluster electrical connector IP10.
Measure the resistance between electrical connector FT3 pin 1 (WB) and electrical connector IP10 pin 8(WB)
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Yes
GO to C7.
No
REPAIR the circuit between FT3 pin 1 (WB) and IP10 pin 8 (WB). For additional information, refer to wiring diagrams.
Yes
GO to C8.
No
Fill the fuel tank.
Yes
No
PINPOINT TEST D : FUEL PUMP CONTROL MODULE. P1234, P1236
TEST
CONDITIONS
D1: CHECK THE POWER SUPPLY TO THE FUEL PUMP MODULE
Disconnect the fuel pump module electrical connector CA105.
Measure the voltage at CA105 pin 9 (NG)
Yes
GO to D2.
No
REPAIR the circuit between electrical connector CA105 pin 9 (NG) and the ignition switch. CLEAR the DTC. TEST the
(This circuit includes the central junction fuse box, ignition relay, and the inertia switch. For additional information, refer to wiring diagrams)
D2: CHECK THE GROUND CIRCUIT TO THE FUEL PUMP MODULE
Measure the resistance between CA105 pin 2 (B) and ground.
Yes
GO to D3.
No
REPAIR the circuit between electrical connector CA105 pin 2 (B) and GROUND. For additional information, refer to
wiring diagrams. CLEAR the DTC. TEST the system for normal operation.
D3: CHECK THE SIGNAL GROUND CIRCUIT TO THE FUEL PUMP MODULE
NOTE: This test would be necessary if there were an EMC (Electro Magnetic Compatibility) issue with the vehicle.
Turn the ignition switch to the CRANK position.
Measure the resistance between electrical connector CA105 pin 4 (BG) and ground.
Yes
GO to D4.
No
REPAIR the circuit between electrical connector CA105 pin 4 (BG) and GROUND. For additional information, refer to
(This circuit includes the ECM)
D4: CHECK THE POWER SUPPLY CIRCUIT TO THE FUEL PUMP
Reconnect the fuel pump module electrical connector CA105.
Disconnect the fuel pump electrical connector FT2.
Measure the voltage between electrical connector FT2 pin 2 (R) and GROUND.
Yes
GO to D5.
No
INSTALL a new fuel pump module.
D5: CHECK THE SIGNAL GROUND CIRCUIT FOR CONTINUITY
Measure the resistance between electrical connector CA105 pin 3 (Y) and electrical connector FT2 pin 4 (Y)
Yes
If the DTC is repeated, INSTALL a new fuel pump.
No
REPAIR the circuit between electrical connector CA105 pin 3 (Y) and electrical connector FT2 pin 4 (Y). For additional
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information, refer to wiring diagrams. CLEAR the DTC. TEST the system for normal operation.
PINPOINT TEST E : FUEL PUMP FEEDBACK CIRCUITS. P1338
TEST
CONDITIONS
E1: CHECK SIGNAL POWER CIRCUIT TO FUEL PUMP MODULE
Disconnect fuel pump module electrical connector CA105.
Measure the voltage between electrical connector CA105 pin 9 (NG) and GROUND.
Yes
GO to E2.
No
GO to E4.
E2: CHECK FEEDBACK CIRCUIT TO FUEL PUMP MODULE
Reconnect fuel pump module electrical connector CA105.
Measure the voltage between ECM electrical connector EN16 pin 25 (W) and GROUND.
Yes
No electrical fault in circuit. Recheck DTCs.
No
GO to E3.
E3: CHECK FEEDBACK CIRCUIT FOR CONTINUITY
Disconnect ECM electrical connector EN16.
Measure the resistance between electrical connector CA105 pin 7 (W) and electrical connector EN16 pin 25 (W).
Yes
GO to E4.
No
REPAIR the circuit between electrical connector CA105 pin 7 (W) and electrical connector EN16 pin 25 (W). For
additional information, refer to wiring diagrams. CLEAR the DTC. TEST the system for normal operation.
E4: CHECK CONTROL CIRCUIT FOR CONTINUITY
Measure the resistance between electrical connector CA105 pin 1 (N) and electrical connector EN16 pin 27 (N).
Yes
CLEAR the DTC. TEST the system for normal operation. If the DTC is repeated, INSTALL a new ECM.
No
REPAIR the circuit between electrical connector CA105 pin 1 (N) and electrical connector EN16 pin 27 (N). For
PINPOINT TEST F : THROTTLE CONTROL POSITION ERROR. P1224, P1229
TEST
CONDITIONS
F1: CHECK THROTTLE CONTROL CIRCUIT FOR CONTINUITY
Disconnect throttle motor electrical connector EN10.
Measure the resistance between ECM electrical connector EN16 pin 80 (G) and throttle motor electrical connector EN10
pin 2 (G).
Yes
GO to F2.
No
REPAIR the circuit between ECM electrical connector EN16 pin 80 (G) and throttle motor electrical connector EN10 pin
2 (G). For additional information, refer to wiring diagrams. CLEAR the DTC. TEST the system for normal operation.
Measure the resistance between ECM electrical connector EN16 pin 106 (R) and throttle motor electrical connector
EN10 pin 1 (R).
Yes
INSTALL a new ECM.
No
REPAIR the circuit between ECM electrical connector EN16 pin 106 (R) and throttle motor electrical connector EN10 pin
1 (R). For additional information, refer to wiring diagrams. CLEAR the DTC. TEST the system for normal operation.
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- Fuel Charging and Controls2.5L NA V6 - AJV6/3.0L NA V6 - AJ27, VIN Range:
J28493->V99999
step.
3.
4. If the concern is not visually evident, use a fault code reader to retrieve fault codes before proceeding to the Symptom Chart. 4.
Symptom Chart
combustion too lean
Engine misfire
Air intake leak between MAF sensor
and throttle
Fuel filter/system restriction
fuel pulse damper failure (low fuel
pressure)
HO2S (1/1; ) harness wiring
condition fault
Exhaust leak (before catalyst)
receiving incorrect signal from one or
more of the following components;
ECT sensor, MAF sensor, IAT sensor,
IP sensor, EFT sensor, TP sensor
REFER to:
(303-07A Engine Ignition - 2.0L NA V6 - AJV6/2.5L NA
V6 - AJV6/3.0L NA V6 - AJ27, Diagnosis and Testing),
Engine (303-01A Engine - 2.0L NA V6 - AJV6/2.5L NA
Exhaust System (309-00 Exhaust System, Diagnosis
and Testing),
Electronic Engine Controls - 2.5L NA V6 - AJV6/3.0L NA
V6 - AJ27, VIN Range: J28493->V99999 (303-14A
V6 - AJV6/3.0L NA V6 - AJ27, Diagnosis and Testing).
combustion too rich
fuel pulse damper failure (high fuel
pressure)
ECM receiving incorrect signal from
one or more of the following
components; ECT sensor, MAF sensor,
IAT sensor, IP sensor, EFT sensor, TP
sensor
REFER to:
Intake Air Distribution and Filtering (303-12A Intake
Air Distribution and Filtering - 2.0L NA V6 - AJV6/2.5L
NA V6 - AJV6/3.0L NA V6 - AJ27, Diagnosis and
Testing),
V6 - AJ27, VIN Range: J28493->V99999 (303-14A
combustion too lean
Engine misfire
Air intake leak between MAF sensor
and throttle
fuel pulse damper failure (low fuel
pressure)
HO2S (2/1; 2/2) harness wiring
condition fault
Exhaust leak (before catalyst)
sensor
REFER to:
(303-07A Engine Ignition - 2.0L NA V6 - AJV6/2.5L NA
Engine (303-01A Engine - 2.0L NA V6 - AJV6/2.5L NA
Exhaust System (309-00 Exhaust System, Diagnosis
and Testing),
V6 - AJ27, VIN Range: J28493->V99999 (303-14A
combustion too rich
fuel pulse damper failure (high fuel
pressure)
sensor
REFER to:
Intake Air Distribution and Filtering (303-12A Intake
Air Distribution and Filtering - 2.0L NA V6 - AJV6/2.5L
NA V6 - AJV6/3.0L NA V6 - AJ27, Diagnosis and
Testing),
V6 - AJ27, VIN Range: J28493->V99999 (303-14A
P1251,
P1631,
P1657,
P1658
Concern with throttle
motor relay
Throttle motor relay circuit
REFER to: Electronic Engine Controls - 2.5L NA V6 -
AJV6/3.0L NA V6 - AJ27, VIN Range: J28493->V99999
(303-14A Electronic Engine Controls - 2.0L NA V6 -
AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27, Diagnosis and
Testing).
P0112,
P0113
Concern with IAT
sensor
Engine faulty leading to overheating
Intake air temperature (IAT) sensor
fault
Harness fault
ECM failure
REFER to:
Acceleration Control (310-02 Acceleration Control,
Diagnosis and Testing),
V6 - AJ27, VIN Range: J28493->V99999 (303-14A
P0121,
P0122,
P0123,
P0222,
P0223
position (TP) sensor
TP sensor fault
Harness fault
ECM failure
Testing).
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P0116,
P0117,
P0118,
P0125
Concern with engine
coolant temperature
Engine coolant temperature sensor
Harness fault
ECM failure
Testing).
P0201,
P0202,
P0203,
P0204,
P0205,
P0206
Concern with fuel
injectors
Faulty injector(s)
Harness fault
ECM failure
Testing).
P0191 Concern with
injection pressure
(IP) sensor
fuel pulse damper sensor
Harness fault
Fuel system leak
Incorrect fuel pump output
IP sensor to ECM sensing circuit; high
resistance, open circuit, short circuit
to high voltage
IP sensor to splice in sensor supply
circuit; high resistance, open circuit
IP sensor to splice in sensor ground
circuit; high resistance, open circuit,
short circuit to ground, short circuit to
high voltage
IP sensor failure
P0192 Concern with
injection pressure
(IP) sensor (low
voltage/low
pressure)
IP sensor disconnected
IP sensor to ECM sensing circuit;
open circuit or short circuit to ground
IP sensor to splice in sensor supply
IP sensor failure
P0193 Concern with
injection pressure
(IP) sensor (high
voltage/high
pressure)
IP sensor to ECM wiring
(supply/sense) short circuit to each
other
IP sensor to ECM sense circuit; short
circuit to high voltage
circuit; open circuit
IP sensor failure
level sensors
Fuel level sensor to instrument
cluster circuit(s); intermittent short
circuit, open circuit, high resistance
Fuel level sensor failure
Instrument cluster fault
P0627,
P0628,
P0629
Concern with fuel
pump commands
ECM to fuel pump control module
control and/or feedback circuits; open
circuit, short circuit, high resistance
Fuel pump control module failure
pump operation
ECM to fuel pump control module
control and/or feedback circuits; open
circuit, short circuit, high resistance
P1250,
P1254
valve return spring
and "limp-home"
spring
Throttle body These DTCs can only be accurately diagnosed using the
Jaguar approved diagnostic system. If this is not available,
INSTALL a new throttle body.
REFER to: Throttle Body (303-04A Fuel Charging and
Controls - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 -
CLEAR the DTC, TEST the system for normal operation.
P2107 Concern with throttle
"watchdog circuit"
circuit
ECM REFER to: Electronic Engine Controls - 2.5L NA V6 -
Testing).
motor control circuit
Throttle motor disconnected
Throttle motor to ECM drive circuits;
short circuit or open circuit
control position
Throttle adaptions not performed
after battery disconnect
TP sensor disconnected
TP sensor to ECM sense circuits; open
circuit, high resistance
Throttle motor relay failure
Throttle motor relay to ECM circuit
fault
Throttle motor relay power supply
open circuit
ECM ground circuit fault (relay coil
drive)
Throttle motor to ECM drive circuits;
Testing). Individual Pinpoint tests for components and
circuits listed
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open circuit, short circuit, high
resistance
Throttle body failure
P1656 Concern with TP
sensor amplifier
circuit
ECM REFER to: Electronic Engine Controls - 2.5L NA V6 -
Testing).
PINPOINT TEST A : FUEL INJECTORS, P0201, P0202, P0203, P0204, P0205, P0206.
NOTE: The DTC set will indicate which cylinder injector or circuit is faulty. Only in the event of multiple cylinder misfires will it be
necessary to check more than one injector or circuit, in which case, multiple DTCs will be set.
TEST
CONDITIONS
A1: CHECK THE INJECTOR COIL RESISTANCE
Disconnect the relevant injector electrical connector (IL1 to 6).
Measure the resistance between the injector pins.
Yes
GO to A2.
No
A2: CHECK THE INJECTOR COIL INSULATION
Are both resistances greater than 10 OHMS?
Yes
GO to A3.
No
A3: CHECK THE INJECTOR SUPPLY VOLTAGE
Disconnect the relevant injector harness electrical connector (IL1 to 6).
Measure the voltage between the relevant injector harness electrical connector (IL1 to 6) pin 2 and GROUND.
Is the voltage greater than 12 Volts?
Yes
GO to A4.
No
REPAIR the circuit between the relevant injector harness electrical connector, (IL1 to 6) pin 2 and battery. This circuit
includes the power distribution fuse box, fuse 41, and the EMS control relay. For additional information, refer to wiring
diagrams. CLEAR DTC. TEST the system for normal operation.
A4: CHECK THE INJECTOR GROUND CIRCUIT
Measure the resistance between the relevant injector harness electrical connector (IL1 to 6) pin 1 and EN16 pins as
follows -
Injector 1 pin 1 (NW) and ECM pin 115.
Injector Cyl 3 pin 1 (N) and ECM pin 114.
Injector Cyl 5 pin 1 (NR) and ECM pin 113.
Injector Cyl 2 pin 1 (NU) and ECM pin 120.
Injector Cyl 4 pin 1 (NG) and ECM pin 119.
Injector Cyl 6 pin 1 (NY) and ECM pin 118.
Yes
GO to A5.
No
REPAIR the circuit between the relevant injector harness electrical connector pin 1 and the ECM electrical connector.
A5: CHECK THE INJECTOR GROUND CIRCUIT FOR SHORT CIRCUIT TO BATTERY
Measure the voltage between the relevant injector harness electrical connector (IL1 to 6) pin 1 and GROUND.
Yes
normal operation.
No
GO to A6.
A6: CHECK THE INJECTOR GROUND CIRCUIT FOR SHORT CIRCUIT TO GROUND
Measure the resistance between the relevant injector harness electrical connector (IL1 to 6) pin 1 and GROUND.
Yes
normal operation.
No
INSTALL a new ECM.
REFER to: Engine Control Module (ECM) (303-14A Electronic Engine Controls - 2.0L NA V6 - AJV6/2.5L NA V6 -
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PINPOINT TEST B : FUEL PULSE DAMPER SENSOR. P0190, P0192, P0193
TEST
CONDITIONS
B1: CHECK THE FUEL PULSE DAMPER SENSOR SUPPLY VOLTAGE
Disconnect the fuel pulse damper sensor electrical connector IL007.
Measure the supply voltage to the fuel pulse damper sensor electrical connector IL007 pin 1 (YG) and GROUND.
Is the supply voltage between 4.5 and 5.5 volts?
Yes
GO to B2.
No
REPAIR the circuit between IL007 pin 1, (YG) and ENS07. For additional information, refer to wiring diagrams. CLEAR
the DTC. TEST the system for normal operation. If the DTC is repeated, INSTALL a new ECM.
B2: CHECK THE FUEL PULSE DAMPER SENSOR GROUND CIRCUIT FOR OPEN CIRCUIT
Measure the resistance between the fuel pulse damper sensor electrical connector IL007 pin 2, (WG) and GROUND.
Yes
REPAIR the circuit between IL007 pin 2 (WG) and ground at ILS02. For additional information, refer to wiring
No
GO to B3.
B3: CHECK THE FUEL PULSE DAMPER SENSOR SIGNAL CIRCUIT FOR OPEN CIRCUIT
Measure the resistance between the fuel pulse damper sensor electrical connector IL007 pin 3 (WG) and EN16 pin 73.
Yes
REPAIR the circuit between IL007 pin 3 (WG) and EN016 pin 73 (WG). For additional information, refer to wiring
No
GO to B4.
B4: CHECK THE FUEL PULSE DAMPER SENSOR SIGNAL CIRCUIT FOR SHORT TO GROUND
Measure the resistance between the fuel pulse damper sensor electrical connector IL007 pin 3 (WG) and GROUND.
Yes
REPAIR the circuit between IL007 pin 3 (WG) and EN016 pin 73 (WG). For additional information, refer to wiring
No
GO to B5.
B5: CHECK THE FUEL PULSE DAMPER SENSOR CIRCUIT RESISTANCE
Disconnect the fuel pulse damper sensor electrical connector IL007.
Measure the resistance between the fuel pulse damper sensor pins 1 and 2.
Yes
GO to B6.
No
Install a new fuel pulse damper sensor.
Yes
GO to B7.
No
Yes
Install a new ECM.
REFER to: Electronic Engine Controls - 2.5L NA V6 - AJV6/3.0L NA V6 - AJ27, VIN Range: J28493->V99999 (303-14A
No
PINPOINT TEST C : FUEL LEVEL SENSORS. P0460
TEST
CONDITIONS
Disconnect the fuel level sensor electrical connector FT2.
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Measure the resistance between electrical connector FT2 pin 3 (B) and GROUND.
Yes
GO to C2.
No
REPAIR the circuit between electrical connector FT2 pin 3 (B) and GROUND. For additional information, refer to wiring
Disconnect the Instrument cluster electrical connector IP10.
Measure the resistance between electrical connector FT2 pin 1 (WU) and electrical connector IP10 pin 7 (WU).
Yes
GO to C3.
No
REPAIR the circuit between FT2 pin 1 (WU) and IP10 pin 7 (WU). For additional information, refer to wiring diagrams.
Yes
GO to C4.
No
INSTALL a new fuel level sensor. REFER to: (310-01 Fuel Tank and Lines)
Fuel Level Sender LH - 2.5L NA V6 - AJV6/3.0L NA V6 - AJ27 (Removal and Installation),
Fuel Level Sender RH - 2.5L NA V6 - AJV6/3.0L NA V6 - AJ27 (Removal and Installation).
Fill the fuel tank.
Yes
REFER to: Instrument Cluster (413-01 Instrument Cluster, Removal and Installation).
No
REFER to: Fuel Level Sender LH - 2.5L NA V6 - AJV6/3.0L NA V6 - AJ27 (310-01 Fuel Tank and Lines, Removal and
Installation) /
Fuel Level Sender RH - 2.5L NA V6 - AJV6/3.0L NA V6 - AJ27 (310-01 Fuel Tank and Lines, Removal and Installation).
Disconnect the fuel level sensor electrical connector, FT3.
Measure the resistance between electrical connector FT3, pin 3 (B) and GROUND.
Yes
GO to C6.
No
REPAIR the circuit between FT3 pin 3 (B) and ground. For additional information, refer to wiring diagrams. CLEAR the
Measure the resistance between electrical connector FT3 pin 1 (WB) and electrical connector IP10 pin 8 (WB).
Yes
GO to C7.
No
REPAIR the circuit between FT3 pin 1 (WB) and IP10 pin 8 (WB). For additional information, refer to wiring diagrams.
Yes
GO to C8.
No
Installation) /
Fill the fuel tank.
Yes
No
Installation) /
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PINPOINT TEST D : FUEL PUMP CONTROL MODULE. P0627, P0628, P0629
TEST
CONDITIONS
D1: CHECK SIGNAL POWER CIRCUIT TO FUEL PUMP MODULE
Measure the voltage between electrical connector CA105 pin 9 (NG) and GROUND.
Yes
GO to D2.
No
GO to D4.
D2: CHECK FEEDBACK CIRCUIT TO FUEL PUMP MODULE
Reconnect fuel pump module electrical connector CA105.
Measure the voltage between ECM electrical connector EN16 pin 25 (W) and GROUND.
Yes
No electrical fault in circuit. Recheck DTCs.
No
GO to D3.
D3: CHECK FEEDBACK CIRCUIT FOR CONTINUITY
Measure the resistance between electrical connector CA105 pin 7 (W) and electrical connector EN16 pin 25 (W).
Yes
GO to D4.
No
REPAIR the circuit between electrical connector CA105 pin 7 (W) and electrical connector EN16 pin 25 (W). For
D4: CHECK CONTROL CIRCUIT FOR CONTINUITY
Measure the resistance between electrical connector CA105 pin 1 (N) and electrical connector EN16 pin 27 (N).
Yes
REFER to: Fuel Pump Module - 2.5L NA V6 - AJV6/3.0L NA V6 - AJ27 (310-01 Fuel Tank and Lines, Removal and
Installation).
No
REPAIR the circuit between electrical connector CA105 pin 1 (N) and electrical connector EN16 pin 27 (N). For
PINPOINT TEST E : FUEL PUMP CONTROL MODULE. P2635
TEST
CONDITIONS
E1: CHECK THE POWER SUPPLY TO THE FUEL PUMP MODULE
Measure the voltage at CA105 pin 9 (NG)
Yes
GO to E2.
No
REPAIR the circuit between electrical connector CA105 pin 9 (NG) and the ignition switch. CLEAR the DTC. TEST the
(This circuit includes the central junction fuse box, ignition relay, and the inertia switch. For additional information, refer to wiring diagrams)
E2: CHECK THE GROUND CIRCUIT TO THE FUEL PUMP MODULE
Measure the resistance between CA105 pin 2 (B) and ground.
Yes
GO to E3.
No
REPAIR the circuit between electrical connector CA105 pin 2 (B) and GROUND. For additional information, refer to
E3: CHECK THE SIGNAL GROUND CIRCUIT TO THE FUEL PUMP MODULE
Measure the resistance between electrical connector CA105 pin 4 (BG) and ground.
Yes
GO to E4.
No
REPAIR the circuit between electrical connector CA105 pin 4 (BG) and GROUND. For additional information, refer to
(This circuit includes the ECM)
E4: CHECK THE POWER SUPPLY CIRCUIT TO THE FUEL PUMP
Reconnect the fuel pump module electrical connector CA105.
Measure the voltage between electrical connector FT2 pin 2 (R) and GROUND.
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Yes
GO to E5.
No
Installation).
E5: CHECK THE SIGNAL GROUND CIRCUIT FOR CONTINUITY
Measure the resistance between electrical connector CA105 pin 3 (Y) and electrical connector FT2 pin 4 (Y)
Yes
Installation).
If the DTC is repeated, INSTALL a new fuel level sender.
Installation) /
No
REPAIR the circuit between electrical connector CA105 pin 3 (Y) and electrical connector FT2 pin 4 (Y). For additional
PINPOINT TEST F : THROTTLE CONTROL CIRCUIT P2118.
TEST
CONDITIONS
Disconnect throttle motor electrical connector EN10.
Measure the resistance between ECM electrical connector EN16 pin 80 (G) and throttle motor electrical connector EN95
pin 2 (G).
Yes
GO to F2.
No
REPAIR the circuit between ECM electrical connector EN16 pin 80 (G) and throttle motor electrical connector EN95 pin
2 (G). For additional information, refer to wiring diagrams. CLEAR the DTC. TEST the system for normal operation.
Measure the resistance between ECM electrical connector EN16 pin 106 (R) and throttle motor electrical connector
EN95 pin 1 (R).
Yes
INSTALL a new ECM.
No
REPAIR the circuit between ECM electrical connector EN16 pin 106 (R) and throttle motor electrical connector EN95 pin
1 (R). For additional information, refer to wiring diagrams. CLEAR the DTC. TEST the system for normal operation.
www.JagDocs.com
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- Fuel Charging Wiring Harness
Removal
1. Remove the intake manifold. For additional information, refer to Section
303-01A EngineSection 303-01B Engine.
2. Disconnect the spring lock coupling. For additional information, refer to
Section 310-00 Fuel System - General Information.
5. Detach the fuel pressure sensor vacuum line.
6. Detach the fuel charging wiring harness.
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7. NOTE: Fuel may still be present in the fuel injection supply manifold.
Detach the fuel injection supply manifold and lower intake manifold and
place to one side.
Remove and discard the lower intake manifold O-ring seals.
9. Remove the lower intake manifolds.
Remove and discard the fuel injector O-ring seals.
10. Remove the fuel charging wiring harness.
11. Remove the fuel rail.
For additional information, refer to Fuel Injection Supply Manifold in this
section.
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Installation
2. NOTE: Install new fuel injector O-ring seals.
NOTE: Install new lower intake manifold O-ring seals.
Tighten to 10 Nm.
Tighten to 10 Nm.
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- Fuel Injection Supply Manifold
Removal
All vehicles
For additional information, refer to Section 414-01 Battery, Mounting
and Cables.
For additional information, refer to Section 310-00 Fuel System -
3. Remove the fuel injectors. For additional information, refer to Fuel
Injectors.
Detach the harness.
5. Remove the engine trim retaining bracket.
6. Remove the injector retaining clip.
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7. Remove the fuel rail retaining bolts.
8. Disconnect the fuel rail from the injectors.
9. Remove the fuel injection rail.
1. Rotate the fuel injection rail through 180.
2. Remove the fuel injection rail.
10. Remove the fuel pressure sensor.
Installation
All vehicles
Lubricate the fuel injector O-ring seals with clean engine oil.
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Tighten to 10 Nm.
4. Tighten to 6 Nm.
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- Fuel Injectors
Removal
For additional information, refer to Fuel Charging Wiring Harness in this
section.
2. Remove the fuel injectors.
Remove the fuel injector retaining clips.
For additional information, refer to Fuel Injection Supply Manifold in this
section.
4. Detach the injectors from the lower intake manifold.
5. Remove the injectors.
All vehicles
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7.
Installation
Lubricate the fuel injector O-ring seals with clean engine oil.
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- Fuel Pulse Damper2.5L NA V6 - AJV6/3.0L NA V6 - AJ27
Removal
1. Remove the throttle body. For additional information, refer to Throttle
Body.
3. Detach the fuel pressure sensor vacuum line.
4. Remove the fuel pressure sensor.
Installation
Tighten to 10 Nm.
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- Throttle Body
Removal
All vehicles
CAUTION: Do not attempt to clean the throttle body. The bore and the throttle plate has a special coating applied during manufacture
which should not be removed.
1. Remove the air cleaner outlet pipe. For additional information, refer to
Section 303-12A Intake Air Distribution and FilteringSection 303-12B
Intake Air Distribution and Filtering.
2. Disconnect the cruise control cable.
3. Disconnect the accelerator cable.
1. Position the accelerator actuator to the open position.
2. Disconnect the accelerator cable.
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8. Remove the throttle body.
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9. Remove the throttle body.
All vehicles
Installation
All vehicles
CAUTION: Do not attempt to clean the throttle body. The bore and the throttle plate has a special coating applied during manufacture
which should not be removed.
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Fuel Charging and Controls - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS)
- Puma -
High-pressure fuel supply lines 40 30 -
High-pressure fuel supply line support bracket retaining nut 8 - 71
Fuel injectors 47 35 -
Fuel injection supply manifold retaining bolts 23 17 -
Fuel injection supply manifold support bracket retaining bolts 14 10 -
Fuel pump shield lower retaining bolt 33 24 -
Fuel pump shield upper retaining bolts 8 - 71
Fuel pump support bracket to fuel pump retaining bolts 33 24 -
Fuel pump support bracket to cylinder block retaining bolts 23 17 -
Fuel pump retaining bolts 22 16 -
Fuel pump sprocket retaining bolts 32 24 -
Fuel supply line to fuel pump union retaining nut 20 15 -
Exhaust gas recirculation (EGR) valve retaining bolts 10 - 89
Intake manifold retaining bolts 15 11 -
Fuel return line venturi retaining bolt 6 - 53
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- Puma - Fuel Charging and Controls
High Pressure Fuel Injection Components
1 - Fuel injection supply manifold support bracket
2 - Fuel injection supply manifold
3 - High-pressure fuel supply lines (fuel injection supply manifold to fuel injectors)
4 - Fuel injection supply manifold support bracket
5 - Fuel injector
6 - Fuel injector sealing washer
7 - High-pressure fuel supply line (fuel pump to fuel injection supply manifold)
8 - Fuel pump
Fuel Pump
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1 - Fuel pump retaining bolt
2 - Fuel pump gasket
3 - Fuel pump fuel return line
4 - Fuel pump fuel supply line
5 - Fuel pump
6 - Fuel pump shield
7 - Fuel return line venturi
8 - Fuel pump sprocket retaining bolt
9 - Fuel pump sprocket
Fuel Injectors
The fuel injectors are operated electrically by the engine control module (ECM) and inject a precise amount of fuel into the combustion
chamber at the required time.
The injectors have been designed to:
allow pilot and main injections with short intervals between each injection.
be fully electrically controlled.
Each injector is calibrated and given its own unique identification number at manufacture. The identification number is a set of letters and
numbers located near to the top of the injector.
CAUTION: If any of the high pressure fuel pipe retaining nuts are loosened, the high pressure fuel pipe it is installed to must be
renewed. Failure to follow this instruction may allow metal fragments to enter the fuel system and result in damage to the fuel system
components.
When the injectors are fitted to an engine, the injector identification number and the cylinder number to which it is installed must be
programmed into the ECM. This gives the ECM a base calibration for each cylinder of the engine, as the vehicle is run the ECM will adapt
from this calibration. If any of the injectors are replaced the ECM will have to be reprogrammed with all of the injector identification
numbers and cylinder number to which each is fitted.
Fuel Injection Supply Manifold
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The fuel injection supply manifold is a reservoir for the pressurized fuel that is produced by the fuel pump. It also incorporates a pressure
sensor so that the ECM can monitor/adjust the pressure of the fuel to be injected into the cylinder. The fuel injection supply manifold and
the pressure sensor are serviced as an assembly and must not under any circumstance be disassembled.
Fuel Pump
The fuel pump is located under the intake manifold and is driven by the timing chain at the front of the engine. The fuel pump includes a
transfer pump and a high pressure pump which are serviced as one unit.
The transfer pump draws the fuel from the fuel tank and through the fuel filter, it then pumps the fuel to the high pressure pump. The
transfer pump maintains a constant pressure of 6 bar (87.02 lb/in) via a regulating valve within the fuel pump, this is known as transfer
pressure.
The high pressure pump receives fuel at transfer pressure from the transfer pump and increases the fuel pressure to between 200 and 1600
bar. The high pressure fuel is then transferred from the high pressure pump to the fuel injection supply manifold.
Fuel Return Line Venturi
The fuel return system incorporates a fuel return line venturi, installed to the back of the fuel pump. The fuel return line venturi is a partial
restriction in the fuel return line, which creates a negative pressure in the fuel return system prior to its position in the system. The
negative pressure created by the fuel return line venturi helps in the removal and the return to the fuel tank of the fuel leaked off by the
fuel injectors.
Fuel Filter
The fuel filter is located at the top of the bulkhead on the right-hand side of the vehicle. The fuel filter incorporates a fuel pre heat
function, which utilizes a ball valve operated by a bimetallic strip. When the temperature is less than 15 C (59 F), the ball valve allows
the warm fuel in the fuel return system to pass back through the fuel filter to the fuel pump to improve cold running. Once the temperature
exceeds 31 C (88 F) a bimetallic strip closes the ball valve in the fuel filter and all of the fuel in the fuel return system is directed back to
the fuel tank.
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- Puma - Fuel Charging and Controls
This section covers the fuel system from the fuel filter to the fuel injectors, and includes the fuel rail and pump.
For additional information on the description and operation of the system:
REFER to: Fuel Charging and Controls (303-04B Fuel Charging and Controls - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) - Puma,
Inspection and verification
WARNING: Make sure that all suitable safety precautions are observed when carrying out any work on the fuel system. failure to
observe this warning may result in personal injury:
REFER to: Important Safety Instructions (100-00 General Information, Description and Operation).
CAUTION: Make sure that absolute cleanliness is observed when working with these components. Always install blanking plugs to any
open orifices or lines. failure to follow this instruction may result in damage to the vehicle.
2. Visually inspect for obvious mechanical or electrical faults. 2.
Fuel level (minimum of four liters for run out of fuel strategy)
Contaminated fuel
Fuel leak(s)
Fuel filter
Air cleaner element
Vacuum line(s)/vacuum connections
Hose(s)/hose connections
Tube(s)/tube connections
Fuel supply line(s)
Fuel return line(s)
High-pressure fuel supply line(s)
Fuel injection supply manifold
Fuel injectors
Fuel pump
- Investigate other fuel system components before condemning a pump
Glow plug indicator
Sensor(s)
Engine control module (ECM)
Fuel metering valve
Fuel temperature sensor
Inertia fuel shutoff (IFS) switch
Fuel injectors
Injector programming
Fuel rail pressure (FRP) sensor
Crankshaft position (CKP) sensor
Camshaft position (CMP) sensor
step.
3.
4. Use the approved diagnostic system or a scan tool to retrieve any diagnostic trouble codes (DTCs) before moving onto the
symptom chart or DTC index.
Make sure that all DTCs are cleared following rectification.
4.
Symptom Chart
Symptom
(general)
Symptom
(specific) Possible source Action
Non-Start Engine does
not crank
Security system
/Immobilizer engaged
Battery condition/charge
Starter relay fault
Starting system fault
Engine control module
(ECM) relay fault
Park/Neutral switch
fault
Engine siezed
Make sure that the immobilizer system is disarmed. Check the battery condition
and state of charge. Check that the engine turns by hand. Check the starting
system and circuits. Refer to the electrical guides. Check for DTCs indicating an
ECM relay or park/neutral switch fault. Rectify as necessary.
Engine cranks,
but does not
start
Security system
Low/Contaminated fuel
Air ingress
Blocked air cleaner
Blocked fuel filter
Low-pressure circuit
fault
Fuel metering valve
blocked/contaminated
Injector(s)
fault/programming
(IAT) sensor fault
Glow plug(s)/circuit
fault
fault
Camshaft position
(CMP) sensor fault
Make sure that the immobilizer system is disarmed. Check the fuel level and
condition. Draw off approximately 1 ltr (2.11 pints) of fuel and allow to stand for
1 minute. Check to make sure there is no separation of the fuel indicating water
or other liquid in the fuel. Check the low-pressure fuel system for leaks/damage,
check for air ingress. Check the air cleaner element. Check that fuel flows
through the fuel filter. Check for DTCs indicating a fuel metering valve or
injector fault. Check for DTCs indicating an engine management sensor fault.
Check the valve train, check the compressions,
REFER to: Engine (303-00 Engine System - General Information, Diagnosis and
Testing).
Check the catalytic converter condition, etc. Check for diesel particulate filter
DTCs. Refer to the warranty policy and procedures manual if an ECM is suspect.
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Symptom
(general)
Symptom
Crankshaft position
(CKP) sensor fault
Cylinder head
temperature (CHT)
sensor fault
Fuel pump fault
Low compression
Valve train fault
Blocked catalyst
(ECM) fault
Difficult to
start
Difficult to
start cold
fault
Contaminated fuel
Air ingress
Blocked air cleaner
Blocked fuel filter
fault
Fuel metering valve
fault
(IAT) sensor fault
Cylinder head
temperature (CHT)
sensor fault
Camshaft position
(CMP) sensor fault
Crankshaft position
(CKP) sensor fault
Injector(s)
fault/programming
Pump fault
Blocked catalyst
Valve train fault
Low compression
Check the glow plugs and circuits. Refer to the electrical guides. Check the fuel
level and condition. Draw off approximately 1 ltr (2.11 pints) of fuel and allow
to stand for 1 minute. Check to make sure there is no separation of the fuel
indicating water or other liquid in the fuel. Check the low-pressure fuel system
for leaks/damage, check for air ingress. Check the air cleaner element. Check
that fuel flows through the fuel filter. Check for DTCs indicating a fuel metering
valve or injector fault. Check for DTCs indicating an engine management sensor
fault. Check the valve train, check the compressions,
Testing).
DTCs.
Difficult to
start hot
Contaminated fuel
Air ingress
Blocked air cleaner
Blocked fuel filter
fault
Fuel metering valve
Exhaust gas
recirculation (EGR) valve
fault
fault
(IAT) sensor fault
Camshaft position
(CMP) sensor fault
Crankshaft position
(CKP) sensor fault
Injector(s)
fault/programming
Pump fault
Blocked catalyst
Valve train fault
Low compression
Check the fuel level and condition. Draw off approximately 1 ltr (2.11 pints) of
fuel and allow to stand for 1 minute. Check to make sure there is no separation
of the fuel indicating water or other liquid in the fuel. Check the low-pressure
fuel system for leaks/damage, check for air ingress. Check the air cleaner
element. Check that fuel flows through the fuel filter. Check for DTCs indicating
a fuel metering valve or injector fault. Check for DTCs indicating an engine
management sensor fault. Check the valve train, check the compressions,
Testing).
DTCs.
Engine cranks
too fast/slow
Low compression
Check the battery condition and state of charge. Check the starting system
circuits. Refer to the electrical guides. Rectify as necessary. Check the
compressions,
Testing).
Driveability Rough idle Low/Contaminated fuel
Air ingress
Injector(s)
fault/programming
Fuel metering valve
Exhaust gas
fault
Blocked air cleaner
Blocked fuel filter
Pump fault
Crankshaft position
(CKP) sensor fault
(IAT) sensor fault
Manifold absolute
pressure (MAP) sensor
fault
Knock sensor (KS) fault
fuel system for leaks/damage, check for air ingress. Check for DTCs indicating
an injector programming or EGR fault. Check the air cleaner element. Check that
fuel flows through the fuel filter. Check for DTCs indicating a fuel metering valve
fault. Check for DTCs indicating an engine management sensor fault. Check the
dual-mass flywheel.
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Symptom
(general)
Symptom
Dual-mass flywheel
fault
Idle speed
high or low
Accelerator pedal
position (APP) sensor
fault
(IAT) sensor fault
Check for DTCs indicating an APP or IAT sensor fault. Rectify as necessary.
Engine speed
out of control
Engine oil level too high
Excessive blow-by
Accelerator pedal
fault
Turbocharger
bearing/seal failure
Check/correct the engine oil level. Check the engine condition. Check for DTCs
indicating an APP sensor fault. Rectify as necessary. Check the turbocharger
bearing/seal condition by assessing the movement in the turbocharger shaft and
the amount of oil in the turbocharger body. Note that a small amount of oil is
normal.
Lack of power
when
accelerating
Contaminated fuel
Air intake circuit fault
Low fuel pressure
Exhaust gas
fault
Fuel filter blocked
Fuel lines
kinked/restricted
Pump fault
Injector(s)
fault/programming
Vehicle speed sensor
fault
Cylinder head
temperature (CHT)
sensor fault
(IAT) sensor fault
Manifold absolute
fault
Accelerator pedal
fault
Fuel rail temperature
(FRT) sensor fault
Fuel rail pressure (FRP)
sensor fault
Fuel metering valve
fault
Turbocharger fault
Catalyst blocked
Valve timing fault
Low compression
of the fuel indicating water or other liquid in the fuel. Check the air intake
system and low-pressure fuel circuit. Rectify as necessary. Check for DTCs
indicating an EGR fault. Check for DTCs indicating an engine management
sensor or injector programming fault. Check the turbocharger condition and
operation. Check the catalytic converter condition. Rectify as necessary. For
valve timing and compression information,
Testing).
Engine
stops/stalls
Air cleaner element
blocked
Fuel metering valve
Pump fault
High-pressure leak
fault (air ingress)
Relay fault
Crankshaft position
(CKP) sensor fault
Camshaft position
(CMP) sensor fault
Cylinder head
temperature (CHT)
sensor fault
sensor fault
Dual-mass flywheel
fault
(ECM) fault
indicating a relay, engine management sensor or ECM fault. Check the
dual-mass flywheel. Refer to the warranty policy and procedures manual if an
ECM is suspect.
Engine judders Low/Contaminated fuel
Fuel metering valve
High-pressure leak
fault (air ingress)
Pump fault
Exhaust gas
fault
Accelerator pedal
fault
indicating an engine management sensor or injector programming fault. Check
the catalytic converter and turbocharger condition. Rectify as necessary. Check
the dual-mass flywheel. For cylinder head, compression and camshaft
information,
Testing).
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Symptom
(general)
Symptom
Cylinder head
temperature (CHT)
sensor fault
Camshaft position
(CMP) sensor fault
Crankshaft position
(CKP) sensor fault
(IAT) sensor fault
Manifold absolute
fault
sensor fault
Injector(s)
fault/programming
Catalyst blocked
Turbocharger fault
Dual-mass flywheel
fault
Cylinder head gasket
fault
Camshafts/Valve
clearances
Low compression
Engine will not
stop
Turbocharger fault
(ECM) fault
Check/correct the engine oil level. Check the turbocharger condition and
operation. Check for DTCs indicating an ECM fault. Refer to the warranty policy
and procedures manual if an ECM is suspect.
General Excessive fuel
consumption
Incorrect engine oil
fault (air ingress/leaks)
Fuel metering
valve/circuit
High-pressure leak
Exhaust gas
fault
Injector(s)
fault/programming
Cylinder head
temperature (CHT)
sensor fault
(IAT) sensor fault
Manifold absolute
fault
Turbocharger fault
Dual-mass flywheel
fault
Valve timing fault
Low compression
Make sure that the correct grade of oil is used in the engine. Check the air
intake and low-pressure circuits. Check for DTCs indicating an EGR, injector
programming or engine management sensor fault. Check the turbocharger
condition and operation. Check the dual-mass flywheel. For valve timing and
compression information,
Testing).
Excessive
black smoke
Exhaust gas
fault
Injector(s)
fault/programming
Accelerator pedal
fault
Crankshaft position
(CKP) sensor fault
sensor fault
Turbocharger
bearings/seals fault
Valve timing fault
Check the air intake circuit. Check for DTCs indicating an EGR, injector
normal. For valve timing information,
Testing).
For a complete list of all diagnostic trouble codes that could be logged on this vehicle.
REFER to: Electronic Engine Controls (303-14B Electronic Engine Controls - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) - Puma,
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Name
Cleaning Fluid
- Puma - Fuel Injection Component Cleaning
General Procedures
General Equipment
Materials
Specification
W-M5B411-A
WARNINGS:
Eye protection must be worn at all times when working on or near any fuel related components. Failure to follow this instruction may
CAUTIONS:
Make sure that the workshop area in which the vehicle is being worked on is as clean and dust-free as possible. Areas in which work
on clutches, brakes or where welding or machining are carried out are not suitable in view of the risk of contamination to the fuel system.
Make sure that clean non-plated tools are used. Clean tools using a new brush that will not lose its bristles and fresh cleaning fluid,
prior to starting work on the vehicle.
Use a steel topped workbench and cover it with clean, lint-free non-flocking material.
Make sure that all parts removed from the vehicle are placed on the lint-free non-flocking material.
Make sure that any protective clothing worn is clean and made from lint-free non-flocking material.
Make sure that any protective gloves worn are new and are of the non-powdered latex type.
Before using the cleaning fluid, protect all electrical components and connectors with lint-free non-flocking material.
1. Using a new brush that will not lose its bristles, brush cleaning fluid
onto the components being removed and onto the surrounding area.
2. Using a pneumatic vacuum gun, remove all traces of cleaning fluid and
foreign material.
3. Dispose of any used cleaning fluid and the brush after completing the
repair.
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- Puma - Fuel Injection Pump
Special Tool(s)
Adapter for 303-681-01
303-681-01
Remover/Installer, Crankshaft Oil Seal
303-679
Locking Tool, Fuel Injection Pump Sprocket
303-681
Locking Tool, Fuel Injection Pump Sprocket
303-1151
Socket, Fuel Injection Pump
303-083A (23-057)
Removal
NOTE: If the fuel injection pump is being renewed in conjunction with the fuel injectors and high-pressure fuel lines, SRO 195010
must be claimed.
All vehicles
WARNINGS:
as 1600 bar (23,206 lb/in). Failure to follow this instruction may result in personal injury.
CAUTIONS:
Do not disassemble or clean inside the fuel injection pump, even with an ultrasonic cleaner. Always install a new fuel injection pump
when required.
NOTE: If the fuel injection pump has suffered a major mechanical failure, new fuel injectors should also be installed.
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1. Remove the exhaust gas recirculation (EGR) cooler to EGR valve tube.
Diesel/2.2L Diesel, Removal and Installation).
4. Detach the EGR valve from the intake manifold.
Discard the EGR valve gasket.
5. Detach the wiring harness from the intake manifold.
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Discard the intake manifold gaskets.
7. Disconnect the fuel metering valve and fuel temperature sensor
9. Detach the high-pressure fuel supply line support bracket.
10. Clean the fuel injection pump, high-pressure fuel supply line and
surrounding areas.
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11. CAUTIONS:
Make sure the tool used to loosen the high pressure fuel supply line
union.
Maintain pressure on the high pressure fuel supply line to keep the
olive in contact with the fuel injection pump cone while unscrewing the
union. Failure to follow this instruction may result in foreign matter
ingress to the fuel injection system.
Loosen the high-pressure fuel supply line at the fuel injection pump.
remains in contact with both the fuel injection pump and the fuel injection
supply manifold until both unions have been detached and cleaned. Failure
to follow this instruction may result in foreign matter ingress to the fuel
injection system.
high-pressure fuel supply line and the fuel injection pump.
13. CAUTIONS:
union.
While maintaining the pressure on the high pressure fuel supply
Loosen the high-pressure fuel supply line at the fuel injection supply
manifold.
remains in contact with both the fuel injection pump and the fuel injection
supply manifold until both unions have been detached and cleaned. Failure
to follow this instruction may result in foreign matter ingress to the fuel
injection system.
pressure fuel supply line and the fuel injection supply manifold.
15. Remove and discard the high-pressure fuel supply line.
fuel injection pump and the fuel injection supply manifold.
17. Install blanking caps to the open threaded ports on the fuel injection
pump and the fuel injection supply manifold.
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18. Disconnect the fuel injection pump fuel supply and return lines.
Procedures).
Install blanking plugs to the fuel injection pump fuel supply and
19. Loosen the fuel supply and return line support bracket retaining nut.
21. Detach the wiring harness retaining clip.
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23. Detach the fuel supply and fuel return line support bracket.
26. Secure the power steering fluid reservoir to one side.
27. Disconnect the hydraulic control unit electrical (HCU) connector.
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28. Remove the engine mount damper.
29. Disconnect the fuel injection pump fuel supply and return lines.
Procedures).
Install blanking plugs to the fuel injection pump fuel supply and
30. Remove the fuel supply and return line support bracket retaining nut.
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32. Remove the fuel supply and return line support bracket retaining nut.
33. Detach the fuel supply and return lines.
34. Disconnect the HCU electrical connector.
35. Detach the power steering pipe to engine wiring harness retaining clip.
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All vehicles
38. Using the special tool, remove the fuel injection pump sprocket access
cover.
39. NOTE: Turn the engine in the normal direction of rotation only.
Turn the engine until the fuel injection pump sprocket timing hole is at
the 1 o'clock position.
40. NOTE: The fuel injection pump retaining bolts remain captive behind
the fuel injection pump sprocket after removal.
NOTE: Use a torx 45 drive socket with a minimum shaft length of 43 mm
(1.69 in).
Remove the fuel injection pump retaining bolts.
If available use special tool 303-083A.
41. From 2006 MY special tool numbers 303-681 and 303-681-01 have now
been superseded by special tool numbers 303-1151 and 303-083A.
To carry out the procedure using special tool numbers 303-681 and
303-681-01 see steps 43 - 46.
To carry out the procedure using special tool numbers 303-1151
and 303-083A see steps 47 - 49.
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42. NOTE: For additional information, see step 41.
NOTE: The special tool locking pin holes are offset. During installation of
the special tool, check that the offset pin hole is located at the top.
Using the special tools, lock the fuel injection pump sprocket.
Install the special tools.
Remove the fuel injection pump sprocket retaining bolts.
NOTE:
Using the special tool, support the fuel injection pump sprocket.
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NOTE: Access the fuel injection pump retaining bolts through the holes
provided in the special tool (Tool no. 303-1151 and tool no. 303-083A) and
the fuel injection pump sprocket. The fuel injection pump retaining bolts
cannot be completely removed.
Using the special tool, remove the fuel injection pump retaining bolts.
Remove the fuel injection pump sprocket retaining bolts.
49. Disconnect the fuel injector to fuel injection pump fuel return line.
Detach the fuel injector to fuel injection pump return line retaining
clip (if equipped).
Install blanking plugs to the fuel injector to fuel injection pump
fuel return line male and female connectors.
50. Disconnect the fuel pipe.
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51. Disconnect the knock sensor (KS) electrical connector.
53. Remove the fuel injection pump support bracket.
54. Remove the fuel injection pump support bracket to engine cylinder
block retaining bolts.
55. NOTE: When removing the fuel injection pump the special tool locking
pins must not be removed. Failure to follow this instruction will require the
engine front cover to be removed to retrieve the fuel injection pump
sprocket and the valve timing to be reset.
Remove the fuel injection pump.
Discard the fuel injection pump gasket.
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56. Remove the fuel injection pump shield from the fuel injection pump.
57. Detach the fuel return line venturi from the fuel injection pump.
Discard the fuel return line venturi O-ring seal.
58. Remove the fuel injection pump fuel supply line and fuel return line
assembly from the fuel injection pump.
Discard the fuel supply line O-ring seals.
Installation
All vehicles
WARNINGS:
CAUTIONS:
Do not disassemble or clean inside the fuel injection pump, even with an ultrasonic cleaner. Always install a new fuel injection pump
when required.
Install a new high-pressure fuel supply line. Failure to follow this instruction may result in damage to the vehicle.
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1. NOTE: Install new fuel injection pump supply line O-ring seals.
Install the fuel injection pump fuel supply line and fuel return line
assembly to the fuel injection pump.
Tighten 20 Nm.
2. NOTE: Install a new O-ring seal to the fuel return line venturi.
Attach the fuel return line venturi to the fuel injection pump.
3. Install the fuel injection pump shield to the fuel injection pump.
Tighten to 8 Nm.
4. Install the fuel injection pump shield retaining bolt.
Tighten to 33 Nm.
5. NOTE: Install a new fuel injection pump gasket.
NOTE: Apply a small bead of loctite 572 on the fuel injection pump
retaining bolts.
Install the fuel injection pump.
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6. NOTE: Install the fuel injection pump retaining bolts evenly in order to
pull the fuel injection pump squarely into position.
Loosely install the fuel injection pump support bracket to engine cylinder
block retaining bolts.
7. NOTE: Do not fully tighten the fuel injection pump support bracket bolts
at this stage.
Install the fuel injection pump support bracket to the fuel injection
pump.
9. Connect the KS electrical connector.
10. Connect the fuel pipe.
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11. Connect the fuel injector to fuel injection pump fuel return line.
Attach the fuel injector to fuel injection pump return line retaining
clip (if equipped).
Remove the blanking plugs from the fuel injector to fuel injection
pump fuel return line male and female connectors.
12. From 2006 MY special tool numbers 303-681 and 303-681-01 have now
been superseded by special tool numbers 303-1151 and 303-083A.
To carry out the procedure using special tool numbers 303-1151
and 303-083A see steps 13 - 15.
To carry out the procedure using special tool numbers 303-681 and
303-681-01 see steps 16 - 18.
Using the special tool tighten the fuel injection pump retaining bolts.
Tighten to 22 Nm.
Install the fuel injection pump sprocket retaining bolts.
Tighten to 32 Nm.
Remove the special tools.
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16. Install the fuel injection pump sprocket retaining bolts.
Tighten to 32 Nm.
17. Remove the special tools.
18. NOTE: Install the fuel injection pump retaining bolts evenly in order to
pull the fuel injection pump squarely into position.
NOTE: Use a torx 45 drive socket with a minimum shaft length of 43 mm
(1.69 in).
Tighten the fuel injection pump retaining bolts.
Tighten to 22 Nm.
19. Tighten the fuel injection pump support bracket to cylinder block
retaining bolts.
Tighten to 23 Nm.
20. Tighten the fuel injection pump support bracket retaining bolts.
Tighten to 33 Nm.
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21. Using the special tool, install the fuel injection pump sprocket access
cover.
22. Attach the power steering fluid reservoir.
23. Install the power steering fluid reservoir retaining nuts.
24. Attach the power steering pipe to the engine wiring harness securing
clip.
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25. Connect the HCU electrical connector.
26. Attach the fuel supply and return lines.
Tighten to 23 Nm.
27. Install the fuel supply and return lines support bracket retaining nut.
Tighten to 8 Nm.
28. Attach the wiring harness retaining clip.
29. Install the fuel supply and return lines support bracket retaining nut.
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30. Connect the fuel injection pump fuel supply and return lines.
Procedures).
31. Install the engine mount damper.
32. Connect the HCU electrical connector.
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34. Attach the power steering fluid reservoir.
35. Install the power steering fluid reservoir retaining nuts.
36. Attach the fuel supply and fuel return line support bracket.
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39. Attach the power steering fluid hose to the fuel return line.
40. Tighten the fuel supply and return lines support bracket retaining nut.
Tighten to 8 Nm.
41. Connect the fuel injection pump fuel supply and return lines.
Procedures).
Remove the blanking plugs from the fuel injection pump fuel supply
and return line male and female connectors.
All vehicles
42. Using a suitable multipurpose lubricant spray, lubricate the
43. Remove the blanking plugs from the fuel injection pump and fuel
injection supply manifold threaded ports.
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NOTE: Position the high pressure fuel supply line as near to the final
installation position as possible and then remove the blanking plugs from
the high-pressure fuel supply line.
NOTE: The yellow colored collar is fitted at the fuel injection pump end
and the blue colored collar is fitted at the fuel injection supply manifold
end of the high-pressure fuel supply line.
NOTE: To aid identification of the high pressure fuel supply line, the
union at the fuel injection pump end is etched with the word, Pump.
Install the high-pressure fuel supply line.
45. CAUTIONS:
stage.
Loosely install the high-pressure fuel supply line to the fuel injection
supply manifold.
46. CAUTIONS:
stage.
olive in contact with the fuel injection pump cone while installing the
union. Failure to follow this instruction may result in foreign matter
ingress to the fuel injection system.
Loosely install the high-pressure fuel supply line to the fuel injection
pump.
47. Attach the high-pressure fuel supply line support bracket.
Tighten to 8 Nm.
48. CAUTIONS:
union.
union does not come into contact with the inlet metering valve while
tightening the high-pressure fuel supply line union. Failure to follow this
instruction may result in fuel leaking from the union.
pump.
Tighten to 40 Nm.
supply manifold.
Tighten to 40 Nm.
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51. Connect the fuel metering valve and fuel temperature sensor electrical
connectors.
Tighten to 15 Nm.
53. Attach the wiring harness onto the intake manifold.
Attach the EGR valve to the intake manifold.
Tighten to 10 Nm.
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57. Install the EGR cooler to EGR valve tube.
Diesel/2.2L Diesel, Removal and Installation).
58. Install a new fuel filter.
For additional information, refer to: Fuel Filter - 2.0L Duratorq-TDCi/2.2L
Duratorq-TDCi (110kW/150PS) - Puma (310-01 Fuel Tank and Lines,
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Name
High pressure fuel supply line union
lubricant
TBD
- Puma - Fuel Injection Supply Manifold
Special Tool(s)
303-711 (21-258)
General Equipment
Materials
Specification
TBD
Removal
WARNINGS:
CAUTIONS:
injection supply manifold when required.
For additional information, refer to: Intake Manifold (303-01B Engine -
In-vehicle Repair).
2. NOTE: Protect the electrical connectors with lint-free material to
prevent contamination from the cleaning fluid.
Disconnect the fuel metering valve and fuel temperature sensor
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4. Detach the high pressure fuel supply line support bracket.
5. Clean the fuel pump, high pressure fuel supply line and surrounding
areas.
6. CAUTIONS:
union.
olive in contact with the fuel pump cone while unscrewing the union.
Loosen the high pressure fuel supply line at the fuel pump.
injection system.
pressure fuel supply line and the fuel pump.
8. CAUTIONS:
union.
While maintaining the pressure on the high pressure fuel supply
Loosen the high pressure fuel supply line at the fuel injection supply
manifold.
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injection system.
pressure fuel supply line and the fuel injection supply manifold.
fuel pump and the fuel injection supply manifold.
12. Install blanking caps to the open threaded ports on the fuel pump and
13. Clean the fuel injectors, fuel injection supply manifold, high pressure
fuel supply lines and surrounding areas.
14. Disconnect the fuel pressure sensor electrical connector.
15. CAUTIONS:
Make sure that the high pressure fuel supply line remains in contact
unions.
high pressure fuel supply lines. Failure to follow this instruction will result
Loosen the high pressure fuel supply line from the fuel injector and the
fuel injection supply manifold.
injection system.
Using the pneumatic vacuum gun, vacuum foreign material from the fuel
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18. Repeat steps 14 and ,15 to remove the 3 remaining high pressure fuel
supply lines.
fuel injector and the fuel injection supply manifold.
20. Install blanking caps to the open threaded ports on the fuel injectors
and the fuel injection supply manifold.
22. Loosen the fuel injection supply manifold support brackets.
Installation
WARNINGS:
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CAUTIONS:
injection supply manifold when required.
NOTE: Install new high pressure fuel supply lines.
1. NOTE: Do not tighten the fuel injection supply manifold retaining bolt
at this stage.
Install the fuel injection supply manifold.
2. NOTE: Do not tighten the fuel injection supply manifold support bracket
Install the fuel injection supply manifold support brackets.
3. NOTE: Do not tighten the fuel injection supply manifold retaining bolts
at this stage.
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4. Lubricate the new high pressure fuel supply line union threads with
clean lubricant.
NOTE: The yellow colored collar is fitted at the fuel pump end and the
blue colored collar is fitted at the fuel injection supply manifold end of the
high pressure fuel supply line.
NOTE: To aid identification of the high pressure fuel supply lines, the
union at the fuel pump end is etched with the word Pump.
Position the high pressure fuel supply line as near to the final
blanking plugs from the high pressure fuel supply line.
6. Remove the blanking plugs from the fuel pump and the fuel injection
7. CAUTIONS:
Do not tighten the high pressure fuel supply line union at this stage.
olive in contact with the fuel pump cone while hand installing the union.
Install the high pressure fuel supply line to the fuel pump.
8. CAUTIONS:
Do not tighten the high pressure fuel supply line union at this stage.
olive in contact with the fuel injection supply manifold cone while hand
Install the high pressure fuel supply line to the fuel injection supply
manifold.
9. Lubricate the new high pressure fuel supply line union threads with
clean lubricant.
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blue colored collar is fitted at the fuel supply manifold end of the high
pressure fuel supply line.
NOTE: To aid identification of the high pressure fuel supply line, the
Position the high pressure fuel supply line as near to the final
blanking plugs from the high pressure fuel supply line.
11. Remove the blanking plugs from the fuel injector and the fuel injection
12. CAUTION: Maintain pressure on the high pressure fuel supply line
supply manifold cones while hand installing the unions.
NOTE: Install the high pressure fuel supply lines to the fuel injection
NOTE: Do not tighten the high pressure fuel supply line unions at this
stage.
Install new high pressure fuel supply lines.
Tighten the fuel injection supply manifold support brackets.
Tighten to 14 Nm.
Tighten to 23 Nm.
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Tighten to 23 Nm.
16. NOTE: Two fuel injector shown, other fuel injectors similar.
Disconnect the fuel return lines from the fuel injectors.
Discard the fuel return line O-ring seal.
17. NOTE: Two fuel injector shown, other fuel injectors similar.
Disconnect the fuel injector electrical connectors.
18. CAUTIONS:
Make sure the tool used to tighten the high pressure fuel supply line
union.
high pressure fuel supply lines. Failure to follow this instruction will result
Install the special tool and tighten the high pressure fuel supply line
Tighten to 40 Nm.
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supply manifold.
Tighten to 40 Nm.
21. Repeat steps 16, 17 and 18 for tightening the 3 remaining high
pressure fuel supply line unions.
22. NOTE: Cylinders three and four fuel injectors shown, cylinders one and
two fuel injectors similar.
Connect the fuel injector electrical connectors.
23. NOTE: Cylinders three and four fuel injectors shown, cylinders one and
two fuel injectors similar.
Connect the fuel return lines to the fuel injectors.
24. Connect the fuel pressure sensor electrical connector.
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25. Attach the high pressure fuel supply line support bracket.
Tighten to 8 Nm.
26. CAUTIONS:
union.
union does not come into contact with the inlet metering valve while
tightening the high pressure fuel supply line union. Failure to follow this
instruction may result in fuel leaking from the union.
Tighten the high pressure fuel supply line union at the fuel pump.
Tighten to 40 Nm.
supply manifold.
Tighten to 40 Nm.
connectors.
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In-vehicle Repair).
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- Puma - Fuel Injector
Special Tool(s)
Socket, Fuel Injector Remover/Installer
303-677
303-711
General Equipment
Removal
WARNINGS:
as 1600 bar (23,206 lb/in). Failure to follow this instruction may result in personal injury.
CAUTIONS:
required.
NOTE: If the fuel injection pump has suffered a major mechanical failure, new fuel injectors should also be installed.
NOTE: If the fuel injectors are being renewed in conjunction with the fuel injection pump and high-pressure fuel lines, SRO 195010
must be claimed.
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4. CAUTION: Protect the fuel injector electrical connectors with
lint-free material to prevent contamination from the cleaning fluid.
Clean the fuel injector, high-pressure fuel supply line and surrounding
areas.
5. CAUTIONS:
unions.
injection system.
supply manifold.
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7. Remove and discard the high-pressure fuel supply line.
8. Using the pneumatic vacuum gun, vacuum foreign material from the fuel
9. Install blanking caps to the open threaded ports on the fuel injector and
10. Disconnect the fuel return lines from the fuel injectors.
Discard the fuel return line O-ring seals.
11. Disconnect the fuel injector electrical connector.
12. Remove the valve cover fuel injector seal.
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13. CAUTION: Make sure that the fuel injector does not move when
loosening the fuel injector locking collar. Failure to follow this instruction
will result in damage to the fuel injector and the fuel injector sealing
washer.
Using the special tool, remove the fuel injector.
Installation
WARNINGS:
CAUTIONS:
required.
NOTE: Install new high-pressure fuel supply lines.
NOTE: Install a new valve cover fuel injector seal.
NOTE: Install a new injector nut O-ring seal (if equipped).
NOTE: Install new fuel return line O-ring seals.
1. Record the identification code from the new fuel injector to upload into
the Jaguar approved diagnostic system during configuration (graphic
shows an example of the identification code only).
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2. NOTE: Do not tighten the fuel injector locking collar at this stage.
Using the special tool, install the fuel injector.
3. Disconnect the fuel injector electrical connector.
4. Using the special tools, tighten the fuel injector locking collar.
Tighten to 47 Nm.
6. Install the valve cover fuel injector seal.
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Loosen the fuel injection supply manifold retaining bolts.
Loosen the fuel injection supply manifold support brackets.
Loosen the fuel injection supply manifold retaining bolt.
10. Using a suitable multipurpose lubricant spray, lubricate the
12. Remove the blanking plug from the fuel injector and the fuel injection
supply manifold threaded port.
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supply manifold cones while installing the unions.
stage.
Install new high-pressure fuel supply line.
Tighten the fuel injection supply manifold support brackets retaining
bolts.
Tighten to 14 Nm.
Tighten to 23 Nm.
Tighten to 23 Nm.
17. CAUTIONS:
union.
Install the special tool and tighten the high-pressure fuel supply line
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Tighten to 40 Nm.
supply manifold.
Tighten to 40 Nm.
20. Connect the fuel injector electrical connectors.
21. Connect the fuel return lines to the fuel injectors.
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22. NOTE: Remove the oil filler cap and oil level indicator.
Install the engine cover.
25. Using the Jaguar approved diagnostic system, configure the new fuel
injector to the engine control module (ECM).
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- Puma - Fuel Metering Valve
Removal
WARNINGS:
The fuel system remains pressurized after the ignition is switched off. If communications with a suitable tester (able to read fuel rail
pressure and temperature) can be established, wait until the tester indicates pressure of less than 20 bar (290 lb/in), and temperature of
less than 35 degrees C (95 degrees F) before working on the system. If communications with a suitable tester cannot be established, the
fuel system must NOT be worked on for a period of fifteen minutes following the igni tion being switched off. Failure to follow this
If taken internally, DO NOT induce vomiting. Seek medical attention. Failure to follow this instruction may result in personal injury.
If fuel contacts the eyes, flush the eyes with cold water or eyewash solution and seek medical attention. Failure to follow this
Wash hands thoroughly afer handling, as prolonged contact may cause irritation. Should irritation develop, seek medical attention.
CAUTIONS:
Before disconnecting any part of the system, it is imperative that all dust, dirt and debris is removed from around components to
prevent ingress of foreign matter in to the fuel system. Failure to follow this instruction may result in damage to the vehicle.
Remove the air cleaner bracket retaining bolts.
3. CAUTION: Protect the fuel metering valve and fuel temperature
sensor electrical connectors to prevent contamination with the cleaning
fluid.
Clean the fuel pump and surrounding areas.
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4. Disconnect the fuel metering valve and fuel temperature sensor
5. CAUTION: Always carry out the cleaning process before carrying
out any repairs to the fuel injection system components. Failure to follow
this instruction may result in foreign matter ingress to the fuel injection
system.
Remove the fuel metering valve.
Install a new blanking plug to the open port of the fuel pump.
Installation
WARNINGS:
This procedure involves fuel handling, Be prepared for fuel spillage at all times and always observe fuel handling precautions. Failure
CAUTIONS:
Make sure the workshop area in which the vehicle is being worked on is as clean and dust free as possible. Foreign matter from work
on clutches, brakes or from machining or welding operations can contaminate the fuel system and may result in later malfunction.
NOTE: Install a new fuel metering valve and O-ring seal.
1. Remove and discard the blanking plug from the fuel pump.
2. Using a suitable multipurpose lubricant spray, lubricate the O-ring seal.
3. CAUTIONS:
The fuel metering valve must be installed correctly into the fuel
pump so that the mating faces are in contact with each other. Failure to
follow this instruction may result in damage to the fuel metering valve.
Always carry out the cleaning process before carrying out any repairs
to the fuel injection system components. Failure to follow this instruction
Install the fuel metering valve and O-ring seal.
Install the fuel metering valve retaining bolts finger tight.
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4. CAUTION: The fuel metering valve retaining bolts must be
tightened in the following stages. Failure to follow this instruction may
result in damage to the fuel metering valve.
Tighten the fuel metering valve retaining bolts in two stages.
Stage 1: 2.5 Nm
Stage 2: 5.5 Nm
connectors.
Tighten the retaining bolts.
Attach the wiring harness.
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- Puma - Fuel Return Line Venturi
General Equipment
Removal
1. WARNINGS:
Do not smoke or carry lighted tobacco or open flame of any type
when working on or near any fuel related components. Highly flammable
mixtures are always present and may ignite. Failure to follow these
This procedure involves fuel handling. Be prepared for fuel spillage
at all times and always observe fuel handling precautions. Failure to follow
CAUTIONS:
Diesel fuel injection equipment is manufactured to very precise
tolerances and fine clearances. It is therefore essential that absolute
cleanliness is observed when working with these components. Always
install blanking plugs to any open orifices or lines.
Remove the air cleaner.
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4. NOTE: Protect the fuel metering valve electrical connector with lint-free
material to prevent contamination from the cleaning fluid.
Disconnect the fuel metering valve electrical connector.
5. Clean the fuel pump, fuel return lines and surrounding area.
6. Disconnect the fuel filter return line from the fuel pump.
Procedures).
Install blanking plugs to the open orifices.
7. Disconnect the fuel injector to fuel pump return line.
Procedures).
Install blanking plugs to the open orifices.
8. Remove the fuel pump shield lower retaining bolts.
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9. Remove the fuel pump shield upper retaining bolts.
fuel pump, fuel return line venturi and the fuel pump fuel return lines.
11. Remove the fuel pump shield.
12. Remove the fuel return line venturi.
Install a blanking plug to the open port on the fuel pump.
Installation
1. WARNINGS:
mixtures are always present and may ignite. Failure to follow these
CAUTIONS:
Diesel fuel injection equipment is manufactured to very precise
tolerances and fine clearances. It is therefore essential that absolute
cleanliness is observed when working with these components. Always
install blanking plugs to any open orifices or lines.
Tighten to 6 Nm.
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2. Tighten to 8 Nm.
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Fuel Charging and Controls - Turbocharger -
Oil supply tube union retaining bolt 14 10 -
Oil return tube to turbocharger retaining bolts 10 - 89
Oil return tube to cylinder block retaining bolt 10 - 89
Exhaust gas recirculation (EGR) cooler to exhaust manifold retaining bolt 37 27 -
EGR cooler mount bracket retaining nut 10 - 89
EGR cooler mount bracket retaining bolt 10 - 89
Exhaust manifold retaining nuts and bolts 40 30 -
Exhaust manifold gasket retaining bolts 10 - 89
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Fuel Charging and Controls - Turbocharger - Turbocharger
Variable vane turbocharger - Vehicles built up to VIN:E25781
1 - Exhaust manifold gasket/heat shield
2 - Turbocharger/exhaust manifold
3 - Oil supply tube
4 - Oil return tube
Variable vane turbocharger - Vehicles built from VIN:E25782
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1 - Compressor casing
2 - Variable vane adjustment ring
3 - Rotary electronic actuator
4 - Variable vane
5 - Exhaust turbine
6 - Turbine casing
7 - Exhaust manifold
8 - Oil supply line
9 - Oil drain line
The turbocharger and exhaust manifold are a combined assembly and although it is possible to separate them, they are not supplied
separately and should therefore not be disassembled.
The turbocharger consists of two elements, a turbine and a compressor both installed on a single shaft.
The turbocharger bearings are supplied with oil from the engine.
The turbine uses the flow of the exhaust gas to drive the compressor. The compressor draws air through the air cleaner and forces it into
the intake manifold.
Principles of Operation - Variable vane turbocharger
The turbocharger is designed to improve engine induction and engine performance. The list below details the concerns relating to
turbocharger performance.
High engine speed produces excessive turbine speed and therefore creates excessive turbocharger boost pressure.
Low engine speed does not produce sufficient turbine speed and therefore not enough turbocharger boost pressure is achieved.
The turbocharger does not have a wastegate control valve. Instead, it has variable turbocharger vanes which are located in the turbocharger
turbine housing and directs the air flow into the turbocharger turbine. The turbocharger vanes act as the control for the turbocharger boost
pressure.
The turbocharger produces its full turbocharger boost pressure over the entire engine speed range, not just at high engine speed. This is
achieved through the adjustment of the vanes and the resulting change in the flow of the exhaust gas.
The speed of the exhaust gas flow within the turbocharger is increased independent of engine speed by varying the intake cross section in
front of the turbocharger turbine. This is achieved by adjusting the angle of the vanes controlling the air flow into the turbocharger turbine
and drives the turbocharger turbine faster. The higher turbocharger speed produces a high turbocharger boost pressure at all engine speeds.
The engine control module (ECM) controls the turbocharger vanes.
Regulation at Low Engine Speed
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1 - Vane adjustment solenoid valve
2 - Atmospheric pressure
3 - Vacuum
4 - Adjusting ring
5 - Vanes
6 - Vanes
7 - Turbine
8 - Turbine
9 - Vacuum diaphragm unit
10 - ECM
At low engine speeds the ECM actuates the vane adjustment solenoid valve to enable a vacuum to be applied. The vacuum diaphragm unit
moves the adjusting ring so that the vanes are set at a shallow angle. The shallow intake cross section this creates for the stream of
exhaust gas allows the turbocharger boost pressure to build up rapidly and easily at low engine speeds.
Regulation at Moderate Engine Speed
3 - Vacuum
4 - Adjusting ring
5 - Vanes
6 - Vanes
7 - Turbine
8 - Turbine
10 - ECM
As the engine speed increases and the quantity of exhaust gas increases as a result, the vane adjustment solenoid valve adjusts the
vacuum level within the vacuum diaphragm unit. The vacuum diaphragm unit moves the adjusting ring so that the vanes are set at a
steeper angle. The steeper angle opens the intake cross section effectively reducing the gas flow and turbine speed while maintaining
constant turbocharger boost pressure.
Regulation at Maximum Engine Speed
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3 - Vacuum
4 - Adjusting ring
5 - Vanes
6 - Vanes
7 - Turbine
8 - Turbine
10 - ECM
As the engine speed increases the intake cross section in front of the turbocharger turbine is continuously enlarged. The turbine speed and
hence the quantity of the air supplied to the engine, is adjusted to suit the engine speed. This means that the turbocharger boost pressure
remains optimized over all engine speeds.
The maximum position of the turbocharger vanes (maximum opening cross section) is also an emergency position, in the event of an
electrical concern or leak in the vacuum system. This lowers the chance of engine damage due to excessive boost in the event of a
turbocharger control concern.
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Overview
For information on the operation of the turbocharger:
REFER to: Turbocharger (303-04C Fuel Charging and Controls - Turbocharger, Description and Operation).
WARNINGS:
The following tests may involve working in close proximity to hot components. Make sure adequate protection is used. Failure to
The turbocharger can continue to rotate after the engine has stopped. Do not attempt to check the turbocharger until one minute has
elapsed since the engine was switched off. Failure to follow this instruction may result in personal injury.
Visual inspection chart
Intake air system
Hose(s)/hose connections
Turbocharger
General engine condition.
Circuit(s)
Electrical connections and harnesses
Manifold absolute pressure and temperature (MAPT) sensor
Turbocharger actuator
Symptom chart
Symptom Possible source Action
Poor performance
(off-boost)
Low/Contaminated
fuel
Restricted intake air
system
General engine
condition
Engine control
module (ECM) failure
Check the fuel level and condition. Draw off approximately 1 ltr (2.11 pints) of fuel and allow
to stand for 1 minute. Check to make sure there is no separation of the fuel indicating water
or other liquid in the fuel. Check the intake air system for restriction. Check the engine
condition, compressions, etc. if there are indications of a mechanical fault. Check for DTCs
indicating a module fault. Refer to the warranty policy and procedures manual if a module is
suspect.
No boost Electrical
connections and
harnesses
Restricted intake air
system
Charge air cooler
restricted/leaking
Turbocharger
actuator failure
Turbocharger failure
Engine control
module (ECM) failure
Check the electrical connections and harnesses. Check the intake air system for
restriction/leakage. Check the turbocharger actuator and circuit. Refer to the electrical guides.
Check the turbocharger for wear. Disconnect the turbocharger intake and outlet pipework and
turn the turbocharger by hand. Any roughness indicates a fault. Check any up and down
movement in the turbocharger shaft. Excessive movement indicates a fault. If in doubt,
compare the suspect unit with a new turbocharger. Check for DTCs indicating an actuator or
module fault. Refer to the warranty policy and procedures manual if a module is suspect.
No
boost/excessive
noise
Turbocharger failure Disconnect the turbocharger intake and outlet pipework and turn the turbocharger by hand.
Any roughness indicates a fault. Check any up and down movement in the turbocharger shaft.
Excessive movement indicates a fault. If in doubt, compare the suspect unit with a new
turbocharger.
For a complete list of all diagnostic trouble codes that could be logged on this vehicle. REFER to: Electronic Engine Controls (303-14B
Electronic Engine Controls - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) - Puma, Diagnosis and Testing).
Diagnostic Trouble Codes (DTC) Relating to Turbocharger Issues
DTC Description
P2263Turbocharger/Supercharger Boost System Performance
. This vehicle may not feature all of the components listed.
. This DTC may be caused by:
. Damaged or disconnected vacuum hose. Check for air leaks at turbocharger. Vanes on the turbocharger sticking closed. Turbocharger
defective.
. Or
. Fault reported by the rotary electronic actuator.
. CAN communication BUS fault. Rotary electric actuator. Low battery voltage. Turbocharger defective.
P132ATurbocharger/Supercharger Boost Control A Electrical
. Rotary electric actuator. Renew the variable geometry turbocharger.
P132BTurbocharger/Supercharger Boost Control A Performance
. Faulty turbocharger, mechanism may be sticking.
P132CTurbocharger/Supercharger Boost Control A Voltage
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DTC Description
. Low battery voltage. Check the condition of the battery. Check the wiring and the appropriate fuse. High battery voltage. Check the
battery charging system.
P138DTurbocharger/Supercharger Boost Control A Temperature Too High
. Leaking exhaust system. Engine overheat condition.
P179ACAN Engine Control Module (ECM)/Turbocharger Boost Control A Actuator Circuit Malfunction
. Fault reported by the rotary electronic actuator or powertrain control module (PCM).
. Controller area network (CAN) communication BUS fault. Check CAN wiring/CAN Network is functioning. If CAN wiring/CAN Network is
functioning but the vehicle has loss of power, then renew the variable geometry turbocharger.
Diagnostic Procedure
Log any concerns raised by the customer regarding the fault with the vehicle Discuss with workshop supervisor/receptionist
Check logged DTC - Rectify concern
Check the vehicle Integrated Diagnostic System (IDS) DVD patch file calibration Update to the latest level
Quick Check List
Listen for unusual mechanical noise and watch for vibration
Listen for a high pitched noise (it can indicate air or gas leaks)
Listen for noise level cycling. It can indicate a restriction in the air cleaner or ducting
Inspect for missing or loose nuts, bolts, clamps and washers
Inspect for loose or damaged intake and exhaust manifolds and their ducting and clamps
Inspect for damaged or restricted oil supply and drain lines
Inspect for cracked or deteriorating turbocharger housings
Inspect for external oil leakage; external deposits (indicates air, oil, exhaust or coolant leakage)
Inspect for a restricted air filter
Check the turbocharger variable vane actuator arm for normal operation, free movement and damage
Point Health Check:
1. Turbocharger Data Plate:
- 1. Check the turbocharger data stamped on the compressor housing. Record assembly number, serial number and turbocharger
type
- 2. Ensure turbocharger type and assembly number are correct for the engine application
2. Compressor/Turbine Wheel (Turbocharger System Trouble Shooting):
-
WARNING: Ensure wheels have stopped rotating before handling
CAUTION: Never attempt to straighten blades. If any bent blades are detected replace the turbocharger
NOTE: Root cause of failure should be identified to eliminate repeat failure. Please make reference to section 'Turbocharger
Trouble Shooting'
1. Check for cracked/bent or damaged compressor (impeller) blades - Replace turbocharger if damaged
- 2. Check for cracked/bent or damaged turbine blades - Replace turbocharger if damaged
3. Compressor/Turbine Housing:
-
NOTE: Removal of the compressor or turbine housings will invalidate the Warranty
1. Check for foreign objects, damage, or for excessive oil at the compressor housing air inlet and outlet
- 2. Check for foreign objects, damage, or for excessive oil at the turbine housing exhaust inlet and outlet
4. Turbocharger Bearing Clearances:
-
NOTE: If there is contact between compressor/turbine wheel and housing - Replace the turbocharger
1. Gently rotate the compressor wheel and check for smooth operation
- 2. Gently hold to one side and rotate the compressor wheel and check for smooth operation
5. Bearing Housing:
-
NOTE: Removal of the compressor or turbine housings will invalidate the Warranty
1. Check oil feed and drain port for loose fasteners, adapters or damage to flanges, housing faces or threads which may cause
leakage
- 2. Check for loose or broken turbine and compressor housing fasteners. If mounting flanges are damaged, replace or tighten
(torque to manufacturer's specification)
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Point Health Check:
6. Check for loose or broken turbine and compressor housing fasteners. If mounting flanges are damaged, replace or tighten
(torque to manufacturer's specification):
Legend
- 1. Boost pressure actuator
- 2. Actuator arm
- 3. Low flow adjusting screw
- 4. Actuator heel
- 5. Compressor casing
7. Stage 3: Vacuum Actuation:
- 1. Check for correct installation of boost pressure actuator and check for loose bolts etc. If unsure, check and compare with
another vehicle
- 2. Check for DTCs and rectify fault before moving to next step
-
NOTE: If the actuator arm is stuck in the open vane position, check solenoid for correct operation
3. Check/observe actuator arm movement during key ON/OFF calibration
- 3. Start Engine and allow to idle: Actuator (2) will retract under smooth operation and rest on the low flow adjuster screw at
idle (3) Turbocharger vanes closed
- 4. Key off: Actuator will retract to the fully open position Turbocharger vanes fully open
- 5. If the above is not observed, check vacuum supply to boost pressure actuator (1)
- Check system: Utilizing Vacuum Gauge
- 6. Remove hose from actuator and apply a clean regulated vacuum of 47cmHg to the actuator (using a suitable hand-held
vacuum pump) - check for smooth actuator movement, and that the actuator heel rests on the low-flow adjusting screw
- 7. The boost pressure actuator (1) should hold a vacuum of 47cmHg for 20 seconds; if not, replace the turbocharger
- 8. Release the vacuum from regulator, and the actuator should snap open under the boost pressure actuator spring force
(default fully opens the vanes). If not, replace turbocharger
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Point Health Check:
8. Check Vacuum supply system:
Legend
- 1. Atmospheric pipe from air cleaner
- 2. Vacuum from brake booster
- 3. Vacuum to VGT actuator
- 4. Turbo charger solenoid valve
- 5. Vacuum reservoir
WARNING: Keep hands away from rod and mechanism. Finger injury may result from sudden movement of the assembly when
the air pressure is applied
9. Connect a vacuum gauge to the pipe from the vacuum reservoir/solenoid valve:
- 1. Start engine and allow to idle; the vacuum should read 47 cmHg. If not, check vacuum system for leaks, faulty solenoid and
check wiring integrity from the ECM to the solenoid (solenoid located on the side of the transmission)
10. Components:
Legend
- 1. Compressor casing
- 2. Variable vane adjustment ring
- 3. Rotary electronic actuator
- 4. Variable vane
- 5. Exhaust turbine
- 6. Turbine casing
- 7. Exhaust manifold
- 8. Oil supply line
- 9. Oil drain line
11. Stage 4 (2L): Rotary Electronic Actuator
- 1. Check for correct installation of the rotary electronic actuator, and check for loose bolts etc
- 2. Check for DTCs and rectify fault before moving to next step
- 3. Check for DTCs pertaining to a turbocharger fault
-
NOTE: If actuator sticks when extending during start up and idle Check REA Wiring integrity, Recheck DTCs if all OK replace
Turbocharger. If actuator sticks when retracting during key OFF Check REA wiring integrity, recheck DTCs if all OK replace
Turbocharger
4. Check actuator arm movement during key ON/OFF calibration. The actuator should extend during start up and idle, and retract
when the engine is switched OFF - There should be a DTC logged to cover this situation - Check wiring integrity, if OK, replace
Turbocharger
Turbocharger Troubleshooting Guide
Frequently, fully serviceable turbo chargers are replaced due to mis-diagnosis of a problem
Before replacing a turbocharger it is important to identify the cause of the problem
The following troubleshooting guide will determine turbocharger condition and prevent the unnecessary removal, mis-diagnosis and
repeat failures of the turbocharger unit
Familiarize yourself with the intake air system and the turbocharger boost circuit
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1. Legend
- 1. Dirty air duct
- 2. Air Cleaner
- 3. MAF sensor
- 4. EGR valve
- 5. Turbocharger compressor intake air pipe
- 6. Turbocharger
- 7. Post charge air cooler pipe
- 8. Pre charge air cooler pipe
- 9. MAP sensor
- 10. Charge air cooler
NOTE: Discuss concern with customer before carrying out any investigation, record all symptoms and conditions i.e temperatures, drive
conditions including drive patterns etc. Record all customer information with respect to concern on job card. The information will be useful
for future reference. If you are unsure of any operation or component fitment, please compare with another vehicle. If in doubt contact DTS
2. Common Symptoms of failed Turbocharger boost system component
- 1. Poor performance/hesitation
- 2. Smoky exhaust black smoke
- 3. Smoky exhaust blue smoke
- 4. Oil consumption
- 5. Noisy operation
Air Intake System - Check for:
3. Dirty Air Duct:
- 1. Check for restricted air flow
- 2. Blockage from dirt
- 3. Blockage from foreign object (including snow)
- 4. Pipe connection to air cleaner
- 5. Misaligned connection
- 6. Corrective action: Clear restriction, establish pipe connection or replace if damaged
4. Air Cleaner:
- 1. Restricted air filter
- 2. Blockage from dirt
- 3. Blockage from foreign object (including snow)
- 4. Restriction due to water saturation
- 5. Check air cleaner housing for damage and air path restrictions
- 6. Corrective action: Replace sensor as new ONLY if the substitute sensor rectifies fault. Corrective action: Replace air
filter housing if damaged. Replace filter only if clearly blocked or damaged
5. Turbocharger compressor intake air pipe:
- 1. Air leaks air cleaner connection
- 2. Air leaks turbocharger compressor connection
- 3. Air leaks breather pipe connection
- 4. Badly located clamps
- 5. Check pipe for damage
- 6. Check for collapsing of hose breather pipe end
- 7. Corrective action: Ensure clamps/pipe are correctly located change pipe if found to be damaged. Replace sensor as
new, ONLY if the substitute sensor rectifies fault
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Turbocharger Boost Circuit Check for:
6. Pre Charge Air Cooler Pipes:
- 1. Split hose
- 2. Badly located hose
- 3. Badly located clamp
- 4. Incorrect clamp torque
- 5. Oil saturation of hose
- 6. Check for blockage Remove pipes to check
- 7. Check MAP sensor installation and wiring integrity
- 8. Correction action: Realign any badly located pipes or replace any damaged or split pipes
7. Post Charge Air Cooler leaks:
- 1. Split hose
- 4. Check charge air cooler for damage
- 5. Check charge air cooler for oil contamination
-
CAUTION: Engine oil should always be removed from charge air cooler and intake manifold once a concern has been
identified
6. Corrective action: Ensure correct fitment of hose pipes, replace damaged charge air cooler. Ensure oil is removed from
charge air cooler and intake manifold
8. Check Charge Air Cooler for Leaks:
- 3. Incorrect clamp torque
- 4. Oil saturation of hose
- 5. Check for blockage Remove pipes to check
- 6. Check MAP sensor installation and connections
-
CAUTION: Make sure the clips that have been re-used are secure and do not over-tighten - may cause damage to the clip
NOTE: Take care when replacing pipes: Do not introduce additional faults
7. Corrective action: Realign any badly located pipes or replace any damaged or split pipes
Exhaust System - Check for:
9. Exhaust system for gas leaks:
- 1. Distorted manifold flange
- 2. Missing or misaligned gasket
- 3. Check exhaust system for blockages
- 4. Check catalytic converter for blockage Remove and inspect
- 5. Check exhaust manifolds for leaks and loose bolts/incorrect torque
Turbocharger:
10. Remove compressor intake pipe and heat shield
11. Visual and Mechanical Inspection:
-
NOTE: Tools to aid with inspection; inspection lamp and vacuum pump/gauge
1. Check turbocharger exterior for correct installation
- 2. Check turbocharger for oil leaks
- 3. Check for excessive sooting under heat shield. A small amount of sooting is acceptable
12. Turbine wheel:
- 1. Corrective action: Difficult to inspect due to design - Remove exhaust system
13. Compressor wheel:
- 1. Inspect for foreign body
- 2. Inspect for oil residue Do not change turbocharger due to oil deposits. This may be the effect, not the cause
- 3. Inspect blades for damage If damaged, check for foreign object in the intake system
- 4. Check compressor wheel/housing for evidence of rubbing, bending or seizure
-
NOTE: A small amount of lateral movement of the compressor wheel is normal due to the bearing clearance. Do not force the
compressor wheel to touch the housing
5. Check compressor wheel (gently rotate the compressor wheel and check for smooth operation) Check for burrs on the
compressor wheel or rub marks on the housing, that indicate the compressor wheel was rubbing. If possible, compare with a
known good turbocharger
Turbocharger Replacement:
14. Turbocharger:
-
CAUTION: The following must be carried out after turbocharger replacement and before running the engine to avoid engine
damage
1. When replacing turbocharger units where excessive oil is evident in the compressor housing, charge air cooler and associated
pipework, if excessive blue smoke was exhibited from the exhaust, the following should be carried out:
- 2. Remove and clean charge air cooler and associating pipework
- 3. Remove and clean the intake manifold
- 4. The vehicle should be then run for approximately 30miles (48 kilometre) to remove the residual oil from the exhaust system
Motorway road test is recommended
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Removal
All vehicles
For additional information, refer to: Catalytic Converter - 2.0L Duratorq-
TDCi/2.2L Duratorq-TDCi (110kW/150PS) - Puma (309-00 Exhaust
System, Removal and Installation).
For additional information, refer to: Front Halfshaft RH - 2.0L Duratorq-
TDCi/2.2L Duratorq-TDCi (110kW/150PS) - Puma (205-04 Front Drive
3. Detach the oil supply tube from the turbocharger.
Discard the sealing washers.
4. Detach the oil supply tube from the turbocharger.
5. Detach the oil supply tube.
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6. Remove the oil supply tube.
All vehicles
7. Detach the oil return tube from the turbocharger.
Discard the gasket.
8. Remove the oil return tube.
Discard the O-ring seal.
9. Detach the exhaust gas recirculation (EGR) cooler from the exhaust
manifold.
Discard the gasket.
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10. Detach the coolant pipe from the EGR cooler.
13. Remove the exhaust manifold retaining bolts and nuts.
Discard the bolts and nuts.
15. Remove the cowl vent screen.
For additional information, refer to: Cowl Vent Screen (501-02 Front End
Body Panels, Removal and Installation).
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17. Detach the positive crankcase ventilation hose from the valve cover.
Discard the positive crankcase ventilation hose retaining clip.
18. Detach the air cleaner outlet pipe from the turbocharger.
Discard the air cleaner outlet pipe retaining clip.
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20. Detach the positive crankcase ventilation hose from the valve cover.
Discard the positive crankcase ventilation hose retaining clip.
21. Detach the air cleaner outlet pipe from the turbocharger.
Discard the air cleaner outlet pipe retaining clip.
All vehicles
22. Detach the charge air cooler intake pipe from the turbocharger .
23. Remove the exhaust manifold gasket retaining bolts.
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24. Detach the turbocharger from the cylinder head.
25. Remove and discard the exhaust manifold gasket.
26. Remove the turbocharger.
Remove and discard the turbocharger retaining studs.
27. Detach the turbocharger from the cylinder head.
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28. Remove and discard the exhaust manifold gasket.
29. Remove the turbocharger.
Remove and discard the turbocharger retaining studs.
Installation
1. NOTE: Install new turbocharger retaining studs.
Install the turbocharger.
Install the exhaust manifold gasket.
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3. Attach the turbocharger to the cylinder head.
4. NOTE: Install new turbocharger retaining studs.
Install the turbocharger.
Install the exhaust manifold gasket.
6. Attach the turbocharger to the cylinder head.
All vehicles
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7. NOTE: Install new exhaust manifold retaining nuts and bolts
NOTE: Vehicle shown raised for clarity.
Loosely install the exhaust manifold retaining nuts and bolts.
8. Install the exhaust manifold gasket retaining studs.
Tighten to 10 Nm.
9. Attach the charge air cooler intake pipe to the turbocharger.
10. NOTE: Install a new air cleaner outlet pipe retaining clip.
Attach the air cleaner outlet pipe to the turbocharger.
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11. NOTE: Install a new positive crankcase ventilation hose retaining clip.
Attach the positive crankcase ventilation hose to the valve cover.
13. NOTE: Install a new air cleaner outlet pipe retaining clip.
Attach the air cleaner outlet pipe to the turbocharger.
14. NOTE: Install a new positive crankcase ventilation hose retaining clip.
Attach the positive crankcase ventilation hose to the valve cover.
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All vehicles
16. Install the cowl vent screen.
18. Tighten the exhaust manifold retaining nuts and bolts.
Tighten to 40 Nm.
19. Install the EGR cooler mount bracket.
Tighten to 10 Nm.
Tighten to 10 Nm.
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21. Attach the coolant pipe to the EGR cooler.
Attach the EGR cooler to the exhaust manifold.
Tighten to 37 Nm.
Install the oil return tube.
Tighten to 10 Nm.
Attach the oil return tube to the turbocharger.
Tighten to 10 Nm.
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25. CAUTION: If a new oil supply tube is to be installed, ensure that
the blanking caps have been removed prior to installation. Failure to follow
this instruction may result in damage to the turbocharger.
Install the oil supply tube.
Tighten to 14 Nm.
26. Attach the oil supply tube.
Tighten to 23 Nm.
27. CAUTION: When installing the oil supply tube union to the
turbocharger, check the routing of the oil supply tube and make sure that
it is not touching the turbocharger.
Attach the oil supply tube to the turbocharger.
Tighten to 14 Nm.
28. CAUTION: When installing the oil supply tube union to the
turbocharger, check the routing of the oil supply tube and make sure it is
not touching the turbocharger.
NOTE: Install new sealing washers.
Attach the oil supply tube to the turbocharger.
Tighten to 14 Nm.
For additional information, refer to: Front Halfshaft RH - 2.0L Duratorq-
TDCi/2.2L Duratorq-TDCi (110kW/150PS) - Puma (205-04 Front Drive
All vehicles
30. Install the catalytic converter.
31. NOTE: Use oil WSS-M2C913-B or equivalent meeting Jaguar
specification.
Check and top up the engine with oil if necessary.
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Accessory Drive -
Description Nmlb-ftlb-in
Accessory drive belt tensioner retaining bolt - vehicles with 2.0L, 2.5L or 3.0L engine 47 35 -
Belt idler pulley retaining bolt - A bank pulley - vehicles with 2.0L, 2.5L or 3.0L engine 25 18 -
Belt idler pulley retaining bolt - B bank upper pulley - vehicles with 2.0L, 2.5L or 3.0L engine 25 18 -
Belt idler pulley retaining bolt - B bank lower pulley - vehicles with 2.0L, 2.5L or 3.0L engine 25 18 -
Water pump drive belt tensioner retaining bolt - vehicles with 2.0L, 2.5L or 3.0L engine 10 - 89
Accessory drive belt tensioner assembly retaining bolts - vehicles with 2.0L or 2.2L diesel engine 47 35 -
Generator retaining bolt - vehicles with 2.0L or 2.2L diesel engine 47 35 -
Generator retaining nuts - vehicles with 2.0L or 2.2L diesel engine 47 35 -
Generator positive cable retaining nut - vehicles with 2.0L or 2.2L diesel engine 8 - 71
Exhaust gas recirculation (EGR) cooler to EGR valve tube support bracket upper retaining bolt - vehicles with 2.0L or 2.2L
diesel engine
10 - 89
EGR cooler to EGR valve tube support bracket lower retaining bolts - vehicles with 2.0L or 2.2L diesel engine 23 17 -
Power steering pump belt cover retaining nut 10 - 89
Power steering pump belt tensioner retaining bolt - vehicles with 2.0L or 2.2L diesel engine 23 17 -
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Accessory Drive - Accessory Drive
2.0L, 2.5L and 3.0L engine
1 Power steering pump pulley
2 Accessory drive belt idler pulley
3 Accessory drive belt tensioner
6 Generator pulley
7 Air conditioning pump pulley
8 Crankshaft pulley
Crankshaft Pulley
The combined crankshaft pulley and torsional vibration damper drives a single, six ribbed vee belt. The belt drives the following engine-
mounted accessories; the generator, power assisted steering pump, and the air-conditioning compressor. The coolant water pump is driven
by a separate drive on the rear of the engine.
Air Conditioning Compressor Drive
This is positioned at the lowest point of the front-end accessory-drive on the lower left accessory mounting.
Power Assisted Steering Pump Drive
The power assisted steering pump pulley is located on the right of the engine, above the steering gear.
Generator Drive
The generator is fitted on the upper left accessory mounting.
Belt Tensioner
Automatic tensioners are calibrated to provide the correct amount of tension to the belt for a given accessory drive system. Unless a spring
within the tensioner assembly breaks, or some other mechanical part of the tensioner fails, there is no need to check the tensioner for
correct tension.
2.0L and 2.2L diesel engine
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2 Accessory drive belt tensioner
4 Air conditioning pump pulley
5 Accessory drive belt
6 Crankshaft pulley
7 Generator pulley
Crankshaft Pulley
The crankshaft pulley drives a single, six ribbed vee belt. The belt drives the generator and the air-conditioning compressor. The power
assisted steering pump is driven by a separate drive belt on the rear of the engine. The coolant water pump is driven by the power assisted
steering pump.
Air Conditioning Compressor Drive
This is positioned on the upper left accessory mounting.
Generator Drive
The generator is fitted on the lower right accessory mounting.
Belt Tensioner
Automatic tensioners are calibrated to provide the correct amount of tension to the belt for a given accessory drive system. Unless a spring
within the tensioner assembly breaks, or some other mechanical part of the tensioner fails, there is no need to check the tensioner for
correct tension.
Drive Belt
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Item Description
1 Acceptable Drive Belt Cracking
2 Unacceptable Drive Belt Damage
The drive belt should be inspected at every routine service for excessive wear and damage. A drive belt which displays symptoms of cracking
may be perfectly fit for further service.
Should cracking be detected, serviceability may be assessed using the following guidelines:
Fifteen cracks per rib over a 100 mm length of drive belt is acceptable.
Section(s) of belt missing from any rib is not acceptable and the drive belt must be renewed.
Automatic Belt Tensioner
NOTE: Petrol engine belt tensioner shown, diesel engine belt tensioner similar in operation.
The automatic belt tensioners consist of an idler pulley which is free to rotate on a bearing, located at the end of a spring-loaded pivot arm.
The pivot arm can be partially rotated to slacken the belt and allow belt removal and installation.
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*
*
*
*
*
*
*
*
*
*
Accessory Drive - Accessory Drive
Mechanical
Damaged or contaminated belt
Belt tension
Belt tensioner
Pulleys
Loose hardware
step.
3.
4. If the concern is not visually evident, verify the symptom and refer to the symptom chart. 4.
Symptom Chart
Symptom Chart
Belt noise or
squeal
Pulley(s)
Lubricant or other
contamination
Belt
DETERMINE where the noise is coming from. CHECK pulley alignment, freedom of rotation or
damage. REPAIR or INSTALL new parts as necessary.
CHECK belt for contamination. REMOVE belt and wash with detergent and water. If belt cannot be
cleaned or is damaged, INSTALL a new belt. For additional information refer to Accessory Drive
Belt - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27 or
REFER to: Accessory Drive Belt - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) - Puma
(303-05 Accessory Drive, Removal and Installation).
CHECK belt for correct application.
Belt does not
hold tension
Belt cracking or
damaged
Tensioner worn or
damaged
INSPECT belt for cracking or damage. INSTALL a new belt if required. For additional information
refer to Accessory Drive Belt - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27 or
REFER to: Accessory Drive Belt - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) - Puma
(303-05 Accessory Drive, Removal and Installation).
CHECK belt tensioner for damage and correct operation. INSTALL a new belt tensioner if required.
For additional information refer to Accessory Drive Belt Tensioner - 2.0L NA V6 - AJV6/2.5L NA V6
- AJV6/3.0L NA V6 - AJ27 or
REFER to: Accessory Drive Belt Tensioner - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS)
- Puma (303-05 Accessory Drive, Removal and Installation).
Component Tests
Belt Tensioner-Mechanical
The only mechanical check that needs to be made is a check for tensioner "stick, grab or bind".
1. Remove the belt in the area of the tensioner. 1.
2. Using the correct tool, rotate the tensioner from its relaxed position through its full stroke and back to the relaxed position to
make sure there is no "stick, grab or bind", and to make sure that there is tension on the tensioner spring.
2.
3. If the tensioner meets the above criteria, proceed to test the tensioner dynamically. If the tensioner does not meet the above
criteria install a new tensioner. For additional information, refer to Accessory Drive Belt Tensioner - 2.0L Duratorq-TDCi/2.2L
Duratorq-TDCi (110kW/150PS) - Puma or
REFER to: Accessory Drive Belt Tensioner - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27 (303-05 Accessory Drive,
3.
Belt Tensioner-Dynamic
The automatic belt tensioner can be checked dynamically as follows:
1. With the engine running, observe belt tensioner movement. The tensioner should move (respond) when the air conditioning clutch
cycles, or when the engine is accelerated rapidly. If the tensioner movement is not constant without the air conditioning clutch
cycling or engine acceleration, a pulley or shaft is probably bent, or a pulley is out of round. Excessive belt rideout (uneven depth
of grooves in the belt) can cause excessive tensioner movement. Check condition by installing a new belt.
1.
2. With the engine off, check routing of the belt. For additional information, refer to the illustrations under Description and
Operation.
2.
3. Rotate the belt tensioner and check for a binding or seized condition. Install a new belt if necessary. For additional information
refer to Accessory Drive Belt - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27 or
REFER to: Accessory Drive Belt - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) - Puma (303-05 Accessory Drive, Removal
and Installation).
3.
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Accessory Drive - Accessory Drive Belt2.0L Duratorq-TDCi/2.2L Duratorq-TDCi
Special Tool(s)
303-676
Removal
3. Remove the right-hand road wheel.
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Installation
Tighten to 47 Nm.
3. NOTE: Loosely install the generator retaining nuts.
4. Install the generator retaining bolt.
Tighten to 47 Nm.
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Tighten to 8 Nm.
10. Install the right-hand road wheel.
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Accessory Drive - Accessory Drive Belt2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA
V6 - AJ27
Special Tool(s)
Accessory Belt De-tensioner
303-703
Removal
1. Disconnect the battery ground cable. For additional information, refer to
Section 414-01 Battery, Mounting and Cables.
2. Remove the splash shield.
to Section 204-04 Wheels and Tires.
1. Using the special tool, de-tension the accessory drive belt.
1. Slacken the tensioner.
Installation
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Tighten to 47 Nm.
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Accessory Drive - Accessory Drive Belt Tensioner2.0L Duratorq-TDCi/2.2L
Special Tool(s)
303-676
Removal
3. Remove the right-hand road wheel.
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Installation
Tighten to 47 Nm.
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4. NOTE: Loosely install the generator retaining nuts.
5. Install the generator retaining bolt.
Tighten to 47 Nm.
Tighten to 8 Nm.
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11. Install the right-hand road wheel.
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Accessory Drive - Accessory Drive Belt Tensioner2.0L NA V6 - AJV6/2.5L NA V6 -
Removal
1. Remove the accessory drive belt. For additional information, refer to the
Accessory Drive Belt.
Installation
Tighten to 47 Nm.
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Accessory Drive - Power Steering Pump Belt2.0L Duratorq-TDCi/2.2L Duratorq-TDCi
Removal
3. Remove the power steering pump belt cover retaining nut.
4. Remove the power steering pump belt cover.
5. Remove the exhaust gas recirculation (EGR) cooler to EGR valve tube
support bracket lower retaining bolts.
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6. Remove the EGR cooler to EGR valve tube support bracket.
7. Remove the power steering pump belt.
Installation
1. Install the power steering pump belt.
2. NOTE: Do not tighten the EGR cooler to EGR valve tube support bracket
upper retaining bolt at this stage.
Install the EGR cooler to EGR valve tube support bracket.
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3. Install the EGR cooler to EGR valve tube support bracket lower retaining
bolts.
Tighten to 23 Nm.
5. Install the power steering pump belt cover.
6. Install the power steering pump belt cover retaining nut.
Tighten to 10 Nm.
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7. Attach the power steering fluid pipe.
8. Install the air cleaner assembly.
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Accessory Drive - Power Steering Pump Belt Tensioner2.0L Duratorq-TDCi/2.2L
Removal
1. Remove the exhaust gas recirculation (EGR) cooler to EGR valve tube.
Installation).
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6. Remove the power steering pump belt tensioner.
Installation
Tighten to 23 Nm.
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Accessory Drive - Water Pump Belt2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 -
AJ27
Removal
1. Remove the battery tray. For additional information, refer to Section
414-01 Battery, Mounting and Cables.
2. Remove the water pump belt.
1. De-tension the water pump belt.
2. Remove the water pump belt.
Installation
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Accessory Drive - Water Pump Belt Tensioner2.0L NA V6 - AJV6/2.5L NA V6 -
Removal
1. Remove the water pump belt. For additional information, refer to the
Water Pump Belt.
2. Remove the water pump belt tensioner.
Installation
Tighten to 10 Nm.
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Starting System -
Description Nmlb-ft lb-in
Starter motor retaining bolts - vehicles with 2.0L, 2.5L or 3.0L engines 35 26 -
Starter motor cable retaining nut - vehicles with 2.0L, 2.5L or 3.0L engines 12 9 -
Solenoid cable retaining nut - vehicles with 2.0L, 2.5L or 3.0L engines 6 - 53
Starter motor retaining bolts - vehicles with 2.0L and 2.2L diesel engine 25 18 -
Starter motor electrical connector retaining nut - vehicles with 2.0L and 2.2L diesel engine 12 9 -
Starter motor solenoid electrical connector retaining nut - vehicles with 2.0L and 2.2L diesel engine 6 - 53
Vacuum solenoid valves and vacuum reservoir mount bracket securing bolts - vehicles with 2.0L and 2.2L diesel engine 23 17 -
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Starting System - Starting System
The function of the starting system is to crank the engine fast enough to allow the engine to start. Heavy cables, connectors and switches
are used in the system because of the large currents required.
The starting system consists of a pre-engaged type starter motor, battery, remote control switch (ignition switch) and relay. The operation
of the starter relay is controlled by the engine control module (ECM).
To protect the starter motor from damage, the ECM prevents the starter from being engaged when the engine is running. This is done by the
ECM inhibiting the starter relay operation.
Vehicles equipped with automatic transmission have a transmission range sensor attached to the circuit which prevents operation of the
starter motor unless NEUTRAL or PARK are selected.
USA market vehicles equipped with manual transmission have a clutch pedal start inhibit switch which prevents operation of the starter
motor unless the clutch pedal is operated.
The ECM will only operate the starter relay providing the following conditions are met:
The ignition switch has been in the start position for a predetermined time
The security response between the ECM and the instrument cluster (IC) has passed
The engine is not running
The transmission range switch is in the NEUTRAL or PARK position (vehicles fitted wi th automatic transmission)
The clutch pedal is operated (USA vehicles fitted with manual transmission)
The starter relay remains energized until one of the following occur:
The maximum cranking time is exceeded
The ECM detects an engine running signal
The ignition switch is no longer in the start position
The transmission range switch is no longer in the NEUTRAL or PARK position (vehicles fitted with automatic transmission)
The clutch pedal is released (USA vehicles fitted with manual transmission)
The set engine speed is reached (vehicles with 2.0L engine)
The vehicle is cranked for 30 seconds and the engine has failed to start
With the ignition switch in the start position, providing the ECM start conditions are met, the starter relay is energized and the engagement
lever moves the pinion into mesh with the engine ring gear teeth. The electrical contacts within the solenoid complete the high power circuit
and the starter motor operates to turn the engine.
The sequence of operation is as follows:
Ignition switch in the start position
Starter relay activated by the ECM
Voltage provided to the starter motor solenoid
Starter solenoid engages the drive pinion to the ring gear
Starter solenoid switches the battery current to the starter motor
The starter remains engaged until the ECM start conditions are no longer met
Vehicles with 2.0L, 2.5L or 3.0L engines
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1 Engine control module (ECM)
2 Starter motor
3 Starter motor relay
Vehicles with 2.0L and 2.2L diesel engines
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2 Starter motor relay
3 Starter motor
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Starting System - Starting System2.0L NA V6 - AJV6
WARNING: Beware of rotating parts. Failure to follow these instructions may result in personal injury.
1. Visually inspect for obvious signs of mechanical and electrical damage. 1.
3. Make sure the vehicle is in NEUTRAL or PARK for automatic vehicles, NEUTRAL for manual vehicles. 3.
Starter Motor
Flywheel Ring Gear
Engine Seized
Starter Motor
Battery
Fuse 28 (30A)
Fuse 29 (30A)
Fuse 92 (10A)
Starter relay
Transmission range switch
Wiring harness(es)
Damaged, loose or corroded connectors
4. If an obvious cause for an observed or reported concern is found, correct the cause, (if possible) before proceeding to the next
step.
4.
electrical guides are available, the starting system can only be diagnosed using the Jaguar approved diagnostic system, other than
basic electrical faults. For additional information, refer to Dealer technical support.
5.
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1
1
1
2
3
Starting System - Starting System2.5L NA V6 - AJV6/3.0L NA V6 - AJ27
3. Make sure the vehicle is in NEUTRAL or PARK for automatic vehicles, NEUTRAL for manual vehicles. 3.
4. Make sure the clutch pedal is fully depressed for Federal manual vehicles. 4.
Starter Motor
Flywheel Ring Gear
Engine Seized
Starter Motor
Battery
Fuse 28 (15A)
Fuse 29 (30A)
Fuse 92 (10A)
Starter relay
Clutch switch; manual transmission (USA only)
Wiring harness(es)
5. If an obvious cause for an observed or reported concern is found, correct the cause, (if possible) before proceeding to the next
step.
5.
Symptom Chart
DTC Condition Possible Sources Action
P0616,
P0617
The engine does not
crank.
Battery.
Circuit.
Starter motor.
Relay.
Inertia switch.
Ignition switch.
(automatic transmission).
Clutch switch; manual
transmission (USA only).
None. The engine cranks slowly. Battery.
Circuit.
Starter motor.
None. Unusual starter motor
noise.
Starter motor.
Flywheel ring gear.
INSPECT flywheel ring gear. For additional information,
REFER to Section 303-00 Engine System - General Information.
INSPECT starter motor for alignment, cracked case. Make sure the
mounting bolts are tightened. If necessary, INSTALL a new starter
motor.
None. The starter spins, but the
engine does not crank.
Starter motor.
Flywheel ring gear.
INSPECT the flywheel ring gear for missing teeth.
REFER to Section 303-00 Engine System - General Information.
INSPECT starter motor pinion gear for missing teeth. CHECK
starter motor for correct mounting. If concern persists, INSTALL a
new starter motor.
PINPOINT TEST A : P0616, P0617. THE ENGINE DOES NOT CRANK
NOTE: Make sure the vehicle is in NEUTRAL or PARK for automatic vehicles, NEUTRAL for manual vehicles. Make sure the clutch pedal is
fully depressed for Federal manual vehicles.
NOTE: Check that the inertia switch has not tripped.
TEST
CONDITIONS
A1: CHECK THE BATTERY
Check the battery. For additional information.
REFER to Section 414-00 Battery and Charging System - General Information.
Is the battery OK?
Yes
GO to A2.
No
INSTALL a new battery.
REFER to Section 414-01 Battery, Mounting and Cables.
A2: CHECK THE STARTER RELAY
Does the starter relay make an audible click?
Yes
GO to A16.
No
GO to A3.
A3: CHECK FOR CRANK SUPPLY VOLTAGE TO STARTER RELAY
Remove the starter relay.
Turn the ignition switch to the CRANK position, and hold.
Measure the voltage between terminal 1 of the relay base and GROUND.
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2
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1
1
2
3
1
2
1
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1
1
1
2
3
1
2
Yes
GO to A20.
No
GO to A4.
A4: CHECK FOR CRANK SUPPLY VOLTAGE TO ECM
Measure the voltage between EN16 pin 6 (Y) and GROUND.
Yes
GO to A6.
No
GO to A5.
A5: CHECK FUSE 28 IN THE ENGINE COMPARTMENT FUSE BOX.
Check the fuse.
Is the fuse OK?
Yes
CHECK and repair the circuit including the power distribution fuse box, the starter relay base pin 1 and EN16 pin 6.
(This circuit includes the ignition switch)
No
INSTALL a new fuse. TEST the circuit for cause of fuse failure.GO to A6.
A6: CHECK ECM GROUND SIGNAL TO STARTER RELAY
Connect the ECM electrical connector EN16.
Measure the resistance between terminal 2 of the relay base and GROUND.
Yes
INSTALL a new starter relay. For additional information, refer to the Electrical guide. CLEAR the DTC. TEST the system
No
GO to A7.
A7: CHECK ECM GROUND SIGNAL CIRCUIT FOR CONTINUITY
Measure the resistance between terminal 2 of the starter relay base and EN16 pin 41 (GO).
Yes
Automatic transmission vehicles.GO to A8.
Manual transmission vehicles.GO to A12.
Federal spec. manual transmission vehicles.GO to A13.
No
REPAIR the circuit between the starter relay and the ECM. For additional information, refer to wiring diagrams. CLEAR
the DTC. TEST the system for normal operation.
A8: CHECK FOR IGNITION VOLTAGE TO TRANSMISSION RANGE SENSOR
Measure the voltage between JB156 pin 10 and GROUND.
Yes
GO to A11.
No
GO to A9.
A9: CHECK FUSE 92 IN THE CENTRAL JUNCTION FUSE BOX
Check the fuse.
Is the fuse OK?
Yes
Repair the circuit between the power distribution fuse box and the transmission range switch. For additional
(This circuit includes the central junction fuse box, inertia switch, ignition switch, ignition relay, and power distribution fuse box (Fuse 28, See test A5))
No
INSTALL a new fuse. TEST the circuit for cause of fuse failure. CLEAR the DTC. TEST the system for normal operation.
A10: CHECK THE CIRCUIT BETWEEN TRANSMISSION RANGE SENSOR AND ECM FOR CONTINUITY
Measure the resistance between EN16 pin 31 (B) and JB156 pin 6 (B).
Yes
GO to A11.
No
REPAIR the circuit between EN16 pin 31 (B) and JB156 pin 6 (B). For additional information, refer to wiring diagrams.
A11: CHECK THE TRANSMISSION RANGE SENSOR
Disconnect the transmission range sensor electrical connector JB156.
Select PARK or NEUTRAL.
Measure the resistance between pins 6 and 10 of the TR sensor.
Yes
INSTALL a new ECM. REFER to Section 303-14A Electronic Engine Controls / 303-14B Electronic Engine Controls.
No
INSTALL a new transmission range sensor. REFER to Section 307-01A Automatic Transmission/Transaxle / 307-01B
Automatic Transmission/Transaxle. CLEAR the DTC. TEST the system for normal operation.
A12: CHECK FOR IGNITION VOLTAGE TO ECM
Measure the voltage between EN16 pin 31 (B) and GROUND.
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1
2
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2
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3
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1
1
1
Yes
No
REPAIR the circuit between the ECM and the power distribution fuse box. For additional information, refer to wiring
(This circuit includes the central junction fuse box, inertia switch, ignition switch, ignition relay, and power distribution fuse box (Fuse 28, See test A5))
A13: CHECK FOR IGNITION VOLTAGE TO CLUTCH SWITCH; MANUAL TRANSMISSION (USA ONLY)
Measure the voltage between the clutch switch electrical connector PA5 pin 1 (B) and GROUND.
Yes
GO to A15.
No
Repair the circuit between the power distribution fuse box and the clutch switch. For additional information, refer to
(This circuit includes the central junction fuse box, inertia switch, ignition switch, and power distribution fuse box (Fuse 28, See test A5))
A14: CHECK THE CLUTCH SWITCH CIRCUIT FOR CONTINUITY; MANUAL TRANSMISSION (USA ONLY).
Disconnect the clutch switch electrical connector PA5.
Measure the resistance between PA5 pin 2 (W) and EN16 pin 31 (B).
Yes
GO to A15.
No
REPAIR the circuit between PA5 pin 2 (W) and EN16 pin 31 (B). For additional information, refer to wiring diagrams.
A15: CHECK THE CLUTCH SWITCH; MANUAL TRANSMISSION (USA ONLY).
Measure the resistance between PA5 pins 1 and 2.
Operate the clutch pedal while observing the ohmmeter reading.
Does the resistance switch between 0 ohms and 10,000 ohms as the pedal is operated?
Yes
No
INSTALL a new clutch switch. CLEAR the DTC. TEST the system for normal operation.
A16: CHECK THE STARTER SOLENOID INPUT
NOTE: The starter motor will disengage once a start is detected by the ECM.
Measure the voltage between starter motor connector ST3 and GROUND.
Yes
GO to A20.
No
GO to A17.
A17: CHECK THE STARTER SOLENOID INPUT CIRCUIT FOR CONTINUITY
REMOVE the starter relay.
Disconnect starter motor connector ST3
Measure the resistance between ST3 and pin 5 of the starter relay base.
Yes
GO to A18.
No
REPAIR the circuit between ST3 and pin 5 of the starter relay base. For additional information, refer to wiring
A18: CHECK THE STARTER RELAY BASE PIN 3 FOR PERMANENT SUPPLY
Measure the voltage between the starter relay base pin 3 and GROUND.
Yes
GO to A20.
No
GO to A19.
A19: CHECK FUSE 29 OF THE POWER DISTRIBUTION FUSE BOX
Check the fuse.
Is the fuse OK?
Yes
REPAIR the circuit between the starter relay base pin 3 and the battery. For additional information, refer to wiring
No
INSTALL a new fuse. Check the circuit for cause of fuse failure. CLEAR the DTC. TEST the system for normal operation.
A20: CHECK THE STARTER FOR BATTERY VOLTAGE
Measure the voltage between the starter connector ST2 and GROUND.
Yes
GO to A21.
No
REPAIR the starter motor permanent live supply circuit. For additional information, refer to wiring diagrams. CLEAR
A21: CHECK THE STARTER GROUND
Measure the resistance between starter outer casing and GROUND.
Is the resistance less than 2 Ohms?
Yes
INSTALL a new starter motor.
REFER to Section 303-06 Starting System.
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1
2
1
2
No
REPAIR starter GROUND strap or connections. For additional information, refer to wiring diagrams. CLEAR the DTC.
TEST the system for normal operation.
PINPOINT TEST B : THE ENGINE CRANKS SLOWLY
TEST
CONDITIONS
B1: CHECK FOR VOLTAGE DROP
NOTE: The starter motor will disengage once a start is detected by the ECM.
NOTE: Check battery condition before commencing this test.GO to Pinpoint Test A.
Measure the voltage between the starter motor permanent voltage supply terminal and the positive battery terminal
while cranking.
Yes
Turn the ignition switch to the OFF position. GO to B2.
No
CLEAN and TIGHTEN all positive battery cable connections. TEST the system for normal operation. If the concern
persists, INSTALL a new positive battery cable.
B2: CHECK FOR GROUND CONNECTION VOLTAGE DROP
Measure the voltage between the starter motor case and the battery negative terminal .
Yes
INSTALL a new starter motor.
REFER to Section 303-06 Starting System.
No
CLEAN and TIGHTEN all negative battery cable connections, starter motor mounting and starter motor GROUND cable.
TEST the system for normal operation. If the concern persists, INSTALL a new negative battery cable.
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Starting System - Starter Motor2.0L Duratorq-TDCi
Removal
1. Disconnect the battery.
3. Disconnect the vacuum pipes from the vacuum solenoid valves and the
vacuum reservoir.
4. Disconnect the vacuum solenoid valves electrical connectors.
5. Detach the wiring harness from the vacuum solenoids and vacuum
reservoir mount bracket.
6. Remove the vacuum solenoids and vacuum reservoir mount bracket
assembly.
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7. Detach the wiring harness retaining clips from the wiring harness
support bracket.
8. Remove the wiring harness support bracket.
9. Detach the starter motor.
10. Position the starter motor to provide access to the starter motor
cables.
11. Remove the starter motor solenoid cover and electrical connector
retaining nut.
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Remove the starter motor electrical connector retaining nut.
Installation
Tighten to 12 Nm.
2. Tighten to 6 Nm.
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Starting System - Starter Motor2.2L Duratorq-TDCi (110kW/150PS) - Puma
Removal
3. Reposition the starter motor solenoid cover.
4. Remove the starter motor electrical connector retaining nut.
5. Remove the starter motor electrical connector retaining nut.
6. Detach the wiring harness retaining clips from the wiring harness
support bracket.
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7. Remove the wiring harness support bracket.
Reposition the charge air cooler intake pipe for access.
10. Disconnect the vacuum solenoid valve electrical connector.
11. Disconnect the vacuum pipes from the vacuum solenoid valve.
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12. Remove the vacuum solenoid mount bracket assembly.
Installation
Tighten to 25 Nm.
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5. Tighten to 6 Nm.
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Starting System - Starter Motor2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 -
AJ27
Special Tool(s)
HTJ1200-2
Removal
4. Position and adjust the special tool rear height adjuster.
Left-hand shown, right-hand similar.
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5. Position and adjust the special tool front height adjuster.
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9. Detach the starter motor solenoid cover.
12. Remove the starter motor rear retaining bolt.
1. Remove the starter motor front retaining bolt.
Installation
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Tighten to 35 Nm.
3. Tighten to 6 Nm.
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Engine Ignition - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27 -
Item Specification
Firing Order 1,4,2,5,3,6
Spark Plug Gap mm (in) 1.3-1.45 (0.051-0.057)
Spark Plug Type XW4E-12405
Silicone Dielectric Compound D7AZ-19A331-A (Spark Plug Connector) ESE-M1C171-A
High Temperature Nickel Anti-Seize Lubricant F6AZ-9L494-AA (Spark Plug Thread) ESE-M12A4-A
Description Nm lb-ft
Spark plugs 15 11
Ignition coil retaining bolts 6 4
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Engine Ignition - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27 - Engine
Ignition
Component Locations
1 - Ignition Coil
2 - Spark Plug
3 - RH Bank
4 - Ignition Coil Retaining Bolt
5 - LH Bank
In order for the correct firing order to be observed it should be noted that the correct cylinder numbering is, when viewed from the rear of
the engine, the right-hand cylinder bank is numbered 5,3,1 and the left-hand cylinder bank is numbered 6,4,2.
The ignition system consists of an ignition coil for each individual cylinder located on each individual spark plug. This allows the ignition
timing to be adjusted more rapidly and independently.
The crankshaft position (CKP) sensor signal is the basis for ignition timing calculations. The alternating voltage signal from the CKP sensor
is converted by the engine control module (ECM). This digital signal is then used to position the closing time of the primary circuit of the
ignition coil. The effective range for ignition timing control is increased by the fact that there are no rotating parts.
On the basis of engine speed and load inputs, the ECM determines the ignition timing. This function also takes other inputs into
consideration such as engine temperature, throttle position, knock control and electronic transmission control inputs.
This ignition system allows the customer to drive the vehicle home if an ignition coil or ignition coil wiring harness failure occurs. In the
event of a wiring harness failure between the ECM and the ignition coil, the ignition coil will fail instead of its fuse. This will allow the
remaining ignition coils to continue to function.
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Ignition2.0L NA V6 - AJV6
step.
3.
electrical guides are available, the engine ignition system can only be accurately diagnosed using the Jaguar approved diagnostic
4.
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Ignition2.5L NA V6 - AJV6/3.0L NA V6 - AJ27
step.
3.
4. If the concern is not visually evident, refer to the Symptom Chart. 4.
Symptom Chart
DTC Condition Possible Source Action
P0300
P0301
P0302
P0303
P0304
P0305
P0306
Random misfire detected.
Misfire at cylinders 1 to 6
Poor cylinder compression.
Damaged or worn piston
rings.
Inlet/exhaust valve stuck
open/closed.
Worn camshaft.
Damaged cylinder head
gasket.
Spark plug fouled/damaged,
incorrect gap.
REFER to Section 303-01A Engine / 303-01B Engine.
Fuel delivery pressure
high/low.
Faulty injector
inoperative/leaking.
Fuel injector continuously
open.
Fuel contamination.
Fuel injector circuit fault.
REFER to Section 303-04A Fuel Charging and Controls /
303-04B Fuel Charging and Controls / 303-04C Fuel Charging
and Controls - Turbocharger.
Damaged ignition coil.
Damaged electrical
harness/connection.
Damaged spark plug.
P0351
P0353
P0355
Ignition coils 1A, 2A or 3A
primary circuit malfunctions.
Ignition coil open/short
circuit.
Ignition coil insulation
breakdown.
Damaged harness.
Connector pins bent or
corroded.
Ignition circuit ground fault.
Damaged engine control
module (ECM).
P0352
P0354
P0356
Ignition coils 1B, 2B or 3B
primary circuit malfunctions.
circuit.
breakdown.
Damaged harness.
corroded.
Damaged ECM.
P1367 Ignition amplifier group 1
fault. (Cylinders 1, 3, and
5).
circuit.
breakdown.
Damaged harness.
corroded.
Damaged ECM.
P1368 Ignition amplifier group 2
fault. (Cylinders 2, 4, and
6).
circuit.
breakdown.
Damaged harness.
corroded.
Damaged ECM.
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Engine Control Module (ECM) Harness Connector
Pin Number Circuit Function Circuit Color
61 1B ignition coil trigger Green/Blue
62 2B ignition coil trigger Green/white
63 3B ignition coil trigger Green/red
87 1A ignition coil trigger Green/Blue
88 2A ignition coil trigger Green/white
89 3A ignition coil trigger Green/red
1A, 2A, 3A Ignition Coil Harness Connectors
1 Ignition coil voltage supply Red/white
2 Ignition coil diagnostic signal Yellow/green
3 Ignition coil ground supply Black
4 Ignition coil trigger 1A - Green/blue, 2A - Green/white, 3A - Green/red
1B, 2B, 3B Ignition Coil Harness Connectors
1 Ignition coil voltage supply Red/white
2 Ignition coil diagnostic signal Yellow/green
3 Ignition coil ground supply Black
4 Ignition coil trigger 1B - Green/blue, 2B - Green/white, 3B - Green/red
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1
2
1
2
3
4
5
1
2
3
4
5
1
2
1A, 2A, 3A, 1B, 2B, 3B Ignition Coils
Pin Number Circuit Function
1 Ignition coil voltage supply
2 Ignition coil diagnostic signal
3 Ignition coil ground supply
4 Ignition coil trigger
PINPOINT TEST A : IGNITION COILS P0351, P0352, P0353, P0354, P0355, P0356, P1367, P1368
NOTE: Unless multiple cylinder misfires are apparent, only one circuit will normally need to be tested. The DTC set will indicate which
cylinder is misfiring.
TEST
CONDITIONS
A1: CHECK COIL FUNCTION BY SUBSTITUTION
Swap suspect coil for known good unit.
Does the same DTC reoccur? The DTC will indicate if the same cylinder is misfiring.
Yes
GO to A2.
No
A2: CHECK THE IGNITION COIL SUPPLY VOLTAGE CIRCUIT
Disconnect the relevant A bank ignition coil electrical connector(s).
Measure the voltage between:
Cyl A1. EN051 pin 1, (RW) and GROUND.
Disconnect the relevant B bank ignition coil electrical connector(s).
Cyl B1. EN054 pin 1, (RW) and GROUND.
Is the voltage greater than 10.5 Volts?
Yes
GO to A3.
No
REPAIR the relevant ignition coil supply voltage circuit. For additional information, refer to wiring digrams. CLEAR the
DTCs. TEST the system for normal operation.
A3: CHECK THE IGNITION COIL GROUND CIRCUIT
Switch the ignition to the OFF position.
Disconnect the relevant A bank ignition coil electrical connector(s).
Measure the resistance between:
Cyl A1. EN051 pin 3, (B) and GROUND.
Disconnect the relevant B bank ignition coil electrical connector(s).
Cyl B1. EN054 pin 3, (B) and GROUND.
Yes
GO to A4.
No
REPAIR the relevant ignition coil ground circuit. For additional information, refer to wiring diagrams. CLEAR the DTCs.
A4: CHECK THE CONTINUITY OF THE IGNITION COIL TRIGGER SUPPLY CIRCUIT
Check the continuity of the ignition coil trigger supply circuit between the relevant ignition coil electrical connector(s)
and the ECM electrical connector:
Cyl A1. EN051 pin 4, (GU) and EN016 pin 87, (GU)
Cyl A2. EN052 pin 4, (GW) and EN016 pin 88, (GW)
Cyl A3. EN053 pin 4, (GR) and EN016 pin 89, (GR)
Cyl B1. EN054 pin 4, (GU) and EN016 pin 61, (GU)
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1
Cyl B2. EN055 pin 4, (GW) and EN016 pin 62, (GW)
Cyl B3. EN056 pin 4, (GR) and EN016 pin 63, (GR)
Yes
GO to A5.
No
REPAIR the ignition coil trigger supply circuit between the relevant ignition coil electrical connector(s) and the ECM
electrical connector. CLEAR the DTCs. TEST the system for normal operation.
A5: CHECK THE CONTINUITY BETWEEN THE IGNITION COIL AND THE ECM
Check the continuity of the ignition coil diagnostic signal circuit, between the ignition coil electrical connector(s) and
the ECM electrical connector:
Cyl A1. EN051 pin 2, (YG) and EN016 pin 131, (YG)
Cyl B1. EN054 pin 2, (YG) and EN016 pin 132, (YG)
Is the resistance less than 5 Ohms?
Yes
INSTALL a new ECM. For additional information refer to Section 303-14A Electronic Engine ControlsSection 303-14B
Electronic Engine Controls Before replacing a ECM, contact Dealer technical support. CLEAR the DTCs. TEST the system
No
REPAIR the circuit between the ignition coil electrical connector(s) and the ECM electrical connector. CLEAR the DTCs.
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Engine Ignition - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27 - Ignition
Coil-On-Plug LH
Removal
2. Remove the air cleaner. For additional information, refer to Section
Installation
Tighten to 6 Nm.
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Engine Ignition - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27 - Ignition
Coil-On-Plug RH
Removal
2. Remove the intake manifold. For additional information, refer to Section
303-01A EngineSection 303-01B Engine.
Installation
Tighten to 6 Nm.
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Glow Plug System -
Glow plug 13 10 -
Glow plug electrical connector retaining nut 2 - 18
Main wiring harness to glow plug wiring harness nut 4 - 35
Glow plug terminal block retaining screw 5 - 44
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Glow Plug System - Glow Plug System
1 - Glow plug indicator lamp
2 - Glow plug fuse
3 - Glow plug relay
4 - Glow plug wire
5 - Glow plug
The glow plugs are located in the side of the cylinder head and aid engine starting and efficiency. The glow plugs and the glow plug
indicator lamp are controlled by the engine control module (ECM).
The glow plugs preheat the combustion chambers, which aids cold starting. During the preheat stage, the ECM receives an engine
temperature signal from the cylinder head temperature (CHT) sensor and this determines the preheat time. The lower the temperature, the
longer the preheat time. There is a maximum preheat time of 8 seconds at -20 C (-4 F)or lower. At temperatures above 80 C (176 F)
there is no preheat phase.
Once the engine has started, the glow plugs enter an after-glow phase. The after-glow phase helps to improve idling and reduce
hydrocarbon emissions through more efficient combustion just after starting. The after-glow phase only operates at engine speeds below
2500 RPM, above that, the after-glow phase is interrupted to increase the durability of the glow plugs. There is a maximum after-glow time
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of 30 seconds at -20 C (-4 F) or lower. At temperatures above 50C (122 F) there is no after-glow phase.
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Glow Plug System - Glow Plug System
As common rail diesel engines have better cold-starting characteristics than traditional diesel engines, the glow plugs have two functions on
this engine:
Pre-heat stage
In this stage, the glow plugs function as normal, preheating the combustion chambers to aid cold starting.
After-glow stage
At engine speeds below 2,500 rpm, and at temperatures below 50 degrees C (122 degrees F), the glow plugs continue to heat the cylinders
to improve idling and reduce emissions.
Warning light
The glow plug warning light on this vehicle not only informs the driver that the glow plugs are operating, but also as a malfunction indicator
lamp (MIL) for the engine management system. For additional information,
REFER to: Glow Plug System (303-07B Glow Plug System, Description and Operation).
Electrical
Fuse 22, front power distribution box (60 Amp)
Fuse 18, front power distribution box (10 Amp)
Glow plug relay (R10, front power distribution box)
Engine management control relay (R7, front power distribution box)
Wiring harness
Glow plug(s)
3548-1358-00. Failure to follow this instruction may result in damage to the vehicle.
NOTE: This section contains references to Parameter Identifiers (PIDs). Where the Jaguar approved diagnostic system is not available, a
scan tool may be used to access these PIDs, all of which give information, and some of which can be used to both read information and to
activate components. The format of the information may vary, depending on the tool used.
NOTE: As well as carrying out its normal function the glow plug indicator also acts as an engine check lamp which will flash continuously
when a hard diagnostic trouble code (DTC) is detected by the ECM. Soft DTCs are also stored by the ECM but will only be identified if the
system is checked for DTCs using the Jaguar approved diagnostic system or a scan tool.
NOTE: If a DTC is detected, all DTCs must be cleared after the concern is repaired. Failure to clear all DTCs may cause driveability
concerns.
NOTE: When performing voltage or resistance tests, always use a digital multimeter (DMM) accurate to 3 decimal places, and with an
up-to-date calibration certificate. When testing resistance, always take the resistance of the DMM leads into account.
NOTE: If DTCs are recorded and the symptom is not present when performing the pinpoint tests, an intermittent concern may be the
cause. Always check for loose connections and corroded terminals.
step.
3.
Diagnostic trouble code (DTC) index
DTC Condition Possible source Action
P0380Glow plug heater
circuit
Glow plug heater circuit: relay driver open circuit, short
circuit
For glow plug circuit tests, GO to Pinpoint
Test A.
Pinpoint Tests
PINPOINT TEST A : GLOW PLUG CIRCUIT TESTS
A1: CHECK THE GLOW PLUG CIRCUIT(S) FOR SHORT CIRCUIT TO POWER
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1
2
3
4
1
2
1
1
2
1
1
2
3
4
Engine control module (ECM) connector
Circuit Pin
Glow plug - control 20
Glow plug relay connector
Circuit Pin
Glow plug relay - control 02
Permanent 12 volt supply 03
ECM relay controlled 12 volt supply 01
Glow plug relay - output 05
Key off.
Glow plug fuse connector disconnected.
Key on, engine off.
Glow plug relay connector Vehicle battery
Glow plug - control - Pin 02 Positive post
Yes
GO to A3.
No
GO to A2.
A2: CHECK WHETHER THE SHORT CIRCUIT TO POWER IS IN THE HARNESS OR THE GLOW PLUGS
Glow plug assembly connector disconnected.
Glow plug - control - Pin 02 Positive post
Yes
Harness is OK.Suspect :- Glow plug assembly.
REFER to: Glow Plugs (303-07B Glow Plug System, Removal and Installation).
No
REPAIR the short circuit. For additional information, refer to the wiring
diagrams.
A3: CHECK THE GLOW PLUG CIRCUIT CONTINUITY
Glow plug - control - Pin 02 Negative post
Is the resistance between 0.5 ohm - 10 ohms?
Yes
GO to A6.
No
GO to A4.
A4: CHECK THE GLOW PLUG CIRCUIT FOR SHORT CIRCUIT TO GROUND
Glow plug assembly connector disconnected.
Glow plug - control - Pin 02 Negative post
Yes
GO to A5.
No
diagrams.
A5: CHECK THE GLOW PLUG CIRCUIT(S) FOR OPEN CIRCUIT IN THE HARNESS
Glow plug relay connector Glow plug relay connector
Glow plug - control - 15S-RD15 - Pin 01 Glow plug - control - Pin 02
Yes
Suspect:- Glow plug assembly
REFER to: Glow Plugs (303-07B Glow Plug System, Removal and Installation).
- Glow plug assembly GROUND
No
REPAIR the open circuit. For additional information, refer to the wiring
diagrams.
A6: CHECK THE GLOW PLUG CONTROL LINE 'ON' STATE
Scan tool connected.
Access and control the PID.
Activate the glow plugs.
Glow plug relay - output - Pin 01 Negative post
Is the voltage between 9 volts - 15 volts?
Yes
GO to A12.
No
GO to A7.
A7: CHECK THE GLOW PLUG CONTROL LINE FOR SHORT CIRCUIT TO GROUND
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1
1
1
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1
1
2
3
4
1
2
3
4
1
Key off.
Glow plug relay connector disconnected.
Key on, engine off.
Glow plug relay - output - Pin 01 Negative post
Yes
GO to A8.
No
INSTALL a new front power distribution box assembly.
A8: CHECK THE GLOW PLUG CONTROL LINE FOR CONTINUITY
Glow plug relay connector Glow plug relay connector
Glow plug relay - output - Pin 01 Glow plug relay - output - Pin 05
Yes
GO to A9.
No
diagrams.
A9: CHECK SUPPLIES TO THE GLOW PLUG RELAY
ECM relay controlled 12 volt supply - Pin 01 Negative post
Permanent 12 volt supply - Pin 03 Negative post
Are the voltages between 9 volts - 15 volts?
Yes
GO to A10.
No
No supply to the glow plug relay circuit. Check and repair the circuit as
necessary.
A10: CHECK THE ECM CONTROL LINE 'ON' STATE
Access and control the glow plug control PID.
Activate the glow plugs.
Glow plug relay - control - Pin 02 Negative post
Yes
Suspect:- Glow plug relay connector- Glow plug relay fault
No
GO to A11.
A11: CHECK THE ECM CONTROL LINE FOR SHORT CIRCUIT TO POWER
Glow plug relay - control - Pin 02 Positive post
Yes
GO to A17.
No
GO to A16.
A12: CHECK THE GLOW PLUG CONTROL LINE 'OFF' STATE
Access and control the glow plug control PID.
De-activate the glow plugs.
Glow plug relay - output - Pin 01 Positive post
Yes
An intermittent fault may be present in the wiring harness. Visually check for
chaffed wires or other physical damage to the harness. If no fault is found in
the circuit, suspect the following component(s):- Glow plug fuse connector-
Glow plug fuse fault
No
GO to A13.
A13: CHECK THE GLOW PLUG CIRCUIT FOR SHORT CIRCUIT TO POWER IN THE HARNESS
Key off.
Glow plug relay connector disconnected.
Key on, engine off.
Glow plug relay - output - Pin 01 Positive post
Yes
GO to A14.
No
INSTALL a new front power distribution box assembly.
A14: CHECK THE ECM CONTROL LINE FOR A SHORT CIRCUIT TO GROUND
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1
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1
2
3
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1
2
3
Yes
Suspect :- Glow plug relay fault
No
GO to A15.
A15: CHECK WHETHER THE SHORT CIRCUIT TO GROUND IS IN THE ECM HARNESS OR ECU
Key off.
ECM connector disconnected.
Key on, engine off.
Yes
Harness is OK.Suspect :- ECM fault
No
diagrams.
A16: CHECK WHETHER THE SHORT CIRCUIT TO POWER IS IN THE ECM HARNESS OR ECU
Key off.
Key on, engine off.
Glow plug relay - control - Pin 02 Positive post
Yes
Harness is OK.Suspect :- ECM fault
No
diagrams.
A17: CHECK THE ECM CONTROL LINE FOR CONTINUITY
Key off.
Glow plug relay - control - Pin 02 Glow plug - control - Pin 20
Yes
Suspect :- ECM connector fault-ECM fault
No
diagrams.
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Glow Plug System - Glow Plugs
Removal
2. Detach the glow plug wire electrical connector.
In-vehicle Repair).
4. Remove the glow plug wire retaining nuts.
5. Remove the glow plug wire.
6. Remove the glow plugs.
Installation
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Tighten to 13 Nm.
2. Tighten to 2 Nm.
3. Tighten to 5 Nm.
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Engine Emission Control - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) -
Puma -
Exhaust gas recirculation (EGR) valve to intake manifold retaining bolts 10 - 89
EGR valve tube to EGR valve retaining nuts 10 - 89
EGR valve tube to EGR valve retaining studs 11 8 -
EGR cooler to EGR valve tube mounting bracket retaining bolts 10 - 89
EGR cooler to EGR valve tube retaining bolts 10 - 89
Manifold absolute pressure (MAP) sensor retaining bolt 4 - 35
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Puma - Engine Emission Control
1 - EGR valve
2 - EGR valve to intake manifold retaining bolt
3 - EGR cooler to EGR valve tube mounting bracket upper retaining bolt
4 - EGR cooler to EGR valve tube mounting bracket lower retaining bolts
5 - EGR cooler to EGR valve tube
6 - EGR cooler to EGR valve tube to EGR valve retaining nuts
7 - EGR cooler to EGR valve tube to EGR valve gasket
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Puma - Engine Emission Control
Overview
For information on the description and operation of the emission control system:
REFER to: Engine Emission Control (303-08 Engine Emission Control - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) - Puma,
Visual Inspection
Engine breather hoses
Exhaust gas recirculation (EGR) pipes (check for cracks)
EGR valve
EGR cooler
Fuse(s)
Wiring harness
Loose or corroded electrical connector(s)
EGR valve
step.
3.
4.
Symptom chart
Symptom
(specific) Possible cause Action
Difficult to start Exhaust gas recirculation (EGR)
valve(s) stuck open
Check the EGR valve and circuits. Refer to the electrical guides. Check the
mechanical condition of the EGR valves. Rectify as necessary.
Poor/Erratic idle
Lack of power
when accelerating
Engine
stops/stalls
Exhaust gas recirculation (EGR)
valve(s) stuck open
Breather system
disconnected/restricted/blocked
Check the EGR valve and circuits. Refer to the electrical guides. Check the
mechanical condition of the EGR valves. Check the engine breather system.
Check for DTCs indicating an EGR valve, throttle or sensor fault. Rectify as
necessary.
Excessive fuel
consumption
Exhaust gas recirculation (EGR)
valve(s) stuck open
EGR not operating
Breather system
restricted/blocked
Excessive black
smoke
Excessive
emissions
Excessive blow-by Breather system
restricted/blocked
Check the engine breather system. Rectify as necessary.
Engine oil leaks Breather system
restricted/blocked
Check the engine breather system. Rectify as necessary.
For a complete list of all diagnostic trouble codes that could be logged on this vehicle. REFER to: Electronic Engine Controls (303-14B
Electronic Engine Controls - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) - Puma, Diagnosis and Testing).
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Puma - Exhaust Gas Recirculation (EGR) Cooler
Special Tool(s)
303-397 (24-003)
Removal
4. Using the special tool, disconnect the EGR cooler coolant hose from the
thermostat housing.
5. Using the special tool, disconnect the coolant hose from the EGR cooler.
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9. Remove the EGR cooler.
Discard the gasket.
10. Remove the coolant hose from the EGR cooler.
Installation
1. Install the coolant hose to the EGR cooler.
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2. NOTE: Install a new EGR cooler gasket.
Install the EGR cooler.
Tighten to 37 Nm.
3. Install the EGR cooler mount bracket.
Tighten to 10 Nm.
Tighten to 10 Nm.
6. Using the special tool, connect the coolant hose to the EGR cooler.
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7. Using the special tool, connect the EGR cooler coolant hose to the
thermostat housing.
8. Install the air cleaner outlet pipe.
9. Install the catalytic converter.
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Puma - Exhaust Gas Recirculation (EGR) Cooler to EGR Valve Tube
Removal
2. Loosen the exhaust gas recirculation (EGR) cooler to EGR valve tube
mounting bracket upper retaining bolt.
3. Remove the EGR cooler to EGR valve tube mounting bracket lower
retaining bolt.
4. Remove the EGR valve tube to EGR cooler retaining bolts.
5. Remove the EGR valve tube to EGR valve retaining nuts.
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6. Remove the EGR valve tube to EGR valve retaining studs.
7. Remove the EGR cooler to EGR valve tube.
Installation
1. CAUTION: The tightening sequence of the EGR cooler to EGR valve
tube retaining nuts and bolts is critical. Follow the exact order of
tightening shown in the installation procedure. Failure to follow this
Install the EGR cooler to EGR valve tube.
2. NOTE: Install a new EGR valve tube to EGR valve gasket.
Install the EGR valve tube to EGR valve retaining studs.
Tighten to 11 Nm.
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3. Loosely install the EGR valve tube to EGR valve retaining nuts.
4. NOTE: Install a new EGR valve tube to EGR cooler gasket.
Loosely install the EGR valve tube to EGR cooler retaining bolts.
5. Loosely install the EGR cooler to EGR valve tube mounting bracket lower
retaining bolt.
6. Tighten the EGR valve tube to EGR valve retaining nuts.
Tighten to 10 Nm.
7. Tighten the EGR valve tube to EGR cooler retaining bolts.
Tighten to 10 Nm.
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8. Tighten the EGR cooler to EGR valve tube mounting bracket lower
retaining bolt.
Tighten to 10 Nm.
9. Tighten the EGR cooler to EGR valve tube mounting bracket upper
retaining bolt.
Tighten to 10 Nm.
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Puma - Exhaust Gas Recirculation (EGR) Valve
Removal
2. Disconnect the Exhaust Gas Recirculation (EGR) valve electrical
connector.
3. Disconnect the Manifold Absolute Pressure (MAP) sensor electrical
connector.
4. Disconnect the throttle plate position sensor electrical connector.
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6. Detach the charge air cooler hose.
7. Loosen the EGR cooler to EGR valve tube mounting bracket lower
retaining bolt.
8. Remove the EGR valve tube to EGR valve retaining nuts.
9. Remove the EGR valve tube to EGR valve retaining studs.
10. Remove the EGR valve to inlet manifold retaining bolts.
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11. Remove the EGR valve.
Installation
1. NOTE: Install a new EGR valve O-ring seal.
Tighten to 10 Nm.
Tighten to 11 Nm.
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Intake Air Distribution and Filtering - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA
V6 - AJ27 - Intake Air Distribution and Filtering
1 Air cleaner outlet pipe
2 Air cleaner cover
3 Air cleaner element
4 Air cleaner
5 Air cleaner intake pipe
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V6 - AJ27 - Intake Air Distribution and Filtering
Mechanical
Air cleaner intake pipe
Air cleaner outlet pipe
Air cleaner element
step.
3.
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V6 - AJ27 - Air Cleaner
Removal
1. Remove the air cleaner element. For additional information, refer to the
procedure in this section: Air Cleaner Element
2. Detach the air cleaner intake pipe.
1. Remove the air cleaner intake pipe retaining screws.
1. Detach the air cleaner from the retaining grommet.
Installation
1. NOTE: When installing the air cleaner, make sure that the locating peg
is installed correctly into the retaining bracket grommet.
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V6 - AJ27 - Air Cleaner Element
Removal
2. Disconnect the mass airflow sensor electrical connector.
3. Disconnect the air cleaner outlet pipe.
4. Remove the engine cover mounting plate.
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5. Remove the air cleaner cover.
6. Remove the air cleaner element.
Installation
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V6 - AJ27 - Air Cleaner Outlet Pipe
Removal
1. Disconnect the positive crankcase ventilation hose.
Installation
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Intake Air Distribution and Filtering - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi
(110kW/150PS) - Puma -
Charge air cooler retaining bolts 7 62
Charge air cooler outlet hose 4 35
Charge air cooler intake hose 4 35
Power steering fluid cooler retaining bolts 7 62
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(110kW/150PS) - Puma - Intake Air Distribution and Filtering
1 - Air cleaner outlet pipe
2 - Turbo to turbo outlet pipe connecting hose
3 - Turbo outlet pipe
4 - Turbo outlet pipe to charge air cooler intake pipe connecting hose
5 - Air cleaner
6 - Charge air cooler intake pipe
7 - Charge air cooler intake hose
8 - Air cleaner intake pipe
9 - Charge air cooler
10 - Charge air cooler outlet hose
11 - Thermal manifold absolute pressure (TMAP) sensor
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12 - Intake manifold inlet hose
13 - Air cleaner element
14 - Air cleaner cover
1 - Air cleaner outlet pipe
2 - Turbo to turbo outlet pipe connecting hose
3 - Turbo outlet pipe
4 - Turbo outlet pipe to charge air cooler intake pipe connecting hose
5 - Air cleaner
6 - Charge air cooler intake pipe
7 - Charge air cooler intake hose
8 - Air cleaner intake pipe
9 - Charge air cooler
10 - Charge air cooler outlet hose
11 - Thermal manifold absolute pressure (TMAP) sensor
12 - Intake manifold inlet hose
13 - Air cleaner element
14 - Air cleaner cover
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1
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1
(110kW/150PS) - Puma - Intake Air Distribution and Filtering
Mechanical
Check the air cleaner housing for restriction/blockage
Check the air cleaner element for restriction/blockage
Check the charge air cooler for damage
step.
3.
Pinpoint tests
WARNING: The following tests may involve working in close proximity to hot components. Make sure adequate protection is used.
PINPOINT TEST A : CHECK FOR RESTRICTION IN AIR INTAKE
TEST
CONDITIONS
A1: CHECK FOR AIR FLOW THROUGH INTAKE SYSTEM
Inspect the air intake pipes between the air cleaner intake and the charge air cooler inlet (pay particular attention to
the joints between the metal and rubber pipes).
Disconnect the air intake pipe at the charge air cooler inlet and the turbocharger outlet.
Using a suitable length of hose blow gently through the pipe.
Is there an unrestricted flow of air through the hose?
Yes
GO to A2.
No
Remove the pipe and remove the cause of the restriction/blockage. Reassemble the removed parts and test the
vehicle for normal operation.
A2: CHECK FOR AIR FLOW TO THE TURBOCHARGER
Disconnect the air intake pipe between the air cleaner and the turbocharger inlet.
Check the pipe for restriction/blockage (this is a large-bore pipe, and can be checked visually).
Is there an unrestricted flow of air through the hose?
Yes
GO to A3.
No
Clear the restriction/blockage. Reassemble the removed parts and test the vehicle for normal operation.
A3: CHECK FOR AIR FLOW TO THE CHARGE AIR COOLER
Remove the radiator splash shield.
Disconnect the intake pipe from between the charge air cooler and the intake manifold.
Using a suitable length of hose, blow gently through the pipe.
Is there an unrestricted flow of air through the pipe?
Yes
GO to A4.
No
Clear the restriction/blockage. Reassemble the removed parts and test the vehicle for normal operation.
A4: CHECK FOR AIR FLOW THROUGH THE CHARGE AIR COOLER
Using a suitable length of hose, blow through the charge air cooler and monitor the flow.
Is there an unrestricted flow of air through the charge air cooler?
Yes
GO to A5.
No
INSTALL a new charge air cooler.
REFER to: Charge Air Cooler - 2.2L Duratorq-TDCi (110kW/150PS) - Puma (303-12B Intake Air Distribution and
Filtering - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) - Puma, Removal and Installation).
A5: CHECK FOR AIR FLOW THROUGH THE TURBOCHARGER
Using a suitable length of hose, blow through the turbocharger and monitor the flow.
Is there an unrestricted flow of air through the turbocharger?
Yes
No restriction found in the air intake. Check for other possible causes for the customer concern.
No
Remove and inspect the turbocharger. REFER to Section 303-04A Fuel Charging and Controls / 303-04B Fuel Charging
and Controls / 303-04C Fuel Charging and Controls - Turbocharger.
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(110kW/150PS) - Puma - Air Cleaner
Removal
All vehicles
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5. Detach the air cleaner outlet pipe.
All vehicles
8. Detach the vacuum pipe from the air cleaner.
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Installation
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(110kW/150PS) - Puma - Air Cleaner Element
Removal
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6. Detach the air cleaner cover.
7. Remove the air cleaner cover.
Disconnect the breather pipe.
8. Remove the air cleaner element.
Installation
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(110kW/150PS) - Puma - Air Cleaner Outlet Pipe
Removal
All vehicles
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Remove and discard the positive crankcase ventilation hose
retaining clips.
Remove and discard the air cleaner outlet pipe retaining clip.
Remove and discard the positive crankcase ventilation hose
retaining clips.
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Remove and discard the air cleaner outlet pipe retaining clip.
Installation
1. NOTE: Install new positive crankcase ventilation hose retaining clips.
NOTE: Install a new air cleaner outlet pipe retaining clip.
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(110kW/150PS) - Puma - Charge Air Cooler2.0L Duratorq-TDCi
Removal
2. Remove the air splitter grille.
Remove the air splitter grille finish panel.
Detach the power steering fluid cooler.
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6. Detach the charge air cooler intake hose from the charge air cooler.
Remove the charge air cooler retaining bolt.
8. Remove the charge air cooler.
Installation
1. NOTE: Make sure the charge air cooler hoses are not split or cracked
and are free of grease and contaminants.
Tighten to 7 Nm.
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3. Tighten to 4 Nm.
4. Tighten to 4 Nm.
Tighten to 7 Nm.
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(110kW/150PS) - Puma - Charge Air Cooler2.2L Duratorq-TDCi (110kW/150PS) -
Puma
Removal
1. Remove the front bumper cover.
For additional information, refer to: Front Bumper Cover (501-19
Bumpers, Removal and Installation).
Detach the power steering fluid cooler.
4. Detach the charge air cooler intake hose from the charge air cooler.
Remove the charge air cooler.
Installation
1. NOTE: Make sure the charge air cooler hoses are not split or cracked
and are free of grease and contaminants.
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Tighten to 7 Nm.
3. Tighten to 4 Nm.
4. Tighten to 4 Nm.
Tighten to 7 Nm.
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Evaporative Emissions -
Evaporative emission canister retaining nuts and bolts 5 - 44
Accelerator cable retaining bracket retaining bolts - vehicles with 2.0L engine 9 - 80
Fuel tank support strap retaining bolts 25 18 -
Fuel tank filler pipe to fuel tank hose retaining clip 3 - 27
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Evaporative Emissions - Evaporative Emissions
1 Evaporative emission canister - non federal market vehicles
2 Evaporative emission canister - federal market vehicles
The evaporative emission fuel vapor management system consists of an evaporative emission canister and a canister purge valve. A
combination of rigid and flexible low permeation hoses connect the fuel tank to the evaporative emission canister and canister purge valve
intake manifold.
To satisfy LEV2 emission requirements, the fuel vapor management system uses a solenoid controlled canister close valve and a fuel tank
pressure sensor which are used during the engine management system on-board diagnostic routines.
When the canister purge valve is closed, the fuel tank vapor is vented into the cani ster through the fuel tank roll-over valves. The canister
absorbs the fuel vapor and prevents the release of hydrocarbons into the atmosphere. When the vapor management valve is cycled, the
canister is exposed to the intake manifold vacuum and the fuel vapor deposits are drawn into the manifold where they mix with the
incoming air/fuel charge. This air/fuel mixture ratio is controlled by the engine management system.
The evaporative emission fuel vapor management system is controlled by the engine control module (ECM) according to calibrated data
tables.
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Evaporative Emissions - Evaporative Emissions2.0L NA V6 - AJV6
1. Visually inspect for obvious signs of mechanical or electrical damage, blown fuses, etc. 1.
step.
2.
3. If the concern is not visually evident, verify the symptom and proceed with diagnosis, using the Jaguar approved diagnostic
system, where available.
3.
electrical guides are available, the evaporative emissions system can only be accurately diagnosed using the Jaguar approved
diagnostic system. For additional information, refer to Dealer technical support.
4.
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Evaporative Emissions - Evaporative Emissions2.5L NA V6 - AJV6/3.0L NA V6 - AJ27
Preliminary Inspection
1. Visually inspect for obvious signs of mechanical or electrical damage, blown fuses, etc. 1.
step.
2.
3. If the concern is not visually evident, verify the symptom and proceed with diagnosis, using the Jaguar approved diagnostic
system, where available.
3.
4. Where K-Line equipment is available, it should be used as an aid to diagnosis. 4.
Diagnostic Drive Cycles
Following the setting of a DTC, the appropriate repairs must be carried out, and the normal operation of the system checked. This will be
done by performing a series of drive cycles which will enable the vehicle to operate the Evaporative Emissions system as a function check.
The following drive cycles cover the use of the Jaguar approved diagnostic system, GDS510 instrument, and a test with no additional
equipment, where possible.
Flow check monitor drive cycle conditions (non-Federal)
NOTE: These conditions must be satisfied before the test is commenced.
This drive cycle should be performed following rectification work on the system.
Make sure the fuel tank is between one quarter and three quarters full. (Adding fuel will increase vapor generation; the diagnostic
will not run if the vapor concentration is too great).
Make sure the ambient air temperature is above -5C (23F).
Flow check monitor drive cycle (non-Federal)
Drive the vehicle for a minimum of 15 minutes, avoiding severe or excessive fuel movement.
Avoiding excessive fuel movement, gently bring the vehicle to rest. (Coast to a stop).
Allow the vehicle to idle for two minutes.
Full Evaporative system monitor drive cycle conditions
NOTE: These conditions must be satisfied before the test is commenced.
Make sure the fuel filler cap is correctly fitted. (Minimum three clicks).
Clear the DTCs. (Perform a code clear, even if no codes are present. This will reset TIDs).
Make sure the fuel tank is between one quarter and three quarters full. (Adding fuel will increase vapor generation; the diagnostic
will not run if the vapor concentration is too great).
Drive the vehicle for a minimum of two minutes, and until fully warm. (Temperature gauge just below mid-point).
Make sure that the purge valve is operating, either by touch, sound, or using datalogger. (Purge vapor management valve-duty
cycle).
- If the purge is not active, perform the "Drive cycle for green engine control module (ECM)" in this section.
Full Evaporative system monitor drive cycle
Drive the vehicle to a suitable road where the test can be carried out, switch off the ignition.
Leave the ignition switched off for 30 seconds.
Restart the engine, accelerate briskly to 80 Kilometres per hour (50 miles per hour), making sure that the engine speed reaches at
least 3500 RPM for a minimum of five seconds.
40 thou test, using the Jaguar approved diagnostic system
Avoiding high engine loads, drive the vehicle steadily between 64 and 97 Kilometres per hour. (40 and 60 miles per hour). Using the
Jaguar approved diagnostic system, monitor the Evaporative valve duty cycle (Purge vapor management valve-duty cycle), CCV
status (Canister close valve-vapor recovery system), and the FTPS (Fuel tank pressure-vapor recovery system). The Jaguar approved
diagnostic system will give an indication when the test is active. Dependant on the level of vapor concentration, it may take up to
30 minutes for the test to initialise. (Vapor concentration cannot be measured using the Jaguar approved diagnostic equipment).
When the test has initialised (CCV closed), it will take up to 90 seconds to complete. Avoid excessive fuel movement while the test
is active.
20 thou test, using the Jaguar approved diagnostic system
Continue driving the vehicle steadily between 64 and 97 Kilometres per hour. (40 and 60 miles per hour). avoiding high engine loads
for a further 10 minutes.
Allow the vehicle to idle for 2 minutes.
Use the Jaguar approved diagnostic system to monitor the Evaporative valve duty cycle (Purge vapor management valve-duty cycle),
CCV status (Canister close valve-vapor recovery system), and the FTPS (Fuel tank pressure-vapor recovery system). The Jaguar
approved diagnostic system will give an indication when the test is active. When the test has initialised (CCV closed), it will take up
to 90 seconds to complete.
If the 20 thou test has not run, it is likely that the vapor concentration in the purge system is too great. In this case, carry out the
following -
Drive the vehicle steadily for a further 30 minutes, avoiding excessive fuel movement.
Use the Jaguar approved diagnostic system to monitor the Evaporative valve duty cycle (Purge vapor management valve-duty cycle),
CCV status (Canister close valve-vapor recovery system), and the FTPS (Fuel tank pressure-vapor recovery system). The Jaguar
approved diagnostic system will give an indication when the test is active. When the test has initialised (CCV closed), it will take up
to 90 seconds to complete.
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If the 20 thou test fails to run a second time, repeat the entire test.
Check for DTCs. Rectify as indicated.
40 thou test, using GDS510
Avoiding high engine loads, drive the vehicle steadily between 64 and 97 Kilometres per hour. (40 and 60 miles per hour)
When the test has initialised, using the GDS510, monitor the Evaporative valve duty cycle, CCV status, and the FTPS. (The GDS510
will give an indication when the test is active).
When the test has initialised (CCV closed), it will take up to 90 seconds to complete.
To make sure that the test has completed, TID 08 in mode 6 must be checked. (If the test has not completed, this TID will display
0. Any other value indicates test completion).
If the test did not complete, repeat the test.
20 thou test, using GDS510
Continue driving the vehicle steadily between 64 and 97 Kilometres per hour. (40 and 60 miles per hour) avoiding high engine loads
for a further 10 minutes.
When the test has initialised, using the GDS510, monitor the Evaporative valve duty cycle, CCV status, and the FTPS. (The GDS510
will give an indication when the test is active).
When the test has initialised (CCV closed), it will take up to 90 seconds to complete.
To make sure that the test has completed, TID 06 in mode 6 must be checked. (If the test has not completed, this TID will display
0. Any other value indicates test completion).
If the test did not complete, repeat the test.
If the 20 thou test has not run, it is likely that the vapor concentration in the purge system is too great. In this case, drive the
vehicle steadily for a further 30 minutes, avoiding excessive fuel movement, then repeat the test.
Check for DTCs. Rectify as indicated.
40 thou and 20 thou tests using no additional equipment
The test procedure and conditions are as for the Jaguar approved diagnostic system or GDS510, but no confirmation of the test having run is
possible without the use of one of these instruments. The DTC will be set if the fault still exists, but the possibility exists that the
conditions for the test to run may not have been met, in which case, the DTC may not be set until the owner reproduces the conditions in
which the fault originally occurred.
Drive cycle for "green" ECM
To enable the ECM to re-learn fuelling adaptions.
NOTE: This procedure should be performed whenever the vehicle battery has been disconnected.
Due to component tolerance and wear during the normal running of a vehicle, fuelling and air requirements for an engine will vary over time.
The ECM has the ability to adjust for this variation by "learning" the level of compensation that is required. (These compensation values are
referred to as adaptions)
If the vehicle battery is disconnected, all adaptions held within the ECM will be lost (ie, set to Zero) The ECM is then referred to as "green".
To enable the vehicle to function correctly, the ECM must "relearn" these adaptions.
There are four areas or sites that need to be relearnt.
Allow the vehicle to idle until fully warm. (Temperature gauge just below mid-point).
Allow to idle for a further three minutes, minimum.
Drive the vehicle with the air conditioning OFF on a level road using a constant throttle, or speed control if fitted, for at least one
minute in the following gears, at the stated engine speeds for each of the sites bel ow.
The vehicle speed is for guidance only. DO NOT use the vehicle speed as the target to set adaptions.
"Green" ECM drive cycle chart. Site 1
Engine/transmission software level 3.0L Man Z65 on 3.0L Auto Z65 on 2.5L Man Z65 on 2.5L Auto Z65 on
GEAR N P/N N P/N
ENGINE SPEED Idle Idle Idle Idle
VEHICLE SPEED (GUIDE ONLY) 0MPH 0MPH 0MPH 0MPH
GEAR 3rd 3rd 3rd 3rd
ENGINE SPEED 2000RPM 1750RPM 2000RPM 1750RPM
VEHICLE SPEED (GUIDE ONLY) 45KPH (28MPH) 39KPH (24MPH) 47KPH (29MPH) 37KPH (23MPH)
GEAR 4th 4th 4th 4th
VEHICLE SPEED (GUIDE ONLY) 68KPH (42MPH ) 64KPH (40MPH) 72KPH (45MPH) 69KPH (43MPH )
GEAR 4th 4th 4th 4th
VEHICLE SPEED (GUIDE ONLY) 84KPH (52MPH) 80KPH (50MPH) 87KPH (54MPH) 87KPH (54MPH)
Bring the vehicle to rest, allow to idle for one minute.
WARNING: The following tests may involve parts which are hot.
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If sufficient adaptions have occurred, the Evaporative valve should now be operating. This can be verified manually by either touching or
listening to the valve. By touching the Evaporative valve, it should be possible to feel the valve switching. Listening to the Evaporative
valve is best done using a workshop stethoscope, through which it should be possible to hear the valve operating.
Diagnostic Trouble Code Charts
Diagnostic Trouble Code Chart
Diagnostic Trouble
Code Description Possible Source Action
P0441 Evaporative purge valve flow check. Evaporative purge valve.
Hose and connections.
.
P0442 Leak detected. 40 thou. Hoses and connections.
Fuel tank filler cap.
Carbon canister.
Canister close valve.
.
P0443 Evaporative purge valve leaking. Evaporative purge valve. GO to Pinpoint Test C.
.
P0444 Evaporative purge valve circuit open. Evaporative purge valve or circuit. GO to Pinpoint Test D.
.
P0445 Evaporative purge valve circuit
shorted.
Evaporative purge valve or circuit. GO to Pinpoint Test E.
.
P0446 Canister close valve stuck closed. Filter box.
Hoses and connections.
CCV.
Fuel tank vapor port.
Carbon canister.
.
P0447 Canister close valve circuit open
circuit.
CCV or circuit. GO to Pinpoint Test G.
.
P0448 Canister close valve circuit shorted. CCV or circuit. GO to Pinpoint Test H.
.
P0450 Fuel tank Pressure Sensor
malfunction
FTPS. GO to Pinpoint Test I.
.
P0452 FTPS low input. FTPS or circuit. GO to Pinpoint Test J.
.
P0453 FTPS high input. FTPS or circuit. GO to Pinpoint Test J.
.
P0455 Gross leak. Fuel tank and lines.
Fuel filler cap.
Carbon Canister.
Evaporative purge valve stuck closed.
CCV.
Blockage in vapor lines from engine to fuel
tank.
.
P0456 Leak detected. 20 thou. Fuel tank and lines.
Fuel filler cap.
Carbon Canister.
CCV.
GO to Pinpoint Test L.
.
Pinpoint Tests
PINPOINT TEST A : P0441. EVAPORATIVE PURGE VALVE FLOW CHECK. VALVE STUCK CLOSED
TEST
CONDITIONS
A1: CHECK EVAPORATIVE PURGE VALVE IS OPERATING
Disconnect the Vapor pipe from the inlet port of the Evaporative purge valve (ie, from fuel tank).
RUN the engine for 2 minutes, making sure that the engine reaches normal operating temperature.
CHECK that the Evaporative purge valve is operating, by touch or by sound. (Using a stethoscope, it will be possible
to hear the valve operating).
Is the valve operating?
Yes
GO to A2.
No
CHECK for DTC P0444, P0445. Conduct "green" ECM drive cycle. For additional information, see "diagnostic drive
cycles" above.
A2: CHECK FOR VACUUM AT EVAPORATIVE PURGE VALVE
CHECK for vacuum at the valve.
Is a vacuum present?
Yes
Possible intermittent fault. CLEAR the DTC. Carry out a flow check monitor drive cycle. RECHECK DTCs. For additional
information, see "diagnostic drive cycles" above.
No
GO to A3.
A3: CHECK FOR BLOCKAGES IN THE SYSTEM
CHECK for blockages in the intake manifold drilling, and the pipe from the intake manifold to the Evaporative purge
valve.
Was a blockage found?
Yes
Rectify the blockage. CLEAR the DTC. Carry out a flow check monitor drive cycle. For additional information, see
"diagnostic drive cycles" above.
No
INSTALL a new Evaporative purge valve.
REFER to Evaporative Emission Canister Purge Valve in this section.
CLEAR the DTC. Carry out a flow check monitor drive cycle. RECHECK DTCs. For additional information, see
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PINPOINT TEST B : P0442. LEAK DETECTED. 40 THOU
TEST
CONDITIONS
B1: CHECK FUEL FILLER CAP FITMENT AND CONDITION OF PIPES AND CONNECTORS
Make sure that the fuel filler cap is correctly installed and tightened. (Minimum 3 clicks).
Check the condition of all accessible pipes and connectors in the vapor line.
Are all pipes and connectors in good condition?
Yes
Suspect concern with fuel tank assembly or carbon canister assembly.
No
REPAIR as necessary. CLEAR the DTC. Carry out a full Evaporative system monitor drive cycle. RECHECK DTCs. For
additional information, see "diagnostic drive cycles" above.
PINPOINT TEST C : P0443. EVAPORATIVE PURGE VALVE LEAKING
TEST
CONDITIONS
C1: CHECK EVAPORATIVE PURGE VALVE INTEGRITY
Disconnect the outlet pipe from the Evaporative purge valve. (From valve to manifold).
Apply a vacuum to the valve outlet pipe.
Does the valve hold vacuum?
Yes
Possible intermittent fault. CLEAR the DTC. Carry out a full Evap system monitor drive cycle. RECHECK DTCs. For
No
CLEAR the DTC. Carry out a full Evaporative system monitor drive cycle. RECHECK DTCs. For additional information,
see "diagnostic drive cycles" above.
PINPOINT TEST D : P0444. EVAPORATIVE PURGE VALVE CIRCUIT OPEN CIRCUIT
TEST
CONDITIONS
D1: CHECK SUPPLY VOLTAGE TO EVAPORATIVE PURGE VALVE
Disconnect Evaporative purge valve electrical connector, JB170.
Measure the voltage at JB170, pin 1 (GU).
Yes
GO to D2.
No
REPAIR the circuit between Evaporative purge valve electrical connector, JB170, pin 1 (GU) and the EMS control relay.
For additional information, refer to wiring diagrams. CLEAR the DTC. Turn the ignition switch to the ON position. Leave
switched on for minimum 30 seconds. RECHECK DTCs. For additional information, see "diagnostic drive cycles" above.
D2: CHECK THE EVAPORATIVE PURGE VALVE SIGNAL WIRE FOR CONTINUITY
Disconnect the ECM electrical connector, EN16.
Measure the resistance between EN16, pin 66 (UY) and JB170, pin 2 (UY).
Yes
GO to D3.
No
REPAIR the circuit between EN16, pin 66 (UY) and JB170, pin 2 (UY). CLEAR the DTC. Turn the ignition switch to the
ON position. Leave switched on for minimum 30 seconds. RECHECK DTCs. For additional information, see "diagnostic
drive cycles" above.
D3: CHECK THE EVAPORATIVE PURGE VALVE SIGNAL WIRE FOR SHORT TO GROUND
Measure the resistance between JB170, pin 2 (UY) and GROUND.
Yes
REPAIR the short to ground. For additional information, refer to wiring diagrams. CLEAR the DTC. Turn the ignition
switch to the ON position. Leave switched on for minimum 30 seconds. RECHECK DTCs. For additional information, see
No
GO to D4.
D4: CHECK THE EVAPORATIVE PURGE VALVE SIGNAL WIRE FOR SHORT TO BATTERY
Connect the ECM electrical connector, EN16.
CHECK for a voltage at JB170, pin 2 (UY).
Yes
REPAIR the short to battery. For additional information, refer to wiring diagrams. CLEAR the DTC. Turn the ignition
No
GO to D5.
D5: CHECK THE EVAPORATIVE PURGE VALVE RESISTANCE
CHECK the resistance between pins 1 and 2 of the Evaporative purge valve.
Is the resistance 30 to 34 ohms at 20C (68F)?
Yes
INSTALL a new ECM. REFER to Section 303-14A Electronic Engine Controls / 303-14B Electronic Engine Controls. Before
replacing a ECM, contact Dealer technical support.
No
CLEAR the DTC. Turn the ignition switch to the ON position. Leave switched on for mi nimum 30 seconds. RECHECK
DTCs. For additional information, see "diagnostic drive cycles" above.
PINPOINT TEST E : P0445. EVAPORATIVE PURGE VALVE CIRCUIT SHORTED
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TEST
CONDITIONS
E1: CHECK EVAPORATIVE PURGE VALVE SIGNAL WIRE FOR SHORT TO GROUND
Disconnect Evaporative purge valve electrical connector JB170.
Disconnect ECM electrical connector, EN16.
Measure the resistance between JB170, pin 2 (UY) and ground.
Yes
No
NO short found. A short in the Evaporative purge valve supply circuit may result in a blown fuse 36, PDFB. See initial
checks. CLEAR the DTC. Turn the ignition switch to the ON position. Leave switched on for minimum 30 seconds.
RECHECK DTCs. For additional information, see "diagnostic drive cycles" above.
PINPOINT TEST F : P0446. CANISTER CLOSE VALVE STUCK CLOSED
TEST
CONDITIONS
F1: CHECK FOR FLOW THROUGH SYSTEM
NOTE: Depending on the severity of the blockage, it is possible that some difficul ty has been experienced during refuelling.
Disconnect the vapor line from Evaporative purge valve inlet port and apply low pressure.
CHECK for free flow of air through the following, paying attention to kinked or flattened pipes.
Filter.
Interconnecting pipe. (Filter to CCV).
CCV.
Interconnecting pipe. (CCV to carbon canister).
Carbon canister.
Interconnecting pipe. (Carbon canister to fuel tank).
Is there a restriction?
Yes
RECTIFY as necessary. CLEAR the DTC. Carry out a full Evaporative system monitor drive cycle, RECHECK DTCs. For
No
CLEAR the DTC. Carry out a full Evaporative system monitor drive cycle, RECHECK DTCs. For additional information,
PINPOINT TEST G : P0447. CANISTER CLOSE VALVE CIRCUIT OPEN CIRCUIT
TEST
CONDITIONS
G1: CHECK SUPPLY VOLTAGE TO CCV
Disconnect canister close valve electrical connector, FT5.
Measure the voltage at FT5, pin 1 (GU).
Yes
GO to G2.
No
REPAIR the circuit between FT5, pin 1 (GU) and the EMS control relay. For additional information, refer to wiring
diagrams. CLEAR the DTC. Turn the ignition switch to the ON position. Leave switched on for minimum 30 seconds.
RECHECK DTCs. For additional information, see "diagnostic drive cycles" above.
G2: CHECK THE CCV SIGNAL WIRE FOR CONTINUITY.
Measure the resistance between EN16, pin 67 (O) and FT5, pin 2 (O).
Yes
GO to G4.
No
REPAIR the circuit between EN16, pin 67 (O) and FT5, pin 2 (O). For additional information, refer to wiring diagrams.
CLEAR the DTC. Turn the ignition switch to the ON position. Leave switched on for mi nimum 30 seconds. RECHECK
DTCs. For additional information, see "diagnostic drive cycles" above.
G3: CHECK THE CCV SIGNAL WIRE FOR SHORT TO BATTERY
CHECK for a voltage at FT5, pin 2 (O).
Yes
No
GO to G4.
G4: CHECK THE CCV RESISTANCE
CHECK the resistance between pins 1 and 2 of the CCV.
Is the resistance 25 to 30 Ohms at 20C (68F)?
Yes
No
INSTALL a new CCV. CLEAR the DTC. Turn the ignition switch to the ON position. Leave switched on for minimum 30
seconds. RECHECK DTCs. For additional information, see "diagnostic drive cycles" above.
PINPOINT TEST H : P0448. CCV CIRCUIT SHORTED.
TEST
CONDITIONS
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H1: CHECK CCV SIGNAL WIRE FOR SHORT TO GROUND.
Disconnect CCV electrical connector, FT5.
Measure the resistance between FT5, pin 2 (O) and ground.
Is the resistance less than 10,000 Ohms?
Yes
switch to the ON position. Leave switched on for minimum 30 seconds. RECHECK DTCs. For additional information,
No
NO short found. A short in the CCV supply circuit may result in a blown fuse 36, PDFB. See initial checks.
PINPOINT TEST I : P0450. FUEL TANK PRESSURE SENSOR MALFUNCTION.
NOTE: Prior to commencing this test, REFER to Section 303-14A Electronic Engine Controls / 303-14B Electronic Engine Controls.
Electronic Engine Controls, Diagnosis and Testing, sensor supply and ground circuits.
NOTE: Access to the FTP sensor involves the removal of the fuel tank. To reduce the amount of work necessary, a slave harness and
sensor could be used. This can be connected at the access port beneath the rear seat. Tests can then be carried out via the slave harness
and sensor. If system operation is normal with the slave harness and sensor, the fault lies in the vehicle's harness or sensor.
I1: CHECK EVAPORATIVE PURGE VALVE IS OPERATING.
Disconnect electrical connector CA005. (Beneath rear seat).
Measure the voltage between pins 4 and 6 of CA005.
Is the voltage 2.9 - 3.7 volts?
Yes
GO to I2. Reconnect CA005.
No
INSTALL a new FTPS.
REFER to Section 310-01 Fuel Tank and Lines.
Reconnect CA005. CLEAR the DTC. Turn the ignition switch to the ON position. Leave switched on for minimum 30
seconds. RECHECK DTCs. For additional information, see "diagnostic drive cycles" above.
I2: CHECK SIGNAL VOLTAGE AT FTPS.
Run the engine for two minutes, and until fully warm.
Make sure Evaporative purge valve is operating.
Steadily increase engine speed to 3000 RPM.
Measure the voltage between pins 4 and 6 of CA005.
Does the voltage reduce?
Yes
Possible intermittent fault. RECHECK DTCs, For additional information, see "diagnostic drive cycles" above.
Contact Dealer technical support.
No
INSTALL a new FTPS.
CLEAR the DTC. Carry out a full Evaporative system monitor drive cycle. RECHECK DTCs. For additional
information, see "diagnostic drive cycles" above.
PINPOINT TEST J : P0452, O0453. FUEL TANK PRESSURE SENSOR LOW/HIGH INPUT.
NOTE: Prior to commencing this test, REFER to Section 303-14A Electronic Engine Controls / 303-14B Electronic Engine Controls.
Electronic Engine Controls, Diagnosis and Testing, sensor supply and ground circuits.
NOTE: Access to the FTP sensor involves the removal of the fuel tank. To reduce the amount of work necessary, a slave harness and
sensor could be used. This could be connected at the access port beneath the rear seat. Tests can then be carried out via the slave harness
and sensor. If system operation is normal with the slave harness and sensor, the fault lies in the vehicle's harness or sensor.
TEST
CONDITIONS
J1: CHECK FTPS SIGNAL WIRE FOR CONTINUITY UP TO CONNECTOR CA5.
Disconnect FTPS electrical connector, CA5.
Check for continuity between EN16, pin 104 (RG) and CA5, pin 4 (RG).
This test will not check the continuity of the harness from CA5 to FT1. If the circuit is continuous to CA5, the fuel
tank must be removed and the harness and sensor continuity checked.
Is the circuit continuous?
Yes
INSTALL a new FTPS, (and/or harness, CA5 to FT1). CLEAR the DTC. Turn the ignition switch to the ON position. Leave
switched on for minimum 30 seconds. RECHECK DTCs. For additional information, see "diagnostic drive cycles" above. If
the DTC is repeated, INSTALL a new ECM. REFER to Section 303-14A Electronic Engine Controls / 303-14B Electronic
Engine Controls. Before replacing a ECM, contact Dealer technical support.
No
REPAIR the circuit between EN16, pin 104 (RG) and CA5, pin 4 (RG). CLEAR the DTC. Carry out a full Evaporative
system monitor drive cycle. For additional information, see "diagnostic drive cycles" above. RECHECK DTCs.
J2: CHECK FTPS SUPPLY WIRE FOR SHORT TO GROUND UP TO CONNECTOR CA5
Measure the resistance between CA5, pin 5 (OY) and GROUND.
This test will not check the integrity of the harness from CA5 to FT1. If the circuit is sound to CA5, the fuel tank
must be removed and the harness and sensor continuity checked.
Yes
REPAIR the short to GROUND. For additional information, refer to wiring diagrams. CLEAR the DTC. Turn the ignition
No
GO to J3.
J3: CHECK FTPS SIGNAL WIRE FOR SHORT TO GROUND, UP TO CONNECTOR CA5.
Connect ECM electrical connector, EN16.
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Measure the resistance between CA5, pin 4 (RG) and GROUND.
Yes
REPAIR the short to GROUND. For additional information, refer to wiring diagrams. CLEAR the DTC. Turn the ignition
No
GO to J4.
J4: CHECK FTPS SIGNAL WIRE FOR SHORT TO BATTERY, UP TO CONNECTOR CA5
Check for a voltage at CA5, pin 4 (RG).
Yes
No
GO to J5.
J5: CHECK FTPS GROUND WIRE FOR SHORT TO BATTERY, UP TO CONNECTOR CA5
Check for a voltage at CA5, pin 6 (BG).
Yes
REPAIR the short to battery. For additional information, refer to wiring diagrams. CLEAR the DTC. Carry out a full
Evaporative system monitor drive cycle, RECHECK DTCs. For additional information, see "diagnostic drive cycles" above.
No
GO to J2.
J6: CHECK FTPS SUPPLY WIRE FOR SHORT TO BATTERY UP TO CONNECTOR CA5
Check for a voltage at CA5, pin 5 (OY).
Yes
REPAIR the short to battery. For additional information, refer to wiring diagrams. CLEAR the DTC. Carry out a full
Evaporative system monitor drive cycle, RECHECK DTCs. For additional information, see "diagnostic drive cycles" above.
No
INSTALL a new FTPS, (and/or harness, CA5 to FT1).
CLEAR the DTC. Carry out a full Evaporative system monitor drive cycle, RECHECK DTCs. For additional information, see
"diagnostic drive cycles" above. If the DTC is repeated, INSTALL a new ECM. REFER to Section 303-14A Electronic
Engine Controls / 303-14B Electronic Engine Controls. Before replacing a ECM, contact Dealer technical support.
PINPOINT TEST K : P0455. GROSS LEAK DETECTED.
TEST
CONDITIONS
K1: CHECK FUEL FILLER CAP FITMENT AND CONDITION OF PIPES AND CONNECTORS.
Yes
Suspect concern with - 1. Blockage in vapor line. (Engine to fuel tank).2. Evaporative purge valve stuck closed.3. Fuel
tank assembly.4. Carbon canister assembly.
No
REPAIR as necessary. CLEAR the DTC. Carry out a full Evaporative system monitor drive cycle, RECHECK DTCs. For
PINPOINT TEST L : P0456. LEAK DETECTED. 20 THOU.
TEST
CONDITIONS
L1: CHECK FUEL FILLER CAP FITMENT AND CONDITION OF PIPES AND CONNECTORS.
Yes
Suspect concern with fuel tank assembly or carbon canister assembly.
No
REPAIR as necessary. CLEAR the DTC. Carry out a full Evaporative system monitor drive cycle, RECHECK DTCs. For
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Evaporative Emissions - Evaporative Emission Canister2.0L NA V6 - AJV6
Removal
2. Disconnect the evaporative emission canister pipe.
3. Disconnect the evaporative emission canister pipe.
4. Remove the evaporative emission canister retaining bolts.
5. Remove the evaporative emission canister.
Installation
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Tighten to 5 Nm.
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Evaporative Emissions - Evaporative Emission Canister2.5L NA V6 - AJV6/3.0L NA V6 -
AJ27
Special Tool(s)
Powertrain Assembly Jack (federal market vehicles
only)
HTJ1200-2
Removal
WARNINGS:
Do not smoke or carry lighted tobacco or an open flame of any type when working on or near any fuel related components. Highly
flammable vapors are always present and may ignite. Failure to follow these instructions may result in personal injury.
Do not carry or operate cellular phones when working on or near any fuel related components. Highly flammable vapors are always
present and may ignite. Failure to follow these instructions may result in personal injury.
Due to the heavy weight, make sure that the fuel tank is securely attached to the powertrain assembly jack when installing.
NOTE: Non federal market vehicles, refer to steps 1 to 3.
NOTE: Federal market vehicles, refer to steps 4 to 22.
1. NOTE: Non federal market vehicles only.
Remove the fuel tank.
For additional information, refer to: Fuel Tank - 2.5L NA V6 - AJV6/3.0L
NA V6 - AJ27 (310-01 Fuel Tank and Lines, Removal and Installation).
Remove the evaporative emission canister rear retaining nut.
Remove the evaporative emission canister.
4. NOTE: Federal market vehicles only.
Disconnect the battery ground cable.
Remove the fuel filler cap.
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De-pressurize the fuel system.
For additional information, refer to: Fuel System Pressure Release
(310-00 Fuel System - General Information, General Procedures).
Remove the rear seat cushion.
Detach the wiring harness grommet.
Detach the electrical connector.
Using a suitable suction device drain the fuel tank filler pipe.
Remove the rear subframe.
For additional information, refer to: Rear Subframe (502-00 Uni-Body,
Subframe and Mounting System, Removal and Installation).
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NOTE: Note the orientation of the fuel tank filler pipe to fuel tank hose
retaining clip before loosening.
Detach the fuel tank filler pipe hose from the fuel tank.
Disconnect the evaporative emission canister purge hose quick release
coupling.
Procedures).
Disconnect the fuel filter line quick release coupling.
Procedures).
Install blanking plugs to the male and female connectors.
Disconnect the evaporative emission canister close valve electrical
connector.
Disconnect the evaporative emission canister hose from the evaporative
emission canister.
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Using the special tool, support the fuel tank.
Remove the fuel tank support straps retaining bolts.
Remove the fuel tank support straps.
21. WARNING: The fuel tank cannot be drained in vehicle. Due to the
heavy weight, make sure that the fuel tank is securely attached to the
powertrain assembly jack when removing. Failure to follow this instruction
NOTE: Federal market vehicles only.
Using the special tool, remove the fuel tank.
Detach the fuel filler pipe hose from the fuel tank.
Install blanking plugs to the fuel tank and fuel filler pipe hose.
Remove the evaporative emission canister.
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Installation
WARNINGS:
NOTE: Non federal vehicles, refer to steps 1 to 3.
NOTE: Federal vehicles, refer to steps 1 to 21.
Install the evaporative emission canister.
Tighten to 5 Nm.
Install the evaporative emission canister rear retaining nut.
Tighten to 5 Nm.
Install the fuel tank.
Install the evaporative emission canister.
Tighten to 5 Nm.
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NOTE: Remove the blanking plugs from the fuel tank and fuel filler pipe
hose.
Using the special tool, install the fuel tank.
Attach the fuel filler pipe hose to the fuel tank.
Install the fuel tank support straps.
Install the fuel tank support straps retaining bolts.
Tighten to 25 Nm.
Connect the evaporative emission canister hose to the evaporative
emission canister.
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Connect the evaporative emission canister close valve electrical
connector.
Connect the fuel filter line quick release coupling.
Procedures).
Connect the evaporative emission canister purge hose quick release
coupling.
Procedures).
NOTE: Make sure the fuel tank filler pipe to fuel tank hose retaining clip
is correctly orientated.
Tighten the fuel tank filler pipe to fuel tank hose retaining clip.
Tighten to 3 Nm.
Install the rear subframe.
For additional information, refer to: Rear Subframe (502-00 Uni-Body,
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Attach the electrical connector.
Attach the wiring harness grommet.
Install the rear seat cushion.
Fill the fuel tank with the fuel drained from the fuel filler pipe.
Install the fuel filler cap.
Connect the battery ground cable.
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Evaporative Emissions - Evaporative Emission Canister Purge Valve
Removal
1. Detach the speed control cable.
All vehicles
4. Disconnect the evaporative emission canister purge valve electrical
connector.
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5. Disconnect the upper fuel vapour hose from the evaporative emission
6. Detach the evaporative emission canister purge valve from the retaining
bracket.
7. Remove the evaporative emission canister purge valve.
Disconnect the lower fuel vapour hose from the evaporative
emission canister purge valve.
Installation
All vehicles
2. Tighten to 9 Nm.
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Electronic Engine Controls - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27 -
Camshaft position sensor retaining bolt 7 - 62
Heated oxygen sensor 40 30 -
Catalyst monitor sensor 40 30 -
Crankshaft position sensor retaining bolt 10 7 -
Knock sensor retaining bolt 25 18 -
Variable camshaft timing oil control solenoid retaining bolt 10 7 -
Oil temperature sensor 15 11 -
Engine control module (ECM) retaining nut 10 7 -
ECM electrical connector retaining bolt 10 7 -
Engine block coolant inlet pipe retaining bolts 25 18 -
Water pump coolant outlet pipe retaining bolts 10 7 -
Throttle position sensor retaining screws 7 - 62
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2.0L Engine
1 Intake Manifold Tuning (IMT) Valve - upper
2 Intake Manifold Tuning (IMT) Valve - lower
3 Engine Coolant Temperature (ECT) Sensor
4 Variable Camshaft Timing Oil Control Solenoid LH
5 Camshaft Position (CMP) Sensor LH
6 Camshaft Position (CMP) Sensor RH
7 Variable Camshaft Timing Oil Control Solenoid RH
8 Crankshaft Position (CKP) Sensor
2.5L and 3.0L Engine
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1 Intake Manifold Tuning (IMT) Valve - upper
2 Intake Manifold Tuning (IMT) Valve - lower
3 Engine Coolant Temperature (ECT) Sensor
4 Variable Camshaft Timing Oil Control Solenoid LH
5 Camshaft Position (CMP) Sensor LH
6 Camshaft Position (CMP) Sensor RH
7 Variable Camshaft Timing Oil Control Solenoid RH
8 Crankshaft Position (CKP) Sensor
2.0L, 2.5L and 3.0L Engine
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1 Knock Sensor (KS)
2 Throttle Position (TP) Sensor
3 Oil Temperature Sensor
4 Oil Pressure Switch
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1 Heated Oxygen Sensor (HO2S) LH
2 Catalyst Monitor Sensor RH
3 Heated Oxygen Sensor (HO2S) RH
4 Catalyst Monitor Sensor LH
1 Mass Air flow (MAF) Sensor
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1 Engine Control Module (ECM)
Engine Control Module (ECM)
The electronic engine control system consists of a engine control module (ECM) and a number of sensing and actuating devices. The sensors
supply the ECM with input signals which relate to the engine operating conditions and driver requirements. The sensor information is
evaluated by the ECM using the results to activate the appropriate response from the actuating devices. The system provides the necessary
engine control accuracy and adaptability to:
Minimize exhaust emissions and fuel consumption.
Provide optimum driver control under all conditions.
Minimize evaporative emissions.
Provide system diagnostics.
In addition to these functions the ECM also interfaces with other vehicle systems through the controller area network (CAN).
Camshaft Position (CMP) Sensor
The camshaft position (CMP) sensors monitor the position of both camshafts to allow the ECM to control the phase of the inlet camshafts
relative to the position of the crankshaft.
Variable Camshaft Timing Oil Control Solenoid
The variable camshaft timing oil control solenoid is a hydraulic actuator, which advances and retards the inlet camshaft timing, thereby
altering the camshaft to crankshaft phasing for optimum engine performance.
Intake Manifold Tuning (IMT) Valve
There are two intake manifold tuning (IMT) valves, an upper and a lower, sometimes referred to as number one and two respectively. They
are a two position (open and close) device used to create a variable air intake system. The IMT valve positions are switched by signals from
the ECM to optimize torque across the engine's speed and load range. The IMT valves work in conjunction with the throttle body. The upper
IMT valve opens between 3,000 and 6,000 rpm while the lower IMT valve opens between 5,000 and 6,000 rpm.
Knock Sensor (KS)
The knock sensor (KS) detects combustion knock within the engine cylinders and sends a signal to the ECM. The ECM uses this information
to gradually adjust the ignition timing until the combustion knock is eliminated.
Mass Air flow (MAF) Sensor
The mass air flow (MAF) sensor informs the ECM of the rate of air flow entering the engine by producing a voltage which is proportional to
the rate of air flow into the engine. The voltage produced by the MAF sensor increases as the rate of air flow increases. The MAF sensor also
takes into account the density of the air entering the air intake system so that it is possible to maintain the required air to fuel ratio, and
to compensate for variations in atmospheric pressure.
Integral to the MAF sensor is the intake air temperature sensor (IAT) which measures the temperature of the air entering the air intake
system. The ECM uses this information to compensate for higher than normal air intake temperatures.
Throttle Position (TP) Sensor
The ECM monitors the angle of the throttle plate within the throttle housing through the throttle position (TP) sensor. The TP sends a
voltage to the ECM which is proportional to the angle of the throttle plate. The voltage from the TP increases with the angle of the throttle
plate. There are two sensor tracks within the TP sensor.
Crankshaft Position (CKP) Sensor
The crankshaft position (CKP) sensor is an inductive pulse generator, which scans protrusions on a pulse ring fitted to the front of the
crankshaft to inform the ECM of the crankshaft's position and speed. The CKP sensor produces an alternating voltage which is increases with
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engine speed.
Engine Coolant Temperature (ECT) Sensor
The engine coolant temperature (ECT) sensor is a thermistor type sensor that provides an input signal to the ECM which is proportional to
the engine coolant temperature. The ECT sensor is a negative temperature coefficient (NTC) sensor and its resistance decreases with a
proportional increase in engine coolant temperature.
Oil Temperature Sensor
The oil temperature sensor is a thermistor type sensor that provides an input signal to the ECM which is proportional to the engine oil
temperature.
Oil Pressure Switch
The oil pressure switch is connected to the instrument cluster and is not directly part of the electronic engine control system.
Heated Oxygen Sensor (HO2S)
The heated oxygen sensor (HO2S) is a linear characteristic type sensor, fitted forward of the exhaust system's catalytic converter. The ECM
uses this as it's primary sensor to measure the oxygen content of the exhaust gasses within the exhaust system to provide closed-loop
fuelling control.
Catalyst Monitor Sensor
The catalyst monitor sensor is a non-linear characteristic type sensor fitted to the exhaust system's catalytic converter. The ECM uses this
as it's secondary sensor to measure the oxygen content of the exhaust gasses within the exhaust after they have passed through the
catalytic converter. As well as providing additional closed-loop fuelling control the ECM uses this information to determine the efficiency of
the catalytic converter.
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Electronic Engine Controls2.0L NA V6 - AJV6
Principle of Operation
For a detailed description of the engine control system, refer to the relevant Description and Operation sections in the workshop manual.
REFER to: Electronic Engine Controls (303-14A Electronic Engine Controls - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27,
Engine oil level
Cooling system
Fuel charging system
Fuel contamination
Throttle body
Air intake system
Exhaust system
Vehicle battery (fully charged and correctly connected)
Fuses. (9, 31, 32, 37)
Wiring harness
Sensor(s)
step.
3.
4. If the cause is not visually evident, check for Diagnostic Trouble Codes (DTCs) and refer to the DTC Index. 4.
DTC Index
3548-1358-00
NOTE: If the control module/component is suspect and the vehicle remains under manufacturer warranty, refer to the Warranty Policy and
Procedures manual (section B1.2), or determine if any prior approval program is in operation, prior to the installation of a new
module/component.
NOTE: When performing voltage or resistance tests, always use a digital multimeter (DMM) accurate to three decimal places and with a
current calibration certificate. When testing resistance, always take the resistance of the DMM leads into account.
NOTE: Check and rectify basic faults before beginning diagnostic routines that involve pinpoint tests.
DTC Description Possible Cause Action
P0420Catalyst System
Efficiency Below
Threshold (Bank 1)
bank 1 upstream
HO2 sensor (heater)
failure
bank 1 downstream
HO2 sensor (heater)
failure
bank 1 upstream
HO2 sensor
(sensing) failure
bank 1 downstream
HO2 sensor
(sensing) failure
upstream sensor to
ECM wiring fault
downstream sensor
to ECM wiring fault
Exhaust system
fault
Catalyst conversion
failure
Refer to pinpoint tests for components listed. Visually inspect catalytic
converters.
P0430Catalyst System
Efficiency Below
Threshold (Bank 2)
bank 2 upstream
HO2 sensor (heater)
failure
bank 2 downstream
HO2 sensor (heater)
failure
bank 2 downstream
HO2 sensor
(sensing) failure
upstream sensor to
ECM wiring fault
downstream sensor
to ECM wiring fault
Exhaust system
fault
Refer to pinpoint tests for components listed. Visually inspect catalytic
converters.
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Catalyst conversion
failure
P0300Random Misfire
Detected
Ignition system
components
Ignition system
wiring harness
Check all ignition coils for secure fixing and check wiring harness connector for
damage and correct engagement. Visually confirm condition and grade of all
sparking plugs. Check the crank position sensor is correctly mounted and secure.
Refer to the appropriate circuit diagram, check the crank position sensor cable
screening is intact between the sensor and the engine control module and
connected to ground. Check the security and connection of the ignition relay
located in the front power distribution box. Check ignition relay ground line for
intermittent open circuits between front power distribution box and its ground
point. Check the wiring harness between the ignition relay to the harness splice
where the feeds separate to each ignition module for shorts to ground or
intermittent open circuits. Refer to the appropriate wiring diagram. Inspect
ignition system capacitor for damage or short circuits. Check capacitor wiring back
to harness splice for open circuits or short to power.
P0301Cylinder 1 Misfire
Detected
Ignition system
cylinder 1
Ignition system
wiring harness
Check cylinder 1 ignition coil for secure fixing and check wiring harness connector
for damage and correct engagement. Visually confirm condition and grade of
spark plug. Install a new sparkplug of the correct grade if required. Refer to
appropriate wiring diagram: check power supply line for open circuits or shorts to
ground, check line to ignition coil from ignition relay in front power distribution
box. Check ground connection between ignition coil and ground point for open
circuits. Check ignition line from engine control module to ignition coil for open
circuits, short to power, short to ground. Check feedback line from ignition coil to
engine control module for open circuits or short to ground/power. Minimum supply
voltage at coil is 10.5 volts. maximum resistance in signal lines is 5 ohms. Repair
wiring using appropriate repair kit as required. Minimum supply voltage at coil is
10.5 volts. maximum resistance in signal lines is 5 ohms. Repair wiring using
appropriate repair kit as required. If there are no wiring faults, swap suspect
ignition coil to a different cylinder, clear DTCs. retest vehicle. If the misfire
changes cylinder replace the ignition coil.
Detected
Ignition system
cylinder 3
Ignition system
wiring harness
wiring using appropriate repair kit as required. If there are no wiring faults, swap
suspect ignition coil to a different cylinder, clear DTCs. retest vehicle. If the
misfire changes cylinder replace the ignition coil.
Detected
Ignition system
cylinder 5
Ignition system
wiring harness
Detected
Ignition system
cylinder 2
Ignition system
wiring harness
Detected
Ignition system
cylinder 4
Ignition system
wiring harness
Detected
Ignition system
cylinder 6
Ignition system
wiring harness
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P1313Misfire Rate Catalyst
Damage Fault - Bank 1
Concern with
ignition system and
wiring harness on
bank 1
Refer to the appropriate wiring diagram. Check ignition circuits on bank one for
damage to insulation. Check ignition coil power supply, ground and signal circuits
for open circuits, shorts to ground or power, high resistance. Repair any wiring
defects using appropriate methods and materials. Clear DTC and retest the
system to check for normal operation.
P1314Misfire Rate Catalyst
Damage Fault - Bank 2
Concern with
ignition system and
wiring harness on
bank 2
Refer to the appropriate wiring diagram. Check ignition circuits on bank two for
damage to insulation. Check ignition coil power supply, ground and signal circuits
for open circuits, shorts to ground or power, high resistance. Repair any wiring
defects using appropriate methods and materials. Clear DTC and retest the
system to check for normal operation.
P1316Injector Driver Module
Codes Detected
Ignition system
Ignition system
harness
Refer to repair manual, check ignition system components. Inspect ignition
system harness for evidence of damage. Check power supply to ignition coils,
check EMS control lines. Repair wiring faults using appropriate materials and
methods. Clear DTC and retest system to confirm correct operation.
P0131O2 Circuit Low Voltage
(Bank 1, Sensor 1)
Concern with
upstream O2 sensor
Wiring between
upstream O2 sensor
and ECM
Refer to the appropriate wiring diagram: check the wiring harness connections
between the engine control module and upstream oxygen sensor. Check sensor
signal circuits for short to ground or high resistance.
P0132O2 Circuit High Voltage
(Bank 1, Sensor 1)
Concern with
upstream O2 sensor
Wiring between
upstream O2 sensor
and ECM
Refer to the appropriate wiring diagram: check the wiring harness connections
between the engine control module and upstream oxygen sensor.
P0133O2 Circuit Slow
Response (Bank 1,
Sensor 1)
Exhaust
leak/damage
Concern with
upstream O2 sensor
Upstream O2 sensor
not achieving
normal operating
temperature
Wiring between
upstream O2 sensor
and ECM
Fuel injector flow
partially blocked
Catalyst efficiency
decrease
Inspect exhaust system for damage and evidence of leakage. replace any
defective components. Clear the DTCs and retest the system. Check fuse for
power supply to O2 sensor heater. Install a replacement fuse and inspect wiring
for short circuits if defective. Clear the DTCs and retest the system. Check power
supply line from front power distribution box to O2 sensor heater for open circuits
and high resistance. Repair defects using appropriate harness repair kit. Clear the
DTCs and retest the system. Check ground circuit from O2 sensor heater to
engine control module connector for open circuits. Repair defects using
appropriate wiring repair kit. Clear the DTCs and retest the system. Disconnect
oxygen sensor connector and measure the continuity though the heating circuit of
the sensor. If there is no continuity, replace the sensor. Clear the DTCs and
retest the system
P0031HO2S Heater Control
Circuit Low (Bank 1,
Sensor 1)
Concern with
upstream O2 sensor
heater
Wiring fault
between upstream
O2 sensor and ECM
Wiring fault
between Upstream
O2 sensor and Front
Power Distribution
Box
Inspect wiring harness from O2 sensor for damage. Replace or repair any
damaged components. clear DTCs and retest vehicle. Check voltage supply from
front power distribution box to O2 sensor heater circuit. If less than 10.5 volts
check and repair
Circuit High (Bank 1,
Sensor 1)
Concern with
upstream O2 sensor
heater
Wiring fault
between upstream
O2 sensor and ECM
Wiring fault
between Upstream
O2 sensor and Front
Power Distribution
Box
Check wiring between oxygen sensor and engine control module for obvious
defects. Refer to the appropriate circuit diagram and check the ground connection
from the heater circuit for open circuits or high resistance. Repair circuits, clear
DTC, retest systems.
(Bank 2, Sensor 1)
Concern with
upstream O2 sensor
heater
Wiring fault
between upstream
O2 sensor and ECM
Wiring fault
between Upstream
O2 sensor and Front
Power Distribution
Box
Check wiring between oxygen sensor and engine control module for obvious
defects. Refer to the appropriate circuit diagram and check the signal lines for
short to power. Repair circuits, clear DTC, retest systems.
P0153O2 Circuit Slow
Response (Bank 2,
Sensor 1)
Exhaust
leak/damage
Concern with
upstream O2 sensor
Upstream O2 sensor
not achieving
normal operating
temperature
Check exhaust system is free from defects and is not leaking. Repair as required,
clear DTCs and retest. Check oxygen sensor heater power supply and ground lines
for open circuits and shorts. Repair defective wiring as required. Refer to circuit
diagrams, check oxygen sensor signal lines to engine control module for open
circuits, short circuits and high resistance. Repair circuits as required, clear DTC
and retest system. Clean fuel injectors using approved equipment. clear DTCs,
retest system. Check fuel for evidence of contamination which may have
damaged oxygen sensors or catalysts.
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Wiring between
upstream O2 sensor
and ECM
Fuel injector flow
partially blocked
Catalyst efficiency
decrease
Sensor 1)
Concern with
upstream O2 sensor
heater
Wiring fault
between upstream
O2 sensor and ECM
Wiring fault
between Upstream
O2 sensor and Front
Power Distribution
Box
Check power supply to HO2S heater element connector pin with the ignition on. If
the voltage is less than 10.5 volts check the front power distribution box fuses.
Check the wiring circuit from the front power distribution box to the HO2S sensor
connector for open circuits or shorts to ground. Repair any wiring faults using
approved methods and materials, replace any blown fuses and clear the DTC.
retest the system for correct operation. Check wiring circuit between the HO2S
sensor connector and the engine control module.
Sensor 1)
Concern with
upstream O2 sensor
heater
Wiring fault
between upstream
O2 sensor and ECM
retest the system for correct operation.
(Bank 1, Sensor 2)
Concern with
downstream O2
sensor
Wiring between
downstream O2
sensor and ECM
Check oxygen sensor wiring harness for signs of damage to the insulation. Check
the signal and screen circuits for open circuits, and shorts to ground. Check
heater circuit power circuit is supplied with power and the control line is not open
circuit. Check sensor for evidence of fouling
(Bank 1, Sensor 2)
Concern with
downstream O2
sensor heater
Wiring fault
between
downstream O2
sensor and ECM
Wiring fault
between
downstream O2
sensor and Front
Power Distribution
Box
the signal and screen circuits for shorts to power.
P0140O2 Circuit No Activity
Detected (Bank 1,
Sensor 2)
Power supply to
oxygen sensor
heater not present
Wiring harness fault
Oxygen sensor
faulty
Check power distribution box fuses to ensure the heater element of the oxygen
sensor is powered. Check oxygen sensor heating element control line is not open
circuit or has a high resistance. Check sensor signal lines for open circuits and
shorts to ground. Repair wiring fault using approved methods and materials.
Check oxygen sensor for contamination or masked sensing tip. Replace the
sensor if suspect. Clear DTC, retest the system to confirm correct operation.
Sensor 2)
Concern with
downstream O2
sensor heater
Wiring fault
between
downstream O2
sensor and ECM
Wiring fault
between
downstream O2
sensor and Front
Power Distribution
Box
retest the system for correct operation.
Sensor 2)
Concern with
downstream O2
sensor heater
Wiring fault
between
downstream O2
sensor and ECM
Check engine wiring harness for signs of damage. Check HO2S heater control
circuit for short to power. Check HO2S for internal short circuit. Repair wiring
using appropriate methods and materials, clear DTC and retest system for correct
operation. Replace HO2S if suspect. Clear DTC and retest systems to confirm
correct operation.
(Bank 2, Sensor 2)
Concern with
downstream O2
sensor
Wiring fault
between
downstream O2
sensor and ECM
the signal and screen circuits for open circuits, and shorts to ground. Check
heater circuit power circuit is supplied with power and the control line is not open
circuit. Check sensor for evidence of fouling
(Bank 2, Sensor 2)
Concern with
downstream O2
sensor
Wiring fault
between
downstream O2
sensor and ECM
the signal and screen circuits for shorts to power.
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Electronic Engine Controls2.5L NA V6 - AJV6/3.0L NA V6 - AJ27, VIN Range:
E96603->J28492
Engine oil level
Cooling system coolant level
Fuel Contamination
Throttle body
Fuses (9, 31, 32, 37)
Wiring harness
Sensor(s)
3. Verify the following systems are working correctly: 3.
Air intake system
Cooling system
Charging system
step.
4.
5. If the concern is not visually evident and the Jaguar Approved Diagnostic System is not available, use a fault code reader to
retrieve the fault codes before proceeding to the Diagnostic Trouble Code (DTCs) Index Chart.
5.
6. Make sure that a power supply is present to the ECM from fuse 32 of the engine compartment fuse box before carrying out
diagnostic work on the electronic engine control system.
6.
Diagnostic Trouble Code (DTC) Index
P0116, P0117,
P0118, P0125
Concern with engine coolant
temperature (ECT) sensor.
ECT sensor.
ECT sensor circuit(s).
Low/contaminated
coolant.
Thermostat failure.
Overheating.
P0128 Concern with engine
temperature, set by ECT
sensor inputs.
Thermostat.
ECT sensor.
Mechanical check of thermostat.GO to Pinpoint Test A.
P0335, P0336 Concern with crankshaft
position (CKP) sensor.
CKP sensor.
CKP sensor circuit(s).
CKP sensor air gap.
CKP sensor debris.
P0340, P0341 Concern with right-hand bank
camshaft position (CMP)
sensor.
CMP sensor.
CMP sensor circuit(s).
CMP sensor air gap.
CMP sensor debris.
P1340, P1341 Concern with left-hand bank
camshaft position (CMP)
sensor.
CMP sensor.
CMP sensor air gap.
CMP sensor debris.
heated oxygen sensor (HO2S
1/1) heater.
H02S 1/1 failure.
H02S 1/1 circuit(s).
Fuse 38.
P0181, P0182,
P0183
Concern with fuel temperature
sensor.
Fuel temperature
sensor.
Fuel temperature
sensor circuit(s).
P0327, P0328,
P0332, P0333,
P1648
Concern with knock sensor
(KS).
KS.
KS circuit(s).
Poor contact with
cylinder block.
ECM failure.
P0197, P0198,
P0196
Concern with oil temperature
sensor.
Oil temperature sensor.
Oil temperature sensor
circuit(s).
1/1).
HO2S 1/1.
HO2S 1/1 circuit(s).
GO to Pinpoint Test I.
P0133 Concern with right-hand bank
1/1). Slow response
Engine misfire.
H02S 1/1 disconnected.
H02S 1/1 mechanical
damage.
H02S 1/1 to ECM wiring
fault.
GO to Pinpoint Test I. Refer to pinpoint tests for components
listed,
REFER to: Exhaust System (309-00 Exhaust System,
Diagnosis and Testing) /
Fuel Charging and Controls - 2.5L NA V6 - AJV6/3.0L NA V6 -
AJ27, VIN Range: E96603->J28492 (303-04A Fuel Charging
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H02S 1/1 short circuit
to ground.
H02S 1/1 wiring shield
open circuit.
H02S 1/1 heater circuit
fault.
Exhaust leak.
Low exhaust
temperature.
Injector flow partially
blocked.
Catalyst efficiency
decrease.
H02S 1/1 failure.
and Controls - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA
V6 - AJ27, Diagnosis and Testing).
1/1).
H02S 1/1 heater failure.
H02S 1/1 sensing
ground.
H02S 1/1 sensing
high voltage.
H02S 1/1 sensing
circuit, open circuit.
ECM failure.
GO to Pinpoint Test I. Refer to pinpoint tests for components
listed.
P0037, P0038,
P0137, P0138
Concern with right-hand bank
catalyst monitor sensor (H02S
1/2).
H02S 1/2.
Fuse 38.
GO to Pinpoint Test J.
1/2).
Exhaust leak.
Low exhaust
temperature.
Inspect exhaust system,
2/1).
HO2S 2/1.
P0153
Concern with left-hand bank
2/1). Slow response
Engine misfire.
H02S 2/1 mechanical
damage.
fault.
H02S 2/1 short circuit
to ground.
open circuit.
fault.
Exhaust leak.
Low exhaust
temperature.
blocked.
Catalyst efficiency
decrease.
H02S 2/1 failure.
GO to Pinpoint Test K. Refer to pinpoint tests for
components listed,
P1647 Concern with left-hand bank
2/1).
H02S 2/1 sensing
ground.
H02S 2/1 sensing
high voltage.
H02S 2/1 sensing
circuit, open circuit.
ECM failure.
components listed.
P0057, P0058,
P0157, P0158
catalyst monitor sensor (HO2S
2/2).
HO2S 2/2.
HO2S 2/2 sensor
circuit(s).
Fuse 42.
GO to Pinpoint Test L.
2/2).
Exhaust leak.
Low exhaust
temperature.
Inspect exhaust system,
catalytic converter system.
(Efficiency below threshold)
HO2 sensor
disconnected.
HO2 sensor to ECM
wiring fault.
HO2 sensor heater to
ECM wiring fault.
HO2 sensor heater
failure.
Upstream HO2 sensor
failure.
Downstream HO2
sensor failure.
HO2 sensor failed.
Catalytic converter
Refer to pinpoint tests for components listed. Visually
inspect catalytic converters.
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failure.
catalytic converter system
(Efficiency below threshold).
HO2 sensor
disconnected.
HO2 sensor to ECM
wiring fault.
HO2 sensor heater to
ECM wiring fault.
HO2 sensor heater
failure.
Upstream HO2 sensor
failure.
Downstream HO2
sensor failure.
HO2 sensor failed.
Catalytic converter
failure.
inspect catalytic converters,
P0101, P0102 Concern with mass air flow
(MAF) sensor.
MAF sensor.
MAF sensor circuit(s).
Blocked air filter.
Air intake leak.
Engine breather leak.
Throttle control
malfunction.
GO to Pinpoint Test M. Visually inspect components listed,
REFER to: Intake Air Distribution and Filtering (303-12A
Intake Air Distribution and Filtering - 2.0L NA V6 - AJV6/2.5L
NA V6 - AJV6/3.0L NA V6 - AJ27, Diagnosis and Testing) /
(MAF) sensor.
MAF sensor.
GO to Pinpoint Test M.
P0111 Concern with the intake air
temperature (IAT) sensor.
MAF sensor.
Blocked air filter.
Air intake leak.
GO to Pinpoint Test N. Visually inspect components listed.
P0112, P0113 Concern with the intake air
(IAT) sensor.
(IAT)sensor circuit.
GO to Pinpoint Test N.
P0051, P0052 Concern with the left-hand
bank heated oxygen sensor
(HO2S 2/1) heater.
HO2S 2/1.
HO2S 2/1 circuit.
Fuse 42.
GO to Pinpoint Test O.
P1606 Concern with ECM relay. ECM.
ECM relay.
ECM relay circuit(s).
Fuse 31.
GO to Pinpoint Test P.
P0105, P1107,
P1108
Concern with MAP sensor. MAP sensor.
MAP sensor circuits.
GO to Pinpoint Test Q.
P0106, P0107,
P0108
Concern with barometric (HAC)
sensor.
Barometric sensor within the
ECM.
GO to Pinpoint Test Q. INSTALL a new ECM, for additional
information, refer to dealer technical support.
P0010, P1384 Concern with VVT circuit,
right-hand bank.
VVT solenoid and
circuit.
Oil flow.
Camshaft failure.
GO to Pinpoint Test R. REFER to: Variable Camshaft Timing
(VCT) Oil Control Solenoid (303-14A Electronic Engine
left-hand bank.
VVT solenoid and
circuit.
Oil flow.
Camshaft failure.
GO to Pinpoint Test S. REFER to: Variable Camshaft Timing
(VCT) Oil Control Solenoid (303-14A Electronic Engine
P1251, P1631,
P1657, P1658
Concern with throttle motor
relay.
Throttle motor relay.
circuit.
GO to Pinpoint Test T. Check Fuse 18.
P1549 Concern with IMT Valve 1
circuit.
IMT valve.
IMT valve circuit.
GO to Pinpoint Test U.
P1532 Concern with IMT Valve 2
circuit.
IMT valve.
IMT valve circuit.
GO to Pinpoint Test V.
P1582 "Flight Recorder" data stored. This code does not indicate a
failure of a component or
system.
GO to Pinpoint Test W.
P1240, P1241,
P1242
Concern with sensor power
supply.
ECM.
Power supply circuits.
Sensors within the
circuit.
GO to Pinpoint Test X.
P1243 Concern with sensor ground
circuit.
ECM.
Sensor ground circuits.
Sensors within the
circuit.
GO to Pinpoint Test Y.
P1122, P1123,
P1344
Concern with accelerator pedal
position sensor; Track 1.
APP sensor.
APP sensor circuits.
GO to Pinpoint Test Z.
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P1215, P1216,
P1344
APP sensor.
GO to Pinpoint Test AA.
P0480 Concern with radiator cooling
fan module drive.
Cooling fan module.
Cooling fan module
circuits.
GO to Pinpoint Test AB.
P0646, P0647 Concern with air conditioning
clutch relay drive.
Air conditioning clutch
relay.
relay circuits.
GO to Pinpoint Test AC.
P1516, P1517 Concern with P/N switch
starting/driving malfunctions.
CJFB.
Ignition relay.
TR sensor.
Inertia switch and
circuits.
GO to Pinpoint Test AD.
P1245, P1246 Concern with engine crank
signal, high/low voltage.
Starter relay.
ECM.
Ignition switch.
Associated circuits.
GO to Pinpoint Test AE.
P1260 Security input malfunction. GEM.
Ignition key.
PATS circuits.
CAN network.
Reprogramme key, check CAN network,
REFER to: Communications Network - VIN Range:
E96603->J28492 (418-00 Module Communications Network,
P0506 Idle RPM lower than expected. Air intake restriction.
Accessory drive
overload.
(defective/seized
component).
Throttle valve stuck
closed.
Throttle body failure.
NA V6 - AJV6/3.0L NA V6 - AJ27, Diagnosis and Testing) /
Accessory Drive (303-05 Accessory Drive, Diagnosis and
Testing) / Fuel Charging and Controls - 2.5L NA V6 -
AJV6/3.0L NA V6 - AJ27, VIN Range: E96603->J28492
(303-04A Fuel Charging and Controls - 2.0L NA V6 -
Testing).
P0507 Idle RPM higher than
expected.
Speed control switches
internal steering wheel
circuit; Short circuit to
ground.
Steering wheel cassette
reel; Short circuit to
ground.
Cassette reel to ECM
circuit; Short circuit to
ground.
RESUME switch failure
(stuck ON).
REFER to: Speed Control - 2.5L NA V6 - AJV6/3.0L NA V6 -
AJ27 (310-03 Speed Control, Diagnosis and Testing).
P0603, P1611,
P1633, P1634,
P1656
Concern with powertrain
control module (ECM).
ECM. INSTALL a new ECM. For additional information, refer to
dealer technical support.
P0171, P0172,
P0174, P0175,
P0201, P0202,
P0203, P0204,
P0205, P0206
Concern with fuel system too
lean/rich.
Fuel injector(s).
Fuel delivery fault.
REFER to: Fuel Charging and Controls - 2.5L NA V6 -
Testing).
P0300, P0301,
P0302, P0303,
P0304, P0305,
P0306, P1313,
P1314, P1316
Concern with ignition
system/misfire monitoring.
Ignition system.
Ignition system wiring
harness.
REFER to: Engine Ignition - 2.5L NA V6 - AJV6/3.0L NA V6 -
AJ27 (303-07A Engine Ignition - 2.0L NA V6 - AJV6/2.5L NA
P0351, P0352,
P0353, P0354,
P0355, P0356
Concern with ignition primary
circuits.
Ignition modules.
Ignition module circuits.
P0441, P0442,
P0443, P0444,
P0445, P0446,
P0447, P0448,
P0450, P0452,
P0453, P0455,
P0456
Concern with evaporative
emissions system.
Evaporative/purge valve
and circuits.
Fuel tank and lines.
Filler cap.
Carbon canister.
Canister close valve
and circuits.
Fuel tank pressure
sensor.
Vapor lines.
P0460 Concern with fuel level
sensors.
Fuel level sensors.
Fuel level sensor
circuits.
Instrument cluster.
Testing).
P0560 ECM battery power supply
voltage malfunction. (This DTC
could be set due to a fuel
injection pressure sensor
fault. If P0193 is also set,
rectify P0193 first).
ECM battery power supply
circuit open circuit or high
resistance.
Repair the circuit. For additional information, refer to wiring
diagrams. CLEAR the DTC. TEST the system for normal
operation.
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P0565, P0566,
P0567, P0568,
P0569, P0570,
P0831, P0832,
P0834, P0835,
P1571
Concern with vehicle speed
control.
Switchpack.
Switchpack circuits.
Clutch cancel switch.
Clutch safety switch.
Brake on/off switch.
REFER to: Speed Control - 2.5L NA V6 - AJV6/3.0L NA V6 -
AJ27 (310-03 Speed Control, Diagnosis and Testing).
P0616, P0617 Concern with the starter relay
circuit.
Starter relay.
Starter relay drive
circuit.
REFER to: Starting System - 2.5L NA V6 - AJV6/3.0L NA V6 -
AJ27 (303-06 Starting System, Diagnosis and Testing).
P1224, P1229,
P1250, P1254
Concern with throttle body. Throttle motor.
circuits.
Throttle body.
Throttle position
sensor.
Throttle position sensor
circuits.
Throttle return spring.
Limp-home spring.
Testing).
P1234, P1236,
P1338
Concern with fuel pump
commands.
Fuel pump control
module.
Fuel pump control
module circuits.
ECM.
Testing).
P1244, P1629,
P1632, P1146
Concern with charging system. Charging system.
Charging system wiring
harness.
REFER to: Charging System - 2.0L NA V6 - AJV6/2.5L NA V6 -
AJV6/3.0L NA V6 - AJ27 (414-00 Battery and Charging
System - General Information, Diagnosis and Testing).
P0191, P0192,
P0193
Concern with fuel pressure
sensor.
circuit(s).
Fuel pressure sensor.
Fuel system
leak/blockage.
Testing).
P0121, P0122,
P0123, P0222,
P0223
Concern with throttle position
(TP) sensor.
TP sensor.
TP sensor circuit(s).
REFER to: Throttle Position (TP) Sensor (303-14A Electronic
Engine Controls - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L
NA V6 - AJ27, Removal and Installation).
P1000 System check not complete
since last memory clear.
OBD errors not cleared by
diagnosis.
Carry out comprehensive component monitor drive cycle.
Refer to the DTC section of JTIS, accessed by the icon on the
opening page.
P1111 System check complete since
last memory clear.
This code does not indicate a
system.
No action necessary.
ignition amplifier.
Ignition module.
ignition amplifier.
Ignition module.
P1656 Concern with TP sensor
amplifier circuit.
ECM. INSTALL a new ECM. For additional information, refer to,
P1609 CPU to CPU communications. ECM. INSTALL a new ECM. For additional information, refer to,
P1637, P1638.
P1642, P1643,
P1699
Concern with CAN network. CAN network modules and
circuits.
E96603->J28492 (418-00 Module Communications Network,
PINPOINT TEST A : DTC P0116, P0117, P0118, P0125. ECT SENSOR
TEST
CONDITIONS
A1: CHECK THE ENGINE COOLANT TEMPERATURE (ECT) SENSOR SIGNAL WIRE FOR OPEN CIRCUIT
Disconnect the ECT sensor electrical connector EN18.
Measure the resistance between the ECT sensor electrical connector EN18, pin 2 (UY) and the ECM electrical
connector EN16, pin 70 (UY).
Yes
GO to A2.
No
REPAIR the circuit. For additional information, refer to the wiring diagrams. CLEAR the DTCs. TEST the system for
normal operation.
A2: CHECK THE ECT SENSOR SIGNAL WIRE FOR A SHORT TO GROUND
Measure the resistance between the ECT sensor electrical connector EN18, pin 2 (UY) and EN16, pin 19.
Yes
REPAIR the short to GROUND. For additional information, refer to the wiring diagrams. CLEAR the DTCs. TEST the
No
GO to A3.
A3: CHECK THE ECT SENSOR GROUND CIRCUIT
Measure the resistance between the ECT sensor electrical connector EN18, pin 1 (BG) and EN16, pin 19.
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GO to A4.
No
normal operation.
A4: CHECK THE ECT SENSOR GROUND CIRCUIT FOR A SHORT TO BATTERY POSITIVE
Measure the voltage between the ECT electrical connector EN18, pin 1 (BG) and GROUND.
Yes
REPAIR the short to battery. For additional information, refer to the wiring diagrams. CLEAR the DTCs. TEST the
No
GO to A5.
A5: CHECK THE ECT SENSOR CIRCUIT FOR A SHORT TO BATTERY POSITIVE
Measure the voltage between the ECT sensor electrical connector EN18, pin 2 (UY) and GROUND.
Yes
No
INSTALL a new ECT sensor. CLEAR the DTCs. TEST the system for normal operation. If the DTC is repeated, INSTALL
a new ECM.
REFER to: Engine Control Module (ECM) (303-14B Electronic Engine Controls - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi
Before replacing an ECM, contact dealer technical support.
PINPOINT TEST B : DTC P0335, P0336, P1245, P1246. CRANKSHAFT POSITION (CKP) SENSOR
TEST
CONDITIONS
B1: CHECK THE CKP SENSOR FOR CORRECT INSTALLATION
Check the CKP sensor for correct installation.
Is the CKP sensor correctly installed?
Yes
GO to B2.
No
INSTALL the CKP sensor correctly.
REFER to: Crankshaft Position (CKP) Sensor (303-14A Electronic Engine Controls - 2.0L NA V6 - AJV6/2.5L NA V6 -
Reconnect the sensor. CLEAR the DTCs. TEST the system for normal operation.
B2: CHECK THE CKP SENSOR FOR DEBRIS
Remove the CKP sensor and inspect for debris.
Is the CKP sensor free of debris?
Yes
GO to B3.
No
CLEAN the sensor and wheel. INSTALL the sensor.
B3: CHECK THE CKP SENSOR GROUND WIRE FOR OPEN CIRCUIT
Disconnect the CKP sensor electrical connector EN12.
Measure the resistance between the CKP sensor electrical connector EN12, pin 1 (Y) and the ECM electrical connector
EN16, pin 37 (Y).
Yes
GO to B4.
No
REPAIR the circuit. For additional information, refer to the wiring diagrams. Reconnect all connectors. CLEAR the
B4: CHECK THE CKP SENSOR SIGNAL WIRE FOR OPEN CIRCUIT
Measure the resistance between the CKP sensor electrical connector EN12, pin 2 (P) and the ECM electrical connector
EN16, pin 36 (P).
Yes
GO to B5.
No
B5: CHECK THE CKP SENSOR GROUND WIRE FOR A SHORT TO GROUND
Measure the resistance between the CKP sensor electrical connector EN12 pin 1 (Y) and GROUND.
Yes
REPAIR the short to GROUND. For additional information, refer to the wiring diagrams. Reconnect all connectors.
CLEAR the DTCs. TEST the system for normal operation.
No
GO to B6.
B6: CHECK THE CKP SENSOR SIGNAL WIRE FOR A SHORT TO GROUND
Measure the resistance between the CKP sensor electrical connector EN12 pin 2 (P) and GROUND.
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No
GO to B7.
B7: CHECK THE CKP SENSOR GROUND WIRE FOR A SHORT TO BATTERY
Measure the voltage between the CKP sensor electrical connector EN12 pin 1 (Y) and GROUND.
Yes
REPAIR the short to battery. For additional information, refer to the wiring diagrams. Reconnect all connectors.
No
GO to B8.
B8: CHECK THE CKP SENSOR SIGNAL WIRE FOR A SHORT TO BATTERY
Measure the voltage between the CKP sensor electrical connector EN12 pin 2 (P) and GROUND.
Yes
No
INSTALL a new CKP sensor.
Reconnect all connectors. CLEAR the DTCs. TEST the system for normal operation. If the concern persists INSTALL a
new ECM.
PINPOINT TEST C : DTC P0340, P0341: RIGHT-HAND BANK CAMSHAFT POSITION (CMP) SENSOR
TEST
CONDITIONS
C1: CHECK THE RIGHT-HAND BANK CMP SENSOR FOR CORRECT INSTALLATION
Check the CMP sensor for correct installation.
Is the CMP sensor correctly installed?
Yes
GO to C2.
No
INSTALL the CMP sensor correctly.
REFER to: Camshaft Position (CMP) Sensor (303-14A Electronic Engine Controls - 2.0L NA V6 - AJV6/2.5L NA V6 -
C2: CHECK THE RIGHT-HAND BANK CMP SENSOR FOR FOREIGN DEBRIS
Remove the CMP sensor and inspect for foreign debris.
Is the CMP sensor free of foreign debris?
Yes
GO to C3.
No
C3: CHECK THE RIGHT-HAND BANK CMP SENSOR SIGNAL WIRE FOR OPEN CIRCUIT
Disconnect the CMP sensor electrical connector EN43.
Measure the resistance between the CMP sensor electrical connector EN43, pin 1 (O) and the ECM electrical
connector EN16, pin 94 (O).
Yes
GO to C4.
No
normal operation.
C4: CHECK THE RIGHT-HAND BANK CMP GROUND WIRE FOR OPEN CIRCUIT
Measure the resistance between the CMP sensor electrical connector EN43, pin 2 (B) and the ECM electrical connector
EN16, pin 95 (B).
Yes
GO to C5.
No
normal operation.
C5: CHECK THE RIGHT-HAND BANK CMP SENSOR SIGNAL CIRCUIT FOR A SHORT TO GROUND
Measure the resistance between the CMP sensor electrical connector EN43, pin 1 (O) and GROUND.
Yes
No
GO to C6.
C6: CHECK THE RIGHT-HAND BANK CMP SENSOR GROUND CIRCUIT FOR A SHORT TO GROUND
Measure the resistance between the CMP sensor electrical connector EN43, pin 2 (B) and GROUND.
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Yes
No
GO to C7.
C7: CHECK THE RIGHT-HAND BANK CMP SENSOR SIGNAL CIRCUIT FOR A SHORT TO BATTERY
Measure the voltage between the CMP sensor electrical connector EN43, pin 1 (O) and GROUND.
Yes
No
GO to C8.
C8: CHECK THE RIGHT-HAND BANK CMP SENSOR GROUND CIRCUIT FOR A SHORT TO BATTERY
Measure the voltage between the CMP sensor electrical connector EN43, pin 2 (B) and GROUND.
Yes
No
INSTALL a new CMP sensor.
CLEAR the DTCs. TEST the system for normal operation. If the DTC is repeated, INSTALL a new ECM.
PINPOINT TEST D : DTC P1340, P1341: LEFT-HAND BANK CAMSHAFT POSITION (CMP) SENSOR
TEST
CONDITIONS
D1: CHECK THE LEFT-HAND BANK CMP SENSOR FOR CORRECT INSTALLATION
Yes
GO to D2.
No
D2: CHECK THE LEFT-HAND BANK CMP SENSOR FOR FOREIGN DEBRIS
Yes
GO to D3.
No
D3: CHECK THE LEFT-HAND BANK CMP SENSOR SIGNAL WIRE FOR OPEN CIRCUIT
Measure the resistance between the CMP sensor electrical connector EN33, pin 1 (G) and the ECM electrical
connector EN16, pin 68 (G).
Yes
GO to D4.
No
normal operation.
D4: CHECK THE LEFT-HAND BANK CMP GROUND WIRE FOR OPEN CIRCUIT
Measure the resistance between the CMP sensor electrical connector EN33, pin 2 (N) and the ECM electrical
connector EN16, pin 69 (N).
Yes
GO to D5.
No
normal operation.
D5: CHECK THE LEFT-HAND BANK CMP SENSOR SIGNAL CIRCUIT FOR A SHORT TO GROUND
Measure the resistance between the CMP sensor electrical connector EN33, pin 1 (G) and GROUND.
Yes
No
GO to D6.
D6: CHECK THE LEFT-HAND BANK CMP SENSOR GROUND CIRCUIT FOR A SHORT TO GROUND
Measure the resistance between the CMP sensor electrical connector EN33, pin 2 (N) and GROUND.
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Yes
No
GO to D7.
D7: CHECK THE LEFT-HAND BANK CMP SENSOR SIGNAL CIRCUIT FOR A SHORT TO BATTERY
Measure the voltage between the CMP sensor electrical connector EN33, pin 1 (G) and GROUND.
Yes
No
GO to D8.
D8: CHECK THE LEFT-HAND BANK CMP SENSOR GROUND CIRCUIT FOR A SHORT TO BATTERY
Measure the voltage between the CMP sensor electrical connector EN33, pin 2 (N) and GROUND.
Yes
No
PINPOINT TEST E : DTC P0031, P0032. RIGHT-HAND BANK HO2S HEATER
TEST
CONDITIONS
E1: CHECK THE POWER SUPPLY CIRCUIT TO THE RIGHT-HAND BANK HO2S HEATER
Disconnect HO2S sensor electrical connector, EN37.
Measure the voltage between the HO2S electrical connector EN37, pin 2 (WG) and GROUND.
Yes
GO to E5.
No
GO to E2.
E2: CHECK THE GROUND CIRCUIT TO THE RIGHT-HAND BANK HO2S HEATER FOR OPEN CIRCUIT
Measure the resistance between the HO2S electrical connector EN37, pin 1 (RU) and the ECM electrical connector
EN16, pin 1 and pin 2 (RU).
Is the resistance of each wire less than 5 ohms?
Yes
GO to E3.
No
normal operation.
E3: CHECK THE RIGHT-HAND BANK HO2S GROUND CIRCUIT FOR SHORT TO GROUND
Measure the resistance between the bank 1 HO2S electrical connector EN37, pin 1 (RU) and GROUND.
Yes
No
GO to E4.
E4: CHECK THE RIGHT-HAND BANK HO2S GROUND CIRCUIT FOR SHORT TO BATTERY
Check for a voltage between the HO2S electrical connector EN37, pin 1 (RU) and GROUND.
Yes
No
INSTALL a new HO2S.
REFER to: Heated Oxygen Sensor (HO2S) RH (303-14A Electronic Engine Controls - 2.0L NA V6 - AJV6/2.5L NA V6 -
E5: CHECK FUSE 38 OF THE ENGINE COMPARTMENT FUSE BOX
Check the fuse.
Is the fuse OK?
Yes
GO to E7.
No
GO to E6.
E6: CHECK FUSE 38 OF THE ENGINE COMPARTMENT FUSE BOX FOR A SHORT TO GROUND
Measure the resistance between electrical connector JB34 pin 97 of the engine compartment fuse box and GROUND.
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Yes
REPAIR short to ground between the engine compartment fuse box and the right-hand bank HO2S. For additional
information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation.
No
E7: CHECK THE POWER SUPPLY TO FUSE 38 IN THE ENGINE COMPARTMENT FUSE BOX
Measure the voltage between electrical connector JB34 pin 131 and GROUND.
Yes
Repair the circuit between the battery and the EMS relay. Test the relay, renew as necessary. CLEAR the DTC. TEST
No
Repair the circuit from the ECM control relay to the engine compartment fuse box. For additional information, refer to
the wiring diagrams.GO to P1. CLEAR the DTC. TEST the system for normal operation.
PINPOINT TEST F : DTC P0181, P0182, P0183. FUEL TEMPERATURE SENSOR
TEST
CONDITIONS
F1: CHECK CONTINUITY OF THE FUEL TEMPERATURE SENSOR POWER SUPPLY CIRCUIT
Disconnect the fuel temperature sensor electrical connector IJ8.
Measure the resistance between the fuel temperature sensor electrical connector IJ8, pin 2 (WU) and the ECM
electrical connector EN16, pin 50 (WU).
Yes
GO to F2.
No
normal operation.
F2: CHECK THE FUEL TEMPERATURE SENSOR GROUND CIRCUIT
Measure the resistance between the fuel temperature sensor electrical connector IJ8 pin 1 (NU) and GROUND.
Yes
GO to F3.
No
normal operation.
F3: CHECK THE FUEL TEMPERATURE SENSOR CIRCUIT FOR A SHORT TO GROUND
Measure the resistance between the fuel temperature sensor electrical connector IJ8 pin 2 (WU) and GROUND.
Yes
No
GO to F4.
F4: CHECK THE FUEL TEMPERATURE SENSOR GROUND CIRCUIT FOR A SHORT TO BATTERY
Disconnect the FTP sensor electrical connector, FT1.
Check for a voltage between FT1, pin 3 (BG) and GROUND.
Yes
No
GO to F5.
F5: CHECK THE FUEL TEMPERATURE SENSOR CIRCUIT FOR A SHORT TO BATTERY
Measure the voltage between the fuel temperature sensor electrical connector IJ8, pin 2 (WU) and GROUND.
Yes
No
INSTALL a new fuel temperature sensor.
REFER to: Fuel Temperature Sensor - 2.5L NA V6 - AJV6/3.0L NA V6 - AJ27 (303-14A Electronic Engine Controls - 2.0L
NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27, Removal and Installation).
PINPOINT TEST G : DTC P0327, P0328, P0332, P0333, P1648. KNOCK SENSOR (KS)
TEST
CONDITIONS
G1: CHECK THE KS SIGNAL WIRE FOR OPEN CIRCUIT
Disconnect the KS sensor electrical connector EN23.
Measure the resistance between EN23, pin 1 (N) and EN16, pin 98 (N).
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Yes
GO to G2.
No
normal operation.
G2: CHECK THE KS SIGNAL WIRE FOR SHORT TO BATTERY
Check for a voltage between EN23, pin 1 (N) and GROUND.
Is a voltage present?
Yes
No
GO to G3.
G3: CHECK THE KS SIGNAL WIRE FOR A SHORT TO GROUND
Measure the resistance between the KS sensor electrical connector EN23, pin 1 (N) and GROUND.
Yes
No
INSTALL a new KS.
REFER to: Knock Sensor (KS) (303-14B Electronic Engine Controls - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi
CLEAR DTCs. TEST the system for normal operation. If the DTC is repeated, INSTALL a new ECM.
G4: CHECK THE KS GROUND CIRCUIT FOR OPEN CIRCUIT
Measure the resistance between the KS electrical connector EN23 pin 2 (W) and GROUND.
Yes
REPAIR the circuit between EN23, pin 2 (W) and GROUND. CLEAR the DTCs. TEST the system for normal operation.
(This circuit includes the ECM. For additional information, refer to wiring diagrams)
No
GO to G5.
G5: CHECK THE KS GROUND LEAD FOR OPEN CIRCUIT
Disconnect the KS electrical connector, EN23.
Measure the resistance between EN23, pin2 (W) and EN16, pin 100 (BG).
Yes
GO to G6.
No
REPAIR the circuit between EN23, pin2 (W) and EN16, pin 100 (BG). For additional information, refer to the wiring
diagrams. CLEAR the DTCs. TEST the system for normal operation.
G6: CHECK THE KS GROUND LEAD FOR SHORT TO BATTERY
Connect the KS sensor electrical connector EN23.
Check for a voltage between EN23, pin 2 (W) and GROUND.
Yes
No
INSTALL a new KS.
PINPOINT TEST H : DTC P0196, P0197, P0198. OIL TEMPERATURE SENSOR
TEST
CONDITIONS
H1: CHECK THE OIL TEMPERATURE SENSOR SIGNAL WIRE FOR OPEN CIRCUIT
Disconnect the oil temperature sensor electrical connector EN25.
Measure the resistance between the oil temperature sensor electrical connector EN25, pin 1 (Y) and the ECM
electrical connector EN16, pin 78 (Y).
Yes
GO to H2.
No
normal operation.
H2: CHECK THE OIL TEMPERATURE SENSOR GROUND CIRCUIT FOR OPEN CIRCUIT
Measure the resistance between the oil temperature sensor electrical connector EN25, pin 2 (BG) and GROUND.
Yes
GO to H3.
No
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normal operation.
H3: CHECK THE OIL TEMPERATURE SENSOR GROUND CIRCUIT FOR SHORT TO BATTERY
Measure the voltage between the oil temperature sensor electrical connector EN25, pin 2 (BG) and GROUND.
Yes
REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTCs. TEST the system
No
GO to H4.
H4: CHECK THE OIL TEMPERATURE SENSOR CIRCUIT FOR A SHORT TO GROUND
Measure the resistance between the oil temperature sensor electrical connector EN25, pin 1 (Y) and GROUND.
Yes
No
GO to H5.
H5: CHECK THE OIL TEMPERATURE SENSOR CIRCUIT FOR A SHORT TO BATTERY
Measure the voltage between the oil temperature sensor electrical connector EN25, pin 1 (Y) and GROUND.
Yes
No
INSTALL a new oil temperature sensor.
REFER to: Oil Temperature Sensor (303-14A Electronic Engine Controls - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L
PINPOINT TEST I : DTC P0131, P0132, P0133, P1646. RIGHT-HAND BANK HO2S
TEST
CONDITIONS
I1: CHECK THE CONSTANT CIRCUIT OF THE RIGHT-HAND BANK HO2S FOR OPEN CIRCUIT
Disconnect the HO2S electrical connector EN37.
Measure the resistance between EN16, pin 84 (P) and EN37, pin 4 (P).
Yes
GO to I2.
No
normal operation.
I2: CHECK THE CONSTANT CIRCUIT OF THE RIGHT-HAND BANK HO2S FOR SHORT TO GROUND
Measure the resistance between EN16, pin 84 (P) and GROUND.
Yes
No
GO to I3.
I3: CHECK THE CONSTANT CIRCUIT OF THE RIGHT-HAND BANK HO2S FOR SHORT TO BATTERY
Measure the voltage between EN37, pin 4 (P) and GROUND.
Yes
No
GO to I4.
I4: CHECK THE VARIABLE CIRCUIT OF THE RIGHT-HAND BANK HO2S FOR OPEN CIRCUIT
Measure the resistance between EN16, pin 83 (Y) and EN37, pin 3 (Y).
Yes
GO to I5.
No
normal operation.
I5: CHECK THE VARIABLE CIRCUIT OF THE RIGHT-HAND BANK HO2S FOR SHORT TO GROUND
Measure the resistance between EN16, pin 83 (Y) and GROUND.
Yes
No
GO to I6.
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I6: CHECK THE VARIABLE CIRCUIT OF THE RIGHT-HAND BANK HO2S FOR SHORT TO BATTERY
Measure the voltage between EN37, pin 3 (Y) and GROUND.
Yes
No
INSTALL a new HO2S.
PINPOINT TEST J : DTC P0037, P0038, P0137, P0138, P0140. RIGHT-HAND BANK CATALYST MONITOR
TEST
CONDITIONS
J1: CHECK THE POWER SUPPLY CIRCUIT TO THE RIGHT-HAND BANK CATALYST MONITOR HEATER
Disconnect the catalyst monitor sensor electrical connector EN14.
Measure the voltage between the catalyst monitor sensor electrical connector EN14, pin 2 (WG) and GROUND.
Yes
GO to J6.
No
GO to J2.
J2: CHECK CONTINUITY OF THE RIGHT-HAND BANK CATALYST MONITOR SENSOR GROUND CIRCUIT
Measure the resistance between the catalyst monitor sensor electrical connector EN14, pin 3 (W) and the ECM
electrical connector EN16, pin 130.
Yes
GO to J3.
No
normal operation.
J3: CHECK CONTINUITY OF THE POWER SUPPLY WIRE TO THE RIGHT-HAND BANK CATALYST MONITOR SENSOR
Measure the resistance between the RH bank catalyst monitor sensor electrical connector EN14, pin 4 (N) and the
ECM electrical connector EN16, pin 128 (N).
Yes
GO to J4.
No
normal operation.
J4: CHECK THE RIGHT-HAND BANK CATALYST MONITOR SENSOR POWER SUPPLY WIRE FOR A SHORT TO GROUND
Measure the resistance between the catalyst monitor sensor electrical connector EN14, pin 4 (N) and GROUND.
Yes
REPAIR the short to ground. For additional information, refer to the wiring diagrams. CLEAR the DTCs. TEST the
No
GO to J5.
J5: CHECK THE RIGHT-HAND BANK CATALYST MONITOR SENSOR POWER SUPPLY WIRE FOR A SHORT TO BATTERY
Measure the voltage between the catalyst monitor sensor electrical connector EN14, pin 4 (N) and GROUND.
Yes
No
INSTALL a new RH bank catalyst monitor sensor. For additional information,
REFER to: Catalyst Monitor Sensor RH (303-14A Electronic Engine Controls - 2.0L NA V6 - AJV6/2.5L NA V6 -
CLEAR the DTCs. TEST the system for normal operation. If the DTC is repeated, INSTALL a new ECM. For additional
information,
J6: CHECK THE RIGHT-HAND BANK CATALYST MONITOR SENSOR POWER SUPPLY CIRCUIT
Measure the voltage between the catalyst monitor sensor electrical connector EN14 pin 2 (WG) and GROUND.
Yes
GO to J8.
No
GO to J7.
J7: CHECK CONTINUITY OF THE RIGHT-HAND BANK CATALYST MONITOR SENSOR HEATER GROUND CIRCUIT
Measure the resistance between the catalyst monitor sensor electrical connector EN14, pin 1 (U) and the ECM
electrical connector EN16, pin 92 (U).
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INSTALL a new ECM. For additional information,
No
normal operation.
J8: CHECK FUSE 38 OF THE ENGINE COMPARTMENT FUSE BOX
Check the fuse.
Is the fuse OK?
Yes
GO to J10.
No
GO to J9.
J9: CHECK FUSE 38 OF THE ENGINE COMPARTMENT FUSE BOX FOR A SHORT TO GROUND
Measure the resistance between electrical connector JB34, pin 97 of the engine compartment fuse box and GROUND.
Yes
REPAIR short to ground between the engine compartment fuse box and the right-hand bank HO2S. CLEAR the DTC.
No
INSTALL a new fuse. Check the circuit for cause of fuse failure. CLEAR the DTC. TEST the system for normal
operation.
J10: CHECK THE POWER SUPPLY TO FUSE 38 IN THE ENGINE COMPARTMENT FUSE BOX
Measure the voltage between fuse 38 electrical connector JB34 pin 97 and GROUND.
Yes
Repair the circuit from the ECM control relay to the engine compartment fuse box. CLEAR the DTC. TEST the system
No
Repair the circuit between the engine compartment fuse box and the HO2S. For additional information, refer to wiring
PINPOINT TEST K : P0151, P0152, P0153, P1647. LEFT-HAND BANK HO2S
TEST
CONDITIONS
K1: CHECK THE CONSTANT CIRCUIT OF THE LEFT-HAND BANK HO2S FOR OPEN CIRCUIT
Measure the resistance between EN16, pin 108 (P) and EN32, pin 4 (P)
Yes
GO to K2.
No
normal operation.
K2: CHECK THE CONSTANT CIRCUIT OF THE LEFT-HAND BANK HO2S FOR SHORT TO GROUND
Yes
No
GO to K3.
K3: CHECK THE CONSTANT CIRCUIT OF THE LEFT-HAND BANK HO2S FOR SHORT TO BATTERY
Yes
No
GO to K4.
K4: CHECK THE VARIABLE CIRCUIT OF THE LEFT-HAND BANK HO2S FOR OPEN CIRCUIT
Measure the resistance between EN16, pin 107 (Y) and EN32, pin 3 (Y)
Yes
GO to K5.
No
normal operation.
K5: CHECK THE VARIABLE CIRCUIT OF THE LEFT-HAND BANK HO2S FOR SHORT TO GROUND
Yes
No
GO to K6.
K6: CHECK THE VARIABLE CIRCUIT OF THE LEFT-HAND BANK HO2S FOR SHORT TO BATTERY
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Yes
No
INSTALL a new left-hand HO2S.
REFER to: Heated Oxygen Sensor (HO2S) LH (303-14A Electronic Engine Controls - 2.0L NA V6 - AJV6/2.5L NA V6 -
PINPOINT TEST L : DTC P0057, P0058, P0157, P0158, P0160. LEFT-HAND BANK CATALYST MONITOR
TEST
CONDITIONS
L1: CHECK THE POWER SUPPLY CIRCUIT TO THE LEFT-HAND BANK CATALYST MONITOR HEATER
Measure the voltage between the catalyst monitor sensor electrical connector EN9 pin 2 (WR) and GROUND.
Yes
GO to L6.
No
GO to L2.
L2: CHECK CONTINUITY OF THE LEFT-HAND BANK CATALYST MONITOR SENSOR GROUND CIRCUIT
Measure the resistance between the catalyst monitor sensor electrical connector EN9 pin 3 (W) and EN16, pin 130.
Yes
GO to L3.
No
normal operation.
L3: CHECK CONTINUITY OF THE POWER SUPPLY WIRE TO THE LEFT-HAND BANK CATALYST MONITOR SENSOR
Measure the resistance between the catalyst monitor sensor electrical connector EN9 pin 4 (N) and the ECM electrical
connector EN16 pin 129 (N).
Yes
GO to L4.
No
normal operation.
L4: CHECK THE LEFT-HAND BANK CATALYST MONITOR SENSOR POWER SUPPLY WIRE FOR A SHORT TO GROUND
Measure the resistance between the catalyst monitor sensor electrical connector EN9 pin 4 (N) and GROUND.
Yes
No
GO to L5.
L5: CHECK THE LEFT-HAND BANK CATALYST MONITOR SENSOR POWER SUPPLY WIRE FOR A SHORT TO BATTERY
Measure the voltage between the catalyst monitor sensor electrical connector EN9 pin 4 (N) and GROUND.
Yes
No
INSTALL a new left-hand bank catalyst monitor sensor. For additional information,
REFER to: Catalyst Monitor Sensor LH (303-14A Electronic Engine Controls - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L
information,
L6: CHECK THE LEFT-HAND BANK CATALYST MONITOR SENSOR POWER SUPPLY CIRCUIT
Yes
GO to L8.
No
GO to L7.
L7: CHECK CONTINUITY OF THE LEFT-HAND BANK CATALYST MONITOR SENSOR HEATER GROUND CIRCUIT
Measure the resistance between the catalyst monitor sensor electrical connector EN9 pin 1 (UY) and the ECM
electrical connector EN16 pin 93 (UY).
Yes
No
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normal operation.
L8: CHECK FUSE 42 OF THE ENGINE COMPARTMENT FUSE BOX
Check the fuse.
Is the fuse OK?
Yes
GO to L10.
No
GO to L9.
L9: CHECK FUSE 42 OF THE ENGINE COMPARTMENT FUSE BOX FOR A SHORT TO GROUND
Yes
REPAIR short to ground between the engine compartment fuse box and the left-hand bank HO2S. For additional
No
operation.
L10: CHECK THE POWER SUPPLY TO FUSE 42 IN THE ENGINE COMPARTMENT FUSE BOX
Measure the voltage between Fuse 42 electrical connector JB34 pin 105 and GROUND.
Yes
No
diagrams.
PINPOINT TEST M : DTC P0101, P0102, P0103, P1104. MASS AIR FLOW SENSOR (MAF)
TEST
CONDITIONS
M1: CHECK THE MAF SENSOR POWER SUPPLY
Disconnect the MAF sensor electrical connector EN6.
Measure the voltage between the MAF sensor electrical connector EN6 pin 1 (GU) and GROUND.
Yes
GO to M5.
No
GO to M2.
M2: CHECK CONTINUITY OF THE MAF SENSOR GROUND CIRCUIT
Measure the resistance between the MAF sensor electrical connector EN6 pin 3 (GW) and the ECM electrical connector
EN16 pin 44 (GW).
Yes
GO to M3.
No
normal operation.
Measure the resistance between the MAF sensor electrical connector EN6 pin 2 (BW) and the ECM electrical connector
EN16 pin 45 and pin 46 (BW).
Yes
GO to M4.
No
normal operation.
M4: CHECK THE MAF SENSOR CIRCUIT FOR SHORT TO GROUND
Measure the resistance between the MAF sensor electrical connector EN6 pin 3 (GW) and GROUND.
Yes
INSTALL a new MAF sensor. For additional information,
REFER to: Mass Air Flow (MAF) Sensor (303-14A Electronic Engine Controls - 2.0L NA V6 - AJV6/2.5L NA V6 -
CLEAR DTCs. TEST the system for normal operation. If the DTC is repeated, INSTALL a new ECM. For additional
information,
No
M5: CHECK FUSE 36 OF THE ENGINE COMPARTMENT FUSE BOX
Check the fuse.
Is the fuse OK?
Yes
GO to M7.
No
GO to M6.
M6: CHECK FUSE 36 OF THE ENGINE COMPARTMENT FUSE BOX FOR A SHORT TO GROUND
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Yes
REPAIR short to ground between the engine compartment fuse box and the MAF sensor. For additional information,
refer to wiring diagrams. CLEAR the DTC. TEST the system for normal operation.
No
operation.
M7: CHECK THE POWER SUPPLY FROM FUSE 36 IN THE ENGINE COMPARTMENT FUSE BOX TO THE MAF SENSOR
Measure the voltage between the engine compartment fuse box electrical connector JB34 pin 93 and GROUND.
Yes
Repair the circuit from the engine compartment fuse box to the MAF sensor. For additional information, refer to wiring
No
Recheck DTCs.
PINPOINT TEST N : P0111, P0112, P0113. IAT SENSOR
TEST
CONDITIONS
N1: CHECK CONTINUITY OF THE INTAKE AIR TEMPERATURE (IAT) SENSOR POWER SUPPLY CIRCUIT
Measure the resistance between the MAF sensor electrical connector EN6 pin 4 (O) and the ECM electrical connector
EN16, pin 71 (O).
Yes
GO to N2.
No
normal operation.
N2: CHECK CONTINUITY OF THE IAT SENSOR CIRCUIT
Measure the resistance between the MAF sensor electrical connector EN6 pin 5 (BG) and the ECM electrical connector
EN16, pin 19 (BG).
Yes
GO to N4.
No
normal operation.
N3: CHECK THE IAT SENSOR CIRCUIT FOR SHORT TO BATTERY
Check for a voltage between EN6 pin 5 (BG) and GROUND.
Yes
GO to N1.
No
INSTALL a new MAF sensor.
N4: CHECK THE IAT SENSOR POWER SUPPLY CIRCUIT FOR SHORT TO GROUND
Measure the resistance between the MAF sensor electrical connector EN6 pin 4 (O) and GROUND.
Yes
No
GO to N5.
N5: CHECK THE IAT SENSOR GROUND CIRCUIT FOR SHORT TO BATTERY
Check for voltage at EN6 pin 5 (BG)
Yes
No
PINPOINT TEST O : DTC P0051, P0052. LEFT-HAND BANK H02S HEATER
TEST
CONDITIONS
O1: CHECK THE POWER SUPPLY CIRCUIT TO THE LEFT-HAND BANK HO2S HEATER
Measure the voltage between the HO2S electrical connector EN32 pin 2 (WR) and GROUND.
Yes
GO to O4.
No
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GO to O2.
O2: CHECK THE GROUND CIRCUIT TO THE LEFT-HAND BANK HO2S HEATER
Measure the resistance between the HO2S electrical connector EN32 pin 1 (GO) and the ECM electrical connector
EN16 pins 55 and 56 (GO).
Yes
GO to O3.
No
normal operation.
O3: CHECK THE LEFT-HAND BANK HO2S CIRCUIT FOR SHORT TO GROUND
Measure the resistance between the HO2S electrical connector EN32 pin 1 (GO) and GROUND.
Yes
No
INSTALL a new left-hand bank HO2S. For additional information,
information,
O4: CHECK FUSE 42 OF THE ENGINE COMPARTMENT FUSE BOX
Check the fuse.
Is the fuse OK?
Yes
GO to O6.
No
GO to O5.
O5: CHECK FUSE 42 OF THE ENGINE COMPARTMENT FUSE BOX FOR A SHORT TO GROUND
Measure the resistance between electrical connector JB34 pin 105 of the engine compartment fuse box and GROUND
Yes
information, refer to wiring digrams. CLEAR the DTC. TEST the system for normal operation.
No
operation.
O6: CHECK THE POWER SUPPLY TO FUSE 42 IN THE ENGINE COMPARTMENT FUSE BOX
Measure the voltage between fuse 42, electrical connector JB34 pin 105 and GROUND.
Yes
wiring digrams. CLEAR the DTC. TEST the system for normal operation.
No
digrams. CLEAR the DTC. TEST the system for normal operation.
PINPOINT TEST P : DTC P1606. ECM RELAY.
TEST
CONDITIONS
P1: CHECK THE ECM CONTROL RELAY
Does the ECM relay make an audible click?
Yes
GO to P2.
No
GO to P6.
P2: CHECK FOR POWER SUPPLY FROM THE ECM CONTROL RELAY
Measure the voltage between the ECM control relay JB34 pin 131 and GROUND.
Yes
GO to P3.
No
REPAIR the circuit from the ECM control relay to the ECM. For additional information, refer to wiring digrams. CLEAR
P3: CHECK FUSE 9 IN THE ENGINE COMPARTMENT FUSE BOX
Check the fuse.
Is the fuse OK?
Yes
GO to P4.
No
operation.
P4: CHECK THE POWER SUPPLY TO FUSE 9 IN THE ENGINE COMPARTMENT FUSE BOX
Yes
Repair the circuit from the battery positive to the engine compartment fuse box. CLEAR the DTC. TEST the system for
normal operation.
No
GO to P5.
P5: CHECK THE POWER SUPPLY FROM FUSE 9 IN THE ENGINE COMPARTMENT FUSE BOX TO THE ECM CONTROL RELAY
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Measure the voltage between the ECM control relay electrical connector JB34 pin 132 and GROUND.
Yes
Repair the circuit from the engine compartment fuse box to the ECM control relay. CLEAR the DTC. TEST the system
No
INSTALL a new ECM control relay. For additional information, refer to the electrical guide. CLEAR the DTC. TEST the
P6: CHECK FUSE 31 OF THE ENGINE COMPARTMENT FUSE BOX
Check the fuse.
Is the fuse OK?
Yes
GO to P7.
No
GO to P10.
P7: CHECK POWER SUPPLY TO THE ECM CONTROL RELAY FROM FUSE 31 OF THE ENGINE COMPARTMENT FUSE BOX
Measure the voltage between ECM relay electrical connector JB34 pin 133 and GROUND.
Yes
GO to P8.
No
GO to P12.
P8: CHECK CONTINUITY OF THE ECM CONTROL RELAY GROUND CIRCUIT
Remove the ECM control relay from the engine compartment fuse box.
Measure the resistance between the ECM electrical connector EN16 pin 40 and JB34 pin 134 of the engine
compartment fuse box.
Yes
GO to P9.
No
REPAIR the circuit. For additional information, refer to wiring diagrams. CLEAR the DTC. TEST the system for normal
operation.
(This circuit includes the power distribution fuse box and the EMS relay and diode)
P9: CHECK CONTINUITY OF THE ECM CONTROL RELAY WINDING
Measure the resistance of the ECM control relay winding between pins 1 and 2 of the ECM control relay.
Yes
INSTALL a new ECM control relay. CLEAR the DTC. TEST the system for normal operation.
No
INSTALL a new ECM.
Before replacing an ECM, contact dealer technical support. CLEAR the DTC. TEST the system for normal operation.
P10: CHECK FUSE 31 OF THE ENGINE COMPARTMENT FUSE BOX FOR A SHORT TO GROUND
Yes
REPAIR short to GROUND between the engine compartment fuse box and the ECM control relay. CLEAR the DTC. TEST
No
Yes
REPAIR short to ground between the engine compartment fuse box and the ECM control relay. CLEAR the DTC. TEST
No
P12: CHECK THE ECM CONTROL RELAY DIODE
Remove the ECM control relay diode from the engine compartment fuse box.
Measure the continuity of ECM control relay diode.
Yes
Possible intermittent fault. Recheck DTCs.
No
INSTALL a new ECM control relay diode. Make sure that the ECM control relay diode is installed correctly. For
additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation.
PINPOINT TEST Q : P0105, P0106, P0107, P0108, P1107, P1108. MAP SENSOR
TEST
CONDITIONS
Q1: CHECK THE GROUND CIRCUIT TO THE MAP SENSOR
Disconnect the MAP sensor electrical conector EN8.
Measure the resistance between the MAP sensor electrical conector EN8 pin 4 (BG) and GROUND.
Reconnect electrical connectors following test.
Yes
GO to Q2.
No
REPAIR the circuit between the MAP sensor and GROUND. For additional information, refer to wiring diagrams. CLEAR
Q2: CHECK THE POWER SUPPLY CIRCUIT TO THE MAP SENSOR FOR SHORT TO BATTERY
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Measure the voltage between the MAP sensor electrical connector EN8 pin 2 (OY) and GROUND.
Yes
REPAIR the short to battery. For additional information, refer to wiring diagrams. CLEAR the DTC. TEST the system for
normal operation.
No
GO to Q3.
Q3: CHECK THE POWER SUPPLY CIRCUIT TO THE MAP SENSOR FOR SHORT TO GROUND
Yes
REPAIR the short to GROUND. For additional information, refer to wiring diagrams. CLEAR the DTC. TEST the system
No
GO to Q4.
Q4: CHECK CONTINUITY OF THE MAP SENSOR SIGNAL WIRE
Disconnect the MAP sensor electrical connector EN8.
Measure the resistance of the circuit between MAP sensor electrical connector EN8 pin 1 (BW) and ECM electrical
connector EN16 pin 127 (BW).
Yes
GO to Q5.
No
REPAIR the circuit between the MAP sensor electrical connector EN8 pin 1 (BW) and ECM electrical connector EN16 pin
127 (BW). For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal
operation.
Q5: CHECK THE MAP SENSOR SIGNAL WIRE FOR SHORT TO GROUND
Measure the resistance between EN8 pin 1 (BW) and GROUND.
Yes
REPAIR the short to GROUND. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the
No
GO to Q6.
Q6: CHECK THE MAP SENSOR SIGNAL WIRE FOR SHORT TO BATTERY
Check for a voltage at EN8 pin 1 (BW)
Yes
Repair the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for
normal operation.
No
INSTALL a new MAP sensor. CLEAR the DTC. TEST the system for normal operation.
PINPOINT TEST R : P0010, P1384. VVT RIGHT-HAND BANK
TEST
CONDITIONS
R1: CHECK THE GROUND CIRCUIT TO THE RIGHT-HAND BANK VVT SOLENOID
Disconnect the VVT solenoid electrical connector EN61.
Measure the resistance between the VVT solenoid electrical connector EN61 pin 2 (BG) and GROUND.
Yes
GO to R2.
No
REPAIR the circuit between VVT solenoid electrical connector EN61 pin 2 (BG) and GROUND. For additional
R2: CHECK CONTINUITY OF THE RIGHT-HAND BANK VVT SOLENOID SIGNAL WIRE
Measure the resistance between VVT solenoid electrical connector EN61 pin 1 (RW) and ECM electrical connector EN16
pin 109 (RW).
Yes
GO to R3.
No
REPAIR the circuit between VVT solenoid electrical connector EN61 pin 1 (RW) and ECM electrical connector EN16 pin
109 (RW). For additional information, refer to wiring diagrams. CLEAR the DTC. TEST the system for normal operation.
R3: CHECK FOR SHORT TO GROUND AT THE RIGHT-HAND BANK VVT SOLENOID SIGNAL WIRE
Measure the resistance between EN61 pin 1 (RW) and GROUND.
Yes
No
GO to R4.
R4: CHECK FOR SHORT TO BATTERY AT THE RIGHT-HAND BANK VVT SOLENOID SIGNAL WIRE
TURN the ignition switch to the ON position.
Check for a voltage at EN61 pin 1 (RW).
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normal operation.
No
INSTALL a new right-hand bank VVT solenoid.
REFER to: Variable Camshaft Timing (VCT) Oil Control Solenoid (303-14A Electronic Engine Controls - 2.0L NA V6 -
AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27, Removal and Installation).
PINPOINT TEST S : P0020, P1396. VVT LEFT-HAND BANK
TEST
CONDITIONS
S1: CHECK GROUND CIRCUIT TO THE LEFT-HAND BANK VVT SOLENOID
Disconnect the VVT solenoid electrical connector, EN42.
Yes
GO to S2.
No
S2: CHECK CONTINUITY OF THE LEFT-HAND BANK VVT SOLENOID SIGNAL WIRE.
Measure the resistance between VVT solenoid electrical connector EN42 pin 1 (G) and ECM electrical connector EN16
pin 110 (G).
Yes
GO to S3.
No
REPAIR the circuit between VVT solenoid electrical connector EN42 pin 1 (G) and ECM electrical connector EN16 pin
110 (G). For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal
operation.
S3: CHECK FOR SHORT TO GROUND AT THE LEFT-HAND BANK VVT SOLENOID SIGNAL WIRE
Yes
No
GO to S4.
S4: CHECK FOR SHORT TO BATTERY AT THE LEFT-HAND BANK VVT SOLENOID SIGNAL WIRE
Yes
REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for
normal operation.
No
INSTALL a new left-hand bank VVT solenoid.
PINPOINT TEST T : P1251, P1631, P1657, P1658. THROTTLE MOTOR RELAY
TEST
CONDITIONS
T1: CHECK THE POWER SUPPLY CIRCUIT TO THE THROTTLE MOTOR RELAY
Measure the voltage between pin 1 of the throttle motor relay base and GROUND.
Yes
GO to T2.
No
REPAIR the circuit between pin 1 of the throttle motor relay base and the EMS control relay. For additional
T2: CHECK CONTINUITY OF THE THROTTLE MOTOR RELAY SIGNAL WIRE
Measure the resistance between the throttle motor relay base, pin 2 and the ECM electrical connector EN16 pin 52
(GR).
Yes
GO to T3.
No
REPAIR the circuit between the throttle motor relay base pin 2 and the ECM electrical connector EN16 pin 52 (GR). For
T3: CHECK THE THROTTLE MOTOR RELAY SIGNAL WIRE FOR SHORT TO BATTERY
Remove the throttle motor relay.
Check for a voltage between the throttle motor relay base pin 2 and GROUND.
Yes
REPAIR the short to battery. For additional information, refer to wiring digrams. CLEAR the DTC. TEST the system for
normal operation.
No
GO to T4.
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T4: CHECK THE THROTTLE MOTOR RELAY SIGNAL WIRE FOR SHORT TO GROUND
Measure the resistance between the throttle motor relay base pin 2 and GROUND.
Yes
REPAIR the short to GROUND. For additional information, refer to wiring digrams. CLEAR the DTC. TEST the system for
normal operation.
No
GO to T5.
T5: CHECK CONTINUITY OF THE THROTTLE MOTOR RELAY OUTPUT WIRE
Test for continuity between throttle motor relay base pin 5 and ECM electrical connector EN16 pin 134 (RW).
Yes
INSTALL a new throttle motor relay. CLEAR the DTC. TEST the system for normal operation. If the DTC is repeated,
INSTALL a new ECM.
Before replacing a ECM, contact Dealer technical support
No
REPAIR the circuit between throttle motor relay base pin 2 and ECM electrical connector EN16 pin 134 (RW). For
T6: CHECK THE THROTTLE MOTOR RELAY OUTPUT WIRE FOR SHORT TO BATTERY
Yes
normal operation.
No
GO to T7.
T7: CHECK THE THROTTLE MOTOR RELAY OUTPUT WIRE FOR SHORT TO GROUND
Yes
normal operation.
No
INSTALL a new throttle motor relay. For additional information, refer to the electri cal guide. CLEAR the DTC. TEST the
system for normal operation. If the DTC is repeated, INSTALL a new ECM.
PINPOINT TEST U : P1549. IMT VALVE 1
TEST
CONDITIONS
U1: CHECK THE POWER SUPPLY CIRCUIT TO THE IMT VALVE 1
Measure the voltage between IMT valve 1 electrical connector EN999 pin 1 (NG) and GROUND.
Yes
GO to U2.
No
REPAIR the circuit between the IMT valve 1 electrical connector EN999 pin 1 (NG) and the Battery power bus 2. CLEAR
(This circuit includes the power distribution fuse box and the EMS control relay. For additional information, refer to wiring diagrams)
U2: CHECK CONTINUITY OF THE IMT VALVE 1 SIGNAL WIRE.
Measure the resistance between the IMT valve 1 electrical connector EN999 pin 2 (OY) and the ECM electrical
connector EN16 pin 38 (OY).
Yes
GO to U3.
No
REPAIR the circuit between the IMT valve 1 electrical connector EN999 pin 2 (OY) and the ECM electrical connector
EN16 pin 38 (OY). For additional information, refer to wiring diagrams. CLEAR the DTC. TEST the system for normal
operation.
U3: CHECK IMT VALVE SIGNAL WIRE FOR SHORT TO GROUND
Measure the resistance between EN999 pin 2 (OY) and GROUND.
Yes
normal operation.
No
GO to U4.
U4: CHECK IMT VALVE SIGNAL WIRE FOR SHORT TO BATTERY
Check for a voltage at EN999 pin 2 (OY).
Yes
normal operation.
No
INSTALL a new IMT valve. CLEAR the DTC. TEST the system for normal operation. If the DTC is repeated, INSTALL a
new ECM.
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PINPOINT TEST V : P1532. IMT VALVE 2
TEST
CONDITIONS
V1: CHECK THE POWER SUPPLY CIRCUIT TO THE IMT VALVE 2
Yes
GO to V2.
No
(This circuit includes the power distribution fuse box and the EMS control relay. For additional information, refer to wiring diagrams)
V2: CHECK CONTINUITY OF THE IMT VALVE 2 SIGNAL WIRE
Yes
GO to V3.
No
REPAIR the circuit between the IMT valve 2 electrical connector EN998 pin 2 (OY)and the ECM electrical connector
operation.
V3: CHECK IMT VALVE SIGNAL WIRE FOR SHORT TO GROUND
Yes
normal operation.
No
GO to V4.
V4: CHECK IMT VALVE SIGNAL WIRE FOR SHORT TO BATTERY
Yes
normal operation.
No
new ECM.
Before replacing an ECM, contact dealer technical support
PINPOINT TEST W : P1582. FLIGHT RECORDER DATA STORED
W1: EXTRACT THE FLIGHT RECORDER DATA
NOTE: Flight recorder data can only be extracted using the Jaguar approved diagnostic system, where available.
Connect the Jaguar approved diagnostic system, or code reader.
Is DTC P1582 stored?
Yes
Refer to dealer technical support for information on extracting data.
No
Test not applicable.
PINPOINT TEST X : P1240, P1241, P1242. SENSOR POWER SUPPLY
X1: CHECK THE POWER SUPPLY CIRCUIT TO THE IP SENSOR
Disconnect the IP sensor electrical connector, IJ7.
Measure the voltage between IP sensor electrical connector IJ7 pin 1 (YG) and GROUND.
Yes
GO to X2.
No
REPAIR the circuit between the IP sensor electrical connector IJ7 pin 1 (YG) and the sensor 5 volt supply bus.
(The fault could be in any of the other sensors in this circuit, or in any of the spurs in this circuit. For additional information, refer to wiring diagrams)
X2: CHECK THE POWER SUPPLY CIRCUIT TO THE IP SENSOR FOR SHORT TO BATTERY
Yes
(The short could be in any of the other sensors in this circuit, or in any of the spurs in this circuit. For additional information, refer to wiring diagrams)
No
GO to X3.
X3: CHECK THE POWER SUPPLY CIRCUIT TO THE MAP SENSOR
Measure the voltage between MAP sensor electrical connector EN8 pin 2 (OY) and GROUND.
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Yes
GO to X4.
No
REPAIR the circuit between the MAP sensor electrical connector EN8 pin 2 (OY) and the sensor 5 volt supply bus.
X4: CHECK THE POWER SUPPLY CIRCUIT TO THE MAP SENSOR FOR SHORT TO BATTERY
Yes
No
GO to X5.
X5: CHECK THE POWER SUPPLY CIRCUIT TO THE FTP SENSOR
NOTE: Access to the FTP sensor involves the removal of the fuel tank. To reduce the amount of work necessary, a slave harness could be
used. This can be connected at the access port beneath the rear seat. Tests can then be carried out via the slave harness and sensor. If
system operation is normal with the slave harness and sensor, the fault lies in the vehicle's harness or sensor.
Disconnect the FTP sensor electrical connector FT1. (See note above).
Measure the voltage between FTP sensor electrical connector FT1 pin 1 (OY) and GROUND.
Yes
GO to X6.
No
REPAIR the circuit between the FTP sensor electrical connector FT1 pin 1 (OY) and the sensor 5 volt supply bus.
X6: CHECK THE POWER SUPPLY CIRCUIT TO THE FTP SENSOR FOR SHORT TO BATTERY
Yes
No
GO to X7.
X7: CHECK THE POWER SUPPLY CIRCUIT TO THE APP SENSOR
Disconnect the APP sensor electrical connector.
Measure the voltage between APP sensor electrical connector PA1 pin 5 (OY) and GROUND.
Yes
GO to X8.
No
REPAIR the circuit between the APP sensor electrical connector PA1 pin 5 (OY) and the sensor 5 volt supply bus.
X8: CHECK THE POWER SUPPLY CIRCUIT TO THE APP SENSOR FOR SHORT TO BATTERY
Yes
No
GO to X9.
X9: CHECK THE POWER SUPPLY CIRCUIT TO THE TP SENSOR
Measure the voltage between TP sensor electrical connector EN13 pin 2 (OY) and GROUND.
Yes
GO to X10.
No
REPAIR the circuit between the TP sensor electrical connector EN13 pin 2 (OY) and the sensor 5 volt supply bus.
X10: CHECK THE POWER SUPPLY CIRCUIT TO THE TP SENSOR FOR SHORT TO BATTERY
Yes
No
GO to X11.
X11: CHECK THE POWER SUPPLY CIRCUIT TO THE AIR CONDITIONING PRESSURE (ACP) SENSOR
Measure the voltage between ACP sensor electrical connector JB106 pin 2 (OY) and GROUND.
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Yes
GO to X12.
No
REPAIR the circuit between the ACP sensor electrical connector JB106 pin 2 (OY) and the sensor 5 volt supply
bus. CLEAR the DTC. TEST the system for normal operation.
X12: CHECK THE POWER SUPPLY CIRCUIT TO THE AIR CONDITIONING PRESSURE SENSOR FOR SHORT TO BATTERY
Yes
(The short could be in any of the other sensors in this circuit, or in any of the spurs in this circuit. For additional information, refer to wiring
diagrams.)
No
No electrical fault in power supply circuit. Recheck DTCs using the Jaguar approved diagnostic system, or code
reader.
(This fault could also be a PSV failure within the ECM.)
PINPOINT TEST Y : P1243. SENSOR GROUND CIRCUITS.
Y1: CHECK THE GROUND CIRCUIT TO THE ECT SENSOR
Measure the resistance between ECT sensor electrical connector EN18 pin 1 (BG) and GROUND.
Yes
GO to Y2.
No
REPAIR the circuit between the ECT sensor electrical connector EN18 pin 1 (BG) and GROUND. CLEAR the DTC.
Y2: CHECK THE GROUND CIRCUIT TO THE EOT SENSOR
Measure the resistance between EOT sensor electrical connector EN25 pin 2 (BG) and GROUND.
Yes
GO to Y3.
No
REPAIR the circuit between the EOT sensor electrical connector EN25 pin 2 (BG) and GROUND. CLEAR the DTC.
Y3: CHECK THE GROUND CIRCUIT TO THE IP SENSOR
Measure the resistance between IP sensor electrical connector IJ7 pin 2 (WG) and GROUND.
Yes
GO to Y4.
No
REPAIR the circuit between the IP sensor electrical connector IJ7 pin 2 (WG) and GROUND. CLEAR the DTC.
Y4: CHECK THE GROUND CIRCUIT TO THE EFT SENSOR
Measure the resistance between EFT sensor electrical connector IJ8 pin 1 (NU) and GROUND.
Yes
GO to Y5.
No
REPAIR the circuit between the EFT sensor electrical connector IJ8 pin 1 (NU) and GROUND. CLEAR the DTC.
Y5: CHECK THE GROUND CIRCUIT TO THE MAP SENSOR
Measure the resistance between MAP sensor electrical connector EN8 pin 4 (BG) and GROUND.
Yes
GO to Y6.
No
REPAIR the circuit between the MAP sensor electrical connector EN8 pin 4 (BG) and GROUND. CLEAR the DTC.
Y6: CHECK THE GROUND CIRCUIT TO THE FTP SENSOR
Measure the resistance between FTP sensor electrical connector FT1 pin 3 (BG) and GROUND.
Yes
GO to Y7.
No
REPAIR the circuit between the FTP Sensor electrical connector FT1 pin 3 (BG) and GROUND. CLEAR the DTC.
Y7: CHECK THE GROUND CIRCUIT TO THE APP SENSOR (TRACK 1)
Measure the resistance between APP sensor electrical connector PA1 pin 3 (BG) and GROUND.
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Yes
GO to Y8.
No
REPAIR the circuit between the APP sensor electrical connector PA1 pin 3 (BG) and GROUND. CLEAR the DTC.
Y8: CHECK THE GROUND CIRCUIT TO THE TP SENSOR
Measure the resistance between TP sensor electrical connector EN13 pin 1 (BG) and GROUND.
Yes
GO to Y9.
No
REPAIR the circuit between the TP sensor electrical connector EN13 pin 1 (BG) and GROUND. CLEAR the DTC.
Y9: CHECK THE GROUND CIRCUIT TO THE APP SENSOR (TRACK 3)
Yes
GO to Y10.
No
Y10: CHECK THE GROUND CIRCUIT TO THE AIR CONDITIONING PRESSURE SENSOR
Measure the resistance between ACP sensor electrical connector JB106 pin 1 (BG) and GROUND.
Yes
No electrical fault in ground circuit. Recheck DTCs.
No
REPAIR the circuit between the ACP sensor electrical connector JB106 pin 1 (BG) and GROUND. CLEAR the DTC.
PINPOINT TEST Z : P1122, P1123, P1344. APP SENSOR ( TRACK 1)
TEST
CONDITIONS
Z1: CHECK THE POWER SUPPLY CIRCUIT TO THE APP SENSOR. TRACK 1
Measure the voltage between APP sensor electrical connector PA1 pin 2 (Y) and GROUND.
Is the voltage greater than 4volts?
Yes
GO to Z2.
No
REPAIR the circuit between the APP sensor electrical connector PA1 pin 2 (Y) and the sensor 5 volt supply 2. CLEAR
(This circuit includes the ECM, EMS control relay, and power distribution fuse box. For additional information, refer to wiring diagrams)
Z2: CHECK THE GROUND CIRCUIT TO THE APP SENSOR
Disconnect APP Sensor electrical connector PA1.
Yes
GO to Z5.
No
REPAIR the circuit between the APP sensor electrical connector PA1 pin 6 (BG) and GROUND. CLEAR the DTC. TEST the
Z3: CHECK THE GROUND CIRCUIT TO THE APP SENSOR. FOR CONTINUITY
Disconnect the APP sensor electrical connector PA1.
Measure the resistance between EN16 pin 20 (BG) and PA1 pin 6 (BG).
Yes
GO to Z4.
No
operation.
Z4: CHECK THE GROUND CIRCUIT TO THE APP SENSOR. FOR SHORT TO BATTERY
Check for a voltage at PA1 pin 6 (BG).
Yes
normal operation.
No
GO to Z5.
Z5: CHECK CONTINUITY OF THE APP SENSOR SIGNAL WIRE
Measure the resistance between APP sensor electrical connector PA1 pin 4 (R) and the ECM electrical connector EN16
pin 102 (R).
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Yes
GO to Z6.
No
REPAIR the circuit between the APP sensor electrical connector PA1 pin 4 (R) and the ECM electrical connector EN16
pin 102 (R). For additional information, refer to wiring diagrams. CLEAR the DTC. TEST the system for normal
operation.
Z6: CHECK CONTINUITY OF THE APP SENSOR POTENTIOMETER
Measure the resistance between APP sensor electrical connector PA1 pins 4 and 6.
Operate the accelerator pedal through it's full range while observing the resistance reading.
Does the resistance vary as the pedal is operated?
Yes
INSTALL a new ECM.
No
INSTALL a new accelerator pedal position sensor,
REFER to: Accelerator Pedal (310-02 Acceleration Control, Removal and Installation).
PINPOINT TEST AA : P1215, P1216, P1344. APP SENSOR ( TRACK 3)
TEST
CONDITIONS
AA1: CHECK THE POWER SUPPLY CIRCUIT TO THE APP SENSOR. TRACK 3
Measure the voltage between APP sensor electrical connector PA1 pin 1(Y) and GROUND.
Yes
GO to AA2.
No
REPAIR the circuit between the APP sensor electrical connector PA1 pin 1 (Y) and the sensor 5 volt supply. CLEAR the
(This circuit includes the ECM, EMS control relay, and power distribution fuse box. For additional information, refer to wiring diagrams. This supply is also
linked to other sensors. The fault could be in any of these or their wiring.)
AA2: CHECK THE GROUND CIRCUIT TO THE APP SENSOR
Yes
GO to AA5.
No
(This circuit includes the ECM. For additional information, refer to wiring diagrams.)
AA3: CHECK THE GROUND CIRCUIT TO THE APP SENSOR FOR CONTINUITY
Yes
GO to AA4.
No
operation.
AA4: CHECK THE GROUND CIRCUIT TO THE APP SENSOR FOR SHORT TO BATTERY
Yes
normal operation.
No
GO to AA5.
AA5: CHECK CONTINUITY OF THE APP SENSOR SIGNAL WIRE
Measure the resistance between APP sensor electrical connector PA1 pin 1 (Y) and the ECM electrical connector EN16
pin 103 (Y).
Yes
GO to AA6.
No
REPAIR the circuit between the APP sensor electrical connector PA1 pin 1 (Y) and the ECM electrical connector EN16
pin 103 (Y). For additional information, refer to wiring diagrams. CLEAR the DTC. TEST the system for normal
operation.
AA6: CHECK CONTINUITY OF THE APP SENSOR POTENTIOMETER
Measure the resistance between APP sensor electrical connector PA1 pins 1and 3.
Yes
INSTALL a new ECM.
No
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PINPOINT TEST AB : P0480. RADIATOR COOLING FAN MODULE DRIVE
TEST
CONDITIONS
AB1: CHECK THE PULSE WIDTH MODULATED SIGNAL TO THE COOLING FAN MODULE
Disconnect the radiator cooling fan module electrical connector PWM1.
RUN the engine to a temperature at which the cooling fans would operate.
Using a suitable meter, test for a pulse width modulated signal at PWM1 pin 3 (WU).
Is a PWM signal present?
Yes
INSTALL a new cooling fan module. CLEAR the DTC. TEST the system for normal operation.
No
GO to AB2.
AB2: CHECK CONTINUITY OF THE RADIATOR COOLING FAN MODULE SIGNAL WIRE
Measure the resistance between the radiator cooling fan module electrical connector PWM1 pin 3 (WU) and the ECM
electrical connector EN16 pin 51 (WU).
Yes
INSTALL a new ECM.
No
REPAIR the circuit between the radiator cooling fan module electrical connector PWM1 pin 3 (WU) and the ECM
electrical connector EN16 pin 51 (WU). For additional information, refer to wiring diagrams. CLEAR the DTC. TEST the
PINPOINT TEST AC : P0646, P0647. AIR CONDITIONING CLUTCH RELAY DRIVE
TEST
CONDITIONS
AC1: CHECK THE GROUND SUPPLY TO THE AIR CONDITIONING CLUTCH
WARNING: This test involves working in proximity to rotating parts. Make sure due care is exercised.
Disconnect the air conditioning clutch electrical connector EN30.
Measure the resistance between EN30 pin 2 (B) and GROUND.
Yes
REPAIR the circuit between EN30 pin 2 (B) and GROUND. For additional information, refer to wiring diagrams. CLEAR
No
GO to AC2.
AC2: CHECK THE CIRCUIT INTEGRITY BETWEEN THE ECM AND THE AIR CONDITIONING CLUTCH
Apply a GROUND to the disconnected ECM electrical connector EN16 pin 34 (BG).
Measure the voltage at air conditioning clutch electrical connector EN30 pin 1 (RG).
Yes
GO to AC3.
No
GO to AC4.
AC3: CHECK THE AIR CONDITIONING CLUTCH RELAY TO ECM CIRCUIT FOR SHORT TO GROUND
Measure the resistance between EN16 pin 34 (BG) and GROUND.
Yes
GO to AC4.
No
INSTALL a new air conditioning compressor clutch relay. For additional information, refer to the electrical guide.
AC4: CHECK THE CIRCUIT BETWEEN THE AIR CONDITIONING COMPRESSOR CLUTCH AND THE RELAY FOR SHORT TO BATTERY
Measure the voltage between EN30 pin 1 (RG) and GROUND.
Yes
normal operation.
No
GO to AC5.
AC5: CHECK THE CIRCUIT BETWEEN THE AIR CONDITIONING COMPRESSOR CLUTCH AND THE ACCC RELAY FOR SHORT TO
GROUND
Measure the resistance between EN30 pin 1 (RG) and GROUND.
Yes
normal operation.
No
GO to AC6.
AC6: CHECK THE CIRCUIT BETWEEN FUSE 23 OF THE POWER DISTRIBUTION FUSE BOX AND THE ACCC RELAY FOR SHORT TO
GROUND
Remove Fuse 23.
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Measure the resistance between fuse box electrical connector JB34 pin 79 and GROUND.
Yes
normal operation.
No
GO to AC7.
AC7: CHECK THE ACCC RELAY BASE FOR BATTERY VOLTAGE AT PIN 3
Refit Fuse 23.
Measure the voltage between the ACCC relay base pin 3 and GROUND.
Yes
GO to AC8.
No
Check/replace fuses. REPAIR the circuit between the relay base and the battery power bus 1. For additional
AC8: CHECK THE CIRCUIT BETWEEN PIN 1 OF THE ACCC RELAY BASE AND THE POWER DISTRIBUTION FUSE BOX FOR SHORT TO
GROUND
Remove Fuse 36.
Measure the resistance between the ACCC relay base pin 1 and GROUND.
Yes
normal operation.
No
GO to AC9.
AC9: CHECK THE ACCC RELAY BASE FOR BATTERY VOLTAGE AT PIN 1
Refit Fuse 36.
Measure the voltage between ACCC relay base pin 1 and GROUND.
Yes
GO to AC10.
No
(This circuit includes the EMS relay, and Fuses 9 and 31)
AC10: CHECK THE CIRCUIT BETWEEN THE ECM AND THE ACCC RELAY BASE FOR CONTINUITY
Remove the ACCC relay.
Measure the resistance between the ECM electrical connector EN16 pin 34 (BG) and ACCC relay base pin 2.
Yes
GO to AC11.
No
operation.
AC11: CHECK THE CIRCUIT BETWEEN THE ECM AND THE ACCC RELAY BASE FOR SHORT TO BATTERY
Check for a voltage between the ECM electrical connector EN16 pin 34 (BG) and GROUND.
Yes
normal operation.
No
GO to AC12.
AC12: CHECK THE CIRCUIT BETWEEN THE ECM AND THE ACCC RELAY BASE FOR SHORT TO GROUND
Measure the resistance between the ECM electrical connector EN16 pin 34 (BG) and GROUND.
Yes
normal operation.
No
INSTALL a new ACCC relay. For additional information, refer to the electrical guide. CLEAR the DTC. TEST the system
PINPOINT TEST AD : P1516, P1517. P/N SWITCH STARTING/DRIVING MALFUNCTIONS.
TEST
CONDITIONS
AD1: CHECK THE P/N INPUT TO THE ECM.
Select PARK.
Set the ignition switch to the ON position.
Measure the voltage at the ECM electrical connector EN16 pin 31 (B).
Yes
INSTALL a new ECM.
No
REPAIR the circuit between the ECM electrical connector EN16 pin 31 (B) and the ignition switch. For additional
(On automatic transmission vehicles, this circuit includes the TR sensor, central junction fuse box, ignition relay, and inertia switch. On NAS manual
transmission vehicles, this circuit also includes the clutch safety switch.)
PINPOINT TEST AE : P1245; P1246. IGNITION SWITCH CRANK SIGNAL
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WARNING: Make sure the starter motor does not engage in the course of these tests. Failure to follow these instructions may result
in personal injury.
TEST
CONDITIONS
AE1: CHECK THE START INPUT TO THE ECM
Move the gear selector to the N position.
Remove the starter relay from the power distribution fuse box.
Yes
GO to AE2.
No
REPAIR the circuit between the ECM and the battery. For additional information, refer to wiring diagrams. CLEAR the
(This circuit includes the ignition switch and the power distribution fuse box. [Fuse 28].)
AE2: CHECK THE START INPUT TO THE STARTER RELAY
Turn the ignition switch to the START position and hold.
Measure the voltage between the starter relay base (R10) pin 1 and GROUND.
Yes
GO to AE3.
No
REPAIR the circuit between the starter relay base and the battery. For additional information, refer to wiring
(This circuit includes the ignition switch and the power distribution fuse box)
AE3: CHECK THE START INPUT WIRE FOR SHORT TO BATTERY AT ECM
Yes
normal operation.
No
GO to AE4.
AE4: CHECK THE START INPUT WIRE FOR SHORT TO BATTERY AT RELAY
Yes
normal operation.
No
GO to AE5.
AE5: CHECK THE STARTER RELAY INPUT FROM THE ECM FOR CONTINUITY
Measure the resistance between EN16 pin 41 (GO) and relay base pin 2.
Yes
GO to AE6.
No
REPAIR the open circuit. For additional information, refer to wiring diagrams. CLEAR the DTC. TEST the system for
normal operation.
AE6: CHECK THE STARTER RELAY INPUT FROM THE ECM FOR SHORT TO GROUND
Disconnect ignition switch electrical connector IP18.
Measure the resistance between EN16 pin 41 (GO) and GROUND.
Yes
normal operation.
No
GO to AE7.
AE7: CHECK THE STARTER RELAY INPUT FROM THE ECM FOR SHORT TO BATTERY
Yes
normal operation.
No
INSTALL a new starter relay. For additional information, refer to wiring diagrams. CLEAR the DTC. TEST the system
for normal operation. If the DTC is repeated, INSTALL a new ECM.
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Electronic Engine Controls2.5L NA V6 - AJV6/3.0L NA V6 - AJ27, VIN Range:
J28493->V99999
Engine oil level
Fuel Contamination
Throttle body
Fuses (9, 31, 32, 37)
Wiring harness
Sensor(s)
3. Verify the following systems are working correctly: 3.
Air intake system
Cooling system
Charging system
step.
4.
5. If the concern is not visually evident and the Jaguar Approved Diagnostic System is not available, use a fault code reader to
retrieve the fault codes before proceeding to the Diagnostic Trouble Code (DTCs) Index Chart.
5.
6. Make sure that a power supply is present to the ECM from fuse 32 of the engine compartment fuse box before carrying out
diagnostic work on the electronic engine control system.
6.
P0116, P0117,
P0118, P0125
Concern with engine coolant
temperature (ECT) sensor.
ECT sensor.
Low/contaminated
coolant.
Thermostat failure.
Overheating.
GO to Pinpoint Test A. .
P0128 Concern with engine
temperature, set by ECT sensor
inputs.
Thermostat.
ECT sensor.
Mechanical check of thermostat.GO to Pinpoint Test A. .
P0335, P0336 Concern with crankshaft position
(CKP) sensor.
CKP sensor.
CKP sensor circuit(s).
CKP sensor air gap.
CKP sensor debris.
GO to Pinpoint Test B. .
P0011, P0012,
P0340, P0341
camshaft position (CMP) sensor.
Right-hand camshaft position
timing over-advanced/over-
retarded.
CMP sensor.
CMP sensor air gap.
CMP sensor debris.
GO to Pinpoint Test C. .
P0021, P0022,
P1340, P1341
camshaft position (CMP) sensor.
Left-hand camshaft position
timing over-advanced/over-
retarded.
CMP sensor.
CMP sensor air gap.
CMP sensor debris.
GO to Pinpoint Test D. .
1/1) heater.
H02S 1/1 failure.
Fuse 38.
GO to Pinpoint Test E. .
P0181, P0182,
P0183
Concern with fuel temperature
sensor.
Fuel temperature sensor.
circuit(s).
GO to Pinpoint Test F. ..
P0324, P0327,
P0328, P0332,
P0333
Concern with knock sensor (KS). KS.
KS circuit(s).
Poor contact with cylinder
block.
ECM failure.
GO to Pinpoint Test G. .
P0197, P0198,
P0196
Concern with oil temperature
sensor.
Oil temperature sensor.
Oil temperature sensor
circuit(s).
GO to Pinpoint Test H. .
1/1).
HO2S 1/1.
GO to Pinpoint Test I. .
1/1). Slow response.
Engine misfire.
H02S 1/1 mechanical
damage.
fault.
H02S 1/1 short circuit to
GO to Pinpoint Test I. Refer to pinpoint tests for
components listed,
Fuel Charging and Controls - 2.5L NA V6 - AJV6/3.0L NA
V6 - AJ27, VIN Range: E96603->J28492 (303-04A Fuel
Charging and Controls - 2.0L NA V6 - AJV6/2.5L NA V6 -
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ground.
open circuit.
fault.
Exhaust leak.
Low exhaust temperature.
blocked.
Catalyst efficiency
decrease.
H02S 1/1 failure.
AJV6/3.0L NA V6 - AJ27, Diagnosis and Testing).
1/1).
H02S 1/1 sensing circuit,
short circuit to ground.
short circuit to high
voltage.
open circuit.
ECM failure.
GO to Pinpoint Test I. Refer to pinpoint tests for
components listed.
P0037, P0038,
P0137, P0138
).
H02S .
H02S circuit(s).
Fuse 38.
GO to Pinpoint Test J. .
).
H02S .
H02S circuit(s).
Exhaust leak.
blocked.
GO to Pinpoint Test J. Inspect exhaust system,
Inspect fuel system,
AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27, Diagnosis
and Testing).
2/1).
HO2S 2/1.
GO to Pinpoint Test K. .
2/1). Slow response.
Engine misfire.
H02S 2/1 mechanical
damage.
fault.
H02S 2/1 short circuit to
ground.
open circuit.
fault.
Exhaust leak.
blocked.
Catalyst efficiency
decrease.
H02S 2/1 failure.
components listed,
2/1).
short circuit to ground.
voltage.
open circuit.
ECM failure.
components listed.
P0057, P0058,
P0157, P0158
2/2).
HO2S 2/2.
HO2S 2/2 sensor
circuit(s).
Fuse 42.
GO to Pinpoint Test L. .
2/2).
H02S 2/2.
Exhaust leak.
blocked.
GO to Pinpoint Test L. Inspect exhaust system,
Inspect fuel system,
and Testing).
.
HO2 sensor disconnected.
HO2 sensor to ECM wiring
fault.
HO2 sensor heater to ECM
wiring fault.
HO2 sensor heater
failure.
inspect catalytic converters.
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Upstream HO2 sensor
failure.
Downstream HO2 sensor
failure.
HO2 sensor failed.
Catalytic converter
failure.
HO2 sensor disconnected.
HO2 sensor to ECM wiring
fault.
HO2 sensor heater to ECM
wiring fault.
HO2 sensor heater
failure.
Upstream HO2 sensor
failure.
Downstream HO2 sensor
failure.
HO2 sensor failed.
Catalytic converter
failure.
inspect catalytic converters,
(MAF) sensor.
MAF sensor.
Blocked air filter.
Air intake leak.
Throttle control
malfunction.
GO to Pinpoint Test M. Visually inspect components
listed,
Intake Air Distribution and Filtering - 2.0L NA V6 -
and Testing) /
(MAF) sensor.
MAF sensor.
GO to Pinpoint Test M. .
P0111 Concern with the intake air
MAF sensor.
Blocked air filter.
Air intake leak.
GO to Pinpoint Test N. Visually inspect components
listed.
and Testing).
P0112, P0113 Concern with the intake air
(IAT) sensor.
(IAT)sensor circuit.
GO to Pinpoint Test N. .
P0051, P0052 Concern with the left-hand bank
2/1) heater.
HO2S 2/1.
HO2S 2/1 circuit.
Fuse 42.
GO to Pinpoint Test O. .
P1606 Concern with ECM relay. ECM.
ECM relay.
ECM relay circuit(s).
Fuse 31.
GO to Pinpoint Test P. .
P0106, P0107,
P0108
Concern with MAP sensor. MAP sensor.
MAP sensor circuits.
GO to Pinpoint Test Q. .
P0069, P2228,
P2229
Concern with barometric
pressure (HAC) sensor.
Barometric pressure sensor
within the ECM.
INSTALL a new ECM. For additional information, refer to,
right-hand bank.
VVT solenoid and circuit.
Oil flow.
Camshaft failure.
GO to Pinpoint Test R. REFER to: Variable Camshaft
Timing (VCT) Oil Control Solenoid (303-14A Electronic
Engine Controls - 2.0L NA V6 - AJV6/2.5L NA V6 -
left-hand bank.
VVT solenoid and circuit.
Oil flow.
Camshaft failure.
GO to Pinpoint Test S. REFER to: Variable Camshaft
Timing (VCT) Oil Control Solenoid (303-14A Electronic
Engine Controls - 2.0L NA V6 - AJV6/2.5L NA V6 -
P1251, P1631,
P1657, P1658
Concern with throttle motor
relay.
circuit.
GO to Pinpoint Test T. Check Fuse 18.
P1549 Concern with IMT Valve 1 circuit. IMT valve.
IMT valve circuit.
GO to Pinpoint Test U.
P1532 Concern with IMT Valve 2 circuit. IMT valve.
IMT valve circuit.
GO to Pinpoint Test V. .
P1582 "Flight Recorder" data stored. This code does not indicate a
system.
GO to Pinpoint Test W. .
P0561, P0562,
P0563
Concern with sensor power
circuit.
ECM.
Power supply circuits.
Sensors within the circuit.
GO to Pinpoint Test AC. .
P1243 Concern with sensor ground
circuit.
ECM.
Sensor ground circuits.
Sensors within the circuit.
GO to Pinpoint Test X. .
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P0226, P00227,
P0228
APP sensor.
GO to Pinpoint Test Z. .
P2122, P2123 Concern with accelerator pedal
APP sensor.
GO to Pinpoint Test AA. .
P0480 Concern with radiator cooling
fan module drive.
Cooling fan module.
Cooling fan module
circuits.
GO to Pinpoint Test Y. .
P0646, P0647 Concern with air conditioning
clutch relay drive.
relay.
relay circuits.
GO to Pinpoint Test AE. .
P0851, P0852 Concern with P/N switch
starting/driving malfunctions.
CJFB.
Ignition relay.
TR sensor.
Inertia switch and
circuits.
GO to Pinpoint Test AD. .
P0512, P1245 Concern with engine crank
signal, high/low voltage.
Starter relay.
ECM.
Ignition switch.
Associated circuits.
GO to Pinpoint Test AB. .
P1260 Security input malfunction. GEM.
Ignition key.
PATS circuits.
CAN network.
Reprogram key, check CAN network,
E96603->J28492 (418-00 Module Communications
Network, Diagnosis and Testing).
P0506 Cold start monitor engine speed
low.
Air intake restriction.
Accessory drive overload.
(defective/seized
component).
closed.
and Testing) / Accessory Drive (303-05 Accessory Drive,
Diagnosis and Testing) / Fuel Charging and Controls -
2.5L NA V6 - AJV6/3.0L NA V6 - AJ27, VIN Range:
E96603->J28492 (303-04A Fuel Charging and Controls -
2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27,
P0507 Cold start monitor engine speed
high.
Intake air leak between
MAF sensor and throttle.
throttle and engine.
Engine crankcase breather
leak.
and Testing).
P050A Cold start monitor airflow
low/high.
Air intake restriction.
Accessory drive overload.
(defective/seized
component).
closed.
MAF sensor and throttle.
throttle and engine.
Engine crankcase breather
leak.
and Testing) / Accessory Drive (303-05 Accessory Drive,
Diagnosis and Testing) / Fuel Charging and Controls -
2.5L NA V6 - AJV6/3.0L NA V6 - AJ27, VIN Range:
E96603->J28492 (303-04A Fuel Charging and Controls -
2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27,
P050B Cold start ignition timing
performance.
Blocked intake system.
Sticking/slow throttle.
Poor engine condition.
Check the intake air system, including the air cleaner
element. Carry out a complete vehicle read for related
DTCs. Rectify as necessary.
P0603, P0607,
P1633, P1656
Concern with powertrain control
module (ECM).
ECM. INSTALL a new ECM. For additional information, refer to
P0171, P0172,
P0174, P0175,
P0201, P0202,
P0203, P0204,
P0205, P0206
Concern with fuel system too
lean/rich.
Fuel injector(s).
Fuel delivery fault.
and Testing).
P0300, P0301,
P0302, P0303,
P0304, P0305,
P0306, P1313,
P1314, P1316
Concern with ignition
system/misfire monitoring.
Ignition system.
Ignition system wiring
harness.
REFER to: Engine Ignition - 2.5L NA V6 - AJV6/3.0L NA
V6 - AJ27 (303-07A Engine Ignition - 2.0L NA V6 -
and Testing).
P0351, P0352,
P0353, P0354,
P0355, P0356
Concern with ignition primary
circuits.
Ignition modules.
and Testing).
P0442, P0443,
P0444, P0445,
P0446, P0447,
P0448, P0450,
P0452, P0453,
P0455, P0456,
P0457
Concern with evaporative
emissions system.
Evaporative/purge valve
and circuits.
Fuel tank and lines.
Filler cap.
Carbon canister.
Canister close valve and
circuits.
Fuel tank pressure
sensor.
and Testing).
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Vapor lines.
P0460 Concern with fuel level sensors. Fuel level sensors.
Fuel level sensor circuits.
Instrument cluster.
and Testing).
P0560 ECM battery power supply
voltage malfunction. (This DTC
could be set due to a fuel
injection pressure sensor fault.
If P0193 is also set, rectify
P0193 first).
ECM battery power supply circuit
open circuit or high resistance.
Repair the circuit. For additional information, refer to
wiring diagrams. CLEAR the DTC. TEST the system for
normal operation.
P0565, P0566,
P0567, P0568,
P0569, P0570,
P0831, P0832,
P0834, P0835,
P1571
Concern with vehicle speed
control.
Switchpack.
Switchpack circuits.
Clutch cancel switch.
Clutch safety switch.
Brake on/off switch.
REFER to: Speed Control - 2.5L NA V6 - AJV6/3.0L NA V6
- AJ27 (310-03 Speed Control, Diagnosis and Testing).
P0616, P0617 Concern with the starter relay
circuit.
Starter relay.
Starter relay drive circuit.
REFER to: Starting System - 2.5L NA V6 - AJV6/3.0L NA
V6 - AJ27 (303-06 Starting System, Diagnosis and
Testing).
P1250, P1254, Concern with throttle body. Throttle motor.
circuits.
Throttle body.
Throttle return spring.
Limp-home spring.
and Testing).
P2107 Concern with throttle body
control.
ECM REFER to: Fuel Charging and Controls - 2.5L NA V6 -
and Testing).
P2118, P2119 Concern with throttle body. Throttle actuator control
motor circuit: short circuit
to power.
Throttle actuator control
to ground.
to power.
motor fault.
Throttle body
contaminated/sticking.
and Testing).
P0627, P0628,
P0629, P2635
Concern with fuel pump
commands.
Fuel pump control
module.
circuits.
ECM.
and Testing).
P1244, P1629,
P1632, P1146,
P2503, P2504
Concern with charging system. Charging system.
Charging system wiring
harness.
REFER to: Charging System - 2.0L NA V6 - AJV6/2.5L NA
V6 - AJV6/3.0L NA V6 - AJ27 (414-00 Battery and
Charging System - General Information, Diagnosis and
Testing).
P0191, P0192,
P0193
Concern with fuel pulse damper. fuel pulse damper
circuit(s).
fuel pulse damper.
Fuel system
leak/blockage.
and Testing).
P0122, P0123,
P0222, P0223,
P2135
Concern with throttle position
(TP) sensor.
TP sensor.
TP sensor circuit(s).
REFER to: Throttle Position (TP) Sensor (303-14A
V6 - AJV6/3.0L NA V6 - AJ27, Removal and Installation).
P1000 System check not complete
since last memory clear.
OBD errors not cleared by
diagnosis.
Carry out comprehensive component monitor drive cycle.
Refer to the DTC section of GTR, accessed by the icon on
the opening page.
P1111 System check complete since
last memory clear.
This code does not indicate a
system.
No action necessary.
ignition amplifier.
Ignition module.
and Testing).
ignition amplifier.
Ignition module.
and Testing).
P1656 Concern with TP sensor amplifier
circuit.
P1609 CPU to CPU communications. ECM. INSTALL a new ECM. For additional information, refer to,
P2610 ECM/PCM internal engine off
timer performance.
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P0860, P1637,
P1638. P1642,
P1643, P1699
Concern with CAN network. CAN network modules and
circuits.
PINPOINT TEST A : DTC P0116, P0117, P0118, P0125. ECT SENSOR
TEST
CONDITIONS
A1: CHECK THE ENGINE COOLANT TEMPERATURE (ECT) SENSOR SIGNAL WIRE FOR OPEN CIRCUIT
Disconnect the ECT sensor electrical connector EN18.
Measure the resistance between the ECT sensor electrical connector EN18, pin 2 (UY) and the ECM electrical
connector EN16, pin 70 (UY).
Yes
GO to A2.
No
normal operation.
A2: CHECK THE ECT SENSOR SIGNAL WIRE FOR A SHORT TO GROUND
Measure the resistance between the ECT sensor electrical connector EN18, pin 2 (UY) and EN16, pin 19.
Yes
No
GO to A3.
A3: CHECK THE ECT SENSOR GROUND CIRCUIT
Measure the resistance between the ECT sensor electrical connector EN18, pin 1 (BG) and EN16, pin 19.
Yes
GO to A4.
No
normal operation.
A4: CHECK THE ECT SENSOR GROUND CIRCUIT FOR A SHORT TO BATTERY POSITIVE
Measure the voltage between the ECT electrical connector EN18, pin 1 (BG) and GROUND.
Yes
No
GO to A5.
A5: CHECK THE ECT SENSOR CIRCUIT FOR A SHORT TO BATTERY POSITIVE
Measure the voltage between the ECT sensor electrical connector EN18, pin 2 (UY) and GROUND.
Yes
No
INSTALL a new ECT sensor. CLEAR the DTCs. TEST the system for normal operation. If the DTC is repeated, INSTALL
a new ECM.
PINPOINT TEST B : DTC P0335, P0336. CRANKSHAFT POSITION (CKP) SENSOR
TEST
CONDITIONS
B1: CHECK THE CKP SENSOR FOR CORRECT INSTALLATION
Check the CKP sensor for correct installation.
Is the CKP sensor correctly installed?
Yes
GO to B2.
No
INSTALL the CKP sensor correctly.
B2: CHECK THE CKP SENSOR FOR DEBRIS
Remove the CKP sensor and inspect for debris.
Is the CKP sensor free of debris?
Yes
GO to B3.
No
B3: CHECK THE CKP SENSOR GROUND WIRE FOR OPEN CIRCUIT
Disconnect the CKP sensor electrical connector EN12.
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Measure the resistance between the CKP sensor electrical connector EN12, pin 1 (Y) and the ECM electrical connector
EN16, pin 37 (Y).
Yes
GO to B4.
No
B4: CHECK THE CKP SENSOR SIGNAL WIRE FOR OPEN CIRCUIT
Measure the resistance between the CKP sensor electrical connector EN12, pin 2 (P) and the ECM electrical connector
EN16, pin 36 (P).
Yes
GO to B5.
No
B5: CHECK THE CKP SENSOR GROUND WIRE FOR A SHORT TO GROUND
Measure the resistance between the CKP sensor electrical connector EN12 pin 1 (Y) and GROUND.
Yes
No
GO to B6.
B6: CHECK THE CKP SENSOR SIGNAL WIRE FOR A SHORT TO GROUND
Measure the resistance between the CKP sensor electrical connector EN12 pin 2 (P) and GROUND.
Yes
No
GO to B7.
B7: CHECK THE CKP SENSOR GROUND WIRE FOR A SHORT TO BATTERY
Measure the voltage between the CKP sensor electrical connector EN12 pin 1 (Y) and GROUND.
Yes
No
GO to B8.
B8: CHECK THE CKP SENSOR SIGNAL WIRE FOR A SHORT TO BATTERY
Measure the voltage between the CKP sensor electrical connector EN12 pin 2 (P) and GROUND.
Yes
No
INSTALL a new CKP sensor.
Reconnect all connectors. CLEAR the DTCs. TEST the system for normal operation. If the concern persists INSTALL a
new ECM.
PINPOINT TEST C : DTC P0011, P0012, P0340, P0341: RIGHT-HAND BANK CAMSHAFT POSITION (CMP) SENSOR
TEST
CONDITIONS
C1: CHECK THE RIGHT-HAND BANK CMP SENSOR FOR CORRECT INSTALLATION
Yes
GO to C2.
No
C2: CHECK THE RIGHT-HAND BANK CMP SENSOR FOR FOREIGN DEBRIS
Yes
GO to C3.
No
C3: CHECK THE RIGHT-HAND BANK CMP SENSOR SIGNAL WIRE FOR OPEN CIRCUIT
Measure the resistance between the CMP sensor electrical connector EN43, pin 1 (O) and the ECM electrical
connector EN16, pin 94 (O).
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Yes
GO to C4.
No
normal operation.
C4: CHECK THE RIGHT-HAND BANK CMP GROUND WIRE FOR OPEN CIRCUIT
Measure the resistance between the CMP sensor electrical connector EN43, pin 2 (B) and the ECM electrical
connector EN16, pin 95 (B).
Yes
GO to C5.
No
normal operation.
C5: CHECK THE RIGHT-HAND BANK CMP SENSOR SIGNAL CIRCUIT FOR A SHORT TO GROUND
Measure the resistance between the CMP sensor electrical connector EN43, pin 1 (O) and GROUND.
Yes
No
GO to C6.
C6: CHECK THE RIGHT-HAND BANK CMP SENSOR GROUND CIRCUIT FOR A SHORT TO GROUND
Measure the resistance between the CMP sensor electrical connector EN43, pin 2 (B) and GROUND.
Yes
No
GO to C7.
C7: CHECK THE RIGHT-HAND BANK CMP SENSOR SIGNAL CIRCUIT FOR A SHORT TO BATTERY
Measure the voltage between the CMP sensor electrical connector EN43, pin 1 (O) and GROUND.
Yes
No
GO to C8.
C8: CHECK THE RIGHT-HAND BANK CMP SENSOR GROUND CIRCUIT FOR A SHORT TO BATTERY
Measure the voltage between the CMP sensor electrical connector EN43, pin 2 (B) and GROUND.
Yes
No
PINPOINT TEST D : DTC P0021, P0022, P1340, P1341: LEFT-HAND BANK CAMSHAFT POSITION (CMP) SENSOR
TEST
CONDITIONS
D1: CHECK THE LEFT-HAND BANK CMP SENSOR FOR CORRECT INSTALLATION
Yes
GO to D2.
No
D2: CHECK THE LEFT-HAND BANK CMP SENSOR FOR FOREIGN DEBRIS
Yes
GO to D3.
No
D3: CHECK THE LEFT-HAND BANK CMP SENSOR SIGNAL WIRE FOR OPEN CIRCUIT
Measure the resistance between the CMP sensor electrical connector EN33, pin 1 (G) and the ECM electrical
connector EN16, pin 68 (G).
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Yes
GO to D4.
No
normal operation.
D4: CHECK THE LEFT-HAND BANK CMP GROUND WIRE FOR OPEN CIRCUIT
Measure the resistance between the CMP sensor electrical connector EN33, pin 2 (N) and the ECM electrical
connector EN16, pin 69 (N).
Yes
GO to D5.
No
normal operation.
D5: CHECK THE LEFT-HAND BANK CMP SENSOR SIGNAL CIRCUIT FOR A SHORT TO GROUND
Measure the resistance between the CMP sensor electrical connector EN33, pin 1 (G) and GROUND.
Yes
No
GO to D6.
D6: CHECK THE LEFT-HAND BANK CMP SENSOR GROUND CIRCUIT FOR A SHORT TO GROUND
Measure the resistance between the CMP sensor electrical connector EN33, pin 2 (N) and GROUND.
Yes
No
GO to D7.
D7: CHECK THE LEFT-HAND BANK CMP SENSOR SIGNAL CIRCUIT FOR A SHORT TO BATTERY
Measure the voltage between the CMP sensor electrical connector EN33, pin 1 (G) and GROUND.
Yes
No
GO to D8.
D8: CHECK THE LEFT-HAND BANK CMP SENSOR GROUND CIRCUIT FOR A SHORT TO BATTERY
Measure the voltage between the CMP sensor electrical connector EN33, pin 2 (N) and GROUND.
Yes
No
PINPOINT TEST E : DTC P0031, P0032. RIGHT-HAND BANK HO2S HEATER
TEST
CONDITIONS
E1: CHECK THE POWER SUPPLY CIRCUIT TO THE RIGHT-HAND BANK HO2S HEATER
Disconnect HO2S sensor electrical connector, EN37.
Measure the voltage between the HO2S electrical connector EN37, pin 2 (WG) and GROUND.
Yes
GO to E5.
No
GO to E2.
E2: CHECK THE GROUND CIRCUIT TO THE RIGHT-HAND BANK HO2S HEATER FOR OPEN CIRCUIT
Measure the resistance between the HO2S electrical connector EN37, pin 1 (RU) and the ECM electrical connector
EN16, pin 1 and pin 2 (RU).
Yes
GO to E3.
No
normal operation.
E3: CHECK THE RIGHT-HAND BANK HO2S GROUND CIRCUIT FOR SHORT TO GROUND
Measure the resistance between the bank 1 HO2S electrical connector EN37, pin 1 (RU) and GROUND.
Yes
No
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GO to E4.
E4: CHECK THE RIGHT-HAND BANK HO2S GROUND CIRCUIT FOR SHORT TO BATTERY
Check for a voltage between the HO2S electrical connector EN37, pin 1 (RU) and GROUND.
Yes
No
INSTALL a new HO2S.
E5: CHECK FUSE 38 OF THE ENGINE COMPARTMENT FUSE BOX
Check the fuse.
Is the fuse OK?
Yes
GO to E7.
No
GO to E6.
E6: CHECK FUSE 38 OF THE ENGINE COMPARTMENT FUSE BOX FOR A SHORT TO GROUND
Yes
REPAIR short to ground between the engine compartment fuse box and the right-hand bank HO2S. For additional
No
E7: CHECK THE POWER SUPPLY TO FUSE 38 IN THE ENGINE COMPARTMENT FUSE BOX
Measure the voltage between electrical connector JB34 pin 131 and GROUND.
Yes
Repair the circuit between the battery and the EMS relay. Test the relay, renew as necessary. CLEAR the DTC. TEST
No
the wiring diagrams. GO to P1. CLEAR the DTC. TEST the system for normal operation.
PINPOINT TEST F : DTC P0181, P0182, P0183. FUEL TEMPERATURE SENSOR
TEST
CONDITIONS
F1: CHECK CONTINUITY OF THE FUEL TEMPERATURE SENSOR POWER SUPPLY CIRCUIT
Disconnect the fuel temperature sensor electrical connector IJ8.
Measure the resistance between the fuel temperature sensor electrical connector IJ8, pin 2 (WU) and the ECM
electrical connector EN16, pin 50 (WU).
Yes
GO to F2.
No
normal operation.
F2: CHECK THE FUEL TEMPERATURE SENSOR GROUND CIRCUIT
Measure the resistance between the fuel temperature sensor electrical connector IJ8 pin 1 (NU) and GROUND.
Yes
GO to F3.
No
normal operation.
F3: CHECK THE FUEL TEMPERATURE SENSOR CIRCUIT FOR A SHORT TO GROUND
Measure the resistance between the fuel temperature sensor electrical connector IJ8 pin 2 (WU) and GROUND.
Yes
No
GO to F4.
F4: CHECK THE FUEL TEMPERATURE SENSOR GROUND CIRCUIT FOR A SHORT TO BATTERY
Disconnect the FTP sensor electrical connector, FT1.
Check for a voltage between FT1, pin 3 (BG) and GROUND.
Yes
No
GO to F5.
F5: CHECK THE FUEL TEMPERATURE SENSOR CIRCUIT FOR A SHORT TO BATTERY
Measure the voltage between the fuel temperature sensor electrical connector IJ8, pin 2 (WU) and GROUND.
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Yes
No
INSTALL a new fuel temperature sensor.
REFER to: Fuel Temperature Sensor - 2.5L NA V6 - AJV6/3.0L NA V6 - AJ27 (303-14A Electronic Engine Controls - 2.0L
NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27, Removal and Installation).
PINPOINT TEST G : DTC P0324, P0327, P0328, P0332, P0333. KNOCK SENSOR (KS)
TEST
CONDITIONS
G1: CHECK THE KS SIGNAL WIRE FOR OPEN CIRCUIT
Disconnect the KS sensor electrical connector EN23.
Measure the resistance between EN23, pin 1 (N) and EN16, pin 98 (N).
Yes
GO to G2.
No
normal operation.
G2: CHECK THE KS SIGNAL WIRE FOR SHORT TO BATTERY
Check for a voltage between EN23, pin 1 (N) and GROUND.
Is a voltage present?
Yes
No
GO to G3.
G3: CHECK THE KS SIGNAL WIRE FOR A SHORT TO GROUND
Measure the resistance between the KS sensor electrical connector EN23, pin 1 (N) and GROUND.
Yes
No
INSTALL a new KS.
(110kW/150PS) - Puma, Removal and Installation) /
Knock Sensor (KS) (303-14B Electronic Engine Controls - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) -
CLEAR DTCs. TEST the system for normal operation. If the DTC is repeated, INSTALL a new ECM.
G4: CHECK THE KS GROUND CIRCUIT FOR OPEN CIRCUIT
Measure the resistance between the KS electrical connector EN23 pin 2 (W) and GROUND.
Yes
REPAIR the circuit between EN23, pin 2 (W) and GROUND. CLEAR the DTCs. TEST the system for normal operation.
No
GO to G5.
G5: CHECK THE KS GROUND LEAD FOR OPEN CIRCUIT
Disconnect the KS electrical connector, EN23.
Measure the resistance between EN23, pin2 (W) and EN16, pin 100 (BG).
Yes
GO to G6.
No
REPAIR the circuit between EN23, pin2 (W) and EN16, pin 100 (BG). For additional information, refer to the wiring
diagrams. CLEAR the DTCs. TEST the system for normal operation.
G6: CHECK THE KS GROUND LEAD FOR SHORT TO BATTERY
Connect the KS sensor electrical connector EN23.
Check for a voltage between EN23, pin 2 (W) and GROUND.
Yes
No
INSTALL a new KS.
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PINPOINT TEST H : DTC P0196, P0197, P0198. OIL TEMPERATURE SENSOR
TEST
CONDITIONS
H1: CHECK THE OIL TEMPERATURE SENSOR SIGNAL WIRE FOR OPEN CIRCUIT
Disconnect the oil temperature sensor electrical connector EN25.
Measure the resistance between the oil temperature sensor electrical connector EN25, pin 1 (Y) and the ECM
electrical connector EN16, pin 78 (Y).
Yes
GO to H2.
No
normal operation.
H2: CHECK THE OIL TEMPERATURE SENSOR GROUND CIRCUIT FOR OPEN CIRCUIT
Measure the resistance between the oil temperature sensor electrical connector EN25, pin 2 (BG) and GROUND.
Yes
GO to H3.
No
normal operation.
H3: CHECK THE OIL TEMPERATURE SENSOR GROUND CIRCUIT FOR SHORT TO BATTERY
Measure the voltage between the oil temperature sensor electrical connector EN25, pin 2 (BG) and GROUND.
Yes
No
GO to H4.
H4: CHECK THE OIL TEMPERATURE SENSOR CIRCUIT FOR A SHORT TO GROUND
Measure the resistance between the oil temperature sensor electrical connector EN25, pin 1 (Y) and GROUND.
Yes
No
GO to H5.
H5: CHECK THE OIL TEMPERATURE SENSOR CIRCUIT FOR A SHORT TO BATTERY
Measure the voltage between the oil temperature sensor electrical connector EN25, pin 1 (Y) and GROUND.
Yes
No
INSTALL a new oil temperature sensor.
REFER to: Oil Temperature Sensor (303-14A Electronic Engine Controls - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L
PINPOINT TEST I : DTC P0131, P0132, P0133, P1646. RIGHT-HAND BANK HO2S
TEST
CONDITIONS
I1: CHECK THE CONSTANT CIRCUIT OF THE RIGHT-HAND BANK HO2S FOR OPEN CIRCUIT
Yes
GO to I2.
No
normal operation.
I2: CHECK THE CONSTANT CIRCUIT OF THE RIGHT-HAND BANK HO2S FOR SHORT TO GROUND
Yes
No
GO to I3.
I3: CHECK THE CONSTANT CIRCUIT OF THE RIGHT-HAND BANK HO2S FOR SHORT TO BATTERY
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Yes
No
GO to I4.
I4: CHECK THE VARIABLE CIRCUIT OF THE RIGHT-HAND BANK HO2S FOR OPEN CIRCUIT
Measure the resistance between EN16, pin 83 (Y) and EN37, pin 3 (Y).
Yes
GO to I5.
No
normal operation.
I5: CHECK THE VARIABLE CIRCUIT OF THE RIGHT-HAND BANK HO2S FOR SHORT TO GROUND
Yes
No
GO to I6.
I6: CHECK THE VARIABLE CIRCUIT OF THE RIGHT-HAND BANK HO2S FOR SHORT TO BATTERY
Measure the voltage between EN37, pin 3 (Y) and GROUND.
Yes
No
INSTALL a new HO2S.
PINPOINT TEST J : DTC P0037, P0038, P0137, P0138, P0139, P0140. RIGHT-HAND BANK CATALYST MONITOR
TEST
CONDITIONS
J1: CHECK THE POWER SUPPLY CIRCUIT TO THE RIGHT-HAND BANK CATALYST MONITOR HEATER
Measure the voltage between the catalyst monitor sensor electrical connector EN14, pin 2 (WG) and GROUND.
Yes
GO to J6.
No
GO to J2.
J2: CHECK CONTINUITY OF THE RIGHT-HAND BANK CATALYST MONITOR SENSOR GROUND CIRCUIT
Measure the resistance between the catalyst monitor sensor electrical connector EN14, pin 3 (W) and the ECM
electrical connector EN16, pin 130.
Yes
GO to J3.
No
normal operation.
J3: CHECK CONTINUITY OF THE POWER SUPPLY WIRE TO THE RIGHT-HAND BANK CATALYST MONITOR SENSOR
Measure the resistance between the RH bank catalyst monitor sensor electrical connector EN14, pin 4 (N) and the
ECM electrical connector EN16, pin 128 (N).
Yes
GO to J4.
No
normal operation.
J4: CHECK THE RIGHT-HAND BANK CATALYST MONITOR SENSOR POWER SUPPLY WIRE FOR A SHORT TO GROUND
Measure the resistance between the catalyst monitor sensor electrical connector EN14, pin 4 (N) and GROUND.
Yes
No
GO to J5.
J5: CHECK THE RIGHT-HAND BANK CATALYST MONITOR SENSOR POWER SUPPLY WIRE FOR A SHORT TO BATTERY
Measure the voltage between the catalyst monitor sensor electrical connector EN14, pin 4 (N) and GROUND.
Yes
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INSTALL a new RH bank catalyst monitor sensor. For additional information,
REFER to: Catalyst Monitor Sensor RH (303-14A Electronic Engine Controls - 2.0L NA V6 - AJV6/2.5L NA V6 -
information,
J6: CHECK THE RIGHT-HAND BANK CATALYST MONITOR SENSOR POWER SUPPLY CIRCUIT
Measure the voltage between the catalyst monitor sensor electrical connector EN14 pin 2 (WG) and GROUND.
Yes
GO to J8.
No
GO to J7.
J7: CHECK CONTINUITY OF THE RIGHT-HAND BANK CATALYST MONITOR SENSOR HEATER GROUND CIRCUIT
Measure the resistance between the catalyst monitor sensor electrical connector EN14, pin 1 (U) and the ECM
electrical connector EN16, pin 92 (U).
Yes
No
normal operation.
J8: CHECK FUSE 38 OF THE ENGINE COMPARTMENT FUSE BOX
Check the fuse.
Is the fuse OK?
Yes
GO to J10.
No
GO to J9.
J9: CHECK FUSE 38 OF THE ENGINE COMPARTMENT FUSE BOX FOR A SHORT TO GROUND
Measure the resistance between electrical connector JB34, pin 97 of the engine compartment fuse box and GROUND.
Yes
REPAIR short to ground between the engine compartment fuse box and the right-hand bank HO2S. CLEAR the DTC.
No
operation.
J10: CHECK THE POWER SUPPLY TO FUSE 38 IN THE ENGINE COMPARTMENT FUSE BOX
Measure the voltage between fuse 38 electrical connector JB34 pin 97 and GROUND.
Yes
Repair the circuit from the ECM control relay to the engine compartment fuse box. CLEAR the DTC. TEST the system
No
PINPOINT TEST K : P0151, P0152, P0153, P1647. LEFT-HAND BANK HO2S
TEST
CONDITIONS
K1: CHECK THE CONSTANT CIRCUIT OF THE LEFT-HAND BANK HO2S FOR OPEN CIRCUIT
Yes
GO to K2.
No
normal operation.
K2: CHECK THE CONSTANT CIRCUIT OF THE LEFT-HAND BANK HO2S FOR SHORT TO GROUND
Yes
No
GO to K3.
K3: CHECK THE CONSTANT CIRCUIT OF THE LEFT-HAND BANK HO2S FOR SHORT TO BATTERY
Yes
No
GO to K4.
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K4: CHECK THE VARIABLE CIRCUIT OF THE LEFT-HAND BANK HO2S FOR OPEN CIRCUIT
Measure the resistance between EN16, pin 107 (Y) and EN32, pin 3 (Y)
Yes
GO to K5.
No
normal operation.
K5: CHECK THE VARIABLE CIRCUIT OF THE LEFT-HAND BANK HO2S FOR SHORT TO GROUND
Yes
No
GO to K6.
K6: CHECK THE VARIABLE CIRCUIT OF THE LEFT-HAND BANK HO2S FOR SHORT TO BATTERY
Yes
No
INSTALL a new left-hand HO2S.
PINPOINT TEST L : DTC P0057, P0058, P0157, P0158, P0159, P0160. LEFT-HAND BANK CATALYST MONITOR
TEST
CONDITIONS
L1: CHECK THE POWER SUPPLY CIRCUIT TO THE LEFT-HAND BANK CATALYST MONITOR HEATER
Yes
GO to L6.
No
GO to L2.
L2: CHECK CONTINUITY OF THE LEFT-HAND BANK CATALYST MONITOR SENSOR GROUND CIRCUIT
Measure the resistance between the catalyst monitor sensor electrical connector EN9 pin 3 (W) and EN16, pin 130.
Yes
GO to L3.
No
normal operation.
L3: CHECK CONTINUITY OF THE POWER SUPPLY WIRE TO THE LEFT-HAND BANK CATALYST MONITOR SENSOR
Measure the resistance between the catalyst monitor sensor electrical connector EN9 pin 4 (N) and the ECM electrical
connector EN16 pin 129 (N).
Yes
GO to L4.
No
normal operation.
L4: CHECK THE LEFT-HAND BANK CATALYST MONITOR SENSOR POWER SUPPLY WIRE FOR A SHORT TO GROUND
Measure the resistance between the catalyst monitor sensor electrical connector EN9 pin 4 (N) and GROUND.
Yes
No
GO to L5.
L5: CHECK THE LEFT-HAND BANK CATALYST MONITOR SENSOR POWER SUPPLY WIRE FOR A SHORT TO BATTERY
Measure the voltage between the catalyst monitor sensor electrical connector EN9 pin 4 (N) and GROUND.
Yes
No
INSTALL a new left-hand bank catalyst monitor sensor. For additional information,
REFER to: Catalyst Monitor Sensor LH (303-14A Electronic Engine Controls - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L
information,
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L6: CHECK THE LEFT-HAND BANK CATALYST MONITOR SENSOR POWER SUPPLY CIRCUIT
Yes
GO to L8.
No
GO to L7.
L7: CHECK CONTINUITY OF THE LEFT-HAND BANK CATALYST MONITOR SENSOR HEATER GROUND CIRCUIT
Measure the resistance between the catalyst monitor sensor electrical connector EN9 pin 1 (UY) and the ECM
electrical connector EN16 pin 93 (UY).
Yes
No
normal operation.
L8: CHECK FUSE 42 OF THE ENGINE COMPARTMENT FUSE BOX
Check the fuse.
Is the fuse OK?
Yes
GO to L10.
No
GO to L9.
L9: CHECK FUSE 42 OF THE ENGINE COMPARTMENT FUSE BOX FOR A SHORT TO GROUND
Yes
No
operation.
L10: CHECK THE POWER SUPPLY TO FUSE 42 IN THE ENGINE COMPARTMENT FUSE BOX
Yes
No
diagrams.
PINPOINT TEST M : DTC P0101, P0102, P0103, P1104. MASS AIR FLOW SENSOR (MAF)
TEST
CONDITIONS
M1: CHECK THE MAF SENSOR POWER SUPPLY
Measure the voltage between the MAF sensor electrical connector EN6 pin 1 (GU) and GROUND.
Yes
GO to M5.
No
GO to M2.
Measure the resistance between the MAF sensor electrical connector EN6 pin 3 (GW) and the ECM electrical connector
EN16 pin 44 (GW).
Yes
GO to M3.
No
normal operation.
Measure the resistance between the MAF sensor electrical connector EN6 pin 2 (BW) and the ECM electrical connector
EN16 pin 45 and pin 46 (BW).
Yes
GO to M4.
No
normal operation.
M4: CHECK THE MAF SENSOR CIRCUIT FOR SHORT TO GROUND
Measure the resistance between the MAF sensor electrical connector EN6 pin 3 (GW) and GROUND.
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Yes
INSTALL a new MAF sensor. For additional information,
information,
No
M5: CHECK FUSE 36 OF THE ENGINE COMPARTMENT FUSE BOX
Check the fuse.
Is the fuse OK?
Yes
GO to M7.
No
GO to M6.
M6: CHECK FUSE 36 OF THE ENGINE COMPARTMENT FUSE BOX FOR A SHORT TO GROUND
Yes
REPAIR short to ground between the engine compartment fuse box and the MAF sensor. For additional information,
refer to wiring diagrams. CLEAR the DTC. TEST the system for normal operation.
No
operation.
M7: CHECK THE POWER SUPPLY FROM FUSE 36 IN THE ENGINE COMPARTMENT FUSE BOX TO THE MAF SENSOR
Measure the voltage between the engine compartment fuse box electrical connector JB34 pin 93 and GROUND.
Yes
Repair the circuit from the engine compartment fuse box to the MAF sensor. For additional information, refer to wiring
No
Recheck DTCs.
PINPOINT TEST N : P0111, P0112, P0113. IAT SENSOR
TEST
CONDITIONS
N1: CHECK CONTINUITY OF THE INTAKE AIR TEMPERATURE (IAT) SENSOR POWER SUPPLY CIRCUIT
Measure the resistance between the MAF sensor electrical connector EN6 pin 4 (O) and the ECM electrical connector
EN16, pin 71 (O).
Yes
GO to N2.
No
normal operation.
N2: CHECK CONTINUITY OF THE IAT SENSOR CIRCUIT
Measure the resistance between the MAF sensor electrical connector EN6 pin 5 (BG) and the ECM electrical connector
EN16, pin 19 (BG).
Yes
GO to N4.
No
normal operation.
N3: CHECK THE IAT SENSOR CIRCUIT FOR SHORT TO BATTERY
Check for a voltage between EN6 pin 5 (BG) and GROUND.
Yes
GO to N1.
No
N4: CHECK THE IAT SENSOR POWER SUPPLY CIRCUIT FOR SHORT TO GROUND
Measure the resistance between the MAF sensor electrical connector EN6 pin 4 (O) and GROUND.
Yes
No
GO to N5.
N5: CHECK THE IAT SENSOR GROUND CIRCUIT FOR SHORT TO BATTERY
Check for voltage at EN6 pin 5 (BG)
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No
PINPOINT TEST O : DTC P0051, P0052. LEFT-HAND BANK H02S HEATER
TEST
CONDITIONS
O1: CHECK THE POWER SUPPLY CIRCUIT TO THE LEFT-HAND BANK HO2S HEATER
Measure the voltage between the HO2S electrical connector EN32 pin 2 (WR) and GROUND.
Yes
GO to O4.
No
GO to O2.
O2: CHECK THE GROUND CIRCUIT TO THE LEFT-HAND BANK HO2S HEATER
Measure the resistance between the HO2S electrical connector EN32 pin 1 (GO) and the ECM electrical connector
EN16 pins 55 and 56 (GO).
Yes
GO to O3.
No
normal operation.
O3: CHECK THE LEFT-HAND BANK HO2S CIRCUIT FOR SHORT TO GROUND
Measure the resistance between the HO2S electrical connector EN32 pin 1 (GO) and GROUND.
Yes
No
INSTALL a new left-hand bank HO2S. For additional information,
information,
O4: CHECK FUSE 42 OF THE ENGINE COMPARTMENT FUSE BOX
Check the fuse.
Is the fuse OK?
Yes
GO to O6.
No
GO to O5.
O5: CHECK FUSE 42 OF THE ENGINE COMPARTMENT FUSE BOX FOR A SHORT TO GROUND
Yes
No
operation.
O6: CHECK THE POWER SUPPLY TO FUSE 42 IN THE ENGINE COMPARTMENT FUSE BOX
Measure the voltage between fuse 42, electrical connector JB34 pin 105 and GROUND.
Yes
No
PINPOINT TEST P : DTC P1606. ECM RELAY.
TEST
CONDITIONS
P1: CHECK THE ECM CONTROL RELAY
Does the ECM relay make an audible click?
Yes
GO to P2.
No
GO to P6.
P2: CHECK FOR POWER SUPPLY FROM THE ECM CONTROL RELAY
Measure the voltage between the ECM control relay JB34 pin 131 and GROUND.
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Yes
GO to P3.
No
REPAIR the circuit from the ECM control relay to the ECM. For additional information, refer to wiring diagrams. CLEAR
P3: CHECK FUSE 9 IN THE ENGINE COMPARTMENT FUSE BOX
Check the fuse.
Is the fuse OK?
Yes
GO to P4.
No
operation.
P4: CHECK THE POWER SUPPLY TO FUSE 9 IN THE ENGINE COMPARTMENT FUSE BOX
Yes
Repair the circuit from the battery positive to the engine compartment fuse box. CLEAR the DTC. TEST the system for
normal operation.
No
GO to P5.
P5: CHECK THE POWER SUPPLY FROM FUSE 9 IN THE ENGINE COMPARTMENT FUSE BOX TO THE ECM CONTROL RELAY
Measure the voltage between the ECM control relay electrical connector JB34 pin 132 and GROUND.
Yes
Repair the circuit from the engine compartment fuse box to the ECM control relay. CLEAR the DTC. TEST the system
No
INSTALL a new ECM control relay. For additional information, refer to the electrical guide. CLEAR the DTC. TEST the
P6: CHECK FUSE 31 OF THE ENGINE COMPARTMENT FUSE BOX
Check the fuse.
Is the fuse OK?
Yes
GO to P7.
No
GO to P10.
P7: CHECK POWER SUPPLY TO THE ECM CONTROL RELAY FROM FUSE 31 OF THE ENGINE COMPARTMENT FUSE BOX
Measure the voltage between ECM relay electrical connector JB34 pin 133 and GROUND.
Yes
GO to P8.
No
GO to P12.
P8: CHECK CONTINUITY OF THE ECM CONTROL RELAY GROUND CIRCUIT
Remove the ECM control relay from the engine compartment fuse box.
Measure the resistance between the ECM electrical connector EN16 pin 40 and JB34 pin 134 of the engine
compartment fuse box.
Yes
GO to P9.
No
operation.
(This circuit includes the power distribution fuse box and the EMS relay and diode.)
P9: CHECK CONTINUITY OF THE ECM CONTROL RELAY WINDING
Measure the resistance of the ECM control relay winding between pins 1 and 2 of the ECM control relay.
Yes
INSTALL a new ECM control relay. CLEAR the DTC. TEST the system for normal operation.
No
INSTALL a new ECM.
Yes
REPAIR short to GROUND between the engine compartment fuse box and the ECM control relay. CLEAR the DTC. TEST
No
Yes
REPAIR short to ground between the engine compartment fuse box and the ECM control relay. CLEAR the DTC. TEST
No
P12: CHECK THE ECM CONTROL RELAY DIODE
Remove the ECM control relay diode from the engine compartment fuse box.
Measure the continuity of ECM control relay diode.
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Yes
No
INSTALL a new ECM control relay diode. Make sure that the ECM control relay diode is installed correctly. For
PINPOINT TEST Q : P0106, P0107, P0108. MAP SENSOR
TEST
CONDITIONS
Q1: CHECK THE GROUND CIRCUIT TO THE MAP SENSOR
Disconnect the MAP sensor electrical connecter EN8.
Measure the resistance between the MAP sensor electrical connecter EN8 pin 4 (BG) and GROUND.
Reconnect electrical connectors following test.
Yes
GO to Q2.
No
REPAIR the circuit between the MAP sensor and GROUND. For additional information, refer to wiring diagrams. CLEAR
Q2: CHECK THE POWER SUPPLY CIRCUIT TO THE MAP SENSOR FOR SHORT TO BATTERY
Yes
normal operation.
No
GO to Q3.
Q3: CHECK THE POWER SUPPLY CIRCUIT TO THE MAP SENSOR FOR SHORT TO GROUND
Yes
No
GO to Q4.
Q4: CHECK CONTINUITY OF THE MAP SENSOR SIGNAL WIRE
Measure the resistance of the circuit between MAP sensor electrical connector EN8 pin 1 (BW) and ECM electrical
connector EN16 pin 127 (BW).
Yes
GO to Q5.
No
REPAIR the circuit between the MAP sensor electrical connector EN8 pin 1 (BW) and ECM electrical connector EN16 pin
127 (BW). For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal
operation.
Q5: CHECK THE MAP SENSOR SIGNAL WIRE FOR SHORT TO GROUND
Measure the resistance between EN8 pin 1 (BW) and GROUND.
Yes
(The fault could be in any of the components or sensors in the 5 volt supply circuit, or the ECM.)
No
GO to Q6.
Q6: CHECK THE MAP SENSOR SIGNAL WIRE FOR SHORT TO BATTERY
Check for a voltage at EN8 pin 1 (BW).
Yes
Repair the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for
normal operation.
(The fault could be in any of the components or sensors in the 5 volt supply circuit, or the ECM.)
No
INSTALL a new MAP sensor. CLEAR the DTC. TEST the system for normal operation.
PINPOINT TEST R : P0010, P1384. VVT RIGHT-HAND BANK
TEST
CONDITIONS
R1: CHECK THE GROUND CIRCUIT TO THE RIGHT-HAND BANK VVT SOLENOID
Disconnect the VVT solenoid electrical connector EN61.
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Yes
GO to R2.
No
R2: CHECK CONTINUITY OF THE RIGHT-HAND BANK VVT SOLENOID SIGNAL WIRE
Measure the resistance between VVT solenoid electrical connector EN61 pin 1 (RW) and ECM electrical connector EN16
pin 109 (RW).
Yes
GO to R3.
No
REPAIR the circuit between VVT solenoid electrical connector EN61 pin 1 (RW) and ECM electrical connector EN16 pin
109 (RW). For additional information, refer to wiring diagrams. CLEAR the DTC. TEST the system for normal operation.
R3: CHECK FOR SHORT TO GROUND AT THE RIGHT-HAND BANK VVT SOLENOID SIGNAL WIRE
Yes
No
GO to R4.
R4: CHECK FOR SHORT TO BATTERY AT THE RIGHT-HAND BANK VVT SOLENOID SIGNAL WIRE
Yes
normal operation.
No
INSTALL a new right-hand bank VVT solenoid.
PINPOINT TEST S : P0020, P1396. VVT LEFT-HAND BANK
TEST
CONDITIONS
S1: CHECK GROUND CIRCUIT TO THE LEFT-HAND BANK VVT SOLENOID
Disconnect the VVT solenoid electrical connector, EN42.
Yes
GO to S2.
No
S2: CHECK CONTINUITY OF THE LEFT-HAND BANK VVT SOLENOID SIGNAL WIRE.
Measure the resistance between VVT solenoid electrical connector EN42 pin 1 (G) and ECM electrical connector EN16
pin 110 (G).
Yes
GO to S3.
No
REPAIR the circuit between VVT solenoid electrical connector EN42 pin 1 (G) and ECM electrical connector EN16 pin
110 (G). For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal
operation.
S3: CHECK FOR SHORT TO GROUND AT THE LEFT-HAND BANK VVT SOLENOID SIGNAL WIRE
Yes
No
GO to S4.
S4: CHECK FOR SHORT TO BATTERY AT THE LEFT-HAND BANK VVT SOLENOID SIGNAL WIRE
Yes
REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for
normal operation.
No
INSTALL a new left-hand bank VVT solenoid.
PINPOINT TEST T : P1251, P1631, P1657, P1658. THROTTLE MOTOR RELAY
TEST
CONDITIONS
T1: CHECK THE POWER SUPPLY CIRCUIT TO THE THROTTLE MOTOR RELAY
Measure the voltage between pin 1 of the throttle motor relay base and GROUND.
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Yes
GO to T2.
No
REPAIR the circuit between pin 1 of the throttle motor relay base and the EMS control relay. For additional
T2: CHECK CONTINUITY OF THE THROTTLE MOTOR RELAY SIGNAL WIRE
Measure the resistance between the throttle motor relay base, pin 2 and the ECM electrical connector EN16 pin 52
(GR).
Yes
GO to T3.
No
REPAIR the circuit between the throttle motor relay base pin 2 and the ECM electrical connector EN16 pin 52 (GR). For
T3: CHECK THE THROTTLE MOTOR RELAY SIGNAL WIRE FOR SHORT TO BATTERY
Yes
normal operation.
No
GO to T4.
T4: CHECK THE THROTTLE MOTOR RELAY SIGNAL WIRE FOR SHORT TO GROUND
Yes
No
GO to T5.
T5: CHECK CONTINUITY OF THE THROTTLE MOTOR RELAY OUTPUT WIRE
Test for continuity between throttle motor relay base pin 5 and ECM electrical connector EN16 pin 134 (RW).
Yes
INSTALL a new throttle motor relay. CLEAR the DTC. TEST the system for normal operation. If the DTC is repeated,
INSTALL a new ECM.
No
REPAIR the circuit between throttle motor relay base pin 2 and ECM electrical connector EN16 pin 134 (RW). For
T6: CHECK THE THROTTLE MOTOR RELAY OUTPUT WIRE FOR SHORT TO BATTERY
Yes
normal operation.
No
GO to T7.
T7: CHECK THE THROTTLE MOTOR RELAY OUTPUT WIRE FOR SHORT TO GROUND
Yes
No
INSTALL a new throttle motor relay. For additional information, refer to the electri cal guide. CLEAR the DTC. TEST the
system for normal operation. If the DTC is repeated, INSTALL a new ECM.
PINPOINT TEST U : P1549. IMT VALVE 1
TEST
CONDITIONS
U1: CHECK THE POWER SUPPLY CIRCUIT TO THE IMT VALVE 1
Yes
GO to U2.
No
(This circuit includes the power distribution fuse box and the EMS control relay. For additional information, refer to wiring diagrams.)
U2: CHECK CONTINUITY OF THE IMT VALVE 1 SIGNAL WIRE.
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Yes
GO to U3.
No
REPAIR the circuit between the IMT valve 1 electrical connector EN999 pin 2 (OY) and the ECM electrical connector
operation.
U3: CHECK IMT VALVE SIGNAL WIRE FOR SHORT TO GROUND
Yes
No
GO to U4.
U4: CHECK IMT VALVE SIGNAL WIRE FOR SHORT TO BATTERY
Yes
normal operation.
No
new ECM.
PINPOINT TEST V : P1532. IMT VALVE 2
TEST
CONDITIONS
V1: CHECK THE POWER SUPPLY CIRCUIT TO THE IMT VALVE 2
Yes
GO to V2.
No
(This circuit includes the power distribution fuse box and the EMS control relay. For additional information, refer to wiring diagrams.)
V2: CHECK CONTINUITY OF THE IMT VALVE 2 SIGNAL WIRE
Yes
GO to V3.
No
REPAIR the circuit between the IMT valve 2 electrical connector EN998 pin 2 (OY)and the ECM electrical connector
operation.
V3: CHECK IMT VALVE SIGNAL WIRE FOR SHORT TO GROUND
Yes
No
GO to V4.
V4: CHECK IMT VALVE SIGNAL WIRE FOR SHORT TO BATTERY
Yes
normal operation.
No
new ECM.
PINPOINT TEST W : P1582. FLIGHT RECORDER DATA STORED
W1: EXTRACT THE FLIGHT RECORDER DATA
NOTE: Flight recorder data can only be extracted using the Jaguar approved diagnostic system, where available.
Connect the Jaguar approved diagnostic system, or code reader.
Is DTC P1582 stored?
Yes
Refer to dealer technical support for information on extracting data.
No
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Test not applicable.
PINPOINT TEST X : P1243. SENSOR GROUND CIRCUITS.
X1: CHECK THE GROUND CIRCUIT TO THE ECT SENSOR
Measure the resistance between ECT sensor electrical connector EN18 pin 1 (BG) and GROUND.
Yes
GO to X2.
No
REPAIR the circuit between the ECT sensor electrical connector EN18 pin 1 (BG) and GROUND. CLEAR the DTC.
X2: CHECK THE GROUND CIRCUIT TO THE EOT SENSOR
Measure the resistance between EOT sensor electrical connector EN25 pin 2 (BG) and GROUND.
Yes
GO to X3.
No
REPAIR the circuit between the EOT sensor electrical connector EN25 pin 2 (BG) and GROUND. CLEAR the DTC.
X3: CHECK THE GROUND CIRCUIT TO THE IP SENSOR
Measure the resistance between IP sensor electrical connector IJ7 pin 2 (WG) and GROUND.
Yes
GO to X4.
No
REPAIR the circuit between the IP sensor electrical connector IJ7 pin 2 (WG) and GROUND. CLEAR the DTC.
X4: CHECK THE GROUND CIRCUIT TO THE EFT SENSOR
Measure the resistance between EFT sensor electrical connector IJ8 pin 1 (NU) and GROUND.
Yes
GO to X5.
No
REPAIR the circuit between the EFT sensor electrical connector IJ8 pin 1 (NU) and GROUND. CLEAR the DTC.
X5: CHECK THE GROUND CIRCUIT TO THE MAP SENSOR
Measure the resistance between MAP sensor electrical connector EN8 pin 4 (BG) and GROUND.
Yes
GO to X6.
No
REPAIR the circuit between the MAP sensor electrical connector EN8 pin 4 (BG) and GROUND. CLEAR the DTC.
X6: CHECK THE GROUND CIRCUIT TO THE FTP SENSOR
Measure the resistance between FTP sensor electrical connector FT1 pin 3 (BG) and GROUND.
Yes
GO to X7.
No
REPAIR the circuit between the FTP Sensor electrical connector FT1 pin 3 (BG) and GROUND. CLEAR the DTC.
X7: CHECK THE GROUND CIRCUIT TO THE APP SENSOR (TRACK 1)
Yes
GO to X8.
No
X8: CHECK THE GROUND CIRCUIT TO THE TP SENSOR
Measure the resistance between TP sensor electrical connector EN13 pin 1 (BG) and GROUND.
Yes
GO to X9.
No
REPAIR the circuit between the TP sensor electrical connector EN13 pin 1 (BG) and GROUND. CLEAR the DTC.
X9: CHECK THE GROUND CIRCUIT TO THE APP SENSOR (TRACK 3)
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GO to X10.
No
X10: CHECK THE GROUND CIRCUIT TO THE AIR CONDITIONING PRESSURE SENSOR
Measure the resistance between ACP sensor electrical connector JB106 pin 1 (BG) and GROUND.
Yes
No electrical fault in ground circuit. Recheck DTCs.
No
REPAIR the circuit between the ACP sensor electrical connector JB106 pin 1 (BG) and GROUND. CLEAR the DTC.
PINPOINT TEST Y : P0480. RADIATOR COOLING FAN MODULE DRIVE
TEST
CONDITIONS
Y1: CHECK THE PULSE WIDTH MODULATED SIGNAL TO THE COOLING FAN MODULE
Disconnect the radiator cooling fan module electrical connector PWM1.
RUN the engine to a temperature at which the cooling fans would operate.
Using a suitable meter, test for a pulse width modulated signal at PWM1 pin 3 (WU).
Is a PWM signal present?
Yes
INSTALL a new cooling fan module. CLEAR the DTC. TEST the system for normal operation.
No
GO to Y2.
Y2: CHECK CONTINUITY OF THE RADIATOR COOLING FAN MODULE SIGNAL WIRE
Measure the resistance between the radiator cooling fan module electrical connector PWM1 pin 3 (WU) and the ECM
electrical connector EN16 pin 51 (WU).
Yes
INSTALL a new ECM.
No
REPAIR the circuit between the radiator cooling fan module electrical connector PWM1 pin 3 (WU) and the ECM
electrical connector EN16 pin 51 (WU). For additional information, refer to wiring diagrams. CLEAR the DTC. TEST the
PINPOINT TEST Z : P0226, P0227, P0228. APP SENSOR ( TRACK 1)
TEST
CONDITIONS
Z1: CHECK THE POWER SUPPLY CIRCUIT TO THE APP SENSOR. TRACK 1
Is the voltage greater than 4volts?
Yes
GO to Z2.
No
REPAIR the circuit between the APP sensor electrical connector PA1 pin 2 (Y) and the sensor 5 volt supply 2. CLEAR
(This circuit includes the ECM, EMS control relay, and power distribution fuse box. For additional information, refer to wiring diagrams.)
Z2: CHECK THE GROUND CIRCUIT TO THE APP SENSOR
Disconnect APP Sensor electrical connector PA1.
Yes
GO to Z5.
No
Z3: CHECK THE GROUND CIRCUIT TO THE APP SENSOR. FOR CONTINUITY
Yes
GO to Z4.
No
operation.
Z4: CHECK THE GROUND CIRCUIT TO THE APP SENSOR. FOR SHORT TO BATTERY
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2
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1
Yes
normal operation.
No
GO to Z5.
Z5: CHECK CONTINUITY OF THE APP SENSOR SIGNAL WIRE
Measure the resistance between APP sensor electrical connector PA1 pin 4 (R) and the ECM electrical connector EN16
pin 102 (R).
Yes
GO to Z6.
No
REPAIR the circuit between the APP sensor electrical connector PA1 pin 4 (R) and the ECM electrical connector EN16
pin 102 (R). For additional information, refer to wiring diagrams. CLEAR the DTC. TEST the system for normal
operation.
Z6: CHECK CONTINUITY OF THE APP SENSOR POTENTIOMETER
Yes
INSTALL a new ECM.
No
PINPOINT TEST AA : P2122, P2123. APP SENSOR ( TRACK 3)
TEST
CONDITIONS
AA1: CHECK THE POWER SUPPLY CIRCUIT TO THE APP SENSOR. TRACK 3
Yes
GO to AA2.
No
REPAIR the circuit between the APP sensor electrical connector PA1 pin 1 (Y) and the sensor 5 volt supply. CLEAR the
(This circuit includes the ECM, EMS control relay, and power distribution fuse box. For additional information, refer to wiring diagrams. This supply is also
linked to other sensors. The fault could be in any of these or their wiring.)
AA2: CHECK THE GROUND CIRCUIT TO THE APP SENSOR
Yes
GO to AA5.
No
AA3: CHECK THE GROUND CIRCUIT TO THE APP SENSOR FOR CONTINUITY
Yes
GO to AA4.
No
operation.
AA4: CHECK THE GROUND CIRCUIT TO THE APP SENSOR FOR SHORT TO BATTERY
Yes
normal operation.
No
GO to AA5.
AA5: CHECK CONTINUITY OF THE APP SENSOR SIGNAL WIRE
Measure the resistance between APP sensor electrical connector PA1 pin 1 (Y) and the ECM electrical connector EN16
pin 103 (Y).
Yes
GO to AA6.
No
REPAIR the circuit between the APP sensor electrical connector PA1 pin 1 (Y) and the ECM electrical connector EN16
pin 103 (Y). For additional information, refer to wiring diagrams. CLEAR the DTC. TEST the system for normal
operation.
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2
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4
5
1
2
1
2
1
2
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1
2
1
AA6: CHECK CONTINUITY OF THE APP SENSOR POTENTIOMETER
Yes
INSTALL a new ECM.
No
PINPOINT TEST AB : P0512, P1245. IGNITION SWITCH CRANK SIGNAL
WARNING: Make sure the starter motor does not engage in the course of these tests. Failure to follow these instructions may result
in personal injury.
TEST
CONDITIONS
AB1: CHECK THE START INPUT TO THE ECM
Move the gear selector to the N position.
Remove the starter relay from the power distribution fuse box.
Yes
GO to AB2.
No
REPAIR the circuit between the ECM and the battery. For additional information, refer to wiring diagrams. CLEAR the
(This circuit includes the ignition switch and the power distribution fuse box. [Fuse 28].)
AB2: CHECK THE START INPUT TO THE STARTER RELAY
Turn the ignition switch to the START position and hold.
Measure the voltage between the starter relay base (R10) pin 1 and GROUND.
Yes
GO to AB3.
No
REPAIR the circuit between the starter relay base and the battery. For additional information, refer to wiring
(This circuit includes the ignition switch and the power distribution fuse box.)
AB3: CHECK THE START INPUT WIRE FOR SHORT TO BATTERY AT ECM
Yes
normal operation.
No
GO to AB4.
AB4: CHECK THE START INPUT WIRE FOR SHORT TO BATTERY AT RELAY
Yes
normal operation.
No
GO to AB5.
AB5: CHECK THE STARTER RELAY INPUT FROM THE ECM FOR CONTINUITY
Measure the resistance between EN16 pin 41 (GO) and relay base pin 2.
Yes
GO to AB6.
No
REPAIR the open circuit. For additional information, refer to wiring diagrams. CLEAR the DTC. TEST the system for
normal operation.
AB6: CHECK THE STARTER RELAY INPUT FROM THE ECM FOR SHORT TO GROUND
Disconnect ignition switch electrical connector IP18.
Measure the resistance between EN16 pin 41 (GO) and GROUND.
Yes
normal operation.
No
GO to AB7.
AB7: CHECK THE STARTER RELAY INPUT FROM THE ECM FOR SHORT TO BATTERY
Yes
normal operation.
No
INSTALL a new starter relay. For additional information, refer to wiring diagrams. CLEAR the DTC. TEST the system
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1
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1
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3
for normal operation. If the DTC is repeated, INSTALL a new ECM.
PINPOINT TEST AC : P0561, P0562, P0563. SENSOR POWER SUPPLY
AC1: CHECK THE POWER SUPPLY CIRCUIT TO THE IP SENSOR
Disconnect the IP sensor electrical connector, IJ7.
Yes
GO to AC2.
No
(The fault could be in any of the other sensors in this circuit, or in any of the spurs in this circuit. For additional information, refer to wiring diagrams.)
AC2: CHECK THE POWER SUPPLY CIRCUIT TO THE IP SENSOR FOR SHORT TO BATTERY
Yes
diagrams.)
No
GO to AC3.
AC3: CHECK THE POWER SUPPLY CIRCUIT TO THE MAP SENSOR
Yes
GO to AC4.
No
AC4: CHECK THE POWER SUPPLY CIRCUIT TO THE MAP SENSOR FOR SHORT TO BATTERY
Yes
diagrams.)
No
GO to AC5.
AC5: CHECK THE POWER SUPPLY CIRCUIT TO THE FTP SENSOR
Disconnect the FTP sensor electrical connector FT1. (See note above).
Yes
GO to AC6.
No
AC6: CHECK THE POWER SUPPLY CIRCUIT TO THE FTP SENSOR FOR SHORT TO BATTERY
Yes
diagrams.)
No
GO to AC7.
AC7: CHECK THE POWER SUPPLY CIRCUIT TO THE APP SENSOR
Disconnect the APP sensor electrical connector.
Yes
GO to AC8.
No
AC8: CHECK THE POWER SUPPLY CIRCUIT TO THE APP SENSOR FOR SHORT TO BATTERY
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2
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2
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2
3
4
Yes
diagrams.)
No
GO to AC9.
AC9: CHECK THE POWER SUPPLY CIRCUIT TO THE TP SENSOR
Yes
GO to AC10.
No
AC10: CHECK THE POWER SUPPLY CIRCUIT TO THE TP SENSOR FOR SHORT TO BATTERY
Yes
diagrams.)
No
GO to AC11.
AC11: CHECK THE POWER SUPPLY CIRCUIT TO THE AIR CONDITIONING PRESSURE (ACP) SENSOR
Yes
GO to AC12.
No
AC12: CHECK THE POWER SUPPLY CIRCUIT TO THE AIR CONDITIONING PRESSURE SENSOR FOR SHORT TO BATTERY
Yes
diagrams.)
No
No electrical fault in power supply circuit. Recheck DTCs using the Jaguar approved diagnostic system, or code
reader.
(This fault could also be a PSV failure within the ECM.)
PINPOINT TEST AD : P0851, P0852. P/N SWITCH STARTING/DRIVING MALFUNCTIONS.
TEST
CONDITIONS
AD1: CHECK THE P/N INPUT TO THE ECM.
Select PARK.
Set the ignition switch to the ON position.
Measure the voltage at the ECM electrical connector EN16 pin 31 (B).
Yes
INSTALL a new ECM.
No
REPAIR the circuit between the ECM electrical connector EN16 pin 31 (B) and the ignition switch. For additional
(On automatic transmission vehicles, this circuit includes the TR sensor, central junction fuse box, ignition relay, and inertia switch. On NAS manual
transmission vehicles, this circuit also includes the clutch safety switch.)
PINPOINT TEST AE : P0646, P0647. AIR CONDITIONING CLUTCH RELAY DRIVE
TEST
CONDITIONS
AE1: CHECK THE GROUND SUPPLY TO THE AIR CONDITIONING CLUTCH
WARNING: This test involves working in proximity to rotating parts. Make sure due care is exercised.
Disconnect the air conditioning clutch electrical connector EN30.
Measure the resistance between EN30 pin 2 (B) and GROUND.
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2
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1
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1
2
1
2
1
2
1
2
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1
2
Yes
REPAIR the circuit between EN30 pin 2 (B) and GROUND. For additional information, refer to wiring diagrams. CLEAR
No
GO to AE2.
AE2: CHECK THE CIRCUIT INTEGRITY BETWEEN THE ECM AND THE AIR CONDITIONING CLUTCH
Apply a GROUND to the disconnected ECM electrical connector EN16 pin 34 (BG).
Measure the voltage at air conditioning clutch electrical connector EN30 pin 1 (RG).
Yes
GO to AE3.
No
GO to AE4.
AE3: CHECK THE AIR CONDITIONING CLUTCH RELAY TO ECM CIRCUIT FOR SHORT TO GROUND
Measure the resistance between EN16 pin 34 (BG) and GROUND.
Yes
GO to AE4.
No
INSTALL a new air conditioning compressor clutch relay. For additional information, refer to the electrical guide.
AE4: CHECK THE CIRCUIT BETWEEN THE AIR CONDITIONING COMPRESSOR CLUTCH AND THE RELAY FOR SHORT TO BATTERY
Measure the voltage between EN30 pin 1 (RG) and GROUND.
Yes
normal operation.
No
GO to AE5.
AE5: CHECK THE CIRCUIT BETWEEN THE AIR CONDITIONING COMPRESSOR CLUTCH AND THE ACCC RELAY FOR SHORT TO
GROUND
Measure the resistance between EN30 pin 1 (RG) and GROUND.
Yes
normal operation.
No
GO to AE6.
AE6: CHECK THE CIRCUIT BETWEEN FUSE 23 OF THE POWER DISTRIBUTION FUSE BOX AND THE ACCC RELAY FOR SHORT TO
GROUND
Remove Fuse 23.
Measure the resistance between fuse box electrical connector JB34 pin 79 and GROUND.
Yes
normal operation.
No
GO to AE7.
AE7: CHECK THE ACCC RELAY BASE FOR BATTERY VOLTAGE AT PIN 3
Refit Fuse 23.
Measure the voltage between the ACCC relay base pin 3 and GROUND.
Yes
GO to AE8.
No
AE8: CHECK THE CIRCUIT BETWEEN PIN 1 OF THE ACCC RELAY BASE AND THE POWER DISTRIBUTION FUSE BOX FOR SHORT TO
GROUND
Remove Fuse 36.
Measure the resistance between the ACCC relay base pin 1 and GROUND.
Yes
normal operation.
No
GO to AE9.
AE9: CHECK THE ACCC RELAY BASE FOR BATTERY VOLTAGE AT PIN 1
Refit Fuse 36.
Measure the voltage between ACCC relay base pin 1 and GROUND.
Yes
GO to AE10.
No
(This circuit includes the EMS relay, and Fuses 9 and 31)
AE10: CHECK THE CIRCUIT BETWEEN THE ECM AND THE ACCC RELAY BASE FOR CONTINUITY
Remove the ACCC relay.
Measure the resistance between the ECM electrical connector EN16 pin 34 (BG) and ACCC relay base pin 2.
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1
1
Yes
GO to AE11.
No
operation.
AE11: CHECK THE CIRCUIT BETWEEN THE ECM AND THE ACCC RELAY BASE FOR SHORT TO BATTERY
Check for a voltage between the ECM electrical connector EN16 pin 34 (BG) and GROUND.
Yes
normal operation.
No
GO to AE12.
AE12: CHECK THE CIRCUIT BETWEEN THE ECM AND THE ACCC RELAY BASE FOR SHORT TO GROUND
Measure the resistance between the ECM electrical connector EN16 pin 34 (BG) and GROUND.
Yes
normal operation.
No
INSTALL a new ACCC relay. For additional information, refer to the electrical guide. CLEAR the DTC. TEST the system
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Powertrain Control Module (PCM) Long Drive Cycle Self-Test
General Procedures
WARNING: Where possible, all road tests should be on well surfaced and dry roads. Always comply with speed limits and local traffic
regulations.
NOTE: This procedure is an overcheck only. If fault codes are found, interrogation of the relevant system must be carried out and claimed
against.
NOTE: The vehicle must exceed 50mph (80 km/h) during the road test.
1. Connect the diagnostic equipment to the vehicle.
2. Follow on screen prompts and check for engine management fault
codes.
3. Clear the fault codes following the on screen procedure.
4. Disconnect the diagnostic equipment from the vehicle.
5. NOTE: Make sure cruise control is not engaged.
Make sure the engine temperature is above 60 C (140 F).
Carry out a road test and perform the following operations.
1. Accelerate to 55 mph (88 km/h) in 5th gear and cruise for 2
minutes with the engine speed at or above 1800rpm.
2. Lift off the throttle and allow the vehicle to decelerate until
the engine speed is less than 1000 rpm.
3. Stop the vehicle.
4. Release brake, allow the vehicle to move with no throttle for 1
minute.
5. Road test is now complete.
7. NOTE: If fault codes are found, interrogation of the relevant system
must be carried out and claimed against.
Follow on screen prompts and check for engine management fault codes.
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Powertrain Control Module (PCM) Short Drive Cycle Self-Test
General Procedures
NOTE: This procedure is an overcheck only. If fault codes are found, interrogation of the relevant system must be carried out and claimed
against.
2. Follow on screen prompts and check for engine management fault
codes.
3. Clear the fault codes following the on screen procedure.
4. Start the engine.
Allow the engine to idle for 30 seconds.
Raise the engine speed to 1500 rpm and hold for 3 minutes until a
temperature of 70C (158 F) is achieved.
Allow the engine to idle for 30 seconds.
Switch off the engine.
5. NOTE: If fault codes are found, interrogation of the relevant system
must be carried out and claimed against.
Follow on screen prompts and check for engine management fault codes.
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Removal
2. Disconnect the CMP sensor electrical connector.
3. Remove the CMP sensor.
Installation
Tighten to 7 Nm.
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Catalyst Monitor Sensor LH
Removal
.
3. Detach the catalyst monitor sensor harness from the securing clip.
4. Disconnect the catalyst monitor sensor electrical connector.
5. Detach the catalyst monitor sensor electrical connector from the
securing bracket.
1. Release the retaining tang.
2. Detach the catalyst monitor sensor electrical connector from
the securing bracket.
6. CAUTIONS:
Do not cut the HO2S harness.
Make sure that the catalyst monitor sensor casing and harness is
not damaged.
Using Snap-on socket S6176 remove the catalyst monitor sensor.
Installation
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1. CAUTION: Make sure that the catalyst monitor sensor casing and
cable are not damaged.
Tighten to 40 Nm.
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Catalyst Monitor Sensor RH
Removal
In-vehicle Repair).
.
4. Undo and remove the exhaust shield securing bolt to allow access to
the catalyst monitor sensor.
7. Detach the catalyst monitor sensor electrical connector from the
securing bracket.
2. Detach the catalyst monitor sensor electrical connector from
the securing bracket.
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8. CAUTIONS:
Make sure that the catalyst monitor sensor casing and cable are not
damaged.
Using Snap-on socket YA8875 remove the catalyst monitor sensor.
Installation
1. CAUTION: Make sure that the catalyst monitor sensor casing and
cable are not damaged.
Tighten to 40 Nm.
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Removal
1. Remove the right-hand front road wheel. For additional information,
refer to Section 204-04 Wheels and Tires.
3. Disconnect the CKP sensor electrical connector.
Installation
Tighten to 10 Nm.
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Removal
3. Disconnect the engine control module (ECM) electrical connector.
4. Remove the instrument cluster lower trim panel.
5. Remove the trim panel.
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6. Detach the generic electronic module (GEM) from the ECM.
1. Release the GEM locking tang.
2. Detach the GEM from the ECM.
7. Remove the ECM.
1. Remove the ECM retaining nut.
2. Remove the ECM.
8. Remove the ECM from the ECM retaining bracket.
Installation
Tighten to 10 Nm.
2. CAUTION: Make sure that the electrical connector locates correctly
in the ECM. Do not force or overtighten the electrical connector.
Tighten to 10 Nm.
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Fuel Temperature Sensor2.5L NA V6 - AJV6/3.0L NA V6 - AJ27
Special Tool(s)
Quick fit connector releasing tool
310-045
Removal
2. Remove the retaining clip from the spring lock coupling.
3. Disconnect the fuel temperature sensor electrical connector.
4. Using the special tool, remove the fuel temperature sensor.
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Installation
Install the fuel temperature sensor.
2. Connect the fuel temperature sensor electrical connector.
3. Install the retaining clip to the spring lock coupling.
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Heated Oxygen Sensor (HO2S) LH
Removal
and Cables.
4. Detach HO2S electrical connector from the securing bracket.
5. CAUTIONS:
Make sure that the HO2S casing and harness is not damaged.
Using Snap-on socket S6176 remove the HO2S.
Installation
1. CAUTION: Make sure that the HO2S casing and cable are not
damaged.
Tighten to 40 Nm.
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Heated Oxygen Sensor (HO2S) RH
Removal
and Cables.
4. Turn the steering onto full right-hand lock.
6. CAUTIONS:
Make sure that the HO2S casing and harness is not damaged.
Using Snap-on socket S6176 remove the HO2S.
Installation
1. CAUTION: Make sure that the HO2S casing and harness is not
damaged.
Tighten to 40 Nm.
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Knock Sensor (KS)
Removal
All vehicles
and Cables.
For additional information, refer to Section 310-00 Fuel System -
3. Remove the fuel charging wiring harness. For additional information,
refer to Section 303-04A Fuel Charging and ControlsSection 303-04B
Fuel Charging and ControlsSection 303-04C Fuel Charging and Controls -
Turbocharger.
303-03A Engine Cooling / 303-03B Engine Cooling.
Detach the harness.
6. Remove the engine trim retaining bracket.
Remove and discard the seal.
All vehicles
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8. NOTE: Fuel may still be present in the fuel supply manifold.
Detach the fuel injection supply manifold and lower intake manifold and
place to one side.
Remove and discard the lower intake manifold O-ring seals.
10. Detach the KS electrical connector from the retaining bracket.
11. Disconnect the KS electrical connector.
12. Remove the water pump outlet coolant pipe.
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13. Remove the engine coolant inlet pipe.
14. Remove the KS.
Installation
All vehicles
1. NOTE: Prior to installing the KS, clean the engine block and KS mating
surfaces with metal surface cleaner (WSW-M5B392-A).
Tighten to 19 Nm.
2. Install a new seal.
Tighten to 25 Nm.
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Tighten to 10 Nm.
Tighten to 10 Nm.
Tighten to 9 Nm.
6. Tighten to 6 Nm.
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Mass Air Flow (MAF) Sensor
Removal
1. Remove the battery cover.
2. Disconnect the MAF sensor electrical connector.
3. Remove the MAF sensor.
Installation
If required, carry out a short drive cycle.
Short Drive Cycle Self-Test (303-14A Electronic Engine Controls - 2.0L NA
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Oil Temperature Sensor
Removal
2. Remove and discard the oil filter.
3. Disconnect the oil temperature sensor electrical connector.
4. Remove the oil temperature sensor.
Installation
1. NOTE: Apply a small bead of sealant WSK-M4G328-A3 or equivalent
sealant meeting Jaguar specification on the first three threads of the oil
temperature sensor.
Tighten to 15 Nm.
2. Install a new oil filter.
specification.
Check and top up the engine with oil.
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Throttle Position (TP) Sensor
Removal
1. For additional information, refer to Section 303-04A Fuel Charging and
ControlsSection 303-04B Fuel Charging and ControlsSection 303-04C
Fuel Charging and Controls - Turbocharger .
2. Disconnect the battery
and Cables.
Disconnect the air cleaner outlet pipe.
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6. Remove the the throttle position (TP) sensor.
Installation
2. Tighten to 7 Nm.
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Variable Camshaft Timing (VCT) Oil Control Solenoid
Removal
Right-Hand Bank
1. Remove the right-hand valve cover. For additional information, refer to
For additional information, refer to: Valve Cover RH (303-01A Engine -
Repair).
.
Left-Hand Bank
2. Remove the left-hand valve cover. For additional information, refer to
For additional information, refer to: Valve Cover RH (303-01A Engine -
Repair).
.
Right-Hand and Left-Hand Banks
3. Remove the variable camshaft timing oil control solenoid.
Installation
Tighten to 10 Nm.
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Electronic Engine Controls - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) -
Puma -
Camshaft position sensor retaining bolt 9 80
Crankshaft position sensor retaining bolt 7 62
Cylinder head temperature sensor 10 89
Power steering pump belt cover retaining nut 10 89
Engine oil pressure sensor 15 11
Fuel temperature sensor 15 11
Knock sensor 20 15
Fuel injection supply manifold high-pressure pipe retaining nut 10 89
Manifold absolute pressure and temperature sensor retaining clips 4 35
Radiator support bar retaining bolts 25 18
Charge air cooler upper hose retaining clip 4 35
Charge air cooler lower hose retaining clip 4 35
Catalytic converter temperature sensor 35 26
Diesel particulate filter temperature sensor 35 26
Manifold absolute pressure sensor retaining bolt 4 35
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Puma - Electronic Engine Controls
1 Camshaft position (CMP) sensor
3 Cylinder head temperature (CHT) sensor
4 Crankshaft position (CKP) sensor
5 Mass airflow (MAF) sensor
6 Fuel temperature sensor
7 Engine oil pressure (EOP) sensor
8 Knock (KS) sensor
9 Manifold absolute pressure and temperature (MAP-T) sensor
The camshaft position (CMP) sensor is located on the front of the cylinder head and it is a hall effect type sensor. The CMP sensor takes its
signal from the inlet camshaft lobe. The signal is used to identify cylinder number three and thus allowing the individual cylinders to be
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identified. Should the CMP sensor fail the engine will not start.
The engine control module (ECM) is located in the same position as the petrol version. The engine management system (EMS) uses signals
from the various sensors as inputs to the ECM which contains a series of maps for the engine parameters. Based on the inputs from the
sensors regarding current engine conditions and loads, the ECM determines the optimum settings to use for the EMS, and so gives the best
performance and/or economy for a given set of conditions. The ECM also manages the speed control system, again based on information
from the vehicle sensors to provide the optimum settings.
Cylinder Head Temperature (CHT) Sensor
The cylinder head temperature (CHT) sensor is located at the rear of the engine behind the rear end accessory drive camshaft pulley. The
CHT sensor measures the temperature of the cylinder head and then provides the ECM and the instrument cluster with the engine
temperature.
The crankshaft position (CKP) sensor is located at the rear of the engine mounted to the cylinder block. It is used to detect the engine
position and speed of the crankshaft. It is a permanent inductive type sensor. Should the CKP sensor fail, the engine will not start.
Mass Airflow (MAF) Sensor
The mass airflow (MAF) sensor is mounted on the clean air side of the air filter and upstream of the turbocharger air compressor. The
function of the MAF sensor is to measure the amount of air flow drawn into the engine. This airflow is used by the ECM to control the
exhaust gas recirculation (EGR) operation.
Engine Oil Pressure (EOP) Sensor
The engine oil pressure (EOP) sensor is located on the left-hand side of the engine in the oil filter housing. The EOP is connected to the
instrument cluster and is not directly part of the electronic engine control system.
Knock Sensor (KS)
The knock sensor (KS) is located on the left-hand side of the engine mounted on the cylinder head between cylinders two and three. The KS
allows the ECM to analyze the quality of combustion by measuring the increase in vibration. The ECM will use this signal to calculate the
quantity of fuel to be injected during phased injection. The correction to the fueling for the phased injection minimizes the combustion
noise. Should the KS fail the result would be no phased injection and thus an increase in diesel knock when idling and accelerating.
Manifold Absolute Pressure and Temperature (MAP-T) Sensor
The manifold absolute pressure and temperature (MAP-T) sensor combines the manifold pressure sensor and inlet air temperature sensor in
one component. It is located in the inlet boost pressure pipe, right side front after the charge air cooler. Its function and operation is to
measure the positive charge pressure developed by the turbocharger and its temperature, and to inform the ECM.
Fuel Temperature Sensor
The fuel temperature sensor can be identified by a blue connector located in the low pressure fuel supply circuit on the back of the high
pressure pump. The fuel temperature sensor is a negative thermal coefficient type sensor which measures the fuel temperature in the low
pressure circuit. Should the fuel temperature sensor fail the cold running characteristic will be affected.
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Puma - Electronic Engine Controls
Overview
This section covers the components of the engine management system.
The changes to the engine management for this model year include the addition of a diesel particulate filter system, and this section
includes information on the diagnosis and testing of this system and links to sections dealing specifically with particulate filter checks.
For additional information on the description and operation of the engine management system:
For additional information on the description and operation of the diesel particulate filter system:
REFER to: Exhaust System (309-00 Exhaust System, Description and Operation).
Visual inspection
Engine oil level
Fuel level/contamination
Fuel leaks
Fuel pumps
Intake air system
Accessory drive belt
Sensor fitment/condition
Diesel particulate filter (DPF)
Fuses
Wiring harness
Injectors
Glow plugs
5 volt sensor supply
Sensor(s)
step.
3.
4.
Symptom Chart
Symptom
(general)
Symptom
Non-Start Engine does
not crank
Security system
Starter relay fault
(ECM) relay fault
Park/Neutral switch
fault
Engine seized
Make sure that the immobilizer system is disarmed. Check the battery condition
and state of charge. Check that the engine turns by hand. Check the starting
system and circuits. Refer to the electrical guides. Check for DTCs indicating an
ECM relay or park/neutral switch fault. Rectify as necessary.
Engine cranks,
but does not
start
Security system
Air ingress
Blocked air cleaner
Blocked fuel filter
fault
Fuel metering valve
Injector(s)
fault/programming
(IAT) sensor fault
fault
fault
Camshaft position
(CMP) sensor fault
Crankshaft position
(CKP) sensor fault
Cylinder head
temperature (CHT)
sensor fault
Fuel pump fault
Low compression
Valve train fault
Blocked catalyst
Make sure that the immobilizer system is disarmed. Check the fuel level and
condition. Draw off approximately 1 ltr (2.11 pints) of fuel and allow to stand for
1 minute. Check to make sure there is no separation of the fuel indicating water
or other liquid in the fuel. Check the low-pressure fuel system for leaks/damage,
check for air ingress. Check the air cleaner element. Check that fuel flows
through the fuel filter. Check for DTCs indicating a fuel metering valve or
injector fault. Check for DTCs indicating an engine management sensor fault.
Check the valve train, check the compressions,
Testing).
(DPF)DTCs. Refer to the warranty policy and procedures manual if an ECM is
suspect.
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Symptom
(general)
Symptom
(ECM) fault
Difficult to
start
Difficult to
start cold
fault
Contaminated fuel
Air ingress
Blocked air cleaner
Blocked fuel filter
fault
Fuel metering valve
fault
(IAT) sensor fault
Cylinder head
temperature (CHT)
sensor fault
Camshaft position
(CMP) sensor fault
Crankshaft position
(CKP) sensor fault
Injector(s)
fault/programming
Pump fault
Blocked catalyst
Valve train fault
Low compression
Check the glow plugs and circuits. Refer to the electrical guides. Check the fuel
level and condition. Draw off approximately 1 ltr (2.11 pints) of fuel and allow
to stand for 1 minute. Check to make sure there is no separation of the fuel
indicating water or other liquid in the fuel. Check the low-pressure fuel system
for leaks/damage, check for air ingress. Check the air cleaner element. Check
that fuel flows through the fuel filter. Check for DTCs indicating a fuel metering
valve or injector fault. Check for DTCs indicating an engine management sensor
fault. Check the valve train, check the compressions,
Testing).
DTCs.
Difficult to
start hot
Contaminated fuel
Air ingress
Blocked air cleaner
Blocked fuel filter
fault
Fuel metering valve
Exhaust gas
fault
fault
(IAT) sensor fault
Camshaft position
(CMP) sensor fault
Crankshaft position
(CKP) sensor fault
Injector(s)
fault/programming
Pump fault
Blocked catalyst
Valve train fault
Low compression
fuel system for leaks/damage, check for air ingress. Check the air cleaner
element. Check that fuel flows through the fuel filter. Check for DTCs indicating
a fuel metering valve or injector fault. Check for DTCs indicating an engine
management sensor fault. Check the valve train, check the compressions,
Testing).
DTCs.
Engine cranks
too fast/slow
Low compression
Check the battery condition and state of charge. Check the starting system
circuits. Refer to the electrical guides. Rectify as necessary. Check the
compressions,
Testing).
Driveability Rough idle Low/Contaminated fuel
Air ingress
Injector(s)
fault/programming
Fuel metering valve
Exhaust gas
fault
Blocked air cleaner
Blocked fuel filter
Pump fault
Crankshaft position
(CKP) sensor fault
(IAT) sensor fault
Manifold absolute
fault
Knock sensor fault
Dual-mass flywheel
fault
fuel system for leaks/damage, check for air ingress. Check for DTCs indicating
an injector programming or EGR fault. Check the air cleaner element. Check that
fuel flows through the fuel filter. Check for DTCs indicating a fuel metering valve
fault. Check for DTCs indicating an engine management sensor fault. Check the
dual-mass flywheel.
Idle speed
high or low
Accelerator pedal
fault
(IAT) sensor fault
Check for DTCs indicating an APP or IAT sensor fault. Rectify as necessary.
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Symptom
(general)
Symptom
Engine speed
out of control
Excessive blow-by
Accelerator pedal
fault
Turbocharger
bearing/seal failure
Check/correct the engine oil level. Check the engine condition. Check for DTCs
indicating an APP sensor fault. Rectify as necessary. Check the turbocharger
normal.
Lack of power
when
accelerating
Contaminated fuel
Low fuel pressure
Exhaust gas
fault
Fuel filter blocked
Fuel lines
kinked/restricted
Pump fault
Injector(s)
fault/programming
Vehicle speed sensor
fault
Cylinder head
temperature (CHT)
sensor fault
(IAT) sensor fault
Manifold absolute
fault
Accelerator pedal
fault
Fuel rail temperature
(FRT) sensor fault
sensor fault
Fuel metering valve
fault
Turbocharger fault
Catalyst blocked
Valve timing fault
Low compression
indicating an EGR fault. Check for DTCs indicating an engine management
sensor or injector programming fault. Check the turbocharger condition and
operation. Check the catalytic converter condition. Rectify as necessary. For
valve timing and compression information,
Testing).
Engine
stops/stalls
Air cleaner element
blocked
Fuel metering valve
Pump fault
High-pressure leak
fault (air ingress)
Relay fault
Crankshaft position
(CKP) sensor fault
Camshaft position
(CMP) sensor fault
Cylinder head
temperature (CHT)
sensor fault
sensor fault
Dual-mass flywheel
fault
(ECM) fault
indicating a relay, engine management sensor or ECM fault. Check the
dual-mass flywheel. Refer to the warranty policy and procedures manual if an
ECM is suspect.
Engine judders Low/Contaminated fuel
Fuel metering valve
High-pressure leak
fault (air ingress)
Pump fault
Exhaust gas
fault
Accelerator pedal
fault
Cylinder head
temperature (CHT)
sensor fault
Camshaft position
(CMP) sensor fault
Crankshaft position
(CKP) sensor fault
(IAT) sensor fault
indicating an engine management sensor or injector programming fault. Check
the catalytic converter and turbocharger condition. Rectify as necessary. Check
the dual-mass flywheel. For cylinder head, compression and camshaft
information,
Testing).
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Symptom
(general)
Symptom
Manifold absolute
fault
Knock sensor fault
sensor fault
Injector(s)
fault/programming
Catalyst blocked
Turbocharger fault
Dual-mass flywheel
fault
Cylinder head gasket
fault
Camshafts/Valve
clearances
Low compression
Engine will not
stop
Turbocharger fault
(ECM) fault
Check/correct the engine oil level. Check the turbocharger condition and
operation. Check for DTCs indicating an ECM fault. Refer to the warranty policy
General Excessive fuel
consumption
Incorrect engine oil
fault (air ingress/leaks)
Fuel metering
valve/circuit
High-pressure leak
Exhaust gas
fault
Injector(s)
fault/programming
Cylinder head
temperature (CHT)
sensor fault
(IAT) sensor fault
Manifold absolute
fault
Turbocharger fault
Dual-mass flywheel
fault
Valve timing fault
Low compression
Make sure that the correct grade of oil is used in the engine. Check the air
intake and low-pressure circuits. Check for DTCs indicating an EGR, injector
condition and operation. Check the dual-mass flywheel. For valve timing and
compression information,
Testing).
Excessive
black smoke
Exhaust gas
fault
Injector(s)
fault/programming
Accelerator pedal
fault
Crankshaft position
(CKP) sensor fault
Knock sensor fault
sensor fault
Turbocharger
bearings/seals fault
Valve timing fault
Check the air intake circuit. Check for DTCs indicating an EGR, injector
normal. For valve timing information,
Testing).
DTC index
B1864Battery power supply Engine control module
(ECM) power supply
circuit fault
Check the ECM power and ground circuits. Refer to the electrical
guides. Rectify as necessary. Clear the DTCs and check for normal
operation.
B2139Engine control module (ECM)
ID does not match
Data mismatch between
ECM and passive
anti-theft system (PATS)
Check the configuration of the ECM and anti-theft system.
Reconfigure as necessary using the approved diagnostic system.
C1137Anti-lock brake system (ABS)
control module fault
ABS control module
internal fault, random
access memory, read only
memory
Refer to the warranty policy and procedures manual if a module is
suspect.
C1145Right-hand front wheel speed
sensor input circuit fault
Wheel speed sensor
input circuit: high
resistance
Wheel speed sensor
input circuit: short circuit
to ground
Check the wheel speed sensor and circuits. Refer to the electrical
guides. If no fault is found in the circuits, install a new sensor.
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Wheel speed sensor
to power
C1155Left-hand front wheel speed
Wheel speed sensor
input circuit: high
resistance
Wheel speed sensor
to ground
Wheel speed sensor
to power
C1165Right-hand rear wheel speed
Wheel speed sensor
input circuit: high
resistance
Wheel speed sensor
to ground
Wheel speed sensor
to power
C1175Left-hand rear wheel speed
Wheel speed sensor
input circuit: high
resistance
Wheel speed sensor
to ground
Wheel speed sensor
to power
P0070 Ambient air temperature (AAT)
sensor circuit malfunction
AAT sensor circuit: high
resistance
AAT sensor circuit: short
circuit to ground
AAT sensor circuit: short
circuit to power
AAT sensor fault
Refer to the approved diagnostic system for a guided diagnostic
routine. Check the ambient air temperature sensor and circuits.
Refer to the electrical guides. If no fault is found in the circuits,
install a new sensor. Clear the DTCs, test for normal operation.
P0100 Mass air flow (MAF) sensor
circuit malfunction
MAF sensor circuit: high
resistance
MAF sensor circuit: short
circuit to ground
MAF sensor circuit: short
circuit to signal return
MAF sensor fault
routine. Check the MAF sensor and circuits. Refer to the electrical
REFER to: Mass Air Flow (MAF) Sensor (303-14B Electronic Engine
Controls - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) -
Clear the DTCs, test for normal operation.
P0105 Manifold absolute pressure
temperature (MAPT) sensor
circuit malfunction
MAPT sensor circuit: high
resistance
MAPT sensor circuit:
short circuit to power
MAPT sensor fault
routine. This DTC can be set as a result of other codes. If P1665 is
also set, investigate this first. Check the MAPT sensor and circuits.
install a new sensor. Clear the DTCs, test for normal operation.
P0110 Intake air temperature (IAT)
sensor circuit malfunction (the
intake air temperature sensor
is part of the manifold
absolute pressure and
temperature (MAPT) sensor)
IAT sensor circuit: high
resistance
IAT sensor circuit: short
circuit to ground
IAT sensor circuit: short
circuit to signal return
MAPT sensor fault
routine. Check the MAPT sensor and circuits. Refer to the electrical
REFER to: Manifold Absolute Pressure and Temperature (MAPT)
Sensor (303-14B Electronic Engine Controls - 2.0L Duratorq-
TDCi/2.2L Duratorq-TDCi (110kW/150PS) - Puma, Removal and
Installation).
P0121 Accelerator pedal position
(APP) sensor circuit A
range/performance
APP sensor circuit A: high
resistance
APP sensor circuit A:
APP sensor circuit A:
short circuit to signal
return
APP sensor fault
Check the APP sensor and circuits. Refer to the electrical guides. If
no fault is found in the circuits, install a new sensor.
REFER to: Accelerator Pedal (310-02 Acceleration Control, Removal
and Installation).
P0180 Fuel temperature sensor A
range malfunction
circuit: high resistance
Fuel temperature sensor:
faulty connection
fault
Check the fuel temperature sensor and circuits. Refer to the
electrical guides. If no fault is found in the circuits, install a new
sensor.
REFER to: Fuel Temperature Sensor (303-14B Electronic Engine
Controls - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) -
P0190 Fuel pressure sensor A circuit Fuel pressure sensor
Fuel pressure sensor:
faulty connection
fault
routine. Check the fuel pressure sensor and circuits. Refer to the
fuel injection supply manifold (the pressure sensor cannot be
serviced separately).
REFER to: Fuel Injection Supply Manifold (303-04B Fuel Charging
and Controls - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi
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P0191 Fuel pressure sensor A circuit
range/performance
Pump deterioration
- Contaminated fuel
Leaking fuel rail
circuit fault
fault
Check for contaminated fuel. Draw off approximately 1 litre (2.11
pints) of fuel into a clear container and allow to settle for 1 minute.
Examine the fuel for separation indicating contamination. Check the
fuel rail for leaks, etc. Check the fuel pressure sensor and circuits.
install a new fuel injection supply manifold (the pressure sensor
cannot be serviced separately).
REFER to: Fuel Injection Supply Manifold (303-04B Fuel Charging
and Controls - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi
P0200 Injector circuit fault Blocked, kinked or
crushed fuel return lines
Injector supply circuit:
Injector supply circuit:
Injector resistance
correction invalid
(ECM) fault
Check the fuel return lines for damage, etc. Check the injector
circuits. Refer to the electrical guides. Rectify as necessary. Clear
the DTCs, test for normal operation. Refer to the warranty policy
P0201 Injector circuit open, cylinder 1 Injector 1 circuit: short
circuit to ground
Injector 1 circuit: short
circuit to power
Injector 1 circuit: high
resistance
Injector failure
Check the injector circuits. Refer to the electrical guides. Rectify as
necessary. If no fault is found in the circuits, install a new injector.
REFER to: Fuel Injector (303-04B Fuel Charging and Controls - 2.0L
and Installation).
P0202 Injector 4 (cylinder 2) circuit
malfunction
circuit to ground
circuit to power
resistance
Injector failure
malfunction
circuit to ground
circuit to power
resistance
Injector failure
malfunction
circuit to ground
circuit to power
resistance
Injector failure
(APP) sensor circuit B
range/performance
APP sensor circuit B: high
resistance
APP sensor circuit B:
APP sensor circuit B:
return
APP sensor fault
Check the APP sensor and circuits. Refer to the electrical guides. If
no fault is found in the circuits, install a new sensor.
and Installation).
(APP) sensor circuit C
range/performance
APP sensor circuit C: high
resistance
APP sensor circuit C:
APP sensor circuit C:
return
APP sensor fault
routine. Check the APP sensor and circuits. Refer to the electrical
and Installation).
P0234 Turbocharger over boost
condition
Excessive boost,
detected by manifold
absolute pressure and
temperature (MAPT)
sensor
Check the turbocharger operation, check for sticking turbocharger
vanes, etc. Clear the DTCs, test for normal operation.
P0235 Turbocharger boost sensor A
circuit
Manifold absolute
pressure and temperature
(MAPT) sensor vacuum
hose fault
MAPT sensor circuit: open
circuit
MAPT sensor circuit: high
resistance
short circuit to another
Using the manufacturer approved diagnostic system perform the
(Turbo, exhaust gas recirculation and air path dynamic test)
routine. Refer to the electrical circuit diagrams and check manifold
absolute pressure and temperature sensor circuit - DL1-108 - for
short circuit to ground, short circuit to power, open circuit, high
resistance, short circuit to another circuit. For further diagnostic
information
REFER to: Turbocharger (303-04C Fuel Charging and Controls -
Turbocharger, Diagnosis and Testing).
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circuit (signal return)
MAPT sensor fault
P0243 Turbocharger actuator A circuit Turbocharger actuator
fault
routine. Check the turbocharger actuator and circuits. Refer to the
turbocharger.
Turbocharger, Removal and Installation).
P0251 Injection pump fuel metering
control valve
Contaminated fuel
Air ingress
Pump fault
Excessive injector
leakage
Swarf in system
Inlet metering valve fault
low-pressure fuel system for air ingress, check the fuel pump for
evidence of swarf, etc. Check for injector leakage and DTCs
indicating an inlet metering valve fault.
P0263 Injector 1 (cylinder 1)
contribution/balance
Injector fault Carry out the injector leakage procedure. Rectify as necessary. Clear
the DTCs, test for normal operation.
Injector fault
Injector fault
Injector fault
P0325 Knock sensor (KS) signal
invalid
KS circuit fault Check the KS and circuits. Refer to the electrical guides. Rectify as
necessary. Clear the DTCs, test for normal operation.
P0335 Crankshaft position (CKP)
sensor
Teeth missing from the
crank input, indicating
poor output from the
crankshaft reference
sensor
Extra crank teeth seen,
indicating the presence
of noise
No crank events have
been detected within a
calibratable time (when
events have previously
been detected)
The gap in the flywheel
tooth pattern has not
been seen where
expected, indicating the
presence of noise
CKP sensor circuit fault
Check the CKP sensor fitment and condition. Check the CKP sensor
and circuits. Refer to the electrical guides. Clear the DTCs, test for
normal operation.
P0340 Camshaft position (CMP)
sensor
CMP sensor circuit: high
resistance
CMP sensor circuit: short
circuit to ground
CMP sensor fault
routine. Check the CMP sensor and circuits. Refer to the electrical
guides. Clear the DTCs, test for normal operation.
P0380 Glow plug control circuit Glow plug control circuit:
high resistance
Glow plug control circuit:
Glow plug control circuit:
Glow plug relay fault
routine. Check the glow plug circuits. Refer to the electrical guides.
Activate the glow plug relay and listen for an audible "click". Install
a new relay as necessary. Clear the DTCs, test for normal operation.
P0401 Exhaust gas recirculation (EGR)
insufficient flow detected
Damaged, blocked or
leaking pipes
Disconnected hose
between the air intake
(after the mass air flow
sensor) and the
turbocharger inlet
EGR valve stuck closed
- If P0405 is also set
routine. Check the intake air path hoses and pipework. Rectify as
necessary. If P0405 is also set, check the EGR valve and rectify as
necessary.
excessive flow detected
EGR valve stuck open Using the manufacturer approved diagnostic system perform the
routine
valve control circuit
malfunction
EGR valve connector fault
EGR valve to engine
control module (ECM)
EGR valve to ECM circuit:
open circuit
routine. Note that this code does not indicate a fault in the EGR
valve nor the engine control module (ECM), but possibly in the
connectors to these components. Check the connectors and circuits.
Refer to the electrical guides. Also note that the EGR system will
often set groups of codes rather than a single code. Check out
P0403 first. Refer to the electrical circuit diagrams and check
exhaust gas recirculation (EGR) valve control circuit - DL1-116 - and
- DL1-119 - for short circuit to ground, short circuit to power, open
valve control circuit
range/performance
Excessive soot build-up
on the EGR valve seat
routine. Refer to the electrical circuit diagrams and check exhaust
gas recirculation (EGR) valve control circuit - DL1-008 - , - DL1-116 -
and - DL1-119 - for short circuit to ground, short circuit to power,
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open circuit, high resistance. For further diagnostic information
sensor A circuit low
EGR valve stuck closed
Check for P0401 if this code is logged suspect an exhaust gas
recirculation (EGR) valve internal fault. Using the manufacturer
approved diagnostic system perform the (Turbo, exhaust gas
recirculation and air path dynamic test) routine. Refer to the
electrical circuit diagrams and check exhaust gas recirculation (EGR)
valve sensor circuit - DL1-008 - for short circuit to ground
sensor A circuit high
EGR valve stuck open
Check for P0402 if this code is logged suspect an exhaust gas
recirculation (EGR) valve internal fault. Using the manufacturer
approved diagnostic system perform the (Turbo, exhaust gas
recirculation and air path dynamic test) routine. Refer to the
electrical circuit diagrams and check exhaust gas recirculation (EGR)
valve sensor circuit - DL1-008 - for short circuit to power
sensor A circuit
ECM internal fault
EGR valve to engine
open circuit
Check the EGR valve connections and circuits first. Rectify as
necessary. Using the manufacturer approved diagnostic system
perform the (Turbo, exhaust gas recirculation and air path
dynamic test) routine. Refer to the electrical circuit diagrams and
check exhaust gas recirculation (EGR) valve sensor circuit - DL1-008
- for short circuit to ground, short circuit to power, open circuit, high
resistance
P0480 Fan 1 control circuit Fan control module
Fan control module
circuit: short circuit to
ground
Fan control module
power
Fan motor circuit: high
resistance
Fan motor circuit: short
circuit to ground
Fan motor circuit: short
circuit to power
routine. Check the fan circuits. Refer to the electrical guides. Rectify
as necessary. Clear the DTCs, test for normal operation.
P0481 Fan 2 control circuit High fan control primary
circuit
routine. Check the fan circuits. Refer to the electrical guides. Rectify
P0485 Fan power/ground circuit Fan control module
Fan control module
ground
Fan control module
power
Check the fan circuits. Refer to the electrical guides. Rectify as
sensor B circuit
EGR valve to engine
open circuit
check exhaust gas recirculation throttle position sensor circuit -
DL1-036 - for short circuit to ground, short circuit to power, open
throttle position control circuit
EGR circuit: high
resistance
EGR circuit: short circuit
to ground
routine. Check the EGR valve connections and circuits first. Refer to
the electrical guides. Rectify as necessary. Clear the DTCs, test for
normal operation.
throttle position control
range/performance
EGR valve to engine
open circuit
check exhaust gas recirculation (EGR) valve sensor circuit - DL1-096
- for short circuit to ground, short circuit to power, open circuit, high
resistance
P0500 Vehicle speed sensor A The engine control
module (ECM) cannot
determine the vehicle
speed from the anti-lock
brake system (ABS) or
transmission
Check for DTCs indicating a fault in the ABS or transmission. Rectify
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P0530 Air conditioning refrigerant
pressure sensor circuit
Air conditioning pressure
sensor circuit: high
resistance
sensor circuit: short
circuit to ground
circuit short circuit to
power
sensor fault
Check the air conditioning refrigerant pressure sensor and circuits.
Refer to the electrical guides. Rectify as necessary. Clear the DTCs,
test for normal operation.
P0544 Exhaust gas temperature
sensor circuit, right-hand bank,
upstream sensor
Exhaust gas temperature
circuit to ground
sensor circuit: open
circuit
circuit to power
sensor fault
routine. Check the exhaust gas temperature sensor and circuits.
sensor circuit low, right-hand
bank, upstream sensor
circuit to ground
circuit
sensor fault
sensor circuit high, right-hand
bank, upstream sensor
circuit to power
sensor fault
P0560 System voltage - range failure
of the battery voltage input
Battery voltage high or
low
Check the battery condition and state of charge. Check the charging
system. Rectify as necessary. Clear the DTCs, test for normal
operation.
P0571 Speed control brake switch
circuit failure
Speed control brake
switch circuit: high
resistance
Speed control brake
switch circuit: short
circuit to ground
Speed control brake
switch circuit: short
circuit to power
Speed control brake
switch failure
Check the speed control brake switch and circuits. Refer to the
electrical guides. Rectify as necessary. Clear the DTCs, test for
normal operation.
P0575 Speed control input circuit Speed control steering
wheel switch circuit: high
resistance
Speed control steering
wheel switch circuit:
Speed control steering
wheel switch circuit:
Clockspring failure
Check the speed control steering wheel switch and circuits. Refer to
the electrical guides. Rectify as necessary. Clear the DTCs, test for
normal operation.
P0603 Engine control module (ECM)
keep-alive memory error
ECM power supply circuit
fault
ECM fault
Check the power supplies to the ECM. Refer to the electrical guides.
Rectify as necessary. Clear the DTCs, test for normal operation.
read-only-memory (ROM) error
ECM flash memory error
- Internal ECM fault
Refer to the warranty policy and procedures manual if an ECM is
suspect
P060B Internal control module
analogue to digital processing
performance
Failure of the analogue
to digital converter
- Internal ECM fault
suspect
P0611 Fuel injector control module
performance
Fuel injectors have not
been programmed
Fuel injector
programming is corrupt
and the injectors have
reset to their default
values
Programme the injectors using the approved diagnostic system.
P0622 Generator field terminal circuit Generator monitor circuit:
high resistance
Generator monitor circuit:
Generator monitor circuit:
Generator regulator fault
Check the generator and circuits. Refer to the electrical guides.
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(ECM) fault
P0623 Generator warning lamp circuit Warning lamp failure
Warning lamp circuit:
high resistance
Check the generator and circuits. Refer to the electrical guides.
P0641 Sensor reference voltage A
circuit
This code indicates an
internal engine control
module (ECM) fault
suspect
P0645 Air conditioning (A/C) clutch
relay control circuit
A/C clutch relay control
ground
power
A/C clutch relay
Check the A/C clutch and circuits. Refer to the electrical guides.
Check the operation of the air conditioning clutch relay. Rectify as
P0648 Immobilizer lamp control circuit Immobilizer lamp control
Immobilizer lamp control
ground
Immobilizer lamp control
power
Lamp failure
Check the immobilizer lamp and circuits. Refer to the electrical
guides. Rectify as necessary. Clear the DTCs, test for normal
operation.
main relay control circuit open
Poor battery connections
at the battery or engine
block
ECM relay control circuit:
high resistance
ECM relay fault
Check the connections at the battery and engine block. Check the
relay and circuits. Refer to the electrical guides. Rectify as
P0700 Transmission control system
(MIL Request)
TCM reports unspecified
error to ECM and
requests MIL illumination
Check the TCM for DTCs. Clear the DTCs, test for normal operation.
P1000 Not all diagnostic monitors
have run
One or more on-board
diagnostic routines have
not completed
This code does not indicate a fault, just that additional drive cycles
are required.
P1200 Injector Range/Performance Injector fault This DTC would be accompanied by the code P2336, P2337, P2338
or P2339 indicating which injector is faulty. Install a new injector(s)
as necessary.
REFER to: Fuel Injector (303-04B Fuel Charging and Controls - 2.0L
and Installation).
P1211 Injector control pressure
higher/lower than desired with
the engine running/fuel system
contamination
Contaminated fuel
Air ingress
High-pressure injector
leak
Fuel pressure
sensor/circuit fault
Fuel metering
valve/circuit fault
Fuel pump fault
low-pressure fuel system for air ingress. Check for evidence of a
high-pressure fuel leak. Rectify as necessary. Check the fuel
pressure sensor, metering valve and circuits. Refer to the electrical
guides. Check for DTCs indicating a pump fault.
P1288 Cylinder head temperature
(CHT) sensor out of selftest
range
Coolant
low/contaminated
Poor thermostat
operation
CHT sensor circuit fault
CHT sensor fault
Check the coolant level and condition, check the thermostat
operation. Rectify as necessary. Check the CHT sensor and circuits.
Refer to the electrical guides. Clear the DTCs, test for normal
operation.
P132A Turbocharger boost system
performance
fault
Carry out visual inspection of the rotary electronic actuator arm
during ignition state on/off. Ignition on actuator will retract under
smooth operation to a set position. Ignition off actuator will retract
to the fully open position. If this is not observed inspect the turbo
charger rotary electronic actuator arm for corrosion and check for
ease of vane movement. Using the manufacturer approved
diagnostic system perform the (Turbo, exhaust gas recirculation
and air path dynamic test) routine. For further diagnostic
information
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P132B Turbocharger boost system
performance
Memory check failure
during initialization
Turbocharger vanes
sticking
Turbocharger rotary
electronic actuator
internal failure
Carry out visual inspection of the rotary electronic actuator arm
during ignition state on/off. Ignition on actuator will retract under
smooth operation to a set position. Ignition off actuator will retract
to the fully open position. If this is not observed inspect the turbo
charger rotary electronic actuator arm for corrosion and check for
ease of vane movement. Clear the DTCs cycle the ignition and
recheck. If the DTCs are still present after 3 attempts, check the
turbocharger vanes for deposit build-up, a foreign body or damage
to the compressor/turbine wheels/housing as mechanism may be
sticking. For further diagnostic information
P132C Turbocharger boost system
voltage
Battery voltage out of
range
routine. Check the battery condition and state of charge. Check the
turbocharger circuits. Refer to the electrical guides. Rectify as
P138DTurbocharger boost system
temperature too high
Engine overheating as a
result of exhaust gas
leakage
Carbon deposits on the
exhaust manifold
fault
routine. Check the exhaust manifold for leakage/carbon deposits.
Clear the DTCs, test for normal operation. If the fault persists,
install a new turbocharger.
Turbocharger, Removal and Installation).
P1403 Differential pressure feedback
sensor hoses reversed
DPF pressure sensor
(delta pressure sensor)
crossed hose fault
Check the correct connection of the hoses to the DPF pressure
sensor. Rectify as necessary. Clear the DTCs, test for normal
operation.
P1543 Engine coolant heater A control
circuit
Engine coolant heater A
control circuit: high
resistance
routine. Check the coolant heater and circuits. Refer to the electrical
operation.
P1544 Engine coolant heater B control
circuit
Engine coolant heater B
control circuit: high
resistance
routine. Check the coolant heater and circuits. Refer to the electrical
operation.
P1576 Pedal position not available
(accelerator pedal position
(APP) sensor failed on more
than one track)
APP sensor circuit fault
APP sensor fault
routine. Check the APP sensor and circuits. Refer to the electrical
operation.
P1582 Electronic throttle monitor data
available
Inertia switch tripped Check the inertia switch status and circuits. Refer to the electrical
operation.
internal voltage reference
Internal ECM fault Refer to the approved diagnostic system for a guided diagnostic
routine. Refer to the warranty policy and procedures manual if an
ECM is suspect.
P1632 Smart generator output circuit Generator circuit: high
resistance
Generator circuit: short
circuit to ground
Generator circuit: short
circuit to power
Generator regulator fault
routine. Check the generator and circuits. Refer to the electrical
operation.
P1635 Tire/Axle ratio out of
acceptable range
The tire size stored in
the vehicle identification
(VID) block is out of
range
Check that the tires fitted to the vehicle are of the correct
specification. Rectify as necessary.
P1643 CAN link engine control
module/transmission control
module circuit/network
CAN H open circuit failure
between ECM and TCM
CAN L open circuit failure
between ECM and TCM
Check the CAN circuits between the engine control module (ECM)
and the TCM. Rectify as necessary. Clear the DTCs, test for normal
operation.
P1676 Injector Data Incompatible Injector corrections
download failed
Re-enter the injector codes using the approved diagnostic system.
P1700 Transmission indeterminate
failure (failed to neutral)
TCM has identified a
failure, the ECM is
required to record this
failure
Check the TCM for DTCs. Clear the DTCs, test for normal operation.
P179A Controller area network (CAN)
link, turbocharger boost control
system
CAN feedback messages
not received
Using the manufacturer approved diagnostic system, complete a
CAN network integrity test. Carry out visual inspection of the rotary
electronic actuator arm during ignition state on/off. Ignition on
actuator will retract under smooth operation to a set position.
Ignition off actuator will retract to the fully open position. If this is
not observed inspect the turbo charger rotary electronic actuator
arm for corrosion and check for ease of vane movement. Using the
manufacturer approved diagnostic system perform the (Turbo,
exhaust gas recirculation and air path dynamic test) routine. For
further diagnostic information
P1816 Transmission Neutral Safety
Switch Circuit Failure
Start lock switch
plausibility failure
Start lock STLK circuit:
open circuit
short to ground
Check the Start lock switch and circuits. Refer to the electrical
operation. Refer to the warranty policy and procedures manual if an
ECM / TCM is suspect
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short to power
Failure of ECM
Failure of TCM
P1937 Fuel fired heater (FFH) control
circuit
FFH supply or ground
circuit fault
FFH control circuit: high
resistance
FFH control circuit: short
circuit to ground
FFH control circuit: short
circuit to power
FFH control module fault
routine. Check the FFH and circuits. Refer to the electrical guides.
P2031 Right-hand bank exhaust gas
temperature sensor circuit,
sensor 2
circuit to ground
circuit
circuit to power
sensor fault
temperature sensor circuit low,
sensor 2
circuit to ground
sensor fault
temperature sensor circuit
high, sensor 2
circuit to power
sensor fault
range/performance, sensor 1
circuit to ground
circuit
circuit to power
sensor fault
intermittent, sensor 1
sensor circuit:
intermittent high
resistance
sensor fault
sensor circuit:
intermittent high
resistance
sensor fault
P2288 Injector control pressure too
high
Fuel contaminated
ground
power
Examine the fuel for separation indicating contamination. Rectify as
necessary. Check the fuel pressure sensor and circuits. Refer to the
electrical guides. Rectify as necessary. Clear the DTCs, test for
normal operation.
P2291 Injector control pressure too
low - engine cranking
Low fuel level
Blocked, kinked or
crushed fuel lines
circuit fault
Injector leaking
Fuel pump fault
(ECM) fault
Check the fuel level. Check the fuel lines for damage, etc. Rectify as
necessary. Check the fuel pressure sensor and circuits. Refer to the
electrical guides. Check for DTCs indicating an inlet metering valve,
injector or pump fault. Rectify as necessary. Clear the DTCs, test for
normal operation. Refer to the warranty policy and procedures
manual if an ECM is suspect.
P2336 Cylinder 1 above knock
threshold - knock sensor trim
for cylinder 1 invalid
Natural wear of the
injector
Fuel contaminated
Blocked or dirty fuel
injector(s)
Injector circuit fault
Injector fault
Re-enter the injector codes using the approved diagnostic system.
If after reprogramming and clearing the DTCs the DTC reoccurs,
check for contaminated fuel. Draw off approximately 1 litre (2.11
Examine the fuel for separation indicating contamination. Rectify as
necessary. Carry out the cylinder balance check. Check the injector
circuits. Refer to the electrical guides. Rectify as necessary. Clear
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the DTCs, test for normal operation. P2337 Cylinder 2 above knock
for cylinder 2 (injector 4)
invalid
Natural wear of the
injector
Fuel contaminated
injector(s)
Injector fault
invalid
Natural wear of the
injector
Fuel contaminated
injector(s)
Injector fault
invalid
Natural wear of the
injector
Fuel contaminated
injector(s)
Injector fault
P242F Diesel particulate filter (DPF)
restriction - ash accumulation
DPF blocked Install a new DPF as necessary.
REFER to: Diesel Particulate Filter (DPF) (309-00 Exhaust System,
P244A Diesel particulate filter (DPF)
differential pressure too low
DPF leaking Install a new DPF as necessary.
REFER to: Diesel Particulate Filter (DPF) (309-00 Exhaust System,
P244B Diesel particulate filter (DPF)
differential pressure too high
DPF overloaded Carry out the regeneration procedure. Clear the DTCs, test for
normal operation.
P244C Exhaust temperature too low
for particulate filter
regeneration
Insufficient
mileage/speed for
regeneration
Carry out the regeneration procedure. Clear the DTCs, test for
normal operation.
P2452 Diesel particulate filter (DPF)
pressure sensor A circuit
DPF pressure sensor
circuit fault
DPF pressure sensor
(delta pressure
sensor)fault
Check the DPF pressure sensor (delta pressure sensor)and circuits.
Refer to the electrical guides. Rectify as necessary.
P2453 Diesel particulate filter (DPF)
pressure sensor A circuit
range/performance
DPF pressure sensor
hose fault
DPF pressure sensor
(delta pressure
sensor)fault
routine. Check the condition and fitment of the DPF pressure sensor
(delta pressure sensor) and hoses. Rectify as necessary.
P2623 Injector control pressure
regulator open
Inlet metering valve
circuit fault
Check the inlet metering valve and circuits. Refer to the electrical
operation.
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Puma - Camshaft Position (CMP) Sensor
Removal
3. Remove the camshaft position (CMP) sensor.
Installation
Tighten to 9 Nm.
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Puma - Catalytic Converter Temperature Sensor
Special Tool(s)
Exhaust gas temperature sensor wrench
303-1184
Removal
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4. Remove the turbocharger heatshield.
5. Disconnect the catalytic converter temperature sensor electrical
connector.
6. Remove the catalytic converter temperature sensor.
Installation
1. CAUTION: Make sure the torque wrench setting procedure is
followed correctly. Failure to follow this instruction may result in damage
to the vehicle.
Calculate the setting for the torque wrench.
Stage 1: Multiply the required torque by the effective length of the
torque wrench (1).
Stage 2: Add the effective length of the special tool (2) to the
effective length of the torque wrench.
Stage 3: Divide the total of stage 1 by the total of stage 2.
Stage 4: Set the torque wrench to the figure arrived at in stage 3.
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2. CAUTION: Make sure the torque wrench setting procedure is
followed correctly. Failure to follow this instruction may result in damage
to the vehicle.
Install the catalytic converter temperature sensor.
Tighten to 35 Nm.
3. Connect the catalytic converter temperature sensor electrical connector.
4. Install the turbocharger heatshield.
Tighten to 9 Nm.
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Puma - Crankshaft Position (CKP) Sensor
Removal
2. Remove and discard the crankshaft position (CKP) sensor.
Installation
1. NOTE: Only turn the engine in the normal direction of rotation
Turn the engine until a flywheel trigger tooth is visible through the CKP
sensor housing.
2. CAUTION: The CKP sensor tip must rest on a flywheel trigger
tooth. Incorrect installation may result in the CKP sensor being damaged.
NOTE: Make sure that the CKP sensor housing is clean and free from
foreign material.
Install the CKP sensor.
Tighten to 7 Nm.
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3. Connect the CKP sensor electrical connector.
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Puma - Cylinder Head Temperature (CHT) Sensor
Special Tool(s)
Socket, CHT Sensor
303-680 (21-239)
Removal
2. Detach the power assisted steering fluid pipe.
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5. Detach the cyclinder head temperature (CHT) sensor electrical
connector.
7. Using the special tool 303-680, remove the CHT sensor.
Installation
Tighten to 10 Nm.
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Puma - Diesel Particulate Filter (DPF) Temperature Sensor
Removal
2. Disconnect the diesel particulate filter (DPF) temperature sensor
3. Remove the DPF temperature sensor.
Installation
Tighten to 35 Nm.
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Puma - Engine Control Module (ECM)
Removal
4. Remove the instrument cluster lower trim panel.
5. Remove the trim panel.
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6. Detach the generic electronic module (GEM) from the ECM.
1. Release the GEM locking tang.
2. Detach the GEM from the ECM.
7. Remove the ECM.
1. Remove the ECM retaining nut.
2. Remove the ECM.
8. Remove the ECM from the ECM retaining bracket.
Installation
Tighten to 10 Nm.
2. CAUTION: Make sure that the electrical connector locates correctly
in the ECM. Do not force or overtighten the electrical connector.
Tighten to 10 Nm.
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Puma - Engine Oil Pressure (EOP) Sensor
Removal
2. Remove the engine undertray.
3. Disconnect the engine oil pressure (EOP) sensor electrical connector.
4. Remove the EOP sensor.
Installation
Tighten to 15 Nm.
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Puma - Fuel Temperature Sensor
Removal
5. Remove the fuel temperature sensor.
Installation
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Tighten to 15 Nm.
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Puma - Knock Sensor (KS)
Removal
5. Remove the fuel pump to fuel injection supply manifold high pressure
pipe retaining bracket.
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7. Remove the knock sensor (KS).
Installation
Tighten to 20 Nm.
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Puma - Manifold Absolute Pressure and Temperature (MAPT) Sensor
Removal
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5. CAUTION: Make sure that the radiator is not damaged when
installing the retaining straps.
Fit suitable retaining straps to the radiator.
9. Remove the radiator support bar.
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11. Remove the charge air cooler hoses and manifold absolute pressure
and temperature (MAPT) sensor assembly.
12. Remove the MAPT sensor.
Installation
Tighten to 4 Nm.
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3. Tighten to 4 Nm.
4. Tighten to 4 Nm.
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Puma - Manifold Absolute Pressure (MAP) Sensor
Removal
4. Disconnect the manifold absolute pressure (MAP) Sensor electrical
connector.
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5. Disconnect the hose.
Detach the retaining clip.
6. Remove the MAP sensor.
Installation
Tighten to 4 Nm.
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Puma - Mass Air Flow (MAF) Sensor
Removal
4. Disconnect the mass air flow sensor electrical connector.
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5. Remove the mass air flow (MAF) sensor.
Installation
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Automatic Transmission/Transaxle - Vehicles With: 5-Speed Automatic Transaxle -
JATCO -
Lubricant, Sealers and Solvents
High-temperature grease ESD-M1C220-A
Sealant WSS-M4G323-A6
Fluid Maintenance
CAUTION: Use only WSS-M2C922-A1 automatic transmission fluid. Use of any other fluids may result in a transmission malfunction or
failure.
Intervals
Normal Maintenance Not necessary. Filled for life.
Severe Duty Maintenance Change the fluid at 48,000 km (30,000 miles) intervals.
Engine Approximate Liters
Refill Capacity
1
U.S. Quarts Fluid Type
2.0l, 2.5L and 3.0L 8.8 8.32 WSS-M2C9 22-A1
1 Approximate dry capacity, includes cooler and tubes. Check the level at normal operating temperature. DO NOT OVERFILL. If it is necessary to add or change fluid, use only fluid which
has been certified by the supplier as meeting the Jaguar Cars Ltd specification shown.
Main control valve body screws 8 - 71
Torque converter access cover retaining bolts 10 - 89
Torque converter retaining bolts 55 41 -
Transaxle retaining bolts 48 35 -
Transaxle dust cover retaining bolt 10 - 89
Solenoid retaining bolt 8 - 71
Transaxle support insulator retaining nut 133 98 -
Transaxle mount bracket retaining bolts 80 59 -
Transmission control module retaining nuts 10 - 89
Transmission fluid drain plug 45 33 -
Transmission fluid level plug 15 11 -
Transmission mount to body retaining bolts 80 59 -
Transmission range sensor retaining bolts 10 - 89
Valve body cover retaining bolts 8 - 71
Starter motor retaining bolts 35 26 -
Starter motor solenoid electrical connector retaining nut 6 - 53
Starter motor electrical connector retaining nut 12 9 -
Wiring harness to camshaft cover retaining stud, retaining nut 6 - 53
Intake manifold support bracket retaining bolts 10 - 89
Air cleaner mount bracket retaining nuts and bolt 6 - 53
Left-hand driveshaft retaining nuts - vehicles with 2.0L and 2.0L diesel engine 25 18 -
Shock absorber and spring assembly securing nuts 25 18 -
Transaxle ground lead 25 18 -
Support bar retaining bolts 25 18 -
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JATCO - Transmission DescriptionVehicles With: 5-Speed Automatic Transaxle - JATCO
Automatic transmission JF506E - Up To 2009MY
The newly developed JF506E automatic transmission has been developed for use by Jaguar. The JF506E is built in Japan by JATCO (Japan
Automatic Transmission Company). The JF506E has 5-speed lock-up which provides smooth and fast operation and employs a Transmission
Control Module (TCM), three speed sensors and nine gear change solenoids to realize finer gear change control which provides excellent
response to changing driving conditions.
Automatic transmission JF506E
JF506E:
J = Japan automatic transmission company
F = front wheel drive
5 = 5 Forward gears
06 = Version number
E = Electronic control
The transmission ID is stamped on the transmission, E.G.: PL002 = 2.0 litre, PL 001 = 2.5 litre and PL 000 = 3.0 litre. This is followed by
the production year and month and a 5 digit serial number 08 XXXXX.
Range Selection
Depending on the vehicle options selected the automatic transmission range selector may have different range positions.
The standard range selector has seven positions: P, R, N, D, 4, 3 and 2.
J-Gate Range Selection
"P"
In the PARK position:
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there is no power flow through the automatic transmission.
the parking pawl locks the output shaft to the case.
the engine may be started.
the ignition key may be removed.
"R"
In the REVERSE position:
the vehicle may be operated in a rearward direction, at a reduced gear ratio.
backup lamps are illuminated.
"N"
In the NEUTRAL position:
there is no power flow through the automatic transmission.
the output shaft is not held and is free to turn.
the engine may be started.
"D"
Drive is the normal position for most forward driving.
The D position provides:
automatic shift 1-5 and 5-1.
apply and release of the torque converter clutch.
maximum fuel economy during normal operation.
engine braking in 5th gear.
"4"
The 4 position provides:
automatic shift 1-4 and 4-1.
apply and release of the torque converter clutch.
engine braking in 4th gear.
"3"
third gear start and hold.
the torque converter clutch may apply and release.
improved traction on slippery roads.
engine braking.
"2"
second gear start and hold.
the torque converter clutch may apply and release.
improved traction on slippery roads.
engine braking.
"S"
The Sport mode switch allows:
the driver to select or de-select the automatic transmission sport mode.
the automatic transmission to operate normally when the sport mode is selected, but under acceleration the gear shift points are
extended to make full use of the engine's power reserves.
the driver to drive the vehicle in the "D" position with full automatic transmission shift or manually shift gears in the "2, 3 and 4"
positions.
Disassembled Views
Transmission disassembled Views
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1 Torque converter
2 Terminal assembly
3 Plate
4 Retaining bolt
5 Inhibitor switch
6 Main control valve body cover
7 Main control valve body
8 Air breather
9 Automatic transmission fluid charging pipe cap.
10 Main control valve body cover retaining bolt
11 Automatic transmission fluid level tube
12 Magnet plug
13 Oil seal
14 O-ring
15 Transmission retaining bolts
16 Differential oil seal
Transmission disassembled Views (continued)
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1 Oil pump
2 Oil strainer
3 Input shaft
4 Differential gear
5 Reduction gear
6 Reduction brake band
7 Sun gear
8 Direct clutch
9 One-way clutch inner race
10 Parking mechanism
11 Band servo
12 Manual shaft
13 Low clutch
14 Internal gear
15 Rear planetary carrier
16 Front planetary carrier
17 Low clutch hub
18 High clutch hub
19 Reverse and high clutch assembly
20 Return spring
21 Side cover
22 2-4 brake
23 Low and reverse brake
24 Parking component
Overview
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1 TCM
2 Anti-lock Braking System (ABS)
4 D/4 switch, (test switch), sports mode switch
5 CAN (including torque down switch)
6 Line pressure solenoid
7 Lock-up solenoid
8 Shift solenoid A
9 Shift solenoid B
10 Shift solenoid C
11 Low clutch timing solenoid
12 Reduction timing solenoid
13 2-4 brake timing solenoid
14 2-4 brake duty solenoid
15 Transmission Fluid Temperature (TFT) sensor
16 Control valve
17 Inhibitor switch
18 Select lever
19 Turbine Shaft Speed (TSS) sensor
20 Intermediate Shaft Speed (ISS) sensor
21 Vehicle Speed (VSS) sensor
22 Engine
23 Torque converter
24 Fluid pump
25 Input shaft
26 Four-speed geartrain
27 Clutch, brake, planetary gear etc
28 Output gear
29 Idler gear
30 Reduction geartrain
31 Parking gear
32 Final gear and differential
33 Transfer case
34 Automatic transmission assembly
The transmission gear changes, oil pressure and lock-up operation are all electronically controlled. The TCM located in the left hand A-pillar
receives electrical signals from sensors indicating vehicle speed and throttle opening. In response to these signals the TCM selects the
appropriate gear and regulates other related conditions.
Actual transmission control changes are made by actuators (solenoids) that respond to input signals received from the TCM. These
solenoids operate in response to electrical signals they regulate the control valve operation. The control valves cause changes in the fluid
flow passages. This results in pressure changes within the transmission.
Transmission Construction
A cross-sectional view of the automatic transmission.
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1 Torque converter
2 Input shaft
3 Output gear
4 Low clutch
5 Low and reverse brake
6 Rear planetary pinion gear
7 Low one-way clutch
8 Rear internal gear
9 Rear sun gear
10 Front sun gear
11 Front internal gear
12 Front planetary pinion gear
13 2-4 brake
14 Reverse clutch
15 High clutch
16 Reduction gear
17 Idler gear
18 Reduction internal gear
19 Reduction planetary pinion gear
20 Reduction sun gear
21 Reduction brake band
22 Reduction one-way clutch
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23 Direct clutch
24 Parking gear
25 Parking pawl
26 Final gear
27 Differential gear
28 Driveshaft
Torque Converter
1 Converter clutch and damper
2 Reactor
3 Turbine damper
4 Impeller
5 Fluid motion
6 Transmission input rotation
7 Input shaft
8 Engine rotation
Torque Converter
The torque converter delivers the engine drive power to the transmission. When the lock-up clutch is released, the power delivery is
depended on automatic transmission fluid (ATF). When the lock-up clutch is engaged the engine power is delivered to the transmission
through the lock-up clutch.
The lock-up clutch is controlled electronically and operates in 4th and 5th gears.
A symmetrical element 1-step 2-phase torque converter is used with JF506E automatic transmission. The term "1-step" refers to the single
turbine and runner assembly and "2-step" refers to the turbine runner speed relative to the pump impeller speed. When the turbine runner
speed is lower than the pump impeller speed, the mechanism operates as a simple torque converter. When the turbine runner speed is
higher than pump impeller speed, the mechanism acts as a fluid coupling.
The torque converter transmits and multiplies torque. The torque converter is a four-element device:
impeller assembly
turbine and damper assembly
reactor assembly
clutch
The standard torque converter components operate as follows:
Rotation of the converter housing and impeller set the fluid in motion.
The turbine reacts to the fluid motion from the impeller, transferring rotation to the geartrain through the input shaft.
The reactor redirects fluid going back into the impeller, allowing for torque multiplication.
The clutch and damper assembly dampens powertrain torsional vibration and provides a direct mechanical connection for improved
efficiency.
Power is transmitted from the torque converter to the planetary gearsets and other components through the input shaft.
Oil Pump
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1 Oil seal
2 O-ring
3 Oil pump housing
4 Inner rotor
5 Outer rotor
6 Oil pump cover
7 Seal ring
8 Bolts
A trochoid oil pump is used with JF506E automatic transmission. The trochoid oil pump has the advantage of very low power loss.
1 Outer rotor
2 Inner rotor
3 Suction port
4 Discharge port
The oil pump is driven by the engine. The inner rotor connects to the torque converter sleeve.
Geartrain
Power is transmitted from the torque converter to the planetary gearsets through the input shaft. Bands and clutches are used to hold and
drive certain combinations of gearsets. This results in five forward ratios and one reverse ratio, which are transmitted to the output shaft
and differential.
Gear Ratio
1st 3.801 to 1
2nd 2.131 to 1
3rd 1.364 to 1
4th 0.935 to 1
5th 0.685 to 1
Reverse 2.970 to 1
Planetary Gears
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1 Front sun gear
2 Front pinion gear
3 Rear sun gear
4 Front internal gear
5 Rear pinion gear
6 Rear internal gear
There are 3 planetary gear sets. Front, rear and reduction.
Clutches
There are 4 wet type multi disc clutches (low clutch, high clutch, reverse clutch and direct clutch).
Each clutch has two primary rotating parts (the clutch drum and the clutch hub). Power transmission is effected and controlled by these two
parts.
The clutch drum and hub are connected to a clutch plate. Pressure applied to the clutch plate results in power transfer. When this pressure
is released from the clutch plate, power does not transfer.
The clutch plates at the clutch drum side function as the driven plates. The clutch plates at the clutch hub side function as the drive plates.
The drive plates have friction materials on the faces.
Clutch engagement occurs when oil pressure is applied to the piston in the clutch drum. The dish plate acts as a cushion to prevent sudden
and violent force applied to the clutch plates which may causes a rough clutch engagement.
The retaining plate is attached to the driven plate. The retaining plate also serves as a spacer when the clutch is disengaged. It ensures
specified clutch clearance.
The piston is returned by return spring forces to ordinal position when the oil pressure is removed through the drain hole. As a result the
clutch is disengaged.
The check ball is forced to seal the oil circuit by oil pressure against the oil input hole when the clutch is engaged. When the clutch is
released the check ball moves back from the input hole to open the circuit and air is led into the oil chamber. This prevents residual oil
pressure build-up in the clutch drum.
The clutch drum and the clutch hub are connected to the planetary gears respectively. Planetary gear rotation acts as the controlling
element of the clutch.
Cancel Force Cover
Low Clutch
1 Cancel force cover
2 Low clutch piston
3 Cancel force
4 Low clutch pressure
5 Lubricating pressure
High Clutch
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1 High clutch piston
2 Cancel force
3 High clutch pressure
4 Lubricating pressure
5 Cancel force cover
The JF506E automatic transmission is equipped with the centrifugal oil pressure cancel room in low clutch and high clutch.
The centrifugal oil pressure cancel room improves clutch release time by applying force to the low clutch and the high clutch.
This system improves operating performance of the piston compared with the check ball system.
The piston returns to the original position by centrifugal force that is kept at the pressure room located at the other side of the piston
cylinder.
Therefore, the response of the clutch release operation is improved and quick gear change is obtained.
Low and Reverse Brake, 2-4 Brake
1 Transmission case
2 Brake hub
3 Return spring
4 Piston
The low & reverse brake and the 2-4 brake are multi-disc type brakes. Basic brake operation is similar to the clutch. The clutch drum is
mounted to an appropriate position on the transmission case. The low & reverse brake and the 2-4 brake act to stop the clutch hub rotation
when the clutch plate is engaged.
Reduction Brake Band and Band Servo
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1 Brake band engagement pressure
2 Piston stem
3 Transmission case
4 Anchor end bolt
5 Brake band
6 Direct clutch drum
7 Brake piston
The brake band acts in response to the servo to stop the direct clutch drum rotation.
The servo has a piston that operates in response to changes in oil pressure. The piston expands in P and N ranges, 1st, 2nd, 3rd, 4th, and
reverse gears to stop the direct clutch drum rotation.
When the line pressure reaches to the band servo the servo piston works. The downward piston stroke causes the piston stem to tighten
the brake band. The direct clutch drum rotation stops.
The anchor end bolt is used to maintain appropriate clearance between the brake band and the direct clutch drum when the brake band is
released. This clearance can be adjusted with the adjusting nut on the anchor end bolt.
One Way Clutches
The transmission uses two one way clutches.
Low One Way Clutch
The front planetary carrier is fixed by the inner race which runs free during 1st gear operation.
Reduction One Way Clutch
The reduction sun gear is fixed by the inner race which runs free during 1st, 2nd, 3rd and 4th gear operations.
Roller-Type One-Way Clutch
1 Outer race
2 Roller
3 Spring
4 Inner race
Normally, rollers are energized to the narrower section via a spring. Therefore, in the direction where the rollers are engaged between the
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cam and inner race they are united to transmit torque. In the reverse direction, because the rollers move in the direction where the
clearance is larger, clearances occur between races and the inner and outer races can rotate to each other.
Sprag-Type One-Way Clutch
1 Outer race
2 Sprag
3 Inner race
4 Rotation direction
Note the difference between sprag diameters "A" and "B" If the inner race tries to turn toward the left, radius "B" (longer than gap "C")
firmly locks the sprag to prevent the sprag from moving to the left.
Solenoids
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1 Sub lower body
2 Bracket
3 Clip
4 Line pressure duty solenoid
5 Low clutch timing solenoid
6 Bracket
7 2-4 brake duty timing solenoid
8 2-4 brake timing solenoid
9 Pilot filter
10 Separate plate A
11 Locating bolt
12 Filter
13 Lock-up solenoid
14 Reduction timing solenoid
15 Shift solenoid B
16 Shift solenoid C
17 Shift solenoid A
18 Lower body
19 Separate plate B
20 Internal body
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21 Separate plate C
22 Upper body
23 Manual valve
There are 9 solenoids which can be classified as two types by the way in which they operate. Three of them are duty solenoids, the other
six are on/off types. The solenoids are actuated by the TCM output signals.
On/Off Solenoids
Shift solenoids A, B, C, low clutch solenoid, reduction timing solenoid and the 2/4 brake timing solenoid
The on/off solenoids close the pressure circuit in response to current flow.
Each solenoid has a internal coil. Current passes through coil and actuates the needle valve. The needle valve then opens and closes the
fluid pressure circuits.
Duty Solenoids
Line pressure solenoid, lock-up solenoid and the 2/4 brake duty solenoid.
The duty solenoids repeatedly turn on/off in 50Hz cycles, this opens and closes the fluid pressure circuits.
Sensors
Sensor Schematic
1 Output shaft rotational speed sensor
2 Input shaft rotational speed sensor
3 Engine speed signal
4 Output gear rotational signal
5 TCM
6 Transmission control
8 Intermediate sensor
9 Geartrain
10 Engine
11 Reduction geartrain
12 Turbine sensor
13 Vehicle Speed Sensor (VSS)
Transmission Fluid Temperature (TFT) Sensor
The TFT sensor is installed in the transmission case, it constantly monitors the fluid temperature resistance varies with fluid temperature.
Automatic transmission internal operational resistance varies with automatic transmission fluid temperature change. The TCM detects the
automatic transmission fluid temperature according to the voltage produced by the TFT sensor.
Speed Sensors
There are 3 sensors installed in the transmission casing. They are all of the inductive type.
Turbine Shaft Speed Sensor
The Turbine Shaft Speed Sensor (TSS) detects the reverse clutch drum revolution speed. The reverse clutch drum is connected to the input
shaft and rotates at the same speed. The TCM calculates the input shaft speed to determine the turbine speed.
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The TSS uses a magnetic coil. As the input shaft rotates, the sensor detects a pulse signal according to the gear teeth on the outside of the
reverse clutch drum and sends it to the TCM.
Vehicle Speed Sensor
The vehicle speed sensor (VSS) detects the parking gear rotation speed. The TCM calculates the vehicle speed based on the parking gear
rotation speed.
The VSS uses a magnetic coil. As the parking gear rotates the sensor detects a pulse signal according to the gear teeth rotation speed and
then sends it to the TCM.
Intermediate Shaft Speed Sensor
The Intermediate Shaft Speed Sensor (ISS) detects the output gear rotation speed which is calculated by the TCM.
The ISS uses a magnetic coil. As the output gear rotates the sensor detects a pulse signal according to the gear teeth rotation and sends it
to the TCM.
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JATCO - Diagnostic StrategyVehicles With: 5-Speed Automatic Transaxle - JATCO
The complexity of the electronics involved with the automatic transmission/transaxle preclude the use of workshop general electrical test
equipment. Therefore, reference should be made to the Jaguar approved diagnostic system for detailed instructions on testing the
automatic transmission/transaxle.
Where a fault involving the automatic transmission/transaxle is indicated by the Jaguar approved diagnostic system, some basic diagnostic
methods may be necessary to confirm that connections are good and that the wiring is not damaged, before installing new components.
1. Verify the customer concern by operating the vehicle. Refer to the automatic transmission diagnostic drive cycle in the DTC
summary section.
1.
2. Check the fluid levels and condition of the fluid. 2.
3. Check for non-factory fitted items. 3.
4. Check the shift linkages for correct adjustment. REFER to Section 307-05A Automatic Transmission/Transaxle External Controls /
307-05B Automatic Transmission/Transaxle External Controls.
4.
5. Visually inspect for obvious signs of mechanical, electrical or hydraulic damage.
Mechanical Electrical Hydraulic
Damaged shift mechanism/linkages
Damaged automatic transmission/transaxle
casing
Blown fuse
Wiring harness
Damaged transmission control module
(TCM)
Damaged rotary switch
Fluid level too
high/low
Poor condition of fluid
Fluid leak
5.
Basic diagnosis
Check Fluid Level and Condition
CAUTION: The vehicle should not be driven if the fluid level is low as internal fail ure can result.
NOTE: The transmission oil temperature must not be allowed to exceed 40C whilst checking level. Should the temperature rise above this
figure, abort the check and allow the transmission oil to cool to below 30C.
This vehicle is not equipped with a fluid level indicator. An incorrect level may affect the transmission operation and could result in
transmission damage. To correctly check and add fluid to the transmission,
REFER to Transmission Fluid Level Check in this section.
High Fluid Level
A fluid level that is too high may cause the fluid to become aerated due to the churning action of the rotating internal parts. This will cause
erratic control pressure, foaming, loss of fluid from the vent tube and possible transmission damage. If an overfill reading is indicated,
REFER to Transmission Fluid Drain and Refill in this section.
Low Fluid Level
A low fluid level could result in poor transmission engagement, slipping, or damage. This could also indicate a leak in one of the
transmission seals or gaskets.
Adding Fluid
CAUTION: The use of any other type of transmission fluid than specified can result i n transmission damage.
If fluid needs to be added, add fluid in 0.50 liter increments through the fill hole opening. Do not overfill the fluid. For fluid type, refer to
the General Specification chart in this section.
Fluid Condition Check
1. Check the fluid level. For additional information,
REFER to Transmission Fluid Drain and Refill in this section.
1.
2. Observe the color and the odor. The color under normal circumstances should be reddish, not brown or black. 2.
3. Allow the fluid to drip onto a facial tissue and examine the stain. 3.
4. If evidence of solid material is found, the transmission fluid pan should be removed for further inspection. 4.
NOTE: Being thermostatically controlled, the lubrication system cannot be completely flushed. In the event of a transmission unit
replacement for internal failure, the oil cooler and pipes must also be replaced.
Shift Linkage Check
Hydraulic leakage at the manual control valve can cause delay in engagements and/or slipping while operating if the linkage is not correctly
adjusted; REFER to Section 307-05A Automatic Transmission/Transaxle External Controls / 307-05B Automatic Transmission/Transaxle
External Controls. for shift linkage adjustment.
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1
2
3548-1358-00.
NOTE: When performing electrical voltage or resistance tests, always use a digital multimeter (DMM) accurate to 3 decimal places, and
with an up-to-date calibration certificate. When testing resistance, always take the resistance of the DMM leads into account.
DTC Component Description Condition Action
P0731, P0732,
P0733, P0734,
P0735
Input, intermediate,
and output sensors
Gear ratio errors Gear ratio out of range. Mechanical failure REFER to pinpoint tests for
individual sensors and shift
solenoids.
P1573 This DTC does not
indicate a
component failure
Sympathetic DTCs
from modules in CAN
network
CAN throttle angle signal fail REFER to Section 418-00
Module Communications
Network.
P1601 Transmission control
module (TCM)
Incorrect
configuration
Incorrect configuration Reconfigure module.
P1603 Transmission control
module (TCM)
TCM EEPROM failure TCM has lost it's adaptive values REFER to Section 418-00
Network.
P1796 CAN network Wire or connection in
the CAN network
malfunction
The module does not respond to the Jaguar approved
diagnostic system No modules function
REFER to Section 418-00
Network.
P1745 Low clutch timing
solenoid
Solenoid or circuit
malfunction
Harsh gear shifts GO to Pinpoint Test A.
P1746 Reduction timing
solenoid
Solenoid or circuit
malfunction
Erratic engine braking GO to Pinpoint Test B.
P1747 2/4 Brake timing
solenoid
Solenoid or circuit
malfunction
Erratic 2 and 4 ratios GO to Pinpoint Test C.
P0706 Transmission range
(TR) sensor
TR sensor or circuit
malfunction
TR sensor out of range GO to Pinpoint Test D.
P1777 This DTC does not
indicate a
component failure
Sympathetic DTCs
from modules in CAN
network
CAN torque reduction fail REFER to Section 418-00
Network.
P1780 (To VIN
D15361)
D-4 switch
malfunction
Switch or circuit
malfunction
D-4 switch inoperative or out of range GO to Pinpoint Test E.
P1793 TCM Ignition
switched power
malfunction
TCM, relay, power
distribution fuse box
TCM inoperative GO to Pinpoint Test F.
P1797 Engine control
module (ECM)
Wire or connection in
the CAN network
diagnostic system engine control module (ECM).
No TCM communication to the ECM
Network.
P1799 Anti-Lock Brake
Control Module or
DSC
Wire or connection in
the CAN network
diagnostic system Anti-Lock Brake Control Module
or DSC. No TCM communication to Anti-Lock Brake
System (ABS)
Network.
P0791 (To VIN
C79328)
Intermediate speed
sensor
ISS or circuit Erratic gear shifts GO to Pinpoint Test G.
P0791 (From
VIN C79329)
Intermediate speed
sensor (ISS)
ISS or circuit Erratic gear shifts GO to Pinpoint Test S.
P0720 (To VIN
C79328)
Output speed sensor
(OSS)
OSS or circuit Erratic gear shifts GO to Pinpoint Test H.
P0720 (From
VIN C79328)
Output speed sensor
(OSS)
OSS or circuit Erratic gear shifts GO to Pinpoint Test T.
P0715 (To VIN
C79328)
Turbine speed
sensor (TSS)
TSS or circuit Erratic gear shifts GO to Pinpoint Test I.
P0715 (From
VIN C79329)
Turbine speed
sensor (TSS)
TSS or circuit Erratic gear shifts GO to Pinpoint Test U.
P0710 Oil temperature
sensor (OTS)
OTS or circuit Erratic gear shifts, temperature malfunction GO to Pinpoint Test J.
P0753 Shift solenoid A
(SSA)
SSA Solenoid or
circuit malfunction
Erratic gear shifts, 4th gear engaged GO to Pinpoint Test K.
P0758 Shift solenoid B
(SSB)
SSB Solenoid or
circuit malfunction
Erratic gear shifts, 3rd/5th gear engaged GO to Pinpoint Test L.
P0763 Shift solenoid C
(SSC)
SSC Solenoid or
circuit malfunction
Erratic gear shifts, 4th gear engaged GO to Pinpoint Test M.
P0743 Torque converter
clutch (TCC) solenoid
TCC Solenoid or
circuit malfunction
No lock-up GO to Pinpoint Test N.
P0740 Torque converter
clutch
Torque converter
clutch failure
No lock-up/permanent lock-up INSTALL a new torque
convertor.
P0748 Line pressure control
(LPC) solenoid
LPC solenoid or
circuit malfunction
Erratic transmission operation GO to Pinpoint Test O.
P0778 2/4 Brake pressure
control (BPC) circuit
2/4 BPC solenoid or
circuit malfunction
Erratic gear shifts GO to Pinpoint Test P.
P1710 Control valve
solenoid GROUND
GROUND circuit Erratic gear shifts GO to Pinpoint Test Q.
P0915 J-Gate input J-Gate or circuit
malfunction
Left-hand side of the J-Gate inoperative GO to Pinpoint Test R.
PINPOINT TEST A : P1745. LOW CLUTCH TIMING SOLENOID MALFUNCTION
TEST
CONDITIONS
A1: CHECK THE LOW CLUTCH TIMING SOLENOID GROUND CIRCUIT.
Disconnect transmission electrical connector JB155.
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Yes
GO to A3.
No
GO to A2.
A2: CHECK THE LOW CLUTCH TIMING SOLENOID RESISTANCE.
Measure the resistance between transmission electrical connector JB155 pin 18 and pin 12 at the transmission.
Yes
GO to A3.
No
INSTALL a new timing solenoid. CLEAR the DTC. TEST the system for normal operation.
A3: CHECK THE LOW CLUTCH TIMING SOLENOID GROUND WIRE FOR CONTINUITY.
Disconnect TCM electrical connector JB131.
Yes
REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST
No
Contact dealer technical support for advice on possible module failure.
A4: CHECK THE LOW CLUTCH TIMING SOLENOID SIGNAL WIRE FOR CONTINUITY.
Measure the resistance between JB155, pin 12 (Y) and JB131, pin 53 (Y).
Yes
No
PINPOINT TEST B : P1746. REDUCTION TIMING SOLENOID MALFUNCTION
TEST
CONDITIONS
B1: CHECK THE REDUCTION TIMING SOLENOID GROUND CIRCUIT.
Yes
GO to B3.
No
GO to B2.
B2: CHECK THE REDUCTION TIMING SOLENOID RESISTANCE.
Measure the resistance between JB155, pin 18 and pin 14 at the transmission.
Yes
GO to B3.
No
B3: CHECK THE REDUCTION TIMING SOLENOID GROUND WIRE FOR CONTINUITY.
Yes
No
B4: CHECK THE REDUCTION TIMING SOLENOID SIGNAL WIRE FOR CONTINUITY.
Measure the resistance between JB155, pin 14 (W) and JB131, pin 10 (W).
Yes
No
PINPOINT TEST C : P1747. 2/4 BRAKE TIMING SOLENOID MALFUNCTION
TEST
CONDITIONS
C1: CHECK THE 2/4 BRAKE TIMING SOLENOID GROUND CIRCUIT.
Yes
GO to C3.
No
GO to C2.
C2: CHECK THE 2/4 BRAKE TIMING SOLENOID RESISTANCE.
Measure the resistance between JB155 pin 18 and pin 13 at the transmission.
Yes
GO to C3.
No
C3: CHECK THE 2/4 BRAKE TIMING SOLENOID GROUND WIRE FOR CONTINUITY.
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Yes
No
C4: CHECK THE 2/4 BRAKE TIMING SOLENOID SIGNAL WIRE FOR CONTINUITY.
Measure the resistance between JB155, pin 13 (U) and JB131, pin 04 (U).
Yes
No
PINPOINT TEST D : P0706. TRANSMISSION RANGE SENSOR MALFUNCTION
TEST
CONDITIONS
D1: CHECK TRANSMISSION RANGE SENSOR CONTINUITY IN PARK.
Disconnect TR sensor electrical connector JB156.
Select PARK.
Check for continuity between pins 08 and 09 of the sensor.
Yes
GO to D2.
No
Carry out the adjustment procedure for the transmission range sensor.
REFER to Transmission Range (TR) Sensor Adjustment in this section.
Recheck the circuit. If still open circuit, INSTALL a new transmission range sensor.
REFER to Transmission Range (TR) Sensor in this section.
D2: CHECK TRANSMISSION RANGE SENSOR CONTINUITY IN REVERSE.
Select REVERSE.
Yes
GO to D3.
No
D3: CHECK TRANSMISSION RANGE SENSOR CONTINUITY IN NEUTRAL.
Select NEUTRAL.
Yes
GO to D4.
No
D4: CHECK TRANSMISSION RANGE SENSOR CONTINUITY IN D.
Select D.
Yes
GO to D5.
No
D5: CHECK TRANSMISSION RANGE SENSOR CONTINUITY IN 2 (TO VIN D15361).
Select 2.
Yes
GO to D6.
No
D6: CHECK TRANSMISSION RANGE SENSOR CONTINUITY IN 3 (TO VIN D15361).
Select 3.
Yes
GO to D7.
No
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D7: CHECK TRANSMISSION RANGE SENSOR GROUND CIRCUIT.
Yes
No
GO to D8.
D8: CHECK TRANSMISSION RANGE SENSOR PARK SIGNAL WIRE FOR CONTINUITY.
Disconnect the TCM electrical connector JB131.
Measure the resistance between JB131, pin 30 (U) and the TR sensor electrical connector JB156, pin 09 (U).
Yes
No
GO to D9.
D9: CHECK TRANSMISSION RANGE SENSOR REVERSE SIGNAL WIRE FOR CONTINUITY.
Measure the resistance between JB131, pin 26 (G) and JB156, pin 07 (G).
Yes
No
GO to D10.
D10: CHECK TRANSMISSION RANGE SENSOR NEUTRAL SIGNAL WIRE FOR CONTINUITY.
Yes
No
GO to D11.
D11: CHECK TRANSMISSION RANGE SENSOR DRIVE SIGNAL WIRE FOR CONTINUITY.
Yes
No
GO to D12.
D12: CHECK TRANSMISSION RANGE SENSOR 2 SIGNAL WIRE FOR CONTINUITY (TO VIN D15361).
Measure the resistance between JB131, pin 08 (R) and JB156, pin 03 (R).
Yes
No
GO to D13.
D13: CHECK TRANSMISSION RANGE SENSOR 3 SIGNAL WIRE FOR CONTINUITY (TO VIN D15361).
Measure the resistance between JB131, pin 07 (O) and JB156, pin 04 (O).
Yes
No
INSTALL a new TCM.
REFER to Transmission Control Module (TCM) - in this section.
PINPOINT TEST E : P1780. D-4 SWITCH MALFUNCTION (TO VIN D15361)
NOTE: Incorrect adjustment of the selector cable could result in this DTC being set with no electrical fault being present. REFER to
Section 307-05A Automatic Transmission/Transaxle External Controls / 307-05B Automatic Transmission/Transaxle External Controls.
TEST
CONDITIONS
E1: CHECK POWER SUPPLY TO THE J-GATE.
Disconnect the J-Gate electrical connector, IP14.
Measure the voltage between IP14, pin 01 (WR) and GROUND.
Yes
REPAIR the circuit between IP14, pin 01 (WR) and the ignition switch (this circuit includes the central junction fuse
box, ignition relay, and inertia switch). For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST
No
GO to E2.
E2: CHECK GROUND SUPPLY TO THE J-GATE.
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Yes
REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the
No
GO to E3.
E3: CHECK D-4 SWITCH SIGNAL WIRE FOR HIGH RESISTANCE.
Measure the resistance between IP14, pin 05 (BW) and JB131, pin 45 (BW).
Yes
No
INSTALL a new J-Gate. REFER to Section 307-05A Automatic Transmission/Transaxle External Controls / 307-05B
Automatic Transmission/Transaxle External Controls.
PINPOINT TEST F : P1793. TCM IGNITION SWITCHED POWER MALFUNCTION
TEST
CONDITIONS
F1: CHECK TRANSMISSION CONTROL MODULE IGNITION SWITCHED POWER SUPPLY CIRCUIT.
Disconnect TCM electrical connector, JB131.
Measure the voltage between JB131, pin 36 (WU) and GROUND.
Yes
REPAIR the circuit between TCM electrical connector JB131, pin 36 (WU) and the battery power bus 1 (this circuit
includes the TCM relay and power distribution fuse box). For additional information, refer to the wiring diagrams.
No
GO to F2.
F2: CHECK TRANSMISSION CONTROL MODULE IGNITION SWITCHED POWER SUPPLY CIRCUIT.
Yes
REPAIR the circuit between JB131, pin 54 (WU) and the battery power bus 1 (this circuit includes the TCM relay and
power distribution fuse box). For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system
No
PINPOINT TEST G : P0791. INTERMEDIATE SPEED SENSOR MALFUNCTION (ONLY UP TO VIN C79328)
TEST
CONDITIONS
G1: CHECK THE INTERMEDIATE SPEED SENSOR GROUND CIRCUIT.
Disconnect the transmission electrical connector, JB155.
Measure the resistance between JB155, pin 03 (B) and GROUND (shielded cable).
Yes
No
GO to G3.
G2: CHECK THE INTERMEDIATE SPEED SENSOR GROUND CIRCUIT FOR CONTINUITY.
Disconnect the TCM electrical connector, JB131.
Measure the resistance between transmission electrical connector JB155, pin 03 (B) and TCM electrical connector
JB131, pin 20 (B).
Yes
No
GO to G3.
G3: CHECK THE INTERMEDIATE SPEED SENSOR SIGNAL WIRE FOR CONTINUITY.
Measure the resistance between JB155, pin 04 (N) and JB131, pin 21 (N).
Yes
REPAIR the high resistance circuit . For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST
No
GO to G4.
G4: CHECK THE RESISTANCE OF THE INTERMEDIATE SPEED SENSOR.
Yes
No
INSTALL a new transaxle.
REFER to Transaxle - in this section.
PINPOINT TEST H : P0720. OUTPUT SPEED SENSOR MALFUNCTION (TO VIN C79328)
TEST
CONDITIONS
H1: CHECK THE OUTPUT SPEED SENSOR GROUND CIRCUIT.
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Yes
No
GO to H3.
H2: CHECK THE OUTPUT SPEED SENSOR GROUND CIRCUIT FOR CONTINUITY.
Yes
No
GO to H3.
H3: CHECK THE OUTPUT SPEED SENSOR SIGNAL WIRE FOR CONTINUITY.
Yes
No
GO to H4.
H4: CHECK THE RESISTANCE OF THE OUTPUT SPEED SENSOR.
Yes
No
PINPOINT TEST I : P0715. TURBINE SPEED SENSOR MALFUNCTION (TO VIN C79328)
TEST
CONDITIONS
I1: CHECK THE TURBINE SPEED SENSOR GROUND CIRCUIT.
Yes
No
GO to I3.
I2: CHECK THE TURBINE SPEED SENSOR GROUND CIRCUIT FOR CONTINUITY.
Yes
No
GO to I3.
I3: CHECK THE TURBINE SPEED SENSOR SIGNAL WIRE FOR CONTINUITY.
Measure the resistance between JB155, pin 02 (N) and TCM electrical connector, JB131, pin 24 (N).
Yes
No
GO to I4.
I4: CHECK THE RESISTANCE OF THE OUTPUT SPEED SENSOR.
Yes
No
PINPOINT TEST J : P0710. OIL TEMPERATURE SENSOR MALFUNCTION
TEST
CONDITIONS
J1: CHECK THE OIL TEMPERATURE SENSOR GROUND CIRCUIT.
Yes
No
GO to J3.
J2: CHECK THE OIL TEMPERATURE SENSOR GROUND CIRCUIT FOR CONTINUITY.
Measure the resistance between JB155, pin 08 (B) and JB131 pin 20 (B).
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1
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1
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Yes
No
GO to J3.
J3: CHECK THE OIL TEMPERATURE SENSOR SIGNAL WIRE FOR CONTINUITY.
Yes
No
GO to J4.
J4: CHECK THE OIL TEMPERATURE SENSOR RESISTANCE.
Is the resistance 2,000-5,000 ohms at room temperature?
Yes
No
PINPOINT TEST K : P0753. SHIFT SOLENOID A MALFUNCTION
TEST
CONDITIONS
K1: CHECK THE SHIFT SOLENOID A GROUND CIRCUIT.
Yes
GO to K3.
No
GO to K2.
K2: CHECK THE SHIFT SOLENOID A RESISTANCE.
Yes
GO to K3.
No
INSTALL a new shift solenoid.
REFER to Shift Solenoids (SS) - in this section.
K3: CHECK THE SHIFT SOLENOID A GROUND WIRE FOR CONTINUITY.
Yes
No
K4: CHECK THE SHIFT SOLENOID A SIGNAL WIRE FOR CONTINUITY.
Measure the resistance between JB155, pin 09 (B) and TCM electrical connector JB131, pin 15 (B).
Yes
No
PINPOINT TEST L : P0758. SHIFT SOLENOID B MALFUNCTION
TEST
CONDITIONS
L1: CHECK THE SHIFT SOLENOID B GROUND CIRCUIT.
Yes
GO to L3.
No
GO to L2.
L2: CHECK THE SHIFT SOLENOID B RESISTANCE.
Yes
GO to L4.
No
L3: CHECK THE SHIFT SOLENOID B GROUND WIRE FOR CONTINUITY.
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Yes
No
L4: CHECK THE SHIFT SOLENOID B SIGNAL WIRE FOR CONTINUITY.
Yes
No
PINPOINT TEST M : P0763. SHIFT SOLENOID C MALFUNCTION
TEST
CONDITIONS
M1: CHECK THE SHIFT SOLENOID C GROUND CIRCUIT.
Yes
GO to M3.
No
GO to M2.
M2: CHECK THE SHIFT SOLENOID C RESISTANCE.
Measure the resistance between JB155, pins 11 and 18 at the transmission.
Yes
GO to M4.
No
M3: CHECK THE SHIFT SOLENOID C GROUND WIRE FOR CONTINUITY.
Yes
No
M4: CHECK THE SHIFT SOLENOID C SIGNAL WIRE FOR CONTINUITY.
Yes
No
PINPOINT TEST N : P0743. TORQUE CONVERTER CLUTCH SOLENOID MALFUNCTION
TEST
CONDITIONS
N1: CHECK THE TORQUE CONVERTER CLUTCH SOLENOID GROUND CIRCUIT.
Yes
GO to N3.
No
GO to N2.
N2: CHECK THE TORQUE CONVERTER CLUTCH SOLENOID RESISTANCE.
Is the resistance 12.6 ohms?
Yes
GO to N4.
No
INSTALL a new TCC solenoid. CLEAR the DTC. TEST the system for normal operation.
N3: CHECK THE TORQUE CONVERTER CLUTCH SOLENOID GROUND WIRE FOR CONTINUITY.
Yes
No
N4: CHECK THE TORQUE CONVERTER CLUTCH SOLENOID SIGNAL WIRE FOR CONTINUITY.
Measure the resistance between JB155, pin 17 (O) and JB131, pin 16 (O).
Yes
No
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PINPOINT TEST O : P0748. LINE PRESSURE CONTROL SOLENOID MALFUNCTION
TEST
CONDITIONS
O1: CHECK THE LINE PRESSURE CONTROL SOLENOID GROUND CIRCUIT.
Yes
GO to O3.
No
GO to O2.
O2: CHECK THE LINE PRESSURE CONTROL SOLENOID RESISTANCE.
Yes
GO to O4.
No
INSTALL a new LPC solenoid. CLEAR the DTC. TEST the system for normal operation.
O3: CHECK THE LINE PRESSURE CONTROL SOLENOID GROUND WIRE FOR CONTINUITY.
Yes
No
O4: CHECK THE LINE PRESSURE CONTROL SOLENOID SIGNAL WIRE FOR CONTINUITY.
Measure the resistance between JB155, pin 15 (R) and JB131, pin 18 (R).
Yes
For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system for normal operation.
No
PINPOINT TEST P : P0778. 2/4 BRAKE DUTY PRESSURE CONTROL SOLENOID MALFUNCTION
TEST
CONDITIONS
P1: CHECK THE 2/4 BRAKE DUTY PRESSURE CONTROL SOLENOID GROUND CIRCUIT.
Yes
GO to P3.
No
GO to P2.
P2: CHECK THE 2/4 BRAKE DUTY PRESSURE CONTROL SOLENOID RESISTANCE.
Yes
INSTALL a new 2/4 brake duty pressure control solenoid. CLEAR the DTC. TEST the system for normal operation.
No
GO to P4.
P3: CHECK THE 2/4 BRAKE DUTY PRESSURE CONTROL SOLENOID GROUND WIRE FOR CONTINUITY.
Yes
No
P4: CHECK THE 2/4 BRAKE DUTY PRESSURE CONTROL SOLENOID SIGNAL WIRE FOR CONTINUITY.
Yes
No
PINPOINT TEST Q : P1710. CONTROL VALVE SOLENOID GROUND.
TEST
CONDITIONS
Q1: CHECK CONTROL VALVE SOLENOID GROUND CIRCUIT.
Disconnect transmission electrical connector, JB155.
Yes
GO to Q2.
No
No electrical fault in GROUND circuit. Possible internal fault. Recheck DTCs.
Q2: CHECK CONTROL VALVE SOLENOID GROUND WIRE FOR CONTINUITY.
Disconnect TCM electrical connector, JB131.
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1
2
1
2
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1
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1
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1
1
2
3
Yes
No
PINPOINT TEST R : P0915 J-GATE SIGNAL INPUTS TO THE TCM.
NOTE: Incorrect adjustment of the selector cable could result in this DTC being set with no electrical fault being present. REFER to
Section 307-05A Automatic Transmission/Transaxle External Controls / 307-05B Automatic Transmission/Transaxle External Controls.
TEST
CONDITIONS
R1: CHECK TRANSMISSION RANGE SENSOR CONTINUITY IN D.
Select D.
Check for continuity between JB156, pin 08 and pin 01 at the sensor.
Yes
GO to R2.
No
R2: CHECK TRANSMISSION RANGE SENSOR DRIVE SIGNAL WIRE FOR HIGH RESISTANCE.
Yes
No
GO to R3.
R3: CHECK POWER SUPPLY TO THE J-GATE.
Yes
REPAIR the circuit between IP14, pin 01 (WR) and the ignition switch (this circuit i ncludes the central junction fuse
box, ignition relay, and inertia switch). For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST
No
GO to R4.
R4: CHECK GROUND SUPPLY TO THE J-GATE.
Measure the resistance between J-Gate electrical connector IP14, pin 02 (B) and GROUND.
Yes
No
GO to R5.
R5: CHECK J-GATE SIGNAL INPUT WIRES FOR CONTINUITY (4 RANGE).
Measure the resistance between IP14 pin 05 (BW) and JB131 pin 45 (BW).
Yes
No
GO to R6.
R6: CHECK THE J-GATE SIGNAL INPUT WIRES FOR CONTINUITY (3 RANGE).
Measure the resistance between IP14 pin 15 (O) and JB131 pin 07 (O).
Yes
No
GO to R7.
R7: CHECK THE J-GATE SIGNAL INPUT WIRES FOR CONTINUITY (2 RANGE).
Measure the resistance between IP14 pin 14 (R) and JB131 pin 08 (R).
Yes
GO to R8.
No
R8: J-GATE SIGNALS FUNCTIONALITY
If tests between R1 and R7 have been successfully completed and the fault is still present, INSTALL a new J-Gate.
CLEAR the DTC.
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2
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1
2
1
2
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Does the system function correctly?
Yes
No further action required.
No
PINPOINT TEST S : P0791. INTERMEDIATE SPEED SENSOR MALFUNCTION (FROM VIN C79329)
TEST
CONDITIONS
S1: CHECK THE INTERMEDIATE SPEED SENSOR GROUND CIRCUIT.
Yes
No
GO to S2.
S2: CHECK THE INTERMEDIATE SPEED SENSOR GROUND CIRCUIT FOR CONTINUITY.
Yes
No
GO to S3.
S3: CHECK THE INTERMEDIATE SPEED SENSOR SIGNAL WIRE FOR CONTINUITY.
Yes
No
GO to G4.
S4: CHECK THE RESISTANCE OF THE INTERMEDIATE SPEED SENSOR.
Yes
No
PINPOINT TEST T : P0720. OUTPUT SPEED SENSOR MALFUNCTION (FROM VIN C79329)
TEST
CONDITIONS
T1: CHECK THE OUTPUT SPEED SENSOR GROUND CIRCUIT.
Yes
No
GO to T2.
T2: CHECK THE OUTPUT SPEED SENSOR GROUND CIRCUIT FOR CONTINUITY.
Yes
No
GO to T3.
T3: CHECK THE OUTPUT SPEED SENSOR SIGNAL WIRE FOR CONTINUITY.
Yes
No
GO to T4.
T4: CHECK THE RESISTANCE OF THE OUTPUT SPEED SENSOR.
Yes
No
PINPOINT TEST U : P0715. TURBINE SPEED SENSOR MALFUNCTION (FROM VIN C79329)
TEST
CONDITIONS
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U1: CHECK THE TURBINE SPEED SENSOR GROUND CIRCUIT.
Yes
No
GO to U2.
U2: CHECK THE TURBINE SPEED SENSOR GROUND CIRCUIT FOR CONTINUITY.
Yes
No
GO to U3.
U3: CHECK THE TURBINE SPEED SENSOR SIGNAL WIRE FOR CONTINUITY.
Yes
No
GO to U4.
U4: CHECK THE RESISTANCE OF THE OUTPUT SPEED SENSOR.
Yes
No
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JATCO - Transmission Fluid Drain and Refill
General Procedures
Drain
.
2. Place a suitable container under the transmission drain plug.
3. CAUTION: If the automatic transmission fluid is very dirty or it
contains metallic particles, then along with a new transmission, install a
new automatic transmission fluid cooler and lines.
Remove the transmission drain plug.
4. Install the transmission drain plug.
Tighten to 45 Nm.
Refill
6. Remove the automatic transmission fluid charging pipe cap.
7. NOTE: Use automatic transmission fluid WSS-M2C922-A1 or equivalent
Fill the automatic transmission with 8 litres of automatic transmission
fluid through the automatic transmission fluid charging pipe.
8. Carry out a fluid level check and adjustment. For additional information,
refer to
For additional information, refer to: Transmission Fluid Level Check
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JATCO - Transmission Fluid Level Check
General Procedures
2. Connect the Jaguar Approved Diagnostic System.
3. Make sure J-Gate shift selector is in the Park position (P).
4. With the engine running and the foot brake applied, move the J-Gate
shift selector through "P-R-N-D-4-3-2" and back to the "P" position to
circulate the automatic transmission fluid until the temperature reaches
30 to 40C (86 to 104F) on the Jaguar Approved Diagnostic System.
5. When the automatic transmission fluid temperature reaches 35C
(95F) check that the selector lever is in the "P" position raise the
vehicle.
6. With the engine running, remove the automatic transmission fluid level
tube plug.
Remove and discard the level plug and sealing washer.
7. NOTE: Use automatic transmission fluid WSS-M2C922-A1 or equivalent
If the automatic transmission fluid does not come out of the
transmission fluid level tube the automatic transmission fluid level is
insufficient. If this is the case add the automatic transmission fluid in
0.5 litre units into the automatic transmission fluid charging pipe until
the automatic transmission fluid comes out of the automatic
transmission fluid level tube.
Remove the automatic transmission fluid charging pipe cap.
8. NOTE: Make sure the automatic transmission fluid temperature does not
exceed 40C (104F). If the automatic transmission fluid temperature does
exceed 40C (104F) stop the automatic transmission fluid level check and
allow the automatic transmission fluid to cool until the temperature
reaches 30 to 40C (86 to 104F).
Allow the automatic transmission fluid to come out of the automatic
transmission fluid level tube until the overflow stops at a temperature of
no more than 40C (104F).
9. If when the automatic transmission fluid level plug is first removed and
automatic transmission fluid comes out of the automatic transmission
fluid level tube, allow the automatic transmission fluid to come out of
the automatic transmission fluid level tube until the overflow stops at a
temperature of no more than 40C (104F).
10. Install the transmission fluid level plug.
Install a new level plug and sealing washer.
Tighten to 15 Nm.
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11. Install the automatic transmission fluid charging pipe cap.
13. Disconnect the Jaguar Approved Diagnostic System.
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JATCO - Transmission Range (TR) Sensor Adjustment
General Procedures
Special Tool(s)
Setting plate rotary switch
307-445
2. Loosen the Transmission Range (TR) sensor.
3. Make sure the J-Gate shift selector is in the "N" position.
4. Using the special tool adjust the TR sensor.
Tighten to 10 Nm.
7. NOTE: If the J-Gate shift selector does not illuminate in all positions
repeat the complete procedure.
Make sure the vehicle starts in the "P" and "N" positions and that it does
not start in the R, D, 4, 3 and 2 positions, and that the J-Gate shift
selector illuminates in all positions.
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JATCO - Halfshaft Seal LH
In-vehicle Repair
Special Tool(s)
Link shaft oil seal installer
205-115
308-208
Removal
1. Drain the transmission. For additional information, refer to Transmission
Fluid Drain and Refill.
2. Remove the left-hand drive halfshaft. For additional information, refer
to Section 205-04 Front Drive Halfshafts.
3. Using the special tool, remove the drive halfshaft oil seal.
Installation
1. Using the special tool, install the drive halfshaft oil seal.
2. Install the left-hand drive halfshaft. For additional information, refer to
Section 205-04 Front Drive Halfshafts.
3. Fill the transmission. For additional information, refer to Transmission
Fluid Drain and Refill
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JATCO - Halfshaft Seal RH
In-vehicle Repair
Special Tool(s)
Linkshaft oil seal installer
205-115
308-208
1. Drain the transmission.
For additional information, refer to Transmission Fluid Drain and Refill in
this section.
2. Remove the intermediate shaft.
For additional information, refer to Section 205-04 Front Drive
Halfshafts.
Removal
Using the special tool, remove the halfshaft oil seal.
Installation
1. Using the special tool install, the halfshaft oil seal.
2. Install the intermediate shaft.
For additional information, refer to Section 205-04 Front Drive
Halfshafts.
3. Refill the transmission.
For additional information, refer to Transmission Fluid Drain and Refill in
this section.
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JATCO - Main Control Valve Body
In-vehicle Repair
Removal
2. Remove the main valve body cover.
Drain the transmission fluid into a suitable container.
Clean and inspect the main valve body cover and transmission
sealing surfaces using Metal surface cleaner WSE-M5B392-A or
equivalent meeting Jaguar specification.
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5. Remove the main control valve body.
Installation
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Install the new O-ring seals.
Tighten to 8 Nm.
3. Tighten to 8 Nm.
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4. NOTE: Apply an even bead of silicone gasket sealant WSE-M4G323-A6
or equivalent meeting Jaguar specification to the main valve body cover
sealing surface.
Tighten to 8 Nm.
5. Check and adjust the transmission fluid level. For additional
information, refer to AdjustmentFluid Level Check.
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JATCO - Shift Solenoids (SS)
In-vehicle Repair
Removal
1. Remove the main control valve body. For additional information, refer to
Main Control Valve Body.
3. Remove the shift solenoid.
Installation
1. NOTE: Lubricate the shift solenoid O-ring seal with automatic
transmission fluid WSS-M2C922-A1 or equivalent meeting Jaguar
specification.
Lubricate the shift solenoid O-ring seal.
2. Tighten to 8 Nm.
3. Install the main control valve body. For additional information, refer to
Main Control Valve Body.
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JATCO - Transaxle Support Insulator
In-vehicle Repair
Special Tool(s)
HTJ1200-2
Removal
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9. Remove the transaxle support insulator.
Remove the transaxle support insulator retaining nuts.
Installation
Tighten to 47 Nm.
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JATCO - Transmission Control Module (TCM)
In-vehicle Repair
Removal
1. Remove the rain sensor module. For additional information, refer to
Section 501-16 Wipers and Washers.
2. Remove the mounting plate.
1. Remove the retaining nut.
2. Reposition the mounting plate.
3. Detach the mounting plate.
4. Remove the mounting plate.
3. Detach the Transmission Control Module (TCM).
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4. Remove the TCM.
2. Remove the TCM.
Installation
Tighten to 10 Nm.
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JATCO - Transmission Range (TR) Sensor
In-vehicle Repair
Removal
1. Remove the battery tray. For additional information, refer to Section
414-01 Battery, Mounting and Cables.
3. Remove the tie strap.
4. Remove the Transmission Range (TR) sensor.
Installation
1. Install the TR sensor.
2. Adjust the TR sensor. For additional information, refer to Adjustment
Transmission Range (TR) Sensor.
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JATCO - Transaxle
Removal
Special Tool(s)
Slide hammer
100-012
100-012-02
Slide hammer shaft
204-226
HTJ1200-2
308-208
303-021
Engine support brackets
303-1068
Disconnect tool, fuel line
310-044
Removal
All vehicles
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3. Loosen the left-hand shock absorber and spring assembly securing nuts.
4. Loosen the right-hand shock absorber and spring assembly securing
nuts.
5. Remove the front subframe.
For additional information, refer to: Front Subframe - 2.0L NA V6 -
AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27 (502-00 Uni-Body, Subframe
and Mounting System, Removal and Installation).
6. Remove the fender splash shield access panel.
7. Remove the steering gear heat shield bracket.
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8. Remove the steering gear heat shield.
For additional information, refer to: Transfer Case (308-07 Transfer
Case, Removal).
10. CAUTION: Make sure the halfshaft constant velocity (CV) joints
do not over articulate. Failure to follow this instruction may result in
damage to the CV joints.
Detach the right-hand halfshaft.
Disengage the right-hand halfshaft from the transaxle.
Secure the right-hand halfshaft to one side.
11. NOTE: Plug the transaxle to prevent fluid loss or dirt ingress.
Using the special tool, remove the right-hand halfshaft seal.
All vehicles
12. Support the power steering fluid pipe.
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Using the special tools, detach the left-hand halfshaft.
Support the left-hand halfshaft.
Using the special tool, remove the halfshaft seal.
17. Remove the torque converter retaining bolts access cover.
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18. NOTE: Rotate the torque converter to gain access for the remaining
retaining bolts.
Remove the torque converter retaining bolts.
19. NOTE: Lower transaxle fluid cooler tube shown, upper transaxle fluid
cooler tube similar.
NOTE: Plug the transaxle fluid cooler and transaxle fluid cooler tubes to
prevent fluid loss or dirt ingress.
Using the special tool, detach the transaxle fluid cooler tubes.
1. Install the special tool to the transaxle fluid cooler tube.
2. Using the special tool, detach the transaxle fluid cooler tube.
20. Disconnect the transaxle electrical connectors.
22. Detach the generator wiring harness retaining clip from the camshaft
cover retaining clip.
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25. Detach the positive crankcase ventilation (PCV) hose from the intake
manifold.
26. Detach the electrical connector from the intake manifold support
bracket.
28. Detach the wiring harness from the camshaft cover retaining stud.
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Adjust the engine support bracket to support the weight of the
powertrain assembly.
31. Remove the support bar retaining bolts.
32. Remove the support insulator bar.
33. Install the support insulator retaining nut.
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35. Detach the starter motor electrical connector.
36. Detach the starter motor solenoid electrical connector.
37. Remove the support bar mount bracket/transaxle upper retaining bolt.
38. Remove the support bar mount bracket.
Remove the stater motor front retaining bolt.
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40. Detach the transaxle ground lead.
42. Remove the transaxle mount bracket securing bolts.
44. NOTE: The transaxle retaining bolt remains captive to the cylinder
block flange.
Remove the transaxle retaining nut.
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46. Align the powertrain assembly jack to the transaxle.
Secure the transaxle to the powertrain assembly jack.
47. Remove the transaxle retaining bolt.
48. NOTE: Carry this step if an early condition transaxle is being removed.
NOTE: Vehicles with 2.5L and 3.0L engines shown, vehicles with 2.0L
engine similar.
Remove the transaxle retaining bolt
Remove the transaxle dust cover.
49. NOTE: Carry this step if a later condition transaxle is being removed.
engine similar.
Remove the transaxle dust cover.
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50. NOTE: Carry this step if a later condition transaxle is being removed.
engine similar.
Remove the transaxle retaining bolt.
Remove the transaxle.
Detach the transaxle from the drive plate.
Lower the powertrain assembly jack and transaxle assembly.
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JATCO - Input Shaft Seal
Special Tool(s)
205-115
1. Remove the transmission assembly. For additional information, refer to
Transmission.
2. CAUTION: Do not let the torque converter drop out of the
transmission. Failure to follow this instruction may result in personal
injury.
Remove the torque converter.
Drain any remaining fluid into a suitable container.
3. NOTE: Make sure the transmission housing seal face is not damaged
when removing the torque converter seal.
Using a suitable tool, remove the torque converter seal.
4. NOTE: Using a suitable Metal surface cleaner WSE-M5B392-A or
equivalent meeting Jaguar specification. clean the seal face on the
housing before fitting the new seal.
Clean and inspect the transmission housing seal face.
5. Using the special tool, install a new torque converter seal.
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6. CAUTION: Do not let the torque converter drop out of the
transmission. Failure to follow this instruction may result in personal
injury.
NOTE: The torque converter hub must engage fully in the oil pump drive
gear.
Install the torque converter.
7. Install the transmission assembly. For additional information, refer to
Transmission.
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JATCO - Transaxle
Installation
Special Tool(s)
205-115
HTJ1200-2
303-021
303-1068
Installation
All vehicles
CAUTION: When replacing or installing a new automatic transaxle. The transaxle control module (TCM) adaptation procedure must be
carried out using the Jaguar approved diagnostic system using software issue 19 or higher, where available. If the Jaguar approved
diagnostic system is not available the TCM must be replaced. Failure to follow this instruction will result in damage to the automatic
transaxle.
1. CAUTION: If the automatic transmission fluid is very dirty or it
contains metallic particles, then along with a new transmission, install a
new automatic transmission fluid cooler and lines.
Flush the transaxle fluid cooler and fluid tubes.
2. NOTE: Use high-temperature grease ESD-M1C220-A or equivalent
Apply a thin layer of grease to the centering spigot bore on the torque
converter.
3. CAUTION: The torque converter must remain at the correct
installation depth throughout the whole installation procedure.
NOTE: The torque converter hub must engage fully in the fluid pump
drive gear.
Check the installation depth between the transaxle flange and the
torque converter is at least 0.04 mm (0.015 in).
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Install the transaxle.
5. NOTE: Carry out this step if a later condition transaxle is being
installed.
engine similar.
Install the transaxle retaining bolt.
Tighten to 48 Nm.
6. NOTE: Carry out this step if a later condition transaxle is being
installed.
engine similar.
Install the transaxle dust cover.
Tighten to 10 Nm.
7. NOTE: Carry out this step if an early condition transaxle is being
installed.
engine similar.
Install the transaxle retaining bolt
Install the transaxle dust cover.
Tighten to 48 Nm.
8. Install the transaxle retaining bolt.
Tighten to 48 Nm.
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9. Remove the powertrain assembly jack.
Remove the transaxle to the powertrain assembly jack securing
strap.
Tighten to 48 Nm.
11. Install the transaxle retaining nut.
Tighten to 48 Nm.
13. Install the transaxle mount bracket securing bolts.
Tighten to 48 Nm.
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Tighten to 48 Nm.
15. Attach the transaxle ground lead.
Tighten to 25 Nm.
Tighten to 35 Nm.
17. Install the support bar mount bracket.
Install the starter motor front retaining bolt.
Tighten to 35 Nm.
18. Install support bar mount bracket/transaxle upper retaining bolt.
Tighten to 48 Nm.
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19. Attach the starter motor solenoid electrical connector.
Tighten to 6 Nm.
20. Attach the starter motor electrical connector.
Tighten to 12 Nm.
21. Attach the starter motor solenoid cover.
22. Remove the support insulator retaining nut.
23. Install the support insulator bar.
Tighten to 133 Nm.
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24. Install the support bar retaining bolts.
Tighten to 25 Nm.
27. Attach the wiring harness from the camshaft cover retaining stud.
Tighten to 6 Nm.
28. Install the intake manifold support bracket.
Tighten to 10 Nm.
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29. Attach the electrical connector to the intake manifold support bracket.
30. Attach the positive crankcase ventilation (PCV) hose to the intake
manifold.
Tighten to 6 Nm.
33. Attach the generator wiring harness retaining clip to the camshaft
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35. Connect the transaxle electrical connectors.
36. Connect the transaxle fluid cooler tubes.
37. NOTE: Rotate the torque converter to gain access for the remaining
retaining bolts.
Install the torque converter retaining bolts.
Tighten to 55 Nm.
38. Install the torque converter retaining bolts access cover.
Tighten to 10 Nm.
39. NOTE: Remove the transaxle plug.
Using the special tool, install a new halfshaft seal.
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Detach the halfshaft.
42. CAUTIONS:
Make sure the halfshaft constant velocity (CV) joints do not over
articulate. Failure to follow this instruction may result in damage to the CV
joints.
Make sure the halfshaft seal is not damaged. Failure to follow this
instruction may result in an transaxle fluid leak.
Attach the right-hand halfshaft to the transaxle.
Make sure the halfshaft snap ring is correctly seated.
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Attach the right-hand halfshaft.
Engage the right-hand halfshaft to the transaxle.
Tighten to 25 Nm.
46. Install the transfer case.
Case, Installation).
47. Install the steering gear heat shield.
48. Install the steering gear heat shield bracket.
All vehicles
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Install the fender splash shield access panel.
50. Install the front subframe.
51. Tighten the right-hand shock absorber and spring assembly securing
nuts.
Tighten to 25 Nm.
52. Tighten the left-hand shock absorber and spring assembly securing
nuts.
Tighten to 25 Nm.
55. Check the transaxle fluid level.
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AWF21 -
Lubricant, Sealers, Solvents and Adhesives
High-temperature grease ESD-M1C220-A
Sealant WSK-M4G320-A
Adhesives Loctite 243
Fluid Maintenance
CAUTION: Use only C2S-51628 automatic transmission fluid. Use of any other fluids may result in a transmission malfunction or
failure.
Intervals
Normal Maintenance Not necessary. Filled for life.
Engine Dry Fill - Approximate Liters Refil - Approximate Liters Fluid Type
2.2L 6.6 5.6 C2S-51628
Description Nm lb-ft
Main control valve body screws 10 7
Torque converter retaining bolts 60 44
Transaxle retaining bolts 48 35
Emission control valve retaining bolts 30 22
Transaxle support insulator retaining nut 130 96
Transmission control module retaining nuts 24 18
Transmission fluid drain plug 47 35
Transmission fluid filler plug 40 30
Transmission fluid level plug 7 5
Transmission turbine shaft speed (TSS) sensor 6 4
Transmission fluid pan retaining bolts 13 10
Starter motor retaining bolts 35 26
Starter motor solenoid electrical connector retaining nut 6 4
Starter motor electrical connector retaining nut 12 9
Wiring harness to camshaft cover retaining stud, retaining nut 6 4
Intake manifold support bracket retaining bolts 10 7
Air cleaner mount bracket retaining nuts and bolt 6 4
Left-hand driveshaft retaining nuts 25 18
Shock absorber and spring assembly securing nuts 25 18
Transaxle ground lead 25 18
Support bar retaining bolts 25 18
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AWF21 - Transmission DescriptionVehicles With: 6-Speed Automatic Transaxle -
AWF21
COMPONENT LOCATION - AW F21 6 SPEED AUTOMATIC TRANSMISSION 2009MY
1 - Selector cable
2 - Cable bracket
3 - Transmission selector lever assembly
4 - Transmission Control Module (TCM)
5 - Lever arm
6 - Automatic transmission
7 - Transmission fluid cooler
OVERVIEW
The AW F21 automatic transmission is a 6 speed, electronically controlled unit manufactured by Aisin AW in Japan. The transmission
represents the latest in automatic transmission technology for a transverse unit. The transmission features lock-up slip control, 'Jaguar
Sequential Shift' functions and automatic and driver selectable modes to give the optimum performance.
The transmission is controlled by a TCM (transmission control module) which contains software to provide operation as a semi-automatic
'Jaguar Sequential Shift' transmission. The TCM allows the transmission to be operated as a conventional automatic unit by selecting P, R,
N, D on the selector lever. Movement of the selector lever across the gate to the 'M/S' position puts the transmission into electronic 'Sport'
mode. Further movement of the lever in a longitudinal direction to the + or position puts the transmission into electronic manual 'Jaguar
Sequential Shift' mode.
For additional information, refer to: External Controls - Vehicles With: 6-Speed Automatic Transaxle - AWF21 (307-05B Automatic
Transmission/Transaxle External Controls - Vehicles With: 6-Speed Automatic Transaxle - AWF21, Description and Operation).
The AW F21 transmission has the following features:
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Designed to be maintenance free
Torque capacity of 450 Nm
Transmission fluid is fill for life
The torque converter features a controlled slip feature with electronically regulated lock-up control on gears 2 to 6
Shift programs controlled by the TCM
TCM has an adaptive capability to ensure efficient gear shift quality throughout the service life of the transmission
Diagnostics available from the TCM via the high speed CAN (controller area network) bus.
TRANSMISSION
The transmission comprises the main casing which houses all of the transmission components. The torque converter is located in a separate
converter housing.
AW F21 Automatic Transmission - Sectional View
1 - Clutch - C2
2 - Brake - B2
3 - One-way clutch - F1
4 - Clutch - C1
5 - Brake - B1
6 - Clutch - C3
7 - Torque converter
8 - Fluid pump
9 - Differential assembly
10 - Counter driven gear
11 - Counter drive gear
The main casing retains the fluid at the bottom. A combined drain/filler plug is located in the bottom of the casing. The oil level is checked
by removing the inner fill plug when the transmission fluid is at a temperature of between 50 to 60C (122 to 140F). When the oil flow
becomes a drip from the plug hole, the level is correct.
The transmission has a fluid cooler which is located on the LH (left-hand) end of the engine cooling radiator. The cooler is connected to the
transmission converter housing by 2 pipes. The fluid cooler is connected into the engine cooling system and cools the transmission fluid by
heat transfer through the cooler to the engine coolant.
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For additional information, refer to: Transmission Cooling - Vehicles With: 6-Speed Automatic Transaxle - AWF21 (307-02B
Transmission/Transaxle Cooling - Vehicles With: 6-Speed Automatic Transaxle - AWF21, Description and Operation).
TORQUE CONVERTER
1 - Torque converter housing
2 - Lock-up clutch
3 - Turbine
4 - Impeller
5 - Stator
6 - Fluid pump
7 - Input shaft
The torque converter is the coupling element between the engine and the transmission and is located in the transmission housing, on the
engine side of the transmission. The driven power from the engine crankshaft is transmitted hydraulically and mechanically through the
torque converter to the transmission. The torque converter is connected to the engine by a drive plate.
The torque converter comprises an impeller, a stator and a turbine. The torque converter is a sealed unit with all components located
between the converter housing cover and the impeller. The two components are welded together to form a sealed, fluid filled housing. With
the impeller welded to the converter housing cover, the impeller is therefore driven at engine crankshaft speed.
The torque converter contains a hydraulically operated lock-up clutch which is controlled by the TCM via a solenoid in the valve block which
actuates spool valves to control the hydraulic pressure applied to the clutch. This allows the TCM to provide 3 modes of converter operation;
unlocked, partially locked and fully locked.
VALVE BLOCK
The valve block is located in a vertical position at the front of the transmission main casing, behind a sealed cover. The valve block contains
a number of solenoids, dampers and spool valves to control the transmission operation. The solenoids are controlled by the TCM to provide
gear changes and smooth transition between ratio changes.
Solenoids
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1 - 3-Way solenoid - S2
2 - Shift control solenoid - SLC2
4 - Valve block
5 - Lock-up control solenoid - SLU
7 - Shift control solenoid - SLB1
8 - 3-Way solenoid - S1
9 - Line pressure control solenoid - SLT
Shift Control Solenoids - SLC1, SLC2, SLC3, SLB1
The shift control solenoids (SLC1, SLC2, SLC3 and SLB1) are installed on the front valve body. The solenoids respond to inputs from the TCM
and control the hydraulic pressure applied to the clutches (C1, C2 and C3) and to the brake B1 to provide smooth shifting. The TCM uses a
single or a combination of these solenoids to provide shifts from 1st to 6th gear.
If a solenoid fails, the TCM will remove the current to the shift control solenoids and the transmission will use limp home mode, to prevent
damage to the transmission.
Line Pressure Control Solenoid - SLT
The line pressure control solenoid (SLT) is installed on the front valve body. The solenoid is controlled in a linear manner by the TCM which
uses throttle opening degree signals and engine torque information from the ECM (engine control module) to determine the solenoid
operation. The solenoid controls the line pressure applied to the clutches and brakes to provide smooth shifting.
If the solenoid fails, the TCM will remove the current supplied to the solenoid. Maximum line pressure will be applied to the clutches and
brakes unless the failure is due to the solenoid valve sticking, which may result in low line pressure.
Lock-Up Control Solenoid - SLU
The lock-up control solenoid is installed on the front valve body. The solenoid is controlled in a linear manner by the TCM which uses engine
speed, throttle opening degree signals and transmission speed sensor signals to determine the solenoid operation. The solenoid controls
the amount of lock-up or slip required for the torque converter lock-up clutch.
If the solenoid fails, the TCM removes the current supplied to the solenoid which results in no torque converter lock-up being applied.
3-Way Solenoid - S1, S2
The 3-way solenoid (S1) is located on the center valve body and solenoid (S2) is located on the front valve body. The solenoids are on/off
solenoids controlled by the TCM. A combination of the 2 solenoids is used to operate either the 1st gear engine braking or enable gear
shifts.
If a solenoid fails, the TCM will remove the current supplied to both solenoids.
Speed Sensors
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1 - Speed Sensor (SP) - Output shaft speed
3 - C2 clutch drum
4 - Speed sensor (NIN)
Two speed sensors (NIN and SP) are used in the transmission and are located within the transmission housing. Speed sensor (SP) is located
adjacent to the counter drive gear and reads from the gear teeth to provide an output shaft speed signal. Speed sensor (NIN) is located
adjacent to the clutch C" drum and reads off teeth on the outer circumference of the drum to provide an input shaft speed. Both speed
signals are received by the TCM which uses the 2 signals to calculate engine torque output, shift timing and torque converter lock-up.
Fluid Temperature Sensor
The fluid temperature sensor is integrated into the internal wiring harness within the transmission. It detects the fluid temperature in the
hydraulic pressure control circuit and transmits a signal corresponding to the temperature to the TCM. The TCM monitors the temperature
and provides smooth gear shifts across a wide range of temperatures.
DRIVE CLUTCHES
Multiplate Drive or Brake Clutch Typical
1 - Input shaft
2 - Main pressure supply port
3 - Piston
4 - Cylinder External plate carrier
5 - Clutch plate assembly
6 - Baffle plate
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7 - Diaphragm spring
8 - Output shaft
9 - Bearing
10 - Dynamic pressure equalisation chamber
11 - Piston chamber
12 - Lubrication channel
There are three drive clutches and two brake clutches (B2 is a multiplate brake clutch & B1 is a double wrap brake band) used in the AW F21
transmission. Each clutch comprises one or more friction plates dependent on the output controlled. A typical clutch consists of a number of
steel outer plates and inner plates with friction material bonded to each face.
Clutch / Brake Operation
C1 Clutch Connects the front planetary carrier to the rear planetary rear sun gear
C2 Clutch Connects the intermediate shaft to the rear planetary carrier
C3 Clutch Connects the front planetary carrier to the rear planetary middle sun gear
B1 Brake Locks the rear planetary middle sun gear
B2 Brake Locks the rear planetary carrier
The clutch plates are held apart mechanically by a diaphragm spring and hydraulically by dynamic pressure. The pressure is derived from a
lubrication channel which supplies fluid to the bearings etc. The fluid is passed via a drilling in the output shaft into the chamber between
the baffle plate and the piston. To prevent inadvertent clutch application due to pressure build up produced by centrifugal force, the fluid in
the dynamic pressure equalization chamber overcomes any pressure in the piston chamber and holds the piston off the clutch plate
assembly.
When clutch application is required, main pressure from the fluid pump is applied to the piston chamber from the supply port. This main
pressure overcomes the low pressure fluid present in the dynamic pressure equalization chamber. The piston moves, against the pressure
applied by the diaphragm spring, and compresses the clutch plate assembly. When the main pressure falls, the diaphragm spring pushes
the piston away from the clutch plate assembly, disengaging the clutch.
One-Way Clutch
One-Way clutch - Typical
1 - Roller
2 - Cage
3 - Spring
4 - Inner race
The roller clutch used on the one-way clutch uses parallel rollers, located between the smooth, cylindrical inner race and the inclined cam
faces of the clutch body. Springs are used to hold the rollers in position between the two contact faces.
When the clutch is rotated in a clockwise direction, the rollers become trapped between the inner race and the inclined cam faces of the
clutch body, providing positive (locked) rotation of the inner race, locking the counter-clockwise rotation of the rear planetary carrier. When
the clutch is rotated in a clockwise direction, the rollers are moved away from the inclined cam faces and can rotate freely (unlocked) with
the clutch body, providing no drive from the clutch to the rear planetary carrier. In this condition the clutch can rotate freely on the inner
race.
PLANETARY GEAR TRAIN
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1 - Clutch C2
2 - Brake B2
3 - One way clutch F1
5 - Brake B1
6 - Clutch C1
7 - Clutch C3
8 - Fluid pump
9 - Input shaft
10 - Differential gear assembly
11 - Counter gear assembly
12 - Pinion gears
13 - Sun gears
14 - Ring gear
15 - Pinion gear
16 - Sun gears
17 - Ring gear
The planetary gear trains used on the AW F21 transmission comprise a single web planetary gear train and a double web planetary gear
train. These gear trains are known as Ravignaux type gear trains and together produce the six forward gears and the one reverse gear.
Engine torque is transferred, via operation of single or combinations of clutches to the two planetary gear trains. Both gear trains are
controlled by reactionary inputs from brake clutches to produce the six forward gears and one reverse gear. The ratios are as follows:
Gear 1st 2nd 3rd 4th 5th 6th Reverse
Ratio 4.148 2.370 1.556 1.155 0.859 0.686 3.394
POWER FLOWS
Operation of the transmission is controlled by the TCM which electrically activates various solenoids to control the transmission gear
selection. The sequence of solenoid activation is based on programmed information in the module memory and physical transmission
operating conditions such as vehicle speed, throttle position, engine load and selector lever position.
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1 - Clutch - C2
2 - Brake - B2
3 - One-way clutch - F1
4 - Brake - B1
5 - Clutch - C1
6 - Clutch - C3
Power Flow - 1st Gear Engine Braking
Solenoid Operation
Transmission Selector Lever Position Solenoid
SLC 1 SLC 2 SLC 3 SLB 1 S1 S2
D Engine Brake - X X X X X
X = Operating
Clutch and Brake Operation
Transmission Selector Lever Position Clutch Brake One-Way clutch
C1 C2 C3 B1 B2 F1
D Engine Brake X - - - X X
X = Operating
When the engine brake is active, driving force is transmitted to the transmission from the road wheels, via the power transfer unit. The rear
planetary carrier is locked from clockwise rotation by the one-way clutch (F1) and brake (B2). This results in torque from the wheels being
transmitted directly to the engine, providing engine braking.
Power Flow - 1st Gear
Solenoid Operation
D 1st Gear - X X X - -
X = Operating
C1 C2 C3 B1 B2 F1
D 1st Gear X - - - - X
X = Operating
The planetary gear trains are in the following conditions:
Front planetary gear train
- Input: Ring gear
- Locked: Sun gear
- Output: Carrier
Rear planetary gear train
- Input: Rear sun gear
- Locked: Carrier
- Output: Ring gear
Front Planetary Gear Train
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The input shaft rotates in a clockwise direction, driven by the torque converter. The planetary ring gear rotates in a clockwise direction along
with the planetary pinion gear which also rotates clockwise on its axis and orbit. The planetary sun gear is locked by the fluid pump which
causes it to press against the planetary ring gear and orbit the sun gear, rotating on its axis.
The front planetary carrier rotates clockwise in the same direction as the planetary pinion gear. The clutch (C1) is activated and locks the
planetary carrier to the rear planetary sun gear.
Rear Planetary Gear Train
The planetary sun gear rotates in a clockwise direction. The planetary short pinion gear rotates in a counter-clockwise direction. The
planetary carrier attempts to rotate in the same direction but is restrained by the one-way clutch (F1).
The long pinion gear rotates clockwise on its axis and the middle sun gear rotates counter-clockwise while idling. The ring gear is rotated by
the long pinion gear and drives the counter drive gear in a clockwise direction.
The counter driven gear is driven in a counter-clockwise direction which in turn drives the differential ring gear in a clockwise direction.
Power Flow - 2nd Gear
Solenoid Operation
D 2nd Gear - X X - - -
X = Operating
C1 C2 C3 B1 B2 F1
D 2nd Gear X - - X - -
X = Operating
- Input: Ring gear
- Locked: Sun gear
- Output: Carrier
- Input: Rear sun gear
- Locked: Middle sun gear
- Output: Ring gear
planetary carrier to the rear planetary sun gear.
The planetary sun gear and the carrier rotate in a clockwise direction. The middle sun gear is locked by the brake (B1). The short pinion
gears rotate counter-clockwise on its axis and orbits in a clockwise direction. The long pinion gears rotates clockwise on its axis and its
orbit.
The ring gear is rotated in a clockwise direction by the long pinion gear. The ring gear and the counter drive gear both rotate in a clockwise
direction.
The counter driven gear is driven in a counter-clockwise direction which in turn drives the differential ring gear in a clockwise direction.
NOTE: Engine braking is available when this gear is selected.
Power Flow - 3rd Gear
Solenoid Operation
D 3rd Gear - X - X - -
X = Operating
C1 C2 C3 B1 B2 F1
D 3rd Gear X - - X - -
X = Operating
- Input: Ring gear
- Locked: Sun gear
- Output: Carrier
- Input: Middle sun gear
- Locked: -
- Output: Ring gear
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planetary carrier to the rear planetary sun gear. Clutch (C3) is also activated and locks the carrier to the middle sun gear.
The planetary short pinion gear and the long pinion gear are engaged which causes both pinion gears to lock due to the different rotational
directions. Torque from the sun gear and middle sun gear is transmitted to the planetary ring gear which rotates clockwise in the same
direction as the planetary carrier.
The counter drive gear rotates in a clockwise direction with the ring gear.
The counter driven gear is rotated in a counter-clockwise direction which in turn drives the differential ring gear in a clockwise direction.
Power Flow - 4th Gear
Solenoid Operation
D 4th Gear - - X X - -
X = Operating
C1 C2 C3 B1 B2 F1
D 4th Gear X X - - - -
X = Operating
- Input: Ring gear
- Locked: Sun gear
- Output: Carrier
- Input: Rear sun gear, Carrier
- Locked: -
- Output: Ring gear
planetary carrier to the rear planetary sun gear. The intermediate shaft rotates in the same direction as the input shaft. Clutch (C2) is also
activated rotates in the same direction as the intermediate shaft.
The planetary carrier rotates in a clockwise direction with the intermediate shaft. The short pinion gear rotates clockwise on its axis and
orbits at a faster speed than the sun gear. The long pinion gear rotates counter-clockwise on its axis and orbit. The rotation of the ring gear
is in a clockwise direction and is slower than the rotation of the carrier due to the long pinion gear's rotation is counteracted by the
planetary carrier.
The counter drive gear rotates in a clockwise direction with the ring gear.
Solenoid Operation
D 5th Gear X - - X - -
X = Operating
C1 C2 C3 B1 B2 F1
D 5th Gear - X X - - -
X = Operating
- Input: Ring gear
- Locked: Sun gear
- Output: Carrier
- Locked: -
- Output: Ring gear
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planetary carrier to the rear planetary middle sun gear. The intermediate shaft rotates in the same direction as the input shaft. Clutch (C2)
is also activated and rotates in the same direction as the intermediate shaft.
The middle sun gear rotates clockwise in the same direction as clutch (C3). The deceleration of the front planetary gear slows the speed of
the input shaft. The intermediate shaft rotates clockwise in the same direction as the input shaft. The planetary carrier also rotates
clockwise in the same direction as the intermediate shaft.
The long pinion gear rotates clockwise on its axis and orbit. The carrier rotates faster than the middle sun gear which causes the middle
pinion gear to be cancelled out by the speed difference. The middle pinion gear orbits and rotates on its axis in a clockwise direction.
The planetary ring gear rotates in a clockwise direction. The speed of the ring gear is faster than the planetary carrier because the long
pinion gear's rotation is combined with the planetary carrier's speed. The counter drive gear rotates in a clockwise direction with the ring
gear.
Solenoid Operation
D 6th Gear X - X - - -
X = Operating
C1 C2 C3 B1 B2 F1
D 6th Gear - X - X - -
X = Operating
- Input: -
- Locked: -
- Output: -
- Input: Carrier
- Locked: Middle sun gear
- Output: Ring gear
The input shaft rotates in a clockwise direction, driven by the torque converter. The intermediate shaft rotates clockwise in the same
direction as the torque converter. Clutch (C2) locks the intermediate shaft to the rear planetary carrier.
The planetary carrier rotates clockwise in the same direction as the intermediate shaft. The planetary long pinion gear rotates clockwise on
its axis and orbit. The rotational speed of the middle sun gear increases with input shaft speed because it is locked.
The planetary ring gear rotates in a clockwise direction. The speed of the ring gear is faster than the planetary carrier because the long
pinion gear's rotation is combined with the planetary carrier's speed. The counter drive gear rotates in a clockwise direction with the ring
gear.
Power Flow - Reverse Gear
Solenoid Operation
R Reverse Gear - Less than 11 volts X X - X - -
R Reverse Gear - More than 11 volts X X X X X X
X = Operating
C1 C2 C3 B1 B2 F1
R Reverse Gear - Less than 11 volts - X - X - -
R Reverse Gear - More than 11 volts - - - - X -
X = Operating
- Input: Ring gear
- Locked: Sun gear
- Output: Carrier
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- Locked: Carrier
- Output: Ring gear
The input shaft rotates in a clockwise direction, driven by the torque converter. The planetary ring gear rotates clockwise with the input
shaft.
The pinion gear rotates clockwise on its axis and orbit. The planetary sun gear is l ocked by the fluid pump which causes it to press against
the planetary ring gear and orbit the sun gear, rotating on its axis. The planetary carrier rotates clockwise with the pinion gear orbit.
Clutch (C3) is activated and rotates clockwise and locks the planetary carrier to the rear planetary middle sun gear.
The middle sun gear rotates clockwise with the clutch (C3), but at a lower speed than the input shaft. Brake (B2) is activated and locks the
planetary carrier. The long pinion gear rotates counter-clockwise which in turn rotates the ring gear counter-clockwise.
The counter drive gear rotates in a counter-clockwise direction with the ring gear at the same speed.
The counter driven gear is rotated in a clockwise direction which in turn drives the differential ring gear in a counter-clockwise direction.
Power Flow Neutral
Solenoid Operation
N Neutral X X X X - -
X = Operating
C1 C2 C3 B1 B2 F1
N Neutral - - - - - -
X = Operating
In neutral, all the solenoids, except the 3 way solenoids, are energised and the clutches and brakes are all disengaged. This allows rotation
from the input shaft to rotate the front planetary gear train without transferring any drive to the differential ring gear.
TOWING FOR RECOVERY
WARNING: If the engine cannot be run whilst the vehicle is being towed, there will be no power assistance for the steering or brakes.
This will result in greater effort being required to steer or slow the vehicle, and greatly increased stopping distances.
CAUTION: The vehicle should only be towed for a maximum of 80 km (50 miles), at a maximum speed of 80 km/h (50 mph). Towing for
a greater distance, or at a higher speed may result in serious damage to the transmi ssion.
NOTE: The recommended recovery method is by trailer or recovery vehicle.
Secure the towing attachment from the recovery vehicle to the front towing eye.
Switch on the ignition to ensure that the steering lock is dis-engaged.
NOTE: Leaving the ignition switched on for extended periods will cause the battery to drain.
Apply the foot brake, and move the selector lever to the neutral 'N' position. With the footbrake still applied, release the park brake. If
electrical power to the selector is not available, the emergency release lever on the selector lever can be used to release the interlock
solenoid.
The vehicle can be towed a maximum of 80 km (50 miles) at a maximum speed of 80 km/h (50 mph).
Park the vehicle on firm, level ground. Apply the park brake and move the selector lever to the park 'P' position.
Switch off the ignition.
CAUTION: The vehicle cannot be towed in a reverse direction.
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AWF21 - Transmission Electronic Control SystemVehicles With: 6-Speed Automatic
Transaxle - AWF21
CONTROL DIAGRAM - AW F21 6 SPEED AUTOMATIC TRANSMISSION 2009MY
NOTE: A = Hardwired; D = High speed CAN bus; O = LIN bus
1 - Battery
2 - Battery Junction Box (BJB)
3 - Central Junction Box (CJB)
4 - Transmission Control Module (TCM)
5 - Selector lever
6 - Selector lever PRND and M/S Light Emitting Diode (LED) displays
7 - High speed Controller Area Network (CAN) bus to other vehicle systems
8 - Instrument cluster
9 - Steering angle sensor
10 - Anti-lock Brake System (ABS) module
11 - Engine Control Module (ECM)
TRANSMISSION CONTROL MODULE (TCM)
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1 - TCM
2 - 'Neutral 'N' position
3 - Park 'P' position
4 - Position sensor/manual shaft
5 - Electrical connector
The TCM (transmission control module) is located on the top of the transmission casing and is connected on the high speed CAN (controller
area network) bus to send and receive information to and from other system modules.
The TCM outputs signals to operate the transmission solenoid valves to control the hydraulic operation of the transmission.
The ECM (engine control module) supplies the engine management data on the high speed CAN bus system. The TCM requires engine data
to efficiently control the transmission operation, using for example; crankshaft torque, engine speed, accelerator pedal angle, engine
temperature etc.
The TCM processes signals from the transmission speed and temperature sensors, ECM and other vehicle systems. From the received signal
inputs and pre-programmed data, the module calculates the correct gear, torque converter clutch setting and optimum pressure settings for
gear shift and lock-up clutch control.
The steering angle sensor and the ABS (anti-lock brake system) module also supply data to the TCM on the high speed CAN bus system.
The TCM uses data from these systems to suspend gear changes when the vehicle is cornering and/or the ABS module is controlling braking
or traction control.
The TCM is positioned over the manual shaft which protrudes through an oil seal on the top face of the main casing. The shaft locates in a
rotary position sensor and turns the sensor in the appropriate direction when a selection is made using the selector lever. The rotary
position sensor is a Hall effect sensor which outputs a specified voltage relating to the selected selector lever position.
The selector lever is connected to the automatic transmission and the rotary position sensor in the transmission by a Bowden cable.
Movement of the selector lever moves the position switch via the Bowden cable and the switch position informs the TCM of the selected
position; P, R, N or D. The sport and manual +/- 'Jaguar Sequential Shift' switch passes sport or manual selections to the TCM on a LIN
(local interconnect network) bus. The TCM outputs appropriate information on the high speed CAN bus which is received by the instrument
cluster to display the gear selection information in the message center.
If the TCM or transmission requires replacement, a setting procedure must be performed using a Jaguar approved diagnostic system to allow
the TCM to learn the neutral position of the transmission. The TCM uses the neutral position as a reference point for each of the gear
positions P, R, N and D.
INSTRUMENT CLUSTER
The instrument cluster is connected to the TCM via the CAN.
For additional information, refer to: Instrument Cluster (413-01 Instrument Cluster, Description and Operation).
Message Center Display
The message center is located in the speedometer. The message center is a LCD (liquid crystal display) to relay vehicle status information
to the driver. The message center will display 'SPORT' when sport mode is selected.
For additional information, refer to: Information and Message Center (413-08 Information and Message Center, Description and Operation).
CONTROLLER AREA NETWORK (CAN)
The high speed CAN broadcast bus network is used to connect the powertrain modules. The CAN bus is connected between the following
electronic units:
High Speed CAN Bus
TCM
Instrument cluster
Steering angle sensor
Restraints control module
ECM
ABS module.
Diagnostic socket.
The CAN bus allows a fast exchange of data between modules. The CAN bus comprises two wires which are identified as CAN high (H) and
CAN low (L). The two wires are colored green and yellow and are twisted together to minimise electromagnetic interference (noise) produced
by the CAN bus messages.
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For additional information, refer to: Communications Network (418-00 Module Communications Network, Description and Operation).
In the event of CAN bus failure, the following symptoms may be observed:
Transmission operates in default mode
Torque converter lock-up clutch control is disabled.
DRIVING MODES
A number of different driving modes are available. Some can be selected by the driver and some are automatically initiated by the TCM to
adapt to different driving conditions.
Normal
Sports
Manual 'Jaguar Sequential Shift'
Cooling
Cruise
Limp home
Coast
Fast off recognition
Uphill and Trailer
Downhill
Wide Throttle
Reverse lock-out
Normal
Normal mode is automatically selected by the TCM when the ignition is switched on. In this mode all automatic and adaptive modes are
active. Normal mode uses gear shift and lock-up maps which provides the optimum of fuel consumption, emissions and driveability,
depending on the driving style.
If the transmission is operated in sport mode or 'Jaguar Sequential Shift' mode and the selector lever is moved back to the drive 'D'
position, then normal mode operation is resumed.
Sports
Sports mode provides enhanced acceleration and responsiveness by the use of sports shift maps. This mode allows the transmission to
down shift more readily and hold gears for longer at higher engine speeds.
Manual 'Jaguar Sequential Shift'
Manual 'Jaguar Sequential Shift' mode allows the transmission to operate as a semi-automatic transmission. The driver can change up and
down the six forward gears with the freedom of a manual transmission.
Shift maps are provided to protect the engine at high speeds. The TCM will automatically change up to a higher gear ratio to prevent engine
overspeed and change down to a lower gear ratio to avoid engine laboring and stalling.
When kick-down is requested the TCM shifts down to the lowest available gear. When the vehicle is stationary, the driver can select 1st,
2nd or 3rd to start off.
When moving from a standstill, upshifts can be pre-selected by making '+' selections with the selector lever for the number of upshifts
required. The TCM then performs the requested number of upshifts when appropriate shift points are reached. For example; when moving off
in 1st gear, if 3 '+' selections are made in quick succession, the TCM will automatically upshift through the gears to 4th gear as the vehicle
accelerates, without any further selections being made.
Cooling
Cooling mode is activated when the TCM detects excessively high transmission fluid or engine coolant temperatures. When this mode is
active torque converter lock-up is activated earlier to minimize a further rise in fluid and/or engine coolant temperature and assist fluid
cooling.
Cruise
When speed control is activated, the TCM receives a speed control active message on the high speed CAN bus. The TCM activates a speed
control map which minimizes up and down shifts.
Cruise mode is active when speed control is selected on and the transmission is in drive 'D' or sport 'S'. Unique cruise maps override the
current mode to provide a smooth driving feel and mode reselection.
Limp home
If a transmission fault is detected by the TCM, the TCM adopts a limp home strategy and a message 'TRANSMISSION FAULT LIMITED GEARS
AVAILABLE' is displayed in the message center. If the fault has an effect on engine emissions, the MIL (malfunction indicator lamp) in the
instrument cluster will also be illuminated.
In limp home mode, P, R and N functions operate normally (if the fault allows these selections) and the TCM locks the transmission in 3rd
gear to allow the driver to take the vehicle to a Jaguar dealer or approved repairer. Torque converter lock-up is disabled and reverse-lock-out
will not function.
If the vehicle is stopped and subsequently restarted in the limp home mode condition, the TCM operates normally until the fault which
caused the condition is detected again.
Coast
Coast mode provides earlier downshifts during coasting dependant on output shaft deceleration rate to improve driveability and refinement
by avoiding negative to positive driveline torque reversals transmission during the downshifts.
Fast Off Recognition
Fast off recognition is activated when the TCM detects that the driver has released the accelerator pedal quickly. This is detected by the
TCM monitoring for a high level of negative pedal angle from ECM signals on the high speed CAN bus. If this condition is detected, the TCM
holds the current gear ratio to allow the driver to complete the manoeuvre without the need for a downshift. The mode can remain active for
a predetermined length of time or if the driving style remains passive.
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Fast off recognition mode assists vehicle stability and is used in conjunction with a lateral acceleration input during cornering to maintain
the current gear until the corner is negotiated.
Uphill and Trailer
Uphill and trailer mode can be active when the transmission is operating in normal or sport `modes. When the vehicle is pulling a trailer or
driving up an incline, the TCM detects the increased resistance by monitoring engine torque and speed signals received from the ECM on the
high speed CAN bus and also transmission output shaft speed sensor signals. Uphill and trailer mode will provide downshifts to prevent a
drop in transmission torque output and maintain driving force.
Downhill
Downhill mode can be active when the transmission is operating in normal or sport modes. When the vehicle is descending an incline the
TCM detects a reduction in resistance by monitoring engine torque and speed signals received from the ECM on the high speed CAN bus and
also transmission output shaft speed sensor signals. Downhill mode assists engine braking by selecting an appropriate gear reducing the
load required on the brakes.
Wide Throttle
Wide open throttle mode operates for part throttle upshifts and kick-down upshifts. It provides consistent wide open throttle upshift
performance under all driving conditions. The full engine speed range is used in all driving modes; normal, sport, hill modes and Jaguar
Sequential Shift. Compensation is used for delays (hydraulic and electronic) in gear change request to gear change start to provide smooth
changes and correct shift point correction.
Reverse Lock-Out
If the selector lever is moved from N to R and the vehicle is travelling forwards, reverse selection is prevented if the vehicle speed is 11
km/h (6.8 mph) or more. When reverse lock-out is activated, the clutch (C3) is released without energizing solenoid (SLC3), preventing the
transmission from selecting reverse gear.
TRANSMISSION FAULT STATUS
If the TCM detects a fault with the transmission system, it will enter a default (limp home) mode to prevent further damage to the
transmission and allow the vehicle to be driven. If possible reverse gear will be available and also 3rd gear only.
When a fault is detected a high speed CAN message is sent from the TCM and is received by the instrument cluster. The instrument cluster
illuminates the MIL (if required) and displays an applicable message in the message center.
For additional information, refer to: Information and Message Center (413-08 Information and Message Center, Description and Operation).
Some transmission faults may not illuminate the MIL or display a fault message, but the driver may notice a reduction in shift quality.
ENGINE SPEED AND TORQUE MONITORING
The ECM constantly supplies the TCM with information on engine speed and torque through messages on the CAN bus. The TCM uses this
information to calculate the correct and appropriate timing of shift changes.
If the messages are not received by the ECM, the TCM will implement a back-up strategy to protect the transmission from damage and
allow the vehicle to be driven.
In the event of an engine speed or torque signal failure, the transmission will adopt the electrical limp home mode with the transmission
operating in a fixed gear.
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AWF21 - Diagnostic StrategyVehicles With: 6-Speed Automatic Transaxle - AWF21
For a detailed description of the automatic transmission/transaxle, refer to the relevant Description and Operation sections in the workshop
manual.REFER to: Transmission Description (307-01, Description and Operation).
Mechanical Electrical Hydraulic
Damaged/stuck shift mechanism
Damaged automatic transmission casing
Blown fuse(s)
Wiring harness
Transmission Control Module (TCM)
Gear Selection Module (GSM)
Fluid level too high/low
Poor condition of fluid
Fluid leak
step.
3.
4. If the cause is not visually evident, verify the symptom and refer to the Symptom Chart. 4.
DTC Index
3548-1358-00.
NOTE: If the control module/transmission is suspect and the vehicle remains under manufacturer warranty, refer to the Warranty Policy
and Procedures manual (section B1.2), or determine if any prior approval programme is in operation, prior to the installation of a new
module/transmission.
NOTE: Generic scan tools may not read the codes listed, or may read only five digit codes. Match the five digits from the scan tool to the
first five digits of the seven digit code listed to identify the fault (the last two digits give additional information read by the manufacturer
approved diagnostic system).
NOTE: When performing electrical voltage or resistance tests, always use a digital multimeter (DMM) accurate to three decimal places,
and with an up-to-date calibration certificate. When testing resistance, always take the resistance of the DMM leads into account.
Service Routines
Carry out the service routines listed below when instructed to do so by the repair 'action' of the DTC Index
1. Vehicle Configuration Main Menu, Configure New Modules, Transmission Control Module: This routine is used to install
software into a new TCM. The routine must be performed if a new TCM has been install ed.
1.
2. Vehicle Configuration Main Menu, Configure New Modules, On Demand Self Test: This routine is used to check that the TCM is
installed without any electrical errors. When the routine is activated the TCM will test all outputs for electrical errors. The routine
must be performed if the TCM has been separated from the transmission.
2.
3. Vehicle Configuration Main Menu, Configure Existing Modules, Transmission Control Module: This routine is used to install
software into an existing TCM. The routine must be performed if an existing TCM is having its software updated.
3.
4. Vehicle Configuration Main Menu, Special Applications, Transmission Control Module Neutral Learn:: This routine is used to
re-calibrate the neutral position. The routine must be performed if the TCM has been separated from the transmission, TCM
software is updated or TCM hardware is updated.
4.
5. Vehicle Configuration Main Menu, Special Applications, Clear Self Learning Data: This routine is used to clear the solenoid
adaptation in the TCM. The routine must be performed if the transmission is replaced and TCM is reused.
5.
6. Vehicle Configuration Main Menu, Special Applications, Set Adaption Mode: This routine is used when the transmission is
replaced. When this is done the transmission must be pre adapted before the customer drives the car, otherwise bad shifts might
occur.
6.
7. Vehicle Configuration Main Menu, Special Applications, Oil Change Reset: This routine is used to clear the counter that counts
the oil degradation. The data needs to be erased if the oil is exchanged or if the transmission is replaced and the TCM is reused.
7.
8. Vehicle Configuration Main Menu, Special Applications, TCM Adaption Clear: This routine is used to rest the self learning data
in the TCM. The routine must be performed after a software update, if the TCM has been installed to another vehicle or if any
mechanical components have been replaced in the transmission.
8.
P021868 Transmission Fluid
Over temperature
Condition
Event information. System
event not caused by the TCM,
but requiring the TCM to
record this DTC
Check the transmission fluid level and condition. Check the
transmission fluid cooler/hoses for signs of obstruction, damage,
blockage. Replace as required. Check the engine cooling system and
engine cooling fans operation. Suspect the TCM/transmission, check
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Transmission fluid level low
Transmission fluid
cooler/hoses are obstructed,
damaged, blocked
Mechanical fault in the
transmission
Engine cooling system failure
and install a new TCM/transmission as required, refer to the new
module/component installation note at the top of the DTC Index.
Refer to service routines at the top of the DTC Index and carry out
service routines as required using the manufacturer approved
diagnostic system
P050000 Vehicle Speed Sensor
A
Vehicle speed sensor circuit
SP+ or SP- open circuit
Vehicle speed sensor failure
Vehicle speed sensor circuit
SP+ short to ground
Internal failure in TCM
Carry out any diagnostic pinpoint tests associated with this DTC using
the manufacturer approved diagnostic system. Suspect the TCM, check
and install a new TCM as required, refer to the new
diagnostic system
P056100 System Voltage
Unstable
Battery voltage too low
Battery voltage too high
High contact resistance or
oxidation in the connector on
the TCM or the transmission
Battery charger with incorrect
voltage has been used
Charging system failure
the manufacturer approved diagnostic system. Refer to the electrical
guides and check BAT+ circuit for correct battery voltage, open circuit,
oxidation in connector terminals. Check the vehicle charging system.
Suspect the TCM, check and install a new TCM as required, refer to the
new module/component installation note at the top of the DTC Index.
diagnostic system
P056200 System Voltage Low Battery voltage too low
High contact resistance or
oxidation in the connector on
the TCM or the transmission
Battery charger with incorrect
voltage has been used
Charging system failure
guides and check BAT+ circuit for correct battery voltage, open circuit,
oxidation in connector terminals. Check the vehicle charging system.
diagnostic system
P060100 Internal Control
Module Memory Check
Sum Error
Internal failure in TCM Using the manufacturer approved diagnostic system select the vehicle
configuration main menu, select configure existing modules menu and
programme the transmission control module. Suspect the TCM, check
diagnostic system
Module Keep Alive
Memory (KAM) Error
diagnostic system
Module Random
Access Memory (RAM)
Error
diagnostic system
Module Read Only
Memory (ROM) Error
diagnostic system
P062F00 Internal Control
Module EEPROM Error
diagnostic system
P070500 Transmission Range
Sensor A Circuit
(PRNDL Input)
Incorrect adjustment of gear
selector lever cable
position sensor
Check the adjustment of the gear selector lever cable. Carry out
neutral learn service routine. Suspect the TCM, check and install a new
TCM as required, refer to the new module/component installation note
at the top of the DTC Index. Refer to service routines at the top of
the DTC Index and carry out service routines as required using the
manufacturer approved diagnostic system
Sensor A Circuit
Intermittent
selector lever cable
position sensor
Check the adjustment of the gear selector lever cable. Carry out
neutral learn service routine. Suspect the TCM, check and install a new
Temperature Sensor A
Circuit
Range/Performance
High contact resistance in the
connector terminals
Failure of oil temperature
sensor
Check for high contact resistance in the connector terminals between
the TCM and transmission. Suspect the TCM, check and install a new
at the top of the DTC Index. Suspect the transmission, check and
install a new transmission as required, refer to the new
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diagnostic system
Circuit Low
Short to ground on the OT
circuit of the oil temperature
sensor
sensor
Suspect the transmission, check and install a new transmission as
required, refer to the new module/component installation note at the
top of the DTC Index. Suspect the TCM, check and install a new TCM
as required, refer to the new module/component installation note at
the top of the DTC Index. Refer to service routines at the top of the
DTC Index and carry out service routines as required using the
Circuit High
connector terminals
Short to power on the OT
circuit of the oil temperature
sensor
Open circuit on the OT circuit
of the oil temperature sensor
sensor
diagnostic system
P071500 Turbine/Input Shaft
Speed Sensor A
Circuit
Short to power on the NIN+
circuit of the input speed
sensor
Failure of input speed sensor
top of the DTC Index. Refer to service routines at the top of the DTC
Index and carry out service routines as required using the
Speed Sensor A
Circuit
Range/Performance
connector terminals
Input speed sensor not
correctly installed
the TCM and transmission. Check input speed sensor installed
correctly. Suspect the TCM, check and install a new TCM as required,
refer to the new module/component installation note at the top of the
DTC Index. Suspect the transmission, check and install a new
transmission as required, refer to the new module/component
installation note at the top of the DTC Index. Refer to service routines
at the top of the DTC Index and carry out service routines as required
using the manufacturer approved diagnostic system
Speed Sensor A
Circuit Intermittent
connector terminals
Input speed sensor not
correctly installed
the TCM and transmission. Check input speed sensor installed
P072000 Output Shaft Speed
Sensor Circuit
Short to power SP+ circuit of
vehicle speed sensor
Failure of vehicle speed
sensor
Sensor Circuit
Range/Performance
connector terminals
Vehicle speed sensor not
correctly installed
sensor
The wheel radius does not
agree with the wheel radius
programmed in the vehicle's
configuration file
Check the correct wheels and tires are installed. Using the
manufacturer approved diagnostic system go to vehicle setup and
configuration tab, add/remove accessories and carry out, tire size
rolling circumference test. Check for high contact resistance in the
connector terminals between the TCM and transmission. Check vehicle
speed sensor installed correctly. Suspect the TCM, check and install a
new TCM as required, refer to the new module/component installation
note at the top of the DTC Index. Suspect the transmission, check and
diagnostic system
Sensor Circuit No
Signal
connector terminals
sensor
diagnostic system
Sensor Circuit
Intermittent
connector terminals
Vehicle speed sensor not
correctly installed
sensor
the TCM and transmission. Check vehicle speed sensor installed
P072500 Engine Speed Input
Circuit
Open circuit on CAN circuit
between ECM and TCM
Engine speed signal has not
been updated
Engine speed signal quality
factor has a failure value
Refer to the electrical guides and check CAN circuit for open circuit,
short to ground between ECM and TCM. Check ECM for DTCs and refer
to relevant DTC Index
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Short to ground on CAN circuit
between ECM and TCM
P072900 Gear 6 Incorrect Ratio Incorrectly regulating solenoid
Mechanical failure in
transmission
Transmission components
worn causing low system fluid
pressure and slip
P073000 Incorrect Gear Ratio Internal malfunction in the
transmission
P073095 Incorrect Gear Ratio Incorrect final drive installed
Incorrect assembly. The TCM
has detected that the
transmission has the incorrect
gear ratio
Suspect the final drive unit, check and install a new transmission as
transmission
pressure and slip
transmission
pressure and slip
transmission
pressure and slip
transmission
pressure and slip
transmission
pressure and slip
P073600 Reverse Incorrect
Ratio
transmission
pressure and slip
P073E64 Unable to Engage
Reverse
Signal plausibility failure. The
TCM has detected a
plausibility failure
connector terminals
C3 pressure control SLC3 not
operating when reverse gear
is selected
transmission
diagnostic system
P073F00 Unable to Engage
Gear 1
connector terminals
B1 pressure control SLB1
solenoid has stuck in off or on
position
C2 pressure control SLC2
position
position
transmission
diagnostic system
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P074100 Torque Converter
Clutch Solenoid
Circuit
Performance/Stuck Off
connector terminals
Open circuit of SLU circuit of
lock up control solenoid
Failure of SLU lock up solenoid
SLU lock up solenoid stuck in
closed position
diagnostic system
Clutch Solenoid
Circuit Stuck On
connector terminals
Open circuit of SLU circuit of
lock up control solenoid
Failure of SLU lock up solenoid
diagnostic system
Clutch Solenoid
Circuit Intermittent
record this DTC
Engine stall condition
detected
Mechanical fault in engine
Check for engine related DTCs. Rectify as required
P074A00Unable to Engage
Gear 2
connector terminals
solenoid has stuck in off
position
position
solenoid has stuck in on
position
position
position
transmission
diagnostic system
P074B00Unable to Engage
Gear 3
connector terminals
position
position
position
transmission
diagnostic system
P074C00Unable to Engage
Gear 4
connector terminals
position
position
position
position
transmission
diagnostic system
P074D00Unable to Engage
Gear 5
connector terminals
position
position
position
position
diagnostic system
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transmission
P074E00 Unable to Engage
Gear 6
connector terminals
position
position
position
position
transmission
diagnostic system
P077700 Pressure Control
Solenoid B Stuck On
S2 shift solenoid has jammed
in the on position
Hydraulic fault in the
transmission
Display Circuit
General memory failure
Internal fault in GSM
Suspect the GSM, check and install a new GSM as required, refer to
the new module/component installation note at the top of the DTC
Index
Display Circuit
Internal electronic failure. The
TCM has detected an internal
circuit failure
Index
P081711 Starter Disable Circuit
/ Open
Circuit short to ground. The
TCM has detected a ground
measurement for a period
longer than expected or has
detected a ground
measurement when another
value was expected
connector terminals
Start lock STLK circuit short to
ground
Internal failure in ECM
guides and check Start lock STLK circuit for high resistance in
connector terminals, short to ground. Suspect the TCM, check and
install a new TCM as required, refer to the new module/component
P081712 Starter Disable Circuit
/ Open
Circuit short to power. The
TCM has detected a vehicle
power measurement for a
period longer than expected or
has detected a vehicle power
value was expected
Start lock STLK circuit short to
power
Internal failure in ECM
guides and check Start lock STLK circuit for short to power. Suspect
the TCM, check and install a new TCM as required, refer to the new
diagnostic system
P081C49Park Input Circuit Internal electronic failure. The
GSM has detected an internal
circuit failure
Index
P082601 Up and Down Switch
Circuit
General electrical failure
GSM not working (tiptronic
mode)
Index
P085A00Gear Shift Module B
Communication
Circuit
LIN communication line failure
Refer to the electrical guides and check LIN circuit for open circuit,
short to ground, short to power. Suspect the GSM, check and install a
new GSM as required, refer to the new module/component installation
note at the top of the DTC Index
P086011 Gear Shift Module A
Communication
Circuit
detected a ground
value was expected
Short to ground on the LIN
communication circuit between
the TCM and GSM
Internal failure in GSM
guides and check LIN circuit between TCM and GSM for high resistance
in connector terminals, short to ground. Suspect the GSM, check and
install a new GSM as required, refer to the new module/component
installation note at the top of the DTC Index. Suspect the TCM, check
diagnostic system
Communication
Circuit
guides and check LIN circuit between TCM and GSM for short to power.
Index. Suspect the TCM, check and install a new TCM as required,
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value was expected
Short to power on the LIN
the TCM and GSM
DTC Index. Refer to service routines at the top of the DTC Index and
carry out service routines as required using the manufacturer approved
diagnostic system
Communication
Circuit
Circuit open. The TCM has
determined an open circuit via
lack of bias voltage, low
current flow, no change in the
state of an input in response
to an output
connector terminals
Oxidation in the connector
terminals
Open circuit on the power
supply to the GSM
Open circuit on the ground
supply to the GSM
Open circuit on the LIN
the TCM and GSM
guides and check LIN circuit between TCM and GSM for open circuit.
Check for high contact resistance in the connector terminals. Check for
oxidation in the connector terminals. Check for open circuit on the
power supply to the GSM. Check for open circuit on the ground supply
to the GSM. Suspect the GSM, check and install a new GSM as
Communication
Circuit
Missing message. The TCM
has not received one or more
expected messages from the
GSM.
guides and check LIN circuit between TCM and GSM for open circuit.
Index. Suspect the TCM, check and install a new TCM as required,
diagnostic system
P088513 TCM Power Relay
Control Circuit /Open
to an output
Open circuit on the VSUP
power circuit between the TCM
and GSM
guides and check VSUP power circuit between TCM and GSM for open
circuit. Suspect the GSM, check and install a new GSM as required,
DTC Index. Suspect the TCM, check and install a new TCM as required,
diagnostic system
P088611 TCM Power Relay
Control Circuit Low
detected a ground
value was expected
connector terminals
Short to ground on the VSUP
power circuit between the TCM
and GSM
guides and check VSUP power circuit between TCM and GSM for high
resistance in connector terminals, short to ground. Suspect the GSM,
check and install a new GSM as required, refer to the new
diagnostic system
P089500 Shift Time Too Short Mechanical fault in
transmission
Hydraulic fault in transmission
P089600 Shift Time Too Long Mechanical fault in
transmission
Hydraulic fault in transmission
Deteriorated
Transmission fluid is
degraded, exerted to very
hard strain and high ambient
temperatures and is no longer
serviceable
Replace the transmission fluid. Refer to service routines at the top of
P092813 Gear Shift Lock
Solenoid/Actuator
Circuit A / Open
to an output
Refer to the electrical guides and check the SFL shiftlock circuit for
open circuit, high resistance, corrosion, oxidation of connector
terminals. Refer to the electrical guides and check the ground circuit
between the GSM and ground stud. Suspect the GSM, check and install
a new GSM as required, refer to the new module/component
installation note at the top of the DTC Index
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connector terminals
Open circuit on the SFL
shiftlock circuit between the
TCM and GSM
Open circuit on the ground
circuit between the GSM and
ground stud
Solenoid/Actuator
Circuit A Low
detected a ground
value was expected
Short to ground on the SFL
TCM and GSM
Failure of the shiftlock
solenoid
short to ground. Suspect the GSM, check and install a new GSM as
top of the DTC Index
Solenoid/Actuator
Circuit A High
value was expected
Short to power on the SFL
TCM and GSM
short to power. Suspect the GSM, check and install a new GSM as
Solenoid A Control
Circuit / Open
connector terminals between
TCM and transmission
open circuit of internal wiring
for SLT control signal circuit
for SLT ground signal circuit
SLT line pressure control
solenoid no operation
Check the terminals for corrosion, oxidation between TCM and
transmission. Suspect the TCM, check and install a new TCM as
top of the DTC Index. Suspect the transmission, check and install a
new transmission as required, refer to the new module/component
Solenoid A Control
Circuit
Range/Performance
for SLT control signal circuit
for SLT ground signal circuit
solenoid stuck
Solenoid A Control
Circuit High
Short to power of internal
wiring for SLT line pressure
solenoid control signal circuit
Solenoid B Control
Circuit / Open
for SLU control signal circuit
SLU lock up control solenoid
no operation
Solenoid B Control
Circuit
Range/Performance
for SLU control signal circuit
no operation
stuck
Solenoid B Control
Circuit High
wiring for SLU lock up control
solenoid signal circuit
no operation
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Solenoid C Control
Circuit
Range/Performance
for SLC2 control signal circuit
for SLC2 ground control signal
circuit
SLC2 pressure control solenoid
no operation
stuck
Solenoid C Control
Circuit Low
Short to ground of internal
wiring for SLC2 control signal
circuit
Open circuit of internal wiring
no operation
Solenoid C Control
Circuit High
circuit
no operation
P097300 Shift Solenoid A
Control Circuit Low
wiring for S1 shift solenoid 1
S1 shift solenoid 1 not
working
P097400 Shift Solenoid A
Control Circuit High
for S1 shift solenoid 1
working
P097600 Shift Solenoid B
Control Circuit Low
working
P097700 Shift Solenoid B
Control Circuit High
for S2 shift solenoid 2
working
P171900 Engine Torque Signal CAN message, engine torque
signal has not been updated
CAN message, engine torque
signal quality factor equals
zero
Check for ECM DTCs. Rectify as required
P173D00Ignition Key Lock
Solenoid Circuit /
Open
Open circuit between ignition
switch keylock solenoid and
GSM
guides and check for open circuit between ignition switch keylock
solenoid and GSM
P173E00 Ignition Key Lock
Solenoid Circuit Low
Short to ground between
ignition switch keylock
solenoid and GSM
guides and check for short to ground between ignition switch keylock
solenoid and GSM
P173F00 Ignition Key Lock
Solenoid Circuit High
Short to power between
ignition switch keylock
solenoid and GSM
guides and check for short to power between ignition switch keylock
solenoid and GSM
P178368 Transmission
Overtemperature
Condition
record this DTC
Transmission fluid level low
Transmission fluid
cooler/hoses are
Check the transmission fluid level and condition, correct as required.
Check the transmission fluid cooler hoses for signs of
obstruction/damage/blockage, correct as required. Check the engine
cooling system and engine cooling fans operation. Suspect the
transmission, check and install a new transmission as required, refer
to the new module/component installation note at the top of the DTC
Index. Refer to service routines at the top of the DTC Index and carry
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obstructed/damaged/blocked
Mechanical failure of
transmission
Transmission has been
exposed to excessive high
load and high ambient
temperature greater than 150
degrees C (302 degrees F)
out service routines as required using the manufacturer approved
diagnostic system
P179900 CAN TCM/ABS Circuit
Malfunction
Vehicle speed message has
not been updated on CAN
ABS malfunction
the manufacturer approved diagnostic system. Check ABS for DTCs
rectify as required
P215800 Vehicle Speed Sensor
B
NIN+ input speed sensor
circuit
Short circuit to ground of
internal wiring NIN+ input
speed sensor circuit
Input speed sensor failure
transmission. Check NIN+ circuit for open circuit, short to ground.
Replace Input speed sensor. Suspect the TCM, check and install a new
Solenoid D Control
Circuit
Range/Performance
stuck
circuit
no operation
Solenoid D Control
Circuit Low
circuit
no operation
Solenoid D Control
Circuit High
circuit
no operation
Solenoid E Control
Circuit
Range/Performance
for SLB1 control signal circuit
for SLB1 ground control signal
circuit
SLB1 pressure control solenoid
no operation
stuck
Solenoid E Control
Circuit Low
for SLB1 control signal circuit
for SLB1 ground control signal
circuit
no operation
Solenoid E Control
Circuit High
wiring for SLB1 control signal
circuit
no operation
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Solenoid F Stuck On
SLC1 pressure control not
engaged in drive
Mechanical fault in the
transmission
Solenoid F Control
Circuit
Range/Performance
circuit
no operation
stuck
Solenoid F Control
Circuit Low
circuit
no operation
Solenoid F Control
Circuit High
circuit
no operation
Temperature Too High
record this DTC
Torque converter temperature
greater than 170 degrees C
(338 degrees F)
blockage. Suspect the transmission, check and install a new
P278768 Clutch Temperature
Too High
record this DTC
Torque converter stalled
The transmission fluid
temperature is the same, or
greater than 120 degrees C
(248 degrees F) for longer
than 5 seconds
temperature is greater than
120 degrees C and lower than
150 degrees C (302 degrees F)
for longer than 4 seconds
temperature is greater than
150 degrees (302 degrees F)
for longer than 3 seconds
blockage. Suspect the transmission, check and install a new
Sensor B Circuit
(PRNDL Input)
position sensor
Check the gear selector lever is adjusted correctly. Suspect the TCM,
check and install a new TCM as required, refer to the new
diagnostic system
Sensor B Circuit
Range/Performance
Undefined range when drive
selected
position sensor
GSM or transmission check and install a new TCM, GSM or
Sensor A / B
Correlation
position sensor
check and install a new TCM as required, refer to the new
diagnostic system
U000100High Speed CAN
Communication Bus
CAN bus open circuit
CAN bus short circuit to
ground
CAN bus short circuit to power
Internal fault in another
control module in the same
guides and check CAN circuit for open circuit, short to ground, short to
power. Suspect the TCM, check and install a new TCM as required,
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part of the CAN network
diagnostic system
U210511Switch Pack Signal "A" Circuit short to ground. The
detected a ground
value was expected
Shiftlock solenoid circuit short
to ground
GSM internal failure
Refer to the electrical guides and check shiftlock circuit for short to
ground. Suspect the GSM, check and install a new GSM as required,
DTC Index
U210512Switch Pack Signal "A" Circuit short to power. The
value was expected
Shiftlock solenoid circuit short
to power
Open circuit shiftlock solenoid
circuit
GSM internal failure
Refer to the electrical guides and check shiftlock circuit for short to
power, open circuit. Suspect the GSM, check and install a new GSM as
www.JagDocs.com
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AWF21 - Transmission Fluid Drain and Refill
General Procedures
WARNING: Observe due care when draining, as the fluid can be very hot.
1. Ensure that the automatic transmission is in 'P' and the handbrake is
fully applied.
3. Release the battery carrier bracket and position aside.
4. Clean the area around the transmission fluid filler plug.
5. Remove the transmission fluid filler plug.
NOTE: Make sure that the vehicle is standing on a level surface.
Raise and support the vehicle.
8. Clean the area around the transmission fluid level and drain plugs.
9. Place a container under the transmission.
10. CAUTION: The fluid level plug and drain plug both use the same
point on the transmission. The inner plug is for level indication and the
outer plug is to drain the fluid.
Remove the transmission fluid level plug.
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11. Remove the transmission fluid drain plug.
Allow the transmission fluid to drain.
Install the transmission fluid drain plug.
Tighten to 47 Nm.
14. Fill the transmission with the correct fluid until it runs from the level
plug.
15. Install the transmission fluid level plug.
Tighten to 7 Nm.
16. Add an additional 0.5 litres of transmission fluid.
17. CAUTION: A new O-ring seal is to be installed.
Install the transmission fluid filler plug.
Tighten to 40 Nm.
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18. Secure the battery carrier bracket.
Tighten to 25 Nm.
20. Connect the Jaguar approved diagnostic equipment. Start and run the
engine.
21. Using the diagnostic equipment to monitor the transmission fluid
temperature, allow the temperature to reach 60 degrees C.
22. Move the selector lever from 'P' through all the gear positions, pausing
in each gear position for 2-3 seconds and return to the 'P' position.
24. Remove the transmission fluid level plug.
25. With the engine running a small amount of fluid should drip out of the
level plug.
Install the transmission fluid level plug.
Tighten to 7 Nm.
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AWF21 - Transmission Fluid Level Check
General Procedures
WARNING: Observe due care when draining, as the fluid can be very hot.
1. Ensure that the automatic transmission is in 'P' and the handbrake is
fully applied.
3. Release the battery carrier bracket and position aside.
4. Clean the area around the transmission fluid filler plug.
5. CAUTION: The fluid level plug and drain plug both use the same
point on the transmission. The inner plug is for level indication and the
outer plug is to drain the fluid.
Remove the transmission fluid filler plug.
NOTE: Make sure that the vehicle is standing on a level surface.
8. Clean the area around the transmission fluid level plug.
9. Place a container under the transmission.
11. Add 0.5 litres of transmission fluid.
Install the transmission fluid filler plug.
Tighten to 40 Nm.
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13. Secure the battery carrier bracket.
Tighten to 25 Nm.
15. Connect the Jaguar approved diagnostic equipment. Start and run the
engine.
16. Using the diagnostic equipment to monitor the transmission fluid
temperature, allow the temperature to reach 60 degrees C.
17. Move the selector lever from 'P' through all the gear positions, pausing
in each gear position for 2-3 seconds and return to the 'P' position.
19. Remove the transmission fluid level plug.
20. With the engine running a small amount of fluid should drip out of the
level plug.
Install the transmission fluid level plug.
Tighten to 7 Nm.
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AWF21 - Main Control Valve Body
In-vehicle Repair
Removal
2. Remove the transmission fluid pan.
For additional information, refer to: Transmission Fluid Pan (307-01B
Automatic Transmission/Transaxle - Vehicles With: 6-Speed Automatic
Transaxle - AWF21, In-vehicle Repair).
4. NOTE: Note the position of the electrical connectors.
Release the transmission internal wiring harness.
Remove the bolt.
Release from the clip.
Disconnect the 9 electrical connectors.
5. NOTE: Make sure that the tape has not detached from the edges of the
component.
Position the wiring harness aside.
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Remove the suction cover.
Remove the 2 bolts.
NOTE: With every pass, undo the bolts one turn at a time alternately.
Release the transmission main control valve body.
Remove the 6 bolts.
8. CAUTION: Make sure that no components fall off during removal.
Remove the transmission main control valve body.
Release the selector selector rod.
Installation
1. Install the transmission main control valve body.
Attach the selector rod.
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2. CAUTIONS:
Make sure that new bolts are installed.
Only tighten the bolts finger-tight at this stage.
Secure the transmission main control valve body.
3. CAUTIONS:
Make sure that new bolts are installed.
Only tighten the bolts finger-tight at this stage.
Install the suction cover.
Install the bolts.
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5. CAUTION: Make sure that these components are installed to the
noted removal position.
Secure the transmission internal wiring harness.
Secure in the clips.
Connect the electrical connectors.
Tighten the bolt to 10 Nm.
7. Install the transmission fluid pan.
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AWF21 - Selector Shaft Seal
In-vehicle Repair
Removal
NOTE: Removal steps in this procedure may contain installation details.
2. Remove the transmission control module (TCM).
For additional information, refer to: Transmission Control Module (TCM)
Automatic Transaxle - AWF21, In-vehicle Repair).
3. CAUTIONS:
Take extra care not to damage the mating faces.
Make sure that a new component is installed.
Remove the transmission selector shaft seal.
Installation
1. CAUTIONS:
Make sure that the mating faces are clean and free of foreign
material.
Install the seal, flush with the transmission case.
Install the transmission selector shaft seal.
2. Install the transmission control module (TCM).
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AWF21 - Transmission Control Module (TCM)
In-vehicle Repair
Removal
1. Remove the cover and disconnect the battery ground cable.
3. Release and disconnect the selector lever cable.
4. Remove the transmission selector lever and disconnect the electrical
connector.
Remove the nut.
Remove the 3 bolts.
Installation
1. CAUTIONS:
Make sure that the terminals or pins/sockets of the transmission
control module (TCM) and the TCM connector are not bent or damaged.
The component must be aligned with the installation markings.
NOTE: The new transmission control module (TCM) is set in the N
position at the factory.
Install the transmission control module (TCM).
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2. Install the transmission selector lever and connect the electrical
connector.
3. Secure and connect the selector lever cable.
5. Connect the battery ground cable and install the cover.
6. If a new component has been installed, configure using Jaguar approved
diagnostic equipment.
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AWF21 - Transmission Internal Wiring Harness
In-vehicle Repair
Removal
3. Remove the transmission fluid pan.
5. NOTE: Note the position of the electrical connectors.
Release the transmission internal wiring harness.
Remove the bolt.
Release from the clip.
6. CAUTION: Make sure that the wiring harness does not catch.
Remove the transmission internal wiring harness.
Remove the clip.
Installation
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1. CAUTIONS:
Make sure that the wiring harness does not catch.
The component must be aligned with the installation markings.
Install the transmission internal wiring harness.
Secure with the clip.
2. CAUTION: Make sure that these components are installed to the
noted removal position.
Secure the transmission internal wiring harness.
Secure in the clip.
5. Install the transmission control module (TCM).
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AWF21 - Transmission Fluid Pan
In-vehicle Repair
Removal
NOTE: Removal steps in this procedure may contain installation details.
2. Drain the transmission fluid.
3. Remove the charge air cooler intake pipe.
Release the 2 hose clips.
Remove the 2 bolts.
4. Position the charge air cooler intake hose aside.
5. Disconnect the 2 transmission fluid cooler tubes.
Remove the 2 Torx bolts.
Position aside.
6. CAUTION: Take extra care not to damage the mating faces.
Remove the transmission fluid pan.
Remove the 12 bolts.
Slacken the transmission fluid pan with a plastic hammer, avoid
distorting the pan.
Installation
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1. CAUTION: Make sure that the mating faces are clean and free of
foreign material.
Apply silicone rubber sealant to the transmission fluid pan.
Apply Loctite 243 to the transmission fluid pan bolt threads.
Tighten to 13 Nm.
3. Connect the transmission fluid cooler tubes.
Tighten to 25 Nm.
4. Install the charge air cooler intake pipe.
Tighten the hose clips.
5. Refill the transmission with fluid.
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AWF21 - Torque Converter
Removal
AWF21, Removal).
3. NOTE: Some variation in the illustrations may occur, but the essential
Using the special tools, remove the torque converter.
Installation
1. CAUTIONS:
Align the torque converter and oil pump drive before installing the
torque converter.
material.
Take extra care when handling the component.
AWF21, Removal).
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AWF21 - Torque Converter Seal
Removal
2. Remove the torque converter.
For additional information, refer to: Torque Converter (307-01, Removal
and Installation).
3. Carefully remove and discard the torque converter seal.
Installation
1. CAUTIONS:
Extreme cleanliness must be exercised when handling this
component.
material.
Using the special tool, install a new torque converter seal.
2. CAUTIONS:
Align the torque converter and oil pump drive before installing the
torque converter.
material.
Take extra care when handling the component.
For additional information, refer to: Torque Converter (307-01, Removal
and Installation).
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AWF21 - Turbine Shaft Speed (TSS) Sensor
Removal
1. Remove the main control valve body.
For additional information, refer to: Main Control Valve Body (307-01B
2. Remove the turbine shaft speed (TSS) sensor.
Remove the bolt.
Release the sensor from the transmission.
Installation
Tighten to 6 Nm.
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AWF21 - Transmission
Removal
Special Tool(s)
Impulse extractor
100-012(LRT-99-004)
Slide Hammer Shaft -
100-012-02
Halfshaft Remover Fork -
204-226
Power train assembly jack
HTJ1200-2
303-021
Removal
For additional information, refer to: Front Subframe - 2.0L Duratorq-
TDCi/2.2L Duratorq-TDCi (110kW/150PS) - Puma (502-00 Uni-Body,
6. CAUTION: Make sure the halfshaft constant velocity (CV) joints do
not over articulate. Failure to follow this instruction may result in damage
to the CV joints.
Release the RH halfshaft.
Release the RH halfshaft from the transmission.
Secure the RH halfshaft to one side.
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7. Using the special tools, release the LH halfshaft.
to the CV joints.
Using a suitable tie strap, support the LH halfshaft.
Remove the 2 bolts.
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11. Release the emission control valve.
Remove the 2 bolts.
Position aside.
12. Release coolant pipe from the engine.
Remove the 2 bolts.
13. Remove the flexplate cover.
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14. Release the torque convertor from the flexplate.
Remove the 6 bolts.
15. Disconnect the 2 transmission fluid cooler tubes.
Position aside.
17. Disconnect the transmission control module (TCM) electrical connector.
18. Release the transmission selector cable from the bracket.
Release the locking sleeve and release from the bracket.
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19. Release the transmission selector lever cable from the TCM.
Remove the nut.
Release the selector cable and lever.
Position aside.
Remove the bolt.
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22. Release the transmission mounting.
Remove the nut.
23. Lower the engine sufficiently allowing the transmission assembly to
clear the mounting.
24. Remove the 3 transmission assembly upper bolts.
26. Remove the 2 transmission assembly rear bolts.
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Align the powertrain assembly jack to the transmission.
Secure the transmission to the powertrain assembly jack.
28. Remove the 4 transmission assembly lower bolts.
Detach the transmission from the drive plate.
Lower the powertrain assembly jack and transmission assembly.
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AWF21 - Transmission
Installation
Special Tool(s)
Power train assembly jack
HTJ1200-2
303-021
Installation
Raise the powertrain assembly jack and transmission assembly.
2. Install the transmission assembly lower bolts.
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3. Install the transmission assembly rear bolts.
Remove the powertrain assembly jack.
6. Install the transmission assembly upper bolts.
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7. Raise the engine and transmission assembly onto the mounting.
9. Attach the battery ground cable.
10. Attach the transmission selector cable to the bracket.
Release the locking sleeve and attach to the bracket.
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11. Attach the transmission selector cable and lever to the transmission
control module (TCM).
12. Connect the TCM electrical connector.
14. Connect the transmission fluid cooler tubes.
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15. Secure the torque convertor to the flexplate.
Tighten the bolts 60 Nm.
16. Install the flexplate cover.
17. Secure the coolant pipe to the engine.
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18. Secure the emission control valve.
19. Release the power steering fluid pipe.
Release the LH halfshaft.
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22. Attach the LH halfshaft to the transmission.
Attach the RH halfshaft to the transmission.
Engage the RH halfshaft to the transmission.
27. Refill the transmission with fluid.
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Transmission/Transaxle Cooling - Vehicles With: 5-Speed Automatic Transaxle -
JATCO -
Item Specification
Automatic transmission fluid WSS-M2C922-A1
Automatic transmission fluid cooler tube union 35 26 -
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JATCO - Transmission CoolingVehicles With: 5-Speed Automatic Transaxle - JATCO
1 Automatic transmission
2 Transmission fluid cooler tubes
3 Transmission fluid cooler
Transmission fluid cooler
The transmission fluid cooler is of an aluminium construction consisting of a tube and louvered fin core-type, the tubes are arranged
horizontally for the crossflow of the oil.
A thermostatic control valve is incorporated in the transmission fluid cooler, this maintains the transmission fluid at the optimum
temperature for use in the transmission.
When carrying out automatic transmission procedures any drained fluid should be checked thoroughly for any metal filings or particles. If
metal filings or particles are evident the automatic transmission fault should be located followed by a thorough flushing of the fluid cooler
and fluid cooler lines.
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* *
* *
JATCO - Transmission Cooling
Mechanical
Feed and return tubes
Connections to the automatic transmission and the automatic transmission fluid cooler.
Automatic transmission fluid level
step.
3.
4. If the concern is not visually evident, verify the symptom and refer to the Symptom chart. 4.
Symptom Chart
Symptom Chart
Loss of automatic
transmission fluid.
Connections to the automatic transmission and the
automatic transmission fluid cooler.
Check the torque of the tubes, if correct, check
the tubes and connections.
Loss of the automatic
transmission fluid.
Leak at transmission fluid cooler. INSTALL new transmission fluid cooler.
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JATCO - Transmission Fluid Cooler
Special Tool(s)
Quick fit connector releasing tool
310-044
Removal
WARNING: Whenever releasing the transmission cooling system fluid, take care to prevent fluid scalding. Failure to follow these
1. Remove the front bumper. For additional information, refer to Section
501-19 Bumpers.
2. NOTE: Lower transmission fluid cooler tube shown, upper similar.
NOTE: Allow the fluid to drain into a suitable container.
Detach the transmission cooler tube.
2. Detach the transmission cooler tube.
3. Detach the power assisted steering oil cooler.
4. Remove the transmission fluid cooler.
Installation
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1. Tighten to 7 Nm.
2. Tighten to 7 Nm.
3. CAUTION: Use of any transmission fluid other than the
recommended fluid, will cause transmission damage.
Carry out a transmission fluid level check. For additional information,
refer to Section 307-01A Automatic Transmission/TransaxleSection
307-01B Automatic Transmission/Transaxle.
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JATCO - Transmission Fluid Cooler Tubes
Removal
WARNING: Whenever releasing the transmission cooling system fluid, take care to prevent fluid scalding. Failure to follow these
1. Remove the undertray. For additional information, refer toSection
NOTE: Allow the fluid to drain into a suitable container.
Detach the transmission cooler tube.
2. Detach the transmission cooler tube.
Remove the transmission fluid cooler tube.
Remove and discard the sealing washers.
Installation
To install reverse the removal procedure.
Install new sealing washers.
Tighten to 35 Nm.
2. CAUTION: Use of any transmission fluid other than the
recommended fluid, will cause transmission damage.
Carry out a transmission fluid level check. For additional information,
refer to Section 307-01A Automatic Transmission/TransaxleSection
307-01B Automatic Transmission/Transaxle.
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AWF21 -
Item Specification
Automatic transmission fluid WSS-M2C922-A1
Automatic transmission fluid cooler tube union 35 26 -
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AWF21 - Transmission CoolingVehicles With: 6-Speed Automatic Transaxle - AWF21
COMPONENT LOCATION - AW F21 6 SPEED AUTOMATIC TRANSMISSION - FROM 2009MY
1 - Transmission fluid cooler
2 - Transmission fluid pipe - to transmission
3 - Transmission fluid pipe - from transmission
OVERVIEW
The AW F21 transmission uses an external fluid cooler to reduce the temperature of the transmission fluid.
SYSTEM OPERATION
Fluid is supplied from the transmission fluid pump into the lower connection of the cooler. After passing through the cooler, the fluid passes
out of the upper connection and is returned to the transmission fluid pan.
SYSTEM DESCRIPTION
The transmission fluid cooler is attached to the LH (left-hand) end of the radiator. The fluid cooler is an aluminum housing comprising
louvred fins and plates. The plates allow a cross-flow of transmission fluid and engine coolant through the cooler. The plates are immersed
in engine coolant from the 'cold' side of the radiator which provides cooling of the transmission fluid by the temperature differential between
the transmission fluid and the engine coolant.
The radiator is divided so that any coolant passing through the top quarter of the radiator will also pass through the transmission oil cooler.
There is a variable restrictor in the coolant bottom hose to allow the correct coolant flow through the transmission fluid cooler to optimise
the transmission fluid cooling performance.
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* *
* *
AWF21 - Transmission Cooling
Mechanical
Feed and return tubes
Connections to the automatic transmission and the automatic transmission fluid cooler.
Automatic transmission fluid level
step.
3.
4. If the concern is not visually evident, verify the symptom and refer to the Symptom chart. 4.
Symptom Chart
Symptom Chart
Loss of automatic
transmission fluid.
Connections to the automatic transmission and the
automatic transmission fluid cooler.
Check the torque of the tubes, if correct, check
the tubes and connections.
Loss of the automatic
transmission fluid.
Leak at transmission fluid cooler. INSTALL new transmission fluid cooler.
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AWF21 - Transmission Fluid Cooler
Removal
2. WARNING: Be prepared to catch escaping fluid.
NOTE: Use suitable paper to absorb and escaping fluid.
Disconnect the 2 transmission fluid cooler tubes from the transmission
fluid cooler.
Disconnect the 2 coolant hoses from the transmission fluid cooler.
Release the 2 clips.
4. Remove the Torx screw securing the transmission fluid cooler to the
cooling pack.
Release the transmission fluid cooler from the cooling pack.
Installation
2. Check automatic transmission fluid level.
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AWF21 - Transmission Fluid Cooler Return Tube
Removal
Remove the 2 bolts.
Disconnect the transmission fluid cooler return tube from the
transmission.
Remove the Torx bolt.
Disconnect the transmission fluid cooler return tube from the
transmission fluid cooler.
5. Remove the transmission fluid cooler supply tube.
Installation
1. Install the transmission fluid cooler supply tube.
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2. Connect the transmission fluid cooler return tube to the transmission
fluid cooler.
3. Connect the transmission fluid cooler return tube to the transmission.
Tighten to 10 Nm.
5. Check and top-up the transmission fluid level.
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AWF21 - Transmission Fluid Cooler Supply Tube
Removal
Remove the 2 bolts.
Disconnect the transmission fluid cooler supply tube from the
transmission.
Remove the Torx bolt.
Disconnect the transmission fluid cooler supply tube from the
transmission fluid cooler.
5. Remove the transmission fluid cooler supply tube.
Installation
1. Install the transmission fluid cooler supply tube.
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2. Connect the transmission fluid cooler supply tube to the transmission
fluid cooler.
3. Connect the transmission fluid cooler supply tube to the transmission.
Tighten to 10 Nm.
5. Check and top-up the transmission fluid level.
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Automatic Transmission/Transaxle External Controls - Vehicles With: 5-Speed
Automatic Transaxle - JATCO -
Selector cable shield 10 7 -
Selector cable retaining bracket 10 7 -
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Automatic Transaxle - JATCO - External ControlsVehicles With: 5-Speed Automatic
Transaxle - JATCO
1 Transmission selector lever.
2 Gear selector cable and bracket.
3 Gear selector cable retaining bracket.
4 Gear selector module bracket.
Transmission Selector Lever
The transmission selector lever:
Has seven positions: PARK, REVERSE, NEUTRAL, DRIVE, FOURTH, THIRD and SECOND.
Operates the transmission selector shaft in the PARK, REVERSE, NEUTRAL and DRIVE positions by means of a cable.
Passes driver gearshift requests to the engine control module (ECM) via the rotary switch.
Uses Hall effect switches and a micro controller inside the transmission selector lever to generate the electronic code.
When moved to the left-hand side of the transmission selector lever allows manual electronic selection of FOURTH, THIRD and
SECOND gears.
The NEUTRAL position switch:
Is incorporated within the transmission rotary switch.
The transmission selector illumination module:
Provides a red transmission lever position illumination to indicate the selected gear.
Provides a green background for the transmission selector lever.
The transmission selector interlock solenoid:
Prevents the transmission selector lever from being moved from the PARK position, unless the ignition switch is in ON position, and
the brake pedal is pressed.
Is controlled by an input from the ECM via the CAN bus.
The seven transmission selector positions are:
P: The transmission is mechanically locked (starting enabled).
R: Reverse gear.
N: No power to the road wheels (starting enabled).
D: All 5 forward gears available.
4: Upshift to 4th gear only.
3: Upshift to 3rd gear only.
2: Upshift to 2nd gear only.
The performance mode push button:
is mounted on the transmission selector surround.
selects Normal or Sport mode when pressed by the driver.
is illuminated when Sport mode is selected.
is hard-wired to the ECM.
The transmission selector at the transmission unit:
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is connected to the driver's selector module by a cable.
operates the manual selector valve, which is part of the electro-hydraulic control unit.
operates the rotary switch, which is connected to the ECM.
The transmission selector cable provides the positive link between the selector lever and the transmission. The transmission selector cable
does not require adjustment.
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Automatic Transaxle - JATCO - External Controls
WARNING: Danger of accident. Apply the parking brake. Shift the gear selector to P. Failure to follow these instructions may result in
personal injury.
Gear selector interlock solenoid
Brake pedal switch
Fuse(s)
step.
3.
4. If the cause is not visually evident, verify the symptom and refer to the Jaguar approved diagnostic system. 4.
Symptom Chart
3548-1358-00.
Symptom (general) Symptom (specific) Possible source Action
Erratic operation of brake shift
interlock
Interlock function will not
operate/release
Brake shift interlock solenoid circuit
failure
Brake shift interlock solenoid failure
GO to Pinpoint Test
A.
Five Digit DTC Component Description Condition Action
P1780 (To VIN D15361) D-4 switch malfunctionSwitch or circuit malfunctionD-4 switch inoperative or out of range GO to Pinpoint Test B.
P0915 (From VIN D15362) J-Gate input J-Gate or circuit malfunctionLeft-hand side of the J-Gate inoperative GO to Pinpoint Test C.
PINPOINT TEST A : J-GATE SYSTEM CIRCUIT CHECKS
TEST
CONDITIONS
A1: CHECK IGNITION SUPPLY TO THE J-GATE.
Is the voltage less than 10 Volts?
Yes
REPAIR the circuit between IP14 pin 01 (WR) and the ignition switch. For additional information, refer to the wiring
diagrams. TEST the system for normal operation.
No
GO to A2.
A2: CHECK GROUND SUPPLY TO THE J-GATE.
Yes
REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. TEST the system for
normal operation.
No
CHECK for CAN DTCs.
REFER to Section 418-00 Module Communications Network.
PINPOINT TEST B : P1780. D-4 SWITCH MALFUNCTION (TO VIN D15361)
NOTE: Incorrect adjustment of the selector cable could result in this DTC being set with no electrical fault being present.
REFER to Selector Lever Cable Adjustment - in this section.
TEST
CONDITIONS
B1: CHECK IGNITION SUPPLY TO THE J-GATE.
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1
Yes
REPAIR the circuit between IP14, pin 01 (WR) and the ignition switch (this circuit i ncludes the Central Junction fuse
box, Ignition relay, and inertia switch). For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST
No
GO to B2.
B2: CHECK GROUND SUPPLY TO THE J-GATE.
Yes
No
GO to B3.
B3: CHECK D-4 SWITCH SIGNAL WIRE FOR HIGH RESISTANCE.
Yes
No
INSTALL a new J-Gate.
REFER to Transmission Selector Lever - in this section.
PINPOINT TEST C : P0915 J-GATE SIGNAL INPUTS TO THE TCM (FROM VIN D15362)
TEST
CONDITIONS
C1: CHECK TRANSMISSION RANGE SENSOR CONTINUITY IN D.
Select D.
Yes
GO to C2.
No
Carry out the adjustment procedure for the Transmission Range Sensor.
Recheck the circuit. If still open circuit, INSTALL a new Transmission Range Sensor.
C2: CHECK TRANSMISSION RANGE SENSOR DRIVE SIGNAL WIRE FOR HIGH RESISTANCE.
Yes
REPAIR the high resistance circuit. For additional information, refer to wiring diagrams. CLEAR the DTC. TEST the
No
GO to C3.
C3: CHECK IGNITION SUPPLY TO THE J-GATE.
Measure the voltage between IP14, pin 01 (WR) and ground.
Yes
No
GO to C4.
C4: CHECK GROUND SUPPLY TO THE J-GATE.
Yes
No
GO to C5.
C5: CHECK J-GATE SIGNAL INPUT WIRES FOR CONTINUITY (4 RANGE).
Yes
No
GO to C6.
C6: CHECK THE J-GATE SIGNAL INPUT WIRES FOR CONTINUITY (3 RANGE).
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Yes
No
GO to C7.
Yes
No
GO to C8.
C8: J-GATE SIGNALS FUNCTIONALITY
If tests between C1 and C7 have been successfully completed and the fault is still present, INSTALL a new J-Gate.
CLEAR the DTC.
Yes
No
Contact dealer technical support for advice on possible module.
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Automatic Transaxle - JATCO - Selector Lever Cable Adjustment
General Procedures
Setting Procedure-All Vehicles
1. Apply the parking brake.
2. Apply the footbrake.
3. Turn the ignition switch to position II.
4. Move the gear selector lever to 'N'.
6. Remove the gear selector cover plate.
7. Loosen the gear selector cable retaining bolt.
Vehicles Built up to VIN D15360
NOTE: Before starting the 'J' gate setting procedure, make sure the vehicle is cold, or has been left to cool for at least two hours.
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1. Using the corner of the grey feature line that follows the edge of the 'J'
gate as a datum, use a rule and move the gear selector forwards or
back two millimeters.
All Vehicles
NOTE: Before starting the 'J' gate setting procedure, make sure the vehicle is cold, or has been left to cool for at least two hours.
1. NOTE: Make sure the transmission is in neutral.
Fully tighten the cable retaining bolt
Tighten to 5Nm.
2. Install the gear selector cover plate.
Tighten to 10Nm.
3. Check for correct operation. If setting is incorrect, repeat the above
steps until correct operation is achieved.
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Automatic Transaxle - JATCO - Selector Lever Cable and Bracket
Removal
1. NOTE: To move the gear selector lever, the ignition must be in the RUN
position, with the foot brake pressed.
Move the gear selector lever to "N" position.
2. Remove the center console right-hand side trim panel.
3. Release the gear selector cable locking pin.
4. Remove the center console side retaining screw.
5. Detach the gear selector cable from the J-gate.
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6. Disconnect the gear selector cable from the J-gate.
7. Detach the gear selector cable grommet.
9. Detach the exhaust heat shield.
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10. Remove the gear selector cable shield.
11. Detach the gear selector cable bracket.
12. Disconnect the gear selector cable.
13. Remove the gear selector cable from the gearbox mounting bracket.
1. Pull out the locking pin.
2. Remove the gear selector cable from the gearbox mounting
bracket.
15. Remove the selector cable.
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Installation
Tighten to 10 Nm.
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Automatic Transaxle - JATCO - Selector Lever Assembly
Removal
1. NOTE: To move the selector lever, the ignition must be in the RUN
position, with the foot brake pressed.
Move the selector lever to the 'N' position.
2. Remove the floor console.
For additional information, refer to: Floor Console (501-12 Instrument
Panel and Console, Removal and Installation).
4. NOTE: The floor console bracket cannot be removed at this stage.
Remove the floor console bracket retaining screws.
5. Release the selector lever cable locking pin.
6. Disconnect the selector lever cable from the selector lever.
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7. Remove the ashtray retaining screws.
8. Remove the ashtray.
Disconnect the cigar lighter electrical connector.
9. Remove the selector lever retaining screw.
10. Remove the selector lever.
11. Detach the electrical connector from the selector lever.
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12. Remove the selector lever from the selector lever bracket.
Remove the selector lever retaining screws.
Installation
1. NOTE: Do not fully tighten the selector lever retaining screws at this
stage.
Install the new selector lever to the selector lever bracket.
2. NOTE: The new selector lever is supplied with a setting tool installed,
to hold the selector lever in the correct position for adjustment to be
carried out.
NOTE: The setting tool must remain installed, until the selector lever
cable adjustment has been carried out.
Set the distance between the selector lever pin and the selector lever
bracket.
Adjust the the distance to 97.5 mm (3.84 inches).
3. Tighten the selector retaining screws.
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4. Attach the electrical connector to the selector lever.
5. Install the selector lever.
6. Install the selector lever retaining screw.
7. Install the ashtray.
Connect the cigar lighter electrical connector.
8. Install the ashtray retaining screws.
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9. Connect the selector lever cable to the selector lever.
10. Install the selector lever cable locking pin.
11. Install the floor console bracket retaining screws.
12. Connect the selector lever electrical connector.
13. Set the selector lever cable adjustment.
For additional information, refer to: Selector Lever Cable Adjustment
(307-05B Automatic Transmission/Transaxle External Controls - Vehicles
With: 6-Speed Automatic Transaxle - AWF21, General Procedures).
14. Remove the selector lever setting tool.
15. Install the floor console.
16. Move the selector lever to the 'P' position.
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Automatic Transaxle - AWF21 -
Selector cable shield 10 7 -
Selector cable retaining bracket 10 7 -
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Automatic Transaxle - AWF21 - External ControlsVehicles With: 6-Speed Automatic
Transaxle - AWF21
COMPONENT LOCATION - AW F21 6 SPEED AUTOMATIC TRANSMISSION FROM 2009MY
1 - Selector cable
2 - Selector lever assembly
3 - Selector knob, gaiter and illumination module
OVERVIEW
The automatic transmission external controls comprise a selector lever assembly and a transmission cable. The selector lever allows the
driver to select forward or reverse gears and also to engage sport or manual 'Jaguar Sequential Shift' modes.
Movement of the selector lever is confirmed to the driver by illumination of the applicable position LED (light emitting diode) on the
illumination module and by a message displayed in the instrument cluster message center.
NOTE: PRND is not displayed in the message center. When in sport mode 'S' is displayed and when in Jaguar Sequential Shift mode the
selected gear (1, 2, 3, 4, 5, or 6) is displayed.
SELECTOR LEVER
NOTE: RHD (right-hand drive) version shown
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1 - Interlock solenoid - Emergency release lever
2 - Cable adjustment/setting aperture
3 - Selector lever button
4 - Cable attachment ball pin
5 - Knob
6 - Gaiter
7 - Selector position LED's
8 - Spring clip
9 - Shift housing Left Hand (LH) and Right Hand (RH)
10 - Printed Circuit Board (PCB) ribbon cable and connector
11 - Gear shift module
12 - Sensor arm
13 - Optical sensor alignment mark
14 - Cover
15 - Shift interlock solenoid
16 - Mounting bolt (4 off)
17 - Cable abutment aperture
The selector lever assembly is located in a central position on the transmission tunnel, between the front driver and passenger seats and is
secured to the transmission tunnel with 4 bolts. The selector lever assembly is an electro-mechanical assembly which is used by the driver
to select the required transmission mode. Serviceable parts comprise the shifter mounting plate, the knob, the PRND LED display, gaiter and
illumination module assembly and the base shifter. If other selector components require replacement then a complete shifter assembly will
need to be fitted.
Selections made using the selector lever are passed to the transmission lever arm by a cable. A ball pin is attached to the lever mechanism
and provides for the attachment of the cable.
There are 5 selector lever positions and 2 additional positions for manual 'Jaguar Sequential Shift' operation:
P (Park) - Prevents the vehicle from moving by locking the transmission
R (Reverse) - Select only when the vehicle is stationary and the engine is at idle
N (Neutral) - No torque transmitted to drive wheels
D (Drive) - Select only when the vehicle is stationary and the engine speed is at idle. Allows the transmission to automatically select
the most appropriate of the 6 forward gears
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M/S (Manual/Sport Mode) - Initial selection of this position activates the transmission 'Sport' mode. This position has the same
function as 'D' but forces the transmission to upshift at higher engine speeds to improve acceleration
+ and - (Manual 'Jaguar Sequential Shift' mode) - Movement of the selector lever in the +/- positions, when the lever is in the M/S
position, will operate the transmission in manual (Jaguar Sequential Shift) mode allowing the driver to manually select all 6 forward
gears.
- To change back to Sport mode once Manual 'Jaguar Sequential Shift' mode has been engaged, the selector lever must first be
moved to the 'D' position and then returned to the M/S position.
The selector lever position is shown on the PRND LED display on the selector illumination module. The illumination of the LED's is controlled
by CAN (controller area network) messages from the instrument cluster.
The selector lever position when in 'Sport' or 'Jaguar Sequential Shift' mode is displayed to the driver on the selector position LED and in the
instrument cluster. PRND positions are not displayed. In 'Jaguar Sequential Shift' mode, if a gear is selected but the TCM (transmission
control module) logic prevents selection of that gear, the requested gear will be initially displayed. The TCM will engage the next allowed
gear and then display that gear. In 'Jaguar Sequential Shift' when a gear is selected it will only be displayed in the instrument cluster
message center.
Gear Shift Module
A gear shift module is located on the LH (left-hand) side of the selector lever. The gear shift module is an intelligent unit and controls the
selector position LED operation and also the shift interlock solenoid operation. The module comprises a Printed Circuit Board (PCB) and Hall
sensors which detect the selected position of the selector lever, when in M/S and + and - positions, via a magnet located on the lever
mechanism. The signals from the Hall sensors are passed from a connector on the gear shift module to the TCM on a LIN (local interconnect
network).
The gear shift module main connector uses 4 pins for LIN bus, ground, power and neutral inputs and outputs. A second connector allows for
the connection of a ribbon cable from the selector position LED for background illumination and position illumination. A third connector
supplies power and ground connections to the shift interlock solenoid.
Shift Interlock
The shift interlock solenoid is located on the LH side of the selector lever assembly. The solenoid operates a locking lever which engages
with the lever mechanism and locks it in the Park (P) and Neutral (N) positions. When the ignition is in power mode 6 or the engine is
running, the solenoid is de-energised and prevents the lever from moving from these positions until the brake pedal is pressed.
The neutral interlock feature only operates after a period of approximately 3 seconds. This allows the driver to move the selector lever
between gears ('D' to 'R') without the need to operate the brake pedal.
NOTE: The selector lever cannot be moved from the 'Park' position if the ignition is off.
If a fault occurs with the shift interlock solenoid, the sensor module or the brake switch, an emergency release lever is provided to
disconnect the interlock mechanism. The emergency release lever can be accessed by removal of the RH (right-hand) carpet panel from the
floor console. The panel can be removed to gain access to the release lever which is located at the front of the selector lever assembly and
is colored yellow for identification.
TRANSMISSION CABLE
1 - Transmission eye end
2 - Abutment
3 - Damper weight
4 - Bulkhead grommet
5 - Selector lever arm eye end and adjuster
The transmission cable assembly is a one-piece, push/pull cable connected between the transmission and the selector lever.
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The selector lever end of the cable has an adjustable eye end which locates on a ball pin on the selector lever. An abutment on the cable
outer sheath locates in an aperture in the selector lever shift housing. The transmission end of the cable also has an eye end which locates
on a ball pin on the end of the transmission lever arm. An abutment on the outer sheath locates in a bracket attached to the top of the
transmission. A damper weight is attached to the cable outer sheath to reduce noise and vibration being transmitted to the selector lever.
The purpose of the manual adjuster on the selector lever arm eye end is to accommodate vehicle to vehicle build tolerances. This ensures
that the selector lever movements are correctly aligned with the movements of the transmission selector lever. This is essential to ensure
the correct function of the selector mechanism.
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Automatic Transaxle - AWF21 - External Controls
WARNING: Danger of accident. Apply the parking brake. Shift the gear selector to P. Failure to follow these instructions may result in
personal injury.
Gear selector interlock solenoid
Brake pedal switch
Fuse(s)
step.
3.
Symptom Chart
3548-1358-00.
Symptom (general) Symptom (specific) Possible source Action
Erratic operation of brake shift
interlock
Interlock function will not
operate/release
Brake shift interlock solenoid circuit
failure
Brake shift interlock solenoid failure
GO to Pinpoint Test
A.
Five Digit DTC Component Description Condition Action
P1780 (To VIN D15361) D-4 switch malfunctionSwitch or circuit malfunctionD-4 switch inoperative or out of range GO to Pinpoint Test B.
P0915 (From VIN D15362) J-Gate input J-Gate or circuit malfunctionLeft-hand side of the J-Gate inoperative GO to Pinpoint Test C.
PINPOINT TEST A : J-GATE SYSTEM CIRCUIT CHECKS
TEST
CONDITIONS
A1: CHECK IGNITION SUPPLY TO THE J-GATE.
Is the voltage less than 10 Volts?
Yes
REPAIR the circuit between IP14 pin 01 (WR) and the ignition switch. For additional information, refer to the wiring
diagrams. TEST the system for normal operation.
No
GO to A2.
A2: CHECK GROUND SUPPLY TO THE J-GATE.
Yes
REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. TEST the system for
normal operation.
No
CHECK for CAN DTCs.
REFER to Section 418-00 Module Communications Network.
PINPOINT TEST B : P1780. D-4 SWITCH MALFUNCTION (TO VIN D15361)
TEST
CONDITIONS
B1: CHECK IGNITION SUPPLY TO THE J-GATE.
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Yes
No
GO to B2.
B2: CHECK GROUND SUPPLY TO THE J-GATE.
Yes
No
GO to B3.
B3: CHECK D-4 SWITCH SIGNAL WIRE FOR HIGH RESISTANCE.
Yes
No
INSTALL a new J-Gate.
REFER to Transmission Selector Lever - in this section.
PINPOINT TEST C : P0915 J-GATE SIGNAL INPUTS TO THE TCM (FROM VIN D15362)
TEST
CONDITIONS
C1: CHECK TRANSMISSION RANGE SENSOR CONTINUITY IN D.
Select D.
Yes
GO to C2.
No
Carry out the adjustment procedure for the Transmission Range Sensor.
Recheck the circuit. If still open circuit, INSTALL a new Transmission Range Sensor.
C2: CHECK TRANSMISSION RANGE SENSOR DRIVE SIGNAL WIRE FOR HIGH RESISTANCE.
Yes
REPAIR the high resistance circuit. For additional information, refer to wiring diagrams. CLEAR the DTC. TEST the
No
GO to C3.
C3: CHECK IGNITION SUPPLY TO THE J-GATE.
Measure the voltage between IP14, pin 01 (WR) and ground.
Yes
No
GO to C4.
C4: CHECK GROUND SUPPLY TO THE J-GATE.
Yes
No
GO to C5.
C5: CHECK J-GATE SIGNAL INPUT WIRES FOR CONTINUITY (4 RANGE).
Yes
No
GO to C6.
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Yes
No
GO to C7.
Yes
No
GO to C8.
C8: J-GATE SIGNALS FUNCTIONALITY
If tests between C1 and C7 have been successfully completed and the fault is still present, INSTALL a new J-Gate.
CLEAR the DTC.
Yes
No
Contact dealer technical support for advice on possible module.
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Automatic Transaxle - AWF21 - Selector Lever Cable Adjustment
General Procedures
1. Check the operation of the transmission selector lever.
2. Remove the center console LH side finisher trim panel.
3. CAUTION: Make sure that the selector lever and the gearshift
mechanism are in the park (P) position.
Release the transmission selector cable adjuster.
5. CAUTION: Make sure that the selector lever and the gearshift
mechanism are in the park (P) position.
Adjust the transmission selector cable.
6. Lock the transmission selector cable adjuster.
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8. Install the center console LH side finisher trim panel.
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Automatic Transaxle - AWF21 - Selector Lever Assembly
Removal
2. Remove the floor console reinforcement bracket.
3. Disconnect the selector lever assembly electrical connector.
4. Release the transmission selector cable.
Release from the selector lever assembly.
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5. Remove the selector lever assembly.
Remove the 4 nuts.
Installation
1. NOTE: Tighten the front 2 bolts first.
Install the selector lever assembly.
Tighten to 10 Nm.
2. Attach the transmission selector lever cable.
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3. Connect the selector lever assembly electrical connector.
4. Install the floor console reinforcement bracket.
Tighten to 3 Nm.
5. Install the floor console.
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Automatic Transaxle - AWF21 - Selector Lever Knob
Removal
1. Release the selector lever gaiter from the selector lever knob.
Rotate the chrome finisher clockwise and push downwards.
2. WARNING: The selector lever knob will be released suddenly, keep
face clear during removal.
Remove the selector lever knob.
Pull the selector lever knob upwards.
Installation
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Manual Transmission/Transaxle and Clutch - General Information -
Item Specification
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Manual Transmission/Transaxle and Clutch - General Information - Manual
Transmission and Clutch
The clutch system consists of the following components:
A flywheel
A clutch disc
A clutch pressure plate
A clutch master cylinder
A clutch slave cylinder
A clutch release hub and bearing
The clutch master cylinder transmits fluid pressure to the slave cylinder, which in turn moves the clutch release hub and bearing.
The clutch master cylinder uses brake fluid and shares a common reservoir with the brake master cylinder.
The clutch is a single plate, dry-friction disc with a diaphragm-style spring clutch pressure plate. The clutch disc has a hub which is splined
to the input shaft. The clutch disc has friction material where it contacts the flywheel and the pressure plate. The clutch pressure plate
applies pressure to the clutch disc, holding it tightly against the surface of the flywheel.
In the engaged position, the diaphragm spring holds the clutch pressure plate against the clutch disc, so that engine torque is transmitted
to the input shaft. When the clutch pedal is depressed, the clutch release hub and bearing pushes the diaphragm spring center toward the
flywheel. The diaphragm spring pivots at the fulcrum, relieving the load on the clutch pressure plate. Steel spring straps riveted to the
clutch pressure plate cover pull the clutch pressure plate from the clutch disc, disengaging the engine torque from the transmission and
enabling the gears to be changed.
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Manual Transmission/Transaxle and Clutch - General Information - Manual
Transmission and Clutch
Inspection and Verification -Clutch
As fault diagnosis starts when repairs are taken on, the following procedure is recommended:
Transmission oil leak
Missing screws or nuts
step.
3.
Inspection and Verification - Manual Transmission
The following checks should be carried out before repairing or installing a new transmission:
Transmission Noise
If transmission noises are reported, check the transmission fluid level. If damage has occurred due to a lack of fluid, install a new
transmission.
Oil Leakage
Check that the leaking fluid is actually transmission fluid and not hydraulic fluid (from the hydraulically operated clutch) or engine
oil.
Check the transmission fluid level and, as necessary, drain off any excess fluid.
Clean the transmission and the adjacent areas carefully before the road test.
Symptom Chart - Poor gear shifting
Symptom Chart
Significant effort required when downshifting or
synchronizer crashing
Gear synchronization is inadequate. Check oil level.
Check gear linkage.
INSTALL a new
transmission.
Gear jumps out of engagement while driving Worn or broken synchronizer components.
Manufacturing error (incorrect gear wheel toothing or
synchronizer ring).
INSTALL a new
transmission.
Gearshift problems in different gears (stiff or
partially seized)
Gear linkage. Check oil level.
Check gear linkage.
INSTALL a new
transmission.
Brief scratching noise during gear shifting Inadequate gear synchronization. Check oil level.
Check gear linkage.
INSTALL a new
transmission.
Symptom Chart - Oil leakage
Symptom Chart
Leak from transmission
housing
Leak from breather. CHECK oil level.
Leak from fill plug. TIGHTEN fill plug.
Leak from drain plug. TIGHTEN drain plug.
Sealing lip of the output shaft oil seal
damaged.
INSTALL a new output shaft seal and drive flange if seal is
damaged.
Oil leaking from the selector shaft oil seal. INSTALL a new selector shaft seal.
Leak from crankshaft rear seal. INSTALL a new crankshaft seal.
Leak from clutch hydraulics. For additional information, refer to Pinpoint Test H.
Sealing lip on input shaft damaged. INSTALL a new input shaft seal.
Symptom Chart - General Concerns
Symptom Chart
Clicking noises in
reverse gear
Gear wheels. RUN the vehicle on wheel free ramp to establish that the noise is coming
from the transmission. If the noise is coming from the transmission
INSTALL a new transmission.
Gear wheels banging
when shifting
Damaged clutch. CHECK the clutch is clearing correctly.
No-For additional information, refer to Pinpoint Test A.
Yes-CHECK transmission oil level. If transmission level is okay INSTALL a
new transmission.
Selector forks or synchronizer rings. INSTALL a new transmission.
Noises in the forward Transmission fluid level low FILL the transmission with correct amount of fluid.
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gears
The engine/transmission assembly is
in contact with the chassis/body.
INSPECT for points of contact or damaged engine/transmission isolator,
support insulator.
Engine/transmission flange bolts. TIGHTEN the transmission flange bolts. For additional information, refer
to 308-03.
Input and output shaft bearings. INSTALL a new transmission.
Gears jump out of
engagement
Engine/transmission support
insulator.
Internal components.
REPAIR or INSTALL new components as necessary.
One of the gears
cannot be selected
Gearshift linkage malfunction. CHECK gearshift linkage correctly attached to transmission case, sector
arm and the rear mounted to body.
CHECK gearshift linkage functions correctly.
Transmission internal selection
problem.
Gears jumps out of
engagement
Gearshift linkage fault.
Internal selector mechanism loose.
Synchronizer fault.
CHECK gearshift linkage for correct function.
Clattering, or rattling
noises
Gearshift mechanism foul to body. Make sure that the gearshift mechanism is correctly located onto the
gearbox.
Make sure that there are no components fouling the gearshift linkage.
Gearshift lever joint. CHECK free play in bearing between the lever and support housing, and
between the lever and shift arm.
Gearshift lever knob loose. TIGHTEN the gearshift lever knob or, INSTALL a new knob as necessary.
Gearshift linkage has
excessive play
Gear lever bearing worn.
Gearshift selector rod assembly
damaged or worn
CHECK free play in bearing. INSTALL a new if necessary.
INSTALL a new gearshift selector rod assembly
Gearshift linkage does
not operate freely
Excessive friction in lever bearing.
Gearshift selector rod assembly
damaged or worn
Possible fault in transmission
INSTALL a new lever bearing.
INSTALL new gearshift selector rod assembly
INSTALL new transmission.
Symptom Chart - Clutch
Symptom Chart
Clutch slippage Clutch pedal free play.
Sticking clutch pedal.
Diaphragm springs.
Clutch pressure plate.
Clutch disc facing.
Hardened or oiled clutch disc facing surface.
Flywheel.
Excessive temperature. ALLOW the clutch to fully cool.
Slave cylinder sticking. CHECK slave cylinder travels freely over
its complete travel.
Adjuster ring at fully worn position. INSTALL a new clutch drive plate.
Clutch chatter or
shudder
Engine mounts.
Oil on clutch disc facing.
Diaphragm springs.
Clutch pressure plate.
Clutch disc facing.
Flywheel.
Clutch drag Insufficient brake fluid.
Air in hydraulic system.
Clutch pedal free play.
Diaphragm springs.
Clutch disc.
Clutch disc splines.
Oil on clutch disc facing.
Insufficient clutch pedal travel. Make sure the clutch pedal has its full
range of travel.
Make sure the clutch pedal returns to
the fully released position and the
reservoir is full.
Clutch pedal
pulsation
Clutch and brake pedal pivot shaft not correctly lubricated.
Flywheel.
Damaged springs in pressure plate.
Release bearing noisy or worn. INSTALL a new release bearing.
Cover assembly. CHECK run out of clutch cover. INSTALL
a new clutch cover.
Clutch pedal
related vibrations
Engine component grounding against frame.
Accessory drive belt.
Flywheel bolts.
Flywheel.
Imbalanced clutch pressure plate.
Hard shifting Insufficient brake fluid.
Clutch pedal free play.
Manual transmission concern.
Excessive noise Clutch pedal free play.
Clutch release bearing.
Poor lubrication of clutch release bearing.
Pilot bearing.
Excessive crankshaft end play.
If the noise is heard from the transmission when the engine is started and
switched off with the clutch engaged, and the noise disappears if the
clutch pedal is depressed.
INSTALL a new flywheel.
Fluid leakage Clutch master cylinder.
Clutch slave cylinder.
Clutch hydraulic tubes.
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PINPOINT TEST A : CLUTCH SLIPPAGE
TEST
CONDITIONS
A1: TEST CLUTCH SLIPPAGE
Lock wheels and put parking brake on .
Start the engine and engage 4th gear.
Run the engine at approximately 2000 rpm.
Release clutch pedal slowly.
Does the engine stall when the clutch pedal is fully released?
Yes
Clutch OK.
No
GO to A2.
A2: TEST CLUTCH FOR CLEARING
Start engine, fully depress the clutch pedal, partially engage reverse gear, slowly engage clutch until a grating noise
is heard, depress the clutch slowly until grating stops.
Measure pedal travel from the pedal to the floor.
Is the measurement between 25mm and 45mm?
Yes
GO to A3.
No
GO to B3.
A3: TEST FULL PEDAL TRAVEL
Measure the clutch pedal travel from fully up to fully compressed.
Is the measurement between 140mm and 150mm?
Yes
GO to A4.
No
CHECK clutch pedal for obstructions. TEST the system for normal operation.
A4: TEST CLUTCH PEDAL
Check lubrication.
Is the clutch pedal shaft sufficiently lubricated?
Yes
GO to B3.
No
Lubricate clutch pedal shaft.
PINPOINT TEST B : CLUTCH CHATTER OR SHUDDER
TEST
CONDITIONS
B1: TEST CLUTCH CHATTER OR SHUDDER
Start the engine and engage 1st gear.
Run the engine between 1200 rpm and 1500 rpm.
Release clutch pedal slowly.
Does the vehicle jerk when it starts off?
Yes
GO to B2.
No
Clutch OK.
B2: TEST ENGINE/TRANSMISSION SUPPORT INSULATOR
Check engine/transmission mountings, support insulators for damage or loose bolts.
Are the engine/transmission mountings, support insulators loose or damaged?
Yes
TIGHTEN the bolts or INSTALL new engine/transmission mountings as necessary. TEST the system for normal
operation.
No
GO to B3.
B3: TEST CLUTCH PRESSURE PLATE
Remove clutch pressure plate.
Does the clutch pressure plate have signs of wear or damage?
Yes
INSTALL a new clutch pressure plate.
No
GO to B4.
B4: TEST CLUTCH FRICTION DISC
Visually check the clutch friction disc.
Is the clutch friction disc oil-fouled or does it have burn marks?
Yes
INSTALL a new clutch friction disc. TEST the system for normal operation.
No
CHECK the flywheel.
PINPOINT TEST C : CLUTCH DRAG
C1: CHECK BRAKE FLUID LEVEL
NOTE: The hydraulic clutch fluid is supplied from the brake master cylinder.
Check the brake fluid level.
Is the brake fluid level between the MAX and MIN marks on the brake fluid reservoir?
Yes
GO to C2.
No
FILL brake fluid, the brake and clutch system for leaks. Test system for normal operation.
C2: TEST CLUTCH PEDAL FREE TRAVEL
Operate clutch pedal manually to the point of resistance and release.
Measure pedal travel.
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Is the measured dimension within 15 mm?
Yes
INSTALL a new clutch pressure plate. TEST the system for normal operation.
No
GO to B3.
PINPOINT TEST D : CLUTCH PEDAL PULSATION
D1: TEST CLUTCH PEDAL
Check lubrication.
Is the clutch pedal shaft sufficiently lubricated?
Yes
CHECK the flywheel.
No
LUBRICATE the clutch pedal shaft. TEST the system for normal operation.
PINPOINT TEST E : CLUTCH RELATED VIBRATIONS
TEST
CONDITIONS
E1: CHECK FOR ENGINE COMPONENT GROUNDING
REFER to: Jacking (100-02 Jacking and Lifting, Description and Operation).
Check the engine mountings for grounding on the body frame.
Check the exhaust manifold or other engine component grounding on the body or frame.
Is there evidence of grounding on body or frame?
Yes
REPAIR or INSTALL a new as necessary. TEST the system for normal operation.
No
GO to E2.
E2: CHECK FOR ACCESSORY DRIVE VIBRATIONS
Feel accessory vibration at clutch engage/disengage when engine torque changes.
Disconnect the accessory drive belt and check for vibration.
Does the vibration stop when the drive belt is removed from the engine?
Yes
REPAIR or INSTALL new accessory drive belt components. REFER to:
Accessory Drive - 4.2L/2.5L/3.0L (303-05 Accessory Drive, Diagnosis and Testing),
Noise, Vibration and Harshness (NVH) (100-04 Noise, Vibration and Harshness, Diagnosis and Testing).
No
GO to E3.
E3: CHECK FOR RELEASE BEARING NOISE
Start the engine.
Depress and hold clutch pedal.
Is a whirring, grating or grinding noise present?
Yes
INSTALL a new clutch slave cylinder. . TEST the system for normal operation.
No
GO to E4.
E4: INSPECT FLYWHEEL
Remove the transmission.
Five speed transmission -
REFER to: Manual Transmission (308-03 Manual Transmission/Transaxle - Vehicles With: 5-Speed Manual
Transmission, Diagnosis and Testing).
Six speed transmission -
Inspect for loose flywheel bolts.
Carry out flywheel runout check.
Is the flywheel OK?
Yes
DIAGNOSE engine vibration concern.
REFER to: Engine - 4.2L/2.5L/3.0L (303-00 Engine System - General Information, Diagnosis and Testing).
or
REFER to: Engine - 2.7L Diesel (303-00 Engine System - General Information, Diagnosis and Testing).
No
TIGHTEN flywheel bolts or INSTALL a new flywheel. Test the system for normal operation.
PINPOINT TEST F : HARD SHIFTING
F1: CHECK FLUID LEVEL
NOTE: The hydraulic clutch fluid is supplied from the brake master cylinder.
Inspect the fluid level in the brake master cylinder reservoir.
Is the fluid within the MAX and MIN level marks?
Yes
GO to C2.
No
FILL brake fluid, CHECK for leaks in the clutch and brake system. TEST the system for leaks.
PINPOINT TEST G : EXCESSIVE NOISE
TEST
CONDITIONS
G1: CHECK TRANSMISSION NEUTRAL POSITION
Start the engine and run it in neutral.
Depress clutch pedal fully.
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Are there noises when the clutch is operated?
Yes
GO to G2.
No
System OK.
G2: TEST CLUTCH PEDAL FREE TRAVEL
Press the clutch down manually until resistance is felt, then release it again.
Measure pedal travel.
Is the measured dimension within 15 mm?
Yes
GO to G3.
No
INSTALL a new clutch master cylinder.
G3: TEST CLUTCH SLAVE CYLINDER WITH RELEASE BEARING
Remove the transmission.
Five speed transmission -
Six speed transmission -
Check the clutch slave cylinder bolts.
Check the release bearing for wear and rust.
Are the bolts loose or are there signs of wear or rust?
Yes
TIGHTEN the bolts or INSTALL a new clutch slave cylinder with the release bearing. TEST the system for normal
operation.
No
GO to G4.
G4: CHECK CLUTCH FRICTION DISC TORSION SPRINGS
Check torsion springs for wear.
Do the torsion springs have signs of wear?
Yes
INSTALL a new clutch friction disc. TEST the system for normal operation.
No
Check crankshaft end play.
REFER to: Camshaft End Play (303-00 Engine System - General Information, General Procedures).
PINPOINT TEST H : FLUID LEAKAGE
H1: INSPECT CLUTCH MASTER CYLINDER
Inspect the clutch master cylinder for leakage.
Is the clutch master cylinder OK?
Yes
GO to H2.
No
INSTALL a new clutch master cylinder as necessary.
REFER to: Clutch Master Cylinder (308-02 Clutch Controls, Removal and Installation).
H2: INSPECT CLUTCH SLAVE CYLINDER
Inspect the clutch slave cylinder for leaks.
Is the clutch slave cylinder OK?
Yes
GO to H3.
No
INSTALL a new clutch slave cylinder as necessary.
H3: INSPECT SYSTEM HYDRAULIC TUBES
Inspect the clutch hydraulic tubes for loose or damaged fittings causing leakage.
Are the clutch hydraulic tubes OK?
Yes
CARRY OUT road test to verify customer complaint.
No
INSTALL new components as necessary. Carry out road test.
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Manual Transmission/Transaxle and Clutch - General Information - Clutch System
BleedingVehicles With: 5-Speed Manual Transmission - MT75
General Procedures
injury.
CAUTION: If brake fluid comes into contact with the paintwork, it
should be washed down immediately with cold water.
NOTE: Make sure of absolute cleanliness when filling brake fluid.
NOTE: Do not re-use brake fluid.
Bleed the clutch system.
2. Fill the brake fluid reservoir with brake fluid.
3. Raise and support the vehicle. For additional information, refer
toSection 100-02 Jacking and Lifting
4. Remove the bleed nipple cover.
Attach a proprietary bleed jar to the bleed nipple and open the
bleed nipple one turn.
Depress the clutch pedal repeatedly until the emerging fluid is free
of bubbles; always make sure that there is sufficient fluid (5 mm
above the MAX) in the reservoir.
After bleeding, tighten the bleed nipple.
Install the bleed nipple cover.
Install the dust cover.
After bleeding, depress the clutch ten times and check that it is
functioning correctly.
6. NOTE: Make sure of absolute cleanliness when filling brake fluid.
The fluid level should be between the MIN and MAX marks. If the
level drops below the MIN mark, the brake warning indicator will
light up.
As necessary, fill the brake fluid reservoir with brake fluid.
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Manual Transmission/Transaxle and Clutch - General Information - Clutch System
BleedingVehicles With: 6-Speed Manual Transaxle - MMT6
General Procedures
injury.
CAUTION: If brake fluid comes into contact with the paintwork, it
should be washed down immediately with cold water.
NOTE: Make sure of absolute cleanliness when filling brake fluid.
NOTE: Do not re-use brake fluid.
Bleed the clutch system.
2. Fill the brake fluid reservoir with brake fluid.
4. Remove the bleed nipple cover.
Attach a proprietary bleed jar to the bleed nipple and open the
bleed nipple one turn.
Depress the clutch pedal repeatedly until the emerging fluid is free
of bubbles; always make sure that there is sufficient fluid (5 mm
above the MAX) in the reservoir.
After bleeding, tighten the bleed nipple.
Install the bleed nipple cover.
Install the dust cover.
After bleeding, depress the clutch ten times and check that it is
functioning correctly.
6. NOTE: Make sure of absolute cleanliness when filling brake fluid.
The fluid level should be between the MIN and MAX marks. If the
level drops below the MIN mark, the brake warning indicator will
light up.
As necessary, fill the brake fluid reservoir with brake fluid.
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Manual Transmission/Transaxle and Clutch - General Information - Gearshift Cable
Adjustment
General Procedures
Special Tool(s)
Gearshift selector setting tool
308-436
204-04 Wheels and Tires
2. Detach the gearshift lever surround.
3. NOTE: Upper selector cable shown, lower shift cable similar.
Detach the shift and selector cables.
1. Press the button.
4. NOTE: Lift the reverse gear selector to fit special tool.
Using the special tool, make sure the gearshift lever is in the neutral
position.
5. Make sure the transmission selector is in the fourth gear position.
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NOTE: Shift cable has a black cover to cable end and the selector cable has a white cover to cable end.
6. Detach the red locking tab on the shift cable.
7. Attach the shift cable to the ball pin on the transmission selector.
8. Press the red locking tab to secure the position of the shift cable.
9. Place the transmission selector into the neutral position.
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10. Detach the red locking tab on the selector cable.
11. Attach the selector cable to the ball pin on the gearbox mass damper.
12. Press the red locking tab to secure the position of the selector cable.
13. Remove the gearshift selector setting tool.
14. Install the gearshift lever surround.
15. Check for correct operation of gear controls.
204-04 Wheels and Tires
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Manual Transmission/Transaxle and Clutch - General Information - Release Hub and
Bearing Check
General Procedures
1. Turn the clutch release hub and bearing in both directions and check for
any binding or abnormal noise.
2. CAUTION: The clutch release hub and bearing is sealed and must
not be immersed in any type of cleaning fluid.
Check for worn or damaged clutch release hub and bearing contact
surfaces.
3. Install the clutch release hub and bearing on the input shaft and check
for a smooth sliding condition.
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Clutch -
Pressure plate retaining bolts 25 18 -
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Clutch - Clutch
1 Pressure plate retaining bolt
2 Pressure plate
3 Clutch disc
4 Flywheel retaining bolt
5 Flywheel
The clutch transfers the engine torque to the transmission.
The clutch consists of a disc and a pressure plate with a diaphragm spring, bolted to the flywheel.
When the clutch pedal is operated the power transmission from the engine to the transmission is interrupted. The clutch is therefore
engaged when the pedal is not depressed. Pressing down the pedal disengages the clutch.
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Clutch - Clutch
For additional information, refer to Section 308-00 Manual Transmission/Transaxle and Clutch - General Information.
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Clutch - Clutch Disc and Pressure Plate
Special Tool(s)
Clutch alignment tool
308-441
Removal
1. Remove the manual transmission.
For additional information, refer to: Transaxle - 2.0L NA V6 - AJV6/2.5L
NA V6 - AJV6/3.0L NA V6 - AJ27 (308-03 Manual
Transmission/Transaxle, Removal).
2. Remove the manual transmission.
For additional information, refer to: Transaxle - 2.0L Duratorq-TDCi
(308-03 Manual Transmission/Transaxle, Removal) /
Transaxle - 2.2L Duratorq-TDCi (110kW/150PS) - Puma (308-03 Manual
Transmission/Transaxle, Removal).
All vehicles
3. Remove the clutch disc and pressure plate.
Remove the pressure plate bolts in a uniform sequence.
Installation
1. NOTE: The clutch disc is marked "Transmission side" for correct
installation.
Using the special tool, align the clutch assembly.
All vehicles
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2. NOTE: The clutch disc is marked "Transmission side" for correct
installation.
Locate the clutch pressure plate on the flywheel dowels and tighten the
bolts progressively in a diagonal sequence.
Tighten to 25 Nm.
3. NOTE: Make sure that the input shaft of the transmission is moved
squarely into the hub of the clutch disc. Do not bend in any direction.
Install the manual transmission.
(308-03 Manual Transmission/Transaxle, Installation) /
Transaxle - 2.2L Duratorq-TDCi (110kW/150PS) - Puma (308-03 Manual
Transmission/Transaxle, Installation).
5. NOTE: Make sure that the input shaft of the transmission is moved
squarely into the hub of the clutch disc. Do not bend in any direction.
Install the manual transmission.
For additional information, refer to: Transaxle - 2.0L NA V6 - AJV6/2.5L
NA V6 - AJV6/3.0L NA V6 - AJ27 (308-03 Manual Transmission/Transaxle,
Installation).
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Clutch Controls -
Item Specification
Brake fluid ITT super dot 4
Clutch slave cylinder retaining bolts 10 7 -
Clutch master cylinder retaining nuts and bolts 10 7 -
Clutch pedal retaining nut 23 17 -
Engine wiring harness bracket retaining bolts 10 7 -
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Clutch Controls - Clutch Controls
Vehicles with 5-speed manual transmission
2 Clutch master cylinder supply line
3 Clutch master cylinder
4 Transmission
5 Clutch slave cylinder supply line
6 Clutch slave cylinder
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1 - Flywheel
2 - Bleed nipple
3 - Clutch master cylinder
4 - Vibration damper
5 - Hydraulic line
6 - Clutch slave cylinder
7 - Self-adjusting clutch
This vehicle has a hydraulically operated clutch. The brake master cylinder reservoir has a separate chamber and is used to supply the
hydraulic clutch system with fluid.
Depressing the clutch pedal builds up pressure in the clutch master cylinder and operates the release bearing integrated in the clutch slave
cylinder.
The hydraulic clutch system has the following advantages:
Automatic adjustment.
Low operating effort.
Minimal wear.
Reservoir
The brake fluid reservoir supplies both the hydraulic clutch system and the brake system with brake fluid.
The hydraulic clutch system and the brake system are separate inside the brake fluid reservoir. In the event of any leaks in the hydraulic
clutch system the brake system remains fully operative.
Clutch Master Cylinder
The pressure required to operate the clutch system is produced in the clutch master cylinder.
When the clutch pedal is depressed the piston rod moves the piston in the clutch master cylinder. This displaces the hydraulic fluid in the
clutch master cylinder, which in turn displaces the hydraulic fluid in the clutch slave cylinder via the high - pressure line.
Clutch Slave Cylinder
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1 - Release bearing
2 - Protective cap
3 - Pressure spring
4 - Hydraulic channel
5 - Oil seal
6 - Plastic housing
The central slave cylinder is fixed to the clutch housing with three bolts, together with an integrated release bearing. The release bearing is
a press - fit on the clutch slave cylinder.
The hydraulic fluid which is displaced by the master cylinder piston moves the piston in the clutch slave cylinder, which in turn moves the
release bearing in an axial direction. The release bearing presses against the tongues of the diaphragm spring with the inner bearing ring.
This breaks the friction contact between the clutch disc and the flywheel.
When the clutch pedal is released the diaphragm spring returns the piston in the clutch slave cylinder to its original position. This restores
the friction contact between the clutch disc and the flywheel.
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Clutch Controls - Clutch Controls
For additional information, refer to Section 308-00 Manual Transmission/Transaxle and Clutch - General Information
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Clutch Controls - Clutch Master Cylinder
Removal
All vehicles
1. WARNING: Do not allow brake fluid to contact the skin or eyes. If
brake fluid comes into contact with the skin or eyes, rinse the affected
places immediately with water. Failure to follow this instructions can
CAUTION: If brake fluid is spilt on the paintwork, the affected area
must be immediately washed down with cold water.
3. Detach the engine wiring harness from the intake manifold.
All vehicles
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4. Disconnect the clutch master cylinder supply line.
5. Disconnect the clutch slave cylinder supply line from the clutch master
cylinder.
Release the retaining clip to disconnect the line.
6. Remove the clutch pedal position switch.
2. Remove the clutch pedal position switch.
7. Remove the clutch pedal return spring pin retaining clip and spacer.
1. Remove the clutch pedal return spring pin retaining clip.
2. Remove the clutch pedal return spring pin spacer.
8. Remove the clutch pedal return spring.
1. Remove the clutch pedal return spring pin.
2. Remove the clutch pedal return spring.
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9. Remove the clutch master cylinder retaining nuts and bolts.
10. Remove the clutch master cylinder and clutch pedal.
11. Remove the clutch master cylinder from the clutch pedal.
Installation
All vehicles
1. Install the clutch master cylinder.
Tighten to 10 Nm.
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2. Install the clutch pedal.
1. Attach the clutch pedal to the clutch master cylinder.
2. Attach the clutch pedal to the support bracket.
3. Install the clutch pedal return spring pin.
1. Install the clutch pedal return spring.
2. Install the clutch pedal return spring pin.
4. Install the clutch pedal return spring pin spacer and retaining clip.
1. Install the clutch pedal return spring pin spacer.
2. Install the clutch pedal return spring pin retaining clip.
5. Install the clutch pedal position switch.
1. Install the clutch pedal position switch.
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6. NOTE: Reposition the retaining clip.
Connect the clutch slave cylinder supply line to the clutch master
cylinder.
7. Connect the clutch master cylinder supply line.
8. Attach the engine wiring harness to the intake manifold.
Tighten to 10 Nm.
All vehicles
Procedures).
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Clutch Controls - Clutch Slave CylinderVehicles With: 5-Speed Manual Transmission -
MT75
Removal
1. NOTE: The clutch slave cylinder assembly must be replaced whenever it
is removed.
Remove the manual transmission.
(308-03 Manual Transmission/Transaxle, Removal) /
Transaxle - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27
(308-03 Manual Transmission/Transaxle, Removal).
areas immediately with water. Failure to follow this instructions can result
in personal injury.
CAUTION: Brake fluid will escape when the lines are disconnected.
Remove the clutch slave cylinder.
Detach the rubber grommet.
Installation
1. NOTE: Apply suitable tape to the input shaft to protect the slave
cylinder seal from damage. Remove the tape when the slave cylinder is
installed.
NOTE: Apply sealer to the mating faces of the clutch slave cylinder and
the transmission housing.
Install the clutch slave cylinder.
Attach the rubber grommet.
Tighten to 10 Nm.
2. Install the manual transmission.
(308-03 Manual Transmission/Transaxle, Installation) /
Transaxle - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27
(308-03 Manual Transmission/Transaxle, Installation).
With: 5-Speed Manual Transmission - MT75 (308-00 Manual
Procedures).
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Clutch Controls - Clutch Slave CylinderVehicles With: 6-Speed Manual Transaxle -
MMT6
Removal
1. NOTE: The clutch slave cylinder assembly must be replaced whenever it
is removed.
Remove the manual transmission.
(110kW/150PS) - Puma (308-03 Manual Transmission/Transaxle,
Removal).
areas immediately with water. Failure to follow this instructions can result
in personal injury.
CAUTION: Brake fluid will escape when the lines are disconnected.
Remove the clutch slave cylinder high pressure pipe from the retaining
bracket and clutch slave cylinder bleed union.
3. CAUTION: Brake fluid will escape when the lines are disconnected.
Remove the clutch slave cylinder bleed union.
4. CAUTION: Brake fluid will escape when the lines are disconnected.
Installation
installed.
Install the clutch slave cylinder.
Tighten to 10 Nm.
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2. Install the clutch slave cylinder bleed union.
Fully seat the retaining clip.
3. Install the clutch slave cylinder high pressure pipe to the retaining
bracket and clutch slave cylinder bleed union.
Fully seat the retaining clip.
4. Install the manual transmission.
(110kW/150PS) - Puma (308-03 Manual Transmission/Transaxle,
Installation).
Procedures).
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Manual Transmission/Transaxle -
Manual transaxle fluid WSD-M2C200-C
Capacities
Description Quantity
Manual transmission fluid 1.75 Liters or 0 - 5 mm (0 - 0.20 in) below the lower edge of the fill plug bore
Transaxle retaining bolts 48 35 -
Reversing lamp switch 20 15 -
Starter motor retaining bolts - vehicles with 2.0L, 2.5L and 3.0L engine 35 26 -
Transaxle mount retaining bolt and studs 80 59 -
Transaxle mount retaining nut 133 98 -
Transaxle drain plug 45 33 -
Transaxle fill plug 45 33 -
Starter motor retaining bolts - vehicles with diesel engine 25 18 -
Starter motor electrical connector retaining nut 12 9 -
Starter motor solenoid electrical connector retaining nut 6 - 53
Intake manifold support bracket retaining bolts 10 - 89
Gearshift cable support bracket retaining nuts 25 18 -
Air cleaner mount bracket retaining nuts and bolt - vehicles with 2.0L, 2.5L and 3.0L engine 6 - 53
Left-hand driveshaft retaining nuts - vehicles with 2.0L or diesel engine 25 18 -
Vacuum solenoids and vacuum reservoir mount bracket retaining bolts - vehicles with diesel engine 23 17 -
Wiring harness to camshaft cover retaining stud, retaining nut 6 - 53
Engine cover rear mount bracket retaining bolts - vehicles with diesel engine 23 17 -
Charge air cooler pipe 4 - 35
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Manual Transmission/Transaxle - Manual TransaxleVehicles With: 5-Speed Manual
Transmission - MT75
1 Transaxle housing - clutch side
2 Input shaft
3 Differential
4 Output shaft
5 Reverse gear idler
6 Transaxle housing
7 Selector mechanism
The MTX 75 manual transaxle is a 2-shaft transaxle.
MTX 75 means:
M = Manual
T = Transmission
X = Transaxle (front wheel drive)
75 = The distance from the input and output shafts in mm
The aluminium housing consists of two closed sections. The reinforced ribs on the transaxle housing are to reduce the noise and vibration.
With the '2-shaft transaxle' all the gear wheels are in permanent mesh. In each gear the required ratio is achieved by means of a pair of
geared wheels. When reverse is selected, an idler gear changes the direction of rotation of the output. The input and output shafts run
taper roller bearings. To further improve stability and gear shifting, a maintenance free cable operating mechanism is used. all gear wheels,
including reverse gear, are beveled cut, synchronized and run on needle roller bearings 1st, 2nd, 3rd, gear have doubled synchronization.
The engine rotational torque is transmitted from the crankshaft through the clutch to the transaxle input shaft, which then transmits drive
to the output shaft by utilizing an arrangement of gears. When reverse gear is selected, the direction of the output shaft is changed by an
idler gear assembly.
In neutral, none of the gears are connected to the input or output shaft through the relevant synchronizer unit. No torque is transmitted to
the differential.
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Manual Transmission/Transaxle - Manual TransaxleVehicles With: 6-Speed Manual
Transaxle - MMT6
This vehicle is equipped with a transversely mounted manual transaxle, which combines both the transmission and differential in one unit.
The transaxle is a 6-speed, 3-shaft design with all pairs of gears in continuous mesh.
Each forward gear ratio is produced through a pair of dedicated gears, with the exception of 4th and 6th gears which share the same input
shaft gear.
All gear wheels rotate on needle-roller bearings, and are helical-cut, this type of gearing enables a higher gear contact ratio, which mesh
with minimum rolling noise; resulting in a quiet transaxle operation.
Torque is transmitted from the selected output shaft to the differential, which transmits the torque to the halfshafts to drive the front
wheels. With neutral selected, the gears are not connected via the synchronizers to the output shafts, therefore no torque is transmitted to
the differential.
The aluminum transaxle housing consists of two sections, reinforced by a web of strengthening ribs. The ribs also serve to reduce noise and
vibration, and aid the cooling of the transaxle.
Gear Train
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Item Description Item Description
1 Output shaft 5th/6th and reverse gears 13 Synchronizer assembly 3rd/4th gear
2 Input shaft 14 4th gear wheel
3 1st gear wheel 15 2nd gear wheel
4 Output shaft 1st to 4th gears 16 5th gear wheel
5 Pinion 17 3rd gear wheel
6 Differential assembly 18 4th/6th gear wheel
7 Crown wheel 19 6th gear wheel
8 Reverse idler gear 20 Synchronizer assembly 5th/6th gear
9 1st gear wheel 21 5th gear wheel
10 Synchronizer assembly 1st/2nd gear 22 Synchronizer assembly reverse gear
11 2nd gear wheel 23 Reverse gear wheel
12 3rd gear wheel 24 Pinion
Shafts and Selector Mechanism
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Item Description
1 Selector mechanism
2 Input shaft
3 Output shaft 1st to 4th gears
4 Differential housing
5 Output shaft 5th/6th and reverse gears
Input Shaft
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1 Clutch housing roller bearing 6 3rd gear wheel
2 Oil seal 7 Bearing retainer
3 1st gear wheel 8 Bearing retaining screw
4 2nd gear wheel 9 4th/6th gear wheel
5 5th gear wheel
The input-shaft is a solid unit, which rotates:
in a ball-bearing at the clutch-housing-end of the transaxle, and
a roller bearing at the rear of the transaxle,
due to this mounting arrangement, the bearings do not require preload adjustment on assembly.
1st and 2nd gear wheels are an integral part of the input shaft.
3rd and 5th gear wheels and 4th/6th gear wheel are pressed onto the input shaft.
Output Shaft 1st to 4th Gears
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1 Taper roller bearing, transmission housing 17 Inner synchronizer ring
2 4th gear wheel 18 2nd gear synchronizer cone
3 Needle bearing 19 Outer synchronizer ring - 2nd gear
4 Inner synchronizer ring 20 Snap ring
5 4th gear synchronizer cone 21 Synchronizer assembly - 1st/2nd gear
6 Outer synchronizer ring - 4th gear 22 Outer synchronizer ring - 1st gear
7 Snap ring 23 1st gear synchronizer cone
8 Synchronizer assembly - 3rd/4th gear 24 Inner synchronizer ring
9 Outer synchronizer ring - 3rd gear 25 1st gear wheel
10 3rd gear synchronizer cone 26 Needle bearing
11 Inner synchronizer ring 27 Reverse idler gear
12 3rd gear wheel 28 Output shaft 1st/4th gear
13 Needle bearing 29 Oil collector ring
14 Thrust washers 30 Taper roller bearing, clutch housing
15 2nd gear wheel 31 Bearing retaining bolt (left-hand thread)
16 Needle bearing
The 1st to 4th gear output shaft is a hollow unit, which rotates in tapered roller-bearings; this arrangement requires adjustment of the
bearings preload on assembly.
The output pinion is an integral part of the output shaft. The synchronizer assembli es of the 1st, 2nd, and 3rd, 4th gears are located on the
output shaft.
Internal oil-ways in the output shaft provide lubrication to the gear wheels needle-roller bearings and synchronizer assemblies.
An integrated oil-collector ring and oil-thrower, located on the clutch-housing-end of the output shaft, guides the transmission oil into the
oilway of the output shaft.
Output Shaft 5th/6th and Reverse Gears
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1 Transmission housing taper roller bearing 11 Snap ring
2 Needle bearing 12 Oil collector ring
3 6th gear wheel 13 Taper roller bearing, clutch housing
4 6th gear synchronizer ring 14 Output shaft 5th/6th/reverse gear
5 Snap ring 15 Reverse gear wheel
6 Synchronizer assembly - 5th/6th gear 16 Needle bearing
7 5th gear synchronizer ring 17 Reverse gear synchronizer ring
8 Thrust washers 18 Synchronizer assembly reverse gear
9 Needle bearing 19 Bearing retaining bolt (left-hand thread)
10 5th gear wheel
The 5th/6th and reverse gear output shaft is a hollow unit, which rotates in tapered roller-bearings; this arrangement requires adjustment
of the bearings preload on assembly.
The output pinion is an integral part of the output shaft.
The synchronizer assemblies of the 5th/6th and reverse gears are located on the output shaft.
Internal oil-ways in the output shaft provide lubrication to the gear wheels needle-roller bearings and synchronizer assemblies.
An integrated oil-collector ring and oil-thrower, located on the clutch-housing-end of the output shaft, guides the transmission oil into the
oilway of the output shaft.
Synchronizer Assemblies
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Item Description
1 Sliding block assembly
2 Synchronizer hub
3 Sliding collar
The gears 1st, 2nd, 3rd and 4th have double cone synchronizers, 5th, 6th and reverse gears have single cone synchronizers.
The detent balls, springs and sliding blocks form one unit, this arrangement aids an easier assembly of the synchronizer.
Differential Assembly
1 Taper roller bearing, transmission housing 5 Crown wheel bolts
2 Differential assembly 6 Crown wheel
3 Taper roller bearing, clutch housing 7 Bearing shell, taper roller bearing
4 Bearing shell, taper roller bearing
The differential is identical to that used in the 5 speed transmission, with the exception of the vehicle speed sensor, which has been
deleted along with the sender wheel. Vehicle speed sensing is provided by the wheel-speed sensors.
The differential is mounted on taper-roller bearings, this arrangement requires adjustment of the bearings preload on assembly.
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Gear Selection Power Flow
NOTE: The position of the transaxle shafts has been altered for clarity.
The following diagrams show a schematic representation of the power-flow through transaxle for each gear selection. The power flow is
transmitted through the positively engaged pair of gears onto the output pinion of the relevant output shaft and then to the crown wheel of
the differential.
First Gear
The 1st gear-wheel on the input shaft is positively connected to the 1st gear-wheel on the output shaft by the 1st/2nd gear synchronizer.
Second Gear
The 2nd gear-wheel on the input shaft is positively connected to the 2nd gear-wheel on the output shaft by the 1st/2nd gear synchronizer.
Third Gear
The 3rd gear-wheel on the input shaft is positively connected to the 3rd gear-wheel on the output shaft by the 3rd/4th gear synchronizer.
Fourth Gear
The 4th/6th gear-wheel on the input shaft is positively connected to the 4th gear-wheel on the output shaft by the 3rd/4th gear
synchronizer.
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Fifth Gear
The 5th gear-wheel on the input shaft is positively connected to the 5th gear-wheel on the output shaft by the 5th/6th gear synchronizer.
Sixth Gear
The 4th/6th gear-wheel on the input shaft is positively connected to the 6th gear-wheel on the output shaft by the 5th/6th gear
synchronizer.
Reverse Gear
NOTE: The reverse idler-gear in turn transmits the drive to the reverse gear on the opposite output shaft.
The reverse gear synchronizer, transfers drive from the 1st gear-wheel on the input shaft, to the 1st gear-wheel on the output shaft, which
is fixed to the reverse idler-gear.
Internal Selector Mechanism
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Item Description
1 Counterbalance
2 Reverse gear switch
3 Selector shaft
4 Selector finger
5 Selector gate
The selector interlock mechanism and selector finger are mounted on a sleeve in the selector mechanism housing. A spring-loaded ball
maintains the engagement of the selected gear. A counterbalance weight dampens the synchronized shift resistance of gear selection to
provide a smooth gear change operation.
The reverse lamp switch is mounted on the housings cover.
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Manual Transmission/Transaxle - Manual Transaxle
For additional information, refer to Section 308-00 Manual Transmission/Transaxle and Clutch - General Information
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Manual Transmission/Transaxle - Transaxle Draining and FillingVehicles With:
5-Speed Manual Transmission - MT75
General Procedures
toSection 100-02 Jacking and Lifting
2. Remove the drain plug.
3. Install the drain plug.
4. Remove the fill plug.
5. Fill the transaxle to 0.5 mm (0.02 in) below the lower edge of the fill
plug bore.
6. Install the fill plug.
Tighten to 45 Nm.
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Manual Transmission/Transaxle - Transaxle Draining and FillingVehicles With:
6-Speed Manual Transaxle - MMT6
General Procedures
2. Remove the drain plug and drain the fluid into a suitable container
3. Install the drain plug.
Tighten to 35 Nm.
4. Remove the fill plug.
5. Fill the transaxle to 0 - 5 mm (0 - 0.20 in) below the lower edge of the
fill plug bore.
6. Install the fill plug.
Tighten to 35 Nm.
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Manual Transmission/Transaxle - Halfshaft Seal LH
In-vehicle Repair
Special Tool(s)
205-115
308-208
Removal
Transmission/Transaxle, General Procedures) /
Transaxle Draining and Filling - Vehicles With: 6-Speed Manual
Transaxle - MMT6 (308-03 Manual Transmission/Transaxle, General
Procedures).
2. Remove the left-hand halfshaft.
For additional information, refer to: Front Halfshaft LH (205-04 Front
Drive Halfshafts, Removal and Installation).
3. Using the special tool, remove the halfshaft oil seal.
Installation
1. Using the special tool, install the halfshaft oil seal.
For additional information, refer to: Front Halfshaft LH (205-04 Front
Drive Halfshafts, Removal and Installation).
Procedures).
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Manual Transmission/Transaxle - Halfshaft Seal RH
In-vehicle Repair
Special Tool(s)
205-115
308-208
Procedures).
For additional information, refer to: Front Halfshaft RH - 2.0L NA V6 -
AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27 (205-04 Front Drive
Halfshafts, Removal and Installation) /
Front Halfshaft RH - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi
(110kW/150PS) - Puma (205-04 Front Drive Halfshafts, Removal and
Installation).
Removal
Using the special tool, remove the halfshaft oil seal.
Installation
1. Using the special tool, install the halfshaft oil seal.
For additional information, refer to: Front Halfshaft RH - 2.0L NA V6 -
AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27 (205-04 Front Drive
Halfshafts, Removal and Installation) /
Front Halfshaft RH - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi
(110kW/150PS) - Puma (205-04 Front Drive Halfshafts, Removal and
Installation).
Procedures).
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Manual Transmission/Transaxle - Input Shaft Seal
In-vehicle Repair
Removal
1. Remove the clutch slave cylinder.
For additional information, refer to: Clutch Slave Cylinder - Vehicles
With: 5-Speed Manual Transmission - MT75 (308-02 Clutch Controls,
Removal and Installation) /
Clutch Slave Cylinder - Vehicles With: 6-Speed Manual Transaxle - MMT6
(308-02 Clutch Controls, Removal and Installation).
.
Installation
Vehicles with 5-speed manual transaxle
installed.
Tighten to 10 Nm.
installed.
Tighten to 10 Nm.
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Name
Gasket Eliminator Sealant
Manual Transmission/Transaxle - Selector MechanismVehicles With: 5-Speed Manual
Transmission - MT75
In-vehicle Repair
Special Tool(s)
Engine Support Beam
303-021
Engine Support Brackets
303-1068
Engine lifting eye
303-1067
Gearshift selector setting tool
308-436
Materials
Specification
WSK-M2G348-A5
Removal
All vehicles
2. Remove the air cleaner. For additional information, refer to:
Installation),
and Installation).
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connector.
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manifold.
bracket.
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All vehicles
23. Remove the transaxle mount bracket securing nut.
24. Remove the transaxle support insulator.
25. Detach the clutch master cylinder to clutch slave cylinder high pressure
pipe from the support bracket.
26. Remove the clutch master cylinder to clutch slave cylinder high
pressure pipe support bracket.
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27. Remove the charge air cooler pipe retaining nut.
All vehicles
29. Remove the transaxle mount bracket.
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31. NOTE: Shown from the under side of the vehicle for clarity.
NOTE: Lower shift cable shown, upper shift cable similar.
Disconnect the shift cables from the transaxle selectors.
32. Detach the upper shift cable from the retaining bracket.
33. NOTE: Clean the selector mechanism mating surfaces and make sure
all the sealant is removed.
Remove the selector mechanism.
Installation
All vehicles
1. Apply sealant to the selector mechanism mating surfaces (bead
diameter: 2 mm).
2. Install the selector mechanism.
Tighten to 20 Nm.
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3. Attach the upper shift cable to the retaining bracket.
4. NOTE: Lift the reverse gear selector to fit special tool.
Using the special tool, make sure the gearshift lever is in the neutral
position.
5. Make sure the transmission selector is in the fourth gear position.
Detach the red locking tab on the shift cable.
Attach the shift cable to the ball pin on the transmission selector.
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Press the red locking tab to secure the position of the shift cable.
9. Place the transmission selector into the neutral position.
Detach the red locking tab on the selector cable.
Attach the selector cable to the ball pin on the gearbox mass damper.
Press the red locking tab to secure the position of the selector cable.
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14. Attach the gearshift lever surround.
15. Check for correct operation of gear controls.
17. Install the transaxle mount bracket.
Tighten to 80 Nm.
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pipe support.
All vehicles
21. Attach the clutch master cylinder to clutch slave cylinder high pressure
pipe to the support bracket.
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22. Install the transaxle support insulator.
Tighten to 47 Nm.
23. Install the transaxle mount bracket securing nut.
Tighten to 133 Nm.
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Tighten to 23 Nm.
All vehicles
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31. Attach the wiring harness to the camshaft cover retaining stud.
Tighten to 6 Nm.
Tighten to 10 Nm.
34. Attach the PCV hose to the intake manifold.
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Tighten to 6 Nm.
Tighten to 3 Nm.
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44. Install the air cleaner. For additional information, refer to:
Installation),
and Installation).
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Name
Gasket Eliminator Sealant
Manual Transmission/Transaxle - Selector MechanismVehicles With: 6-Speed Manual
Transaxle - MMT6
In-vehicle Repair
Materials
Specification
WSK-M2G348-A5
Removal
2. Detach the wiring harnesses.
4. Detach the fuse box.
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7. Remove the battery tray retaining bracket retaining bolts.
8. Remove the battery tray retaining bracket retaining bolts.
Reposition the battery tray
9. NOTE: Clean the selector mechanism mating surfaces and make sure all
the sealant is removed.
Remove the selector mechanism.
Installation
1. Apply sealant to the selector mechanism mating surfaces (bead
diameter: 2 mm).
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2. Install the selector mechanism.
Tighten to 20 Nm.
3. Loosly install the battery tray retaining bracket retaining bolts.
Reposition the battery tray.
4. Install the battery tray retaining bracket retaining bolts.
5. Fully tighten the battery tray retaining bracket retaining bolts. J
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8. Attach the fuse box.
9. Attach the wiring harnesses.
10. Attach the wiring harnesses.
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Manual Transmission/Transaxle - Support Insulator
In-vehicle Repair
Special Tool(s)
HTJ1200-2
Removal
All vehicles
Position and adjust the special tool height rear adjuster.
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6. Remove the retaining nut.
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All vehicles
10. Remove the transmission mount.
Remove the transmission mount retaining nuts.
Installation
All vehicles
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1. Install the transmission mount.
Tighten to 47 Nm.
2. Install the spacer.
3. Install the support bar.
All vehicles
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Manual Transmission/Transaxle - Transaxle2.0L Duratorq-TDCi
Removal
Special Tool(s)
Slide hammer
100-012
100-012-02
Slide hammer shaft
204-226
HTJ1200-2
308-208
303-021
Engine lifting eye
303-1067
Removal
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Loosen the shock absorber and spring assembly securing nuts.
5. Disconnect the vacuum pipes from the vacuum solenoid valves and the
vacuum reservoir.
6. Disconnect the vacuum solenoid valves electrical connectors.
7. Detach the wiring harness from the vacuum solenoids and vacuum
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8. Remove the vacuum solenoids and vacuum reservoir mount bracket
assembly.
9. Detach the coolant pipe from the engine.
12. Using the special tools, detach the left-hand halfshaft.
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13. CAUTION: Make sure the halfshaft CV joints do not over
joints.
14. Remove and discard the left-hand halfshaft snap ring.
Using the special tool, remove the left-hand halfshaft seal.
17. Detach the gearshift cables from the transaxle.
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18. Detach the gearshift cable support bracket from the transaxle.
19. Remove the transaxle mount bracket retaining bolt.
21. Detach the generator and starter motor positive cable from the
engine cover mounting bracket.
22. Remove the engine cover rear mount bracket. J
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25. Detach the charge air cooler pipe.
26. Detach the transaxle ground cable.
27. Remove the transaxle upper retaining bolts.
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area must be washed down immediately with cold water. Failure to follow
Detach the clutch master cylinder to clutch slave cylinder high pressure
Install a suitable pipe clamp to the clutch master cylinder to clutch
slave cylinder high pressure pipe.
pipe from the clutch slave cylinder.
Remove the clutch master cylinder to clutch slave cylinder high
pressure pipe retaining clip.
32. Remove the transaxle mount bracket retaining studs.
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33. Using the engine support bracket lower the powertrain assembly
approximately 60 mm (2.36 inches) between the transaxle and transaxle
mount bracket.
37. NOTE: Shown with the powertrain assembly jack removed for clarity.
Remove the transaxle retaining bolts.
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Detach the transaxle from the clutch plate.
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Manual Transmission/Transaxle - Transaxle2.2L Duratorq-TDCi (110kW/150PS) -
Puma
Removal
Special Tool(s)
Slide hammer
100-012
100-012-02
Slide hammer shaft
204-226
HTJ1200-2
308-208
303-021
Removal
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to the CV joints.
7. CAUTION: Make sure the halfshaft CV joints do not over articulate.
Failure to follow this instruction may result in damage to the CV joints.
NOTE: Secure the right-hand halfshaft using tie strap.
8. Remove and discard the left-hand halfshaft snap ring.
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Using the special tool, remove the left-hand halfshaft seal.
10. NOTE: Secure the power steering fluid pipe using tie straps.
Support the power steering fluid pipe.
11. Detach the vacuum solenoid valve assembly.
Secure the vacuum solenoid valve assembly to one side.
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Disconnect the clutch master cylinder to clutch slave cylinder high
pressure hose from the clutch slave cylinder high pressure pipe.
slave cylinder high pressure hose.
15. Detach the battery ground cable.
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21. Remove the transaxle upper retaining bolts.
22. Remove the transaxle mount bracket retaining bolts.
23. Detach the transaxle mount.
Remove the transaxle mount bracket retaining bolts.
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24. Using the special tool, lower the powertrain assembly approximately
60 mm (2.36 inches) between the transaxle and transaxle mount
bracket.
26. Align the special tool to the transaxle.
27. Detach the turbocharger oil feed pipe retaining bracket.
Reposition the retaining bracket.
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29. NOTE: Shown with the special tool removed for clarity.
Remove the transaxle retaining bolts.
30. Using the special tool, remove the transaxle.
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Manual Transmission/Transaxle - Transaxle2.0L NA V6 - AJV6/2.5L NA V6 -
Removal
Special Tool(s)
Slide hammer
100-012
100-012-02
Slide hammer shaft
204-226
HTJ1200-2
308-208
303-021
303-1068
Removal
All vehicles
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3. Loosen the left-hand shock absorber and spring assembly securing nuts.
4. Loosen the right-hand shock absorber and spring assembly securing
nuts.
7. Remove the steering gear heat shield bracket.
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8. Remove the steering gear heat shield.
Case, Removal).
All vehicles
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Support the halfshaft.
17. Detach the gearshift cables from the transaxle.
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18. Detach the gearshift cable support bracket from the transaxle.
19. Remove the transaxle mount bracket retaining bolt.
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manifold.
bracket.
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31. Detach the starter motor electrical connector.
32. Detach the starter motor solenoid electrical connector.
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slave cylinder high pressure pipe
pipe from the clutch slave cylinder.
Remove the clutch master cylinder to clutch slave cylinder high
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pressure pipe support.
40. Remove the transaxle mount bracket securing studs.
41. Using the engine support bracket lower the powertrain assembly
approximately 60 mm between the transaxle and transaxle mount
bracket.
43. NOTE: The transaxle retaining bolt remains captive to the cylinder
block flange.
Remove the transaxle retaining nut.
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47. NOTE: Vehicles with 2.5L and 3.0L engines shown, vehicles with 2.0L
engine similar.
Remove the transaxle retaining bolt.
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Manual Transmission/Transaxle - Transaxle2.0L Duratorq-TDCi
Installation
Special Tool(s)
205-115
HTJ1200-2
303-021
Engine lifting eye
303-1067
Installation
Raise the powertrain assembly jack and transaxle assembly.
Align the transaxle to the clutch plate.
2. NOTE: Shown with the powertrain assembly jack removed for clarity.
Install the transaxle retaining bolts.
Tighten to 48 Nm.
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Tighten to 48 Nm.
strap.
6. Using the engine support bracket raise the powertrain assembly.
Adjust the engine support bracket to align the transaxle to the
transaxle mount bracket.
7. NOTE: Shown from under the vehicle for clarity.
Loosely install the transaxle mount bracket retaining bolt.
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8. Install the transaxle mount bracket retaining studs.
Tighten to 80 Nm.
Attach the clutch master cylinder to clutch slave cylinder high pressure
pipe to the clutch slave cylinder.
Install the clutch master cylinder to clutch slave cylinder high
Remove the pipe clamp from the clutch master cylinder to clutch
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13. Install the transaxle upper retaining bolts.
Tighten to 48 Nm.
14. Attach the transaxle ground cable.
15. Attach the charge air cooler pipe retaining nut.
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Tighten to 23 Nm.
19. Attach the generator and starter motor positive cable from the
21. Tighten the transaxle mount bracket retaining bolt.
Tighten to 80 Nm.
22. Attach the gearshift cable support bracket to the transaxle.
Tighten to 25 Nm.
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23. Attach the gearshift cables to the transaxle.
Using the special tool, install a new right-hand halfshaft seal.
25. Install a new right-hand halfshaft snap ring.
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28. CAUTIONS:
Make sure the halfshaft CV joints do not over articulate. Failure to
follow this instruction may result in damage to the CV joints.
Using the special tool, install a new left-hand halfshaft seal.
joints.
Attach the left-hand halfshaft.
Engage the left-hand halfshaft to the transaxle.
Tighten to 25 Nm.
31. Attach the coolant pipe to the engine.
Tighten to 40 Nm.
32. Install the vacuum solenoids and vacuum reservoir mount bracket
assembly.
Tighten to 23 Nm.
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33. Attach the wiring harness to the vacuum solenoids and vacuum
34. Connect the vacuum solenoid valves electrical connectors.
35. Connect the vacuum pipes to the vacuum solenoid valves and the
vacuum reservoir.
Tighten the shock absorber and spring assembly securing nuts.
Tighten to 25 Nm.
40. Fill the manual transaxle to the correct oil level.
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Manual Transmission/Transaxle - Transaxle2.2L Duratorq-TDCi (110kW/150PS) -
Puma
Installation
Special Tool(s)
205-115
HTJ1200-2
303-021
Installation
1. Using the special tool, install the transaxle.
Using the special tool raise the transaxle assembly.
2. NOTE: Shown with the special tool removed for clarity.
Install the transaxle retaining bolts.
Tighten to 48 Nm.
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Tighten to 48 Nm.
4. Attach the turbocharger oil feed pipe retaining bracket.
Tighten to 22 Nm.
Remove the special tool securing strap.
7. Using the special tool raise the powertrain assembly.
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8. Loosely install the transaxle mount bracket retaining bolts.
9. Install the transaxle mount bracket retaining bolts.
Tighten to 80 Nm.
11. Install the transaxle upper retaining bolts.
Tighten to 48 Nm.
12. Connect the crankshaft position (CKP) sensor electrical connector.
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13. NOTE: Remove the selector cable tie straps.
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Connect the clutch master cylinder to clutch slave cylinder high pressure
hose.
slave cylinder high pressure hose.
21. Attach the vacuum solenoid valve assembly.
23. NOTE: Remove the power steering fluid pipe tie strap.
Detach the power steering fluid pipe.
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Using the special tool, install a new right-hand halfshaft seal.
25. Install a new right-hand halfshaft snap ring.
NOTE: Remove the right-hand halfshaft tie strap.
27. CAUTIONS:
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Using the special tool, install a new left-hand halfshaft seal.
joints.
Attach the left-hand halfshaft.
Engage the left-hand halfshaft to the transaxle.
Tighten to 25 Nm.
Tighten to 35 Nm.
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Manual Transmission/Transaxle - Transaxle2.0L NA V6 - AJV6/2.5L NA V6 -
Installation
Special Tool(s)
205-115
HTJ1200-2
303-021
303-1068
Installation
All vehicles
Raise the powertrain assembly jack and transaxle assembly.
2. NOTE: Vehicles with 2.5L and 3.0L engines shown, vehicles with 2.0L
engine similar.
Install the transaxle retaining bolt.
Tighten to 48 Nm.
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Tighten to 48 Nm.
strap.
Tighten to 48 Nm.
6. Install the transaxle retaining nut.
Tighten to 48 Nm.
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8. Using the engine support bracket raise the powertrain assembly.
9. Install the transaxle mount bracket securing studs.
Tighten to 80 Nm.
Attach the clutch master cylinder to clutch slave cylinder high pressure
pipe to the clutch slave cylinder.
Install the clutch master cylinder to clutch slave cylinder high
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Tighten to 48 Nm.
Tighten to 48 Nm.
Tighten to 35 Nm.
17. Attach the starter motor solenoid electrical connector.
Tighten to 6 Nm.
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18. Attach the starter motor electrical connector.
Tighten to 12 Nm.
19. Attach the starter motor solenoid cover.
22. Attach the wiring harness to the camshaft cover retaining stud.
Tighten to 6 Nm.
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Tighten to 10 Nm.
25. Attach the positive crankcase ventilation (PCV) hose to the intake
manifold.
Tighten to 6 Nm.
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30. Install the transaxle mount bracket retaining bolt.
Tighten to 80 Nm.
31. Attach the gearshift cable support bracket to the transaxle.
Tighten to 25 Nm.
32. Attach the gearshift cables to the transaxle.
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Detach the left-hand halfshaft.
36. CAUTIONS:
Make sure the halfshaft constant velocity (CV) joints do not over
joints.
Attach the left-hand halfshaft to the transaxle.
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Attach the right hand halfshaft.
Engage the right-hand halfshaft from the transaxle.
Tighten to 25 Nm.
40. Install the transfer case.
Case, Installation).
41. Install the steering gear heat shield.
42. Install the steering gear heat shield bracket.
All vehicles
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43. Install the fender splash shield access panel.
45. Tighten the right-hand shock absorber and spring assembly securing
nuts.
Tighten to 25 Nm.
46. Tighten the left-hand shock absorber and spring assembly securing
nuts.
Tighten to 25 Nm.
For additional information, refer to: Battery (414-01 Battery, Mounting
and Cables, Removal and Installation).
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Manual Transmission/Transaxle External Controls -
Selector cable grommet - - 60 lb-in
Gearshift lever mount retaining nuts - - 80 lb-in
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Manual Transmission/Transaxle External Controls - External Controls
1 Gearshift lever knob
2 Shift cable
3 Selector cable
4 Selector lever on the transmission
5 Shift and selector cable grommet
6 Gearshift lever
The shift is white and the selector cable is black. In order to detach the cables from there abutment brackets on the transmission and at
the gear lever, twist the locking tab of each abutment clockwise. As the shift and selector cable have a common grommet where they pass
through the floor, they can only be changed as a pair.
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1 Internal shift mechanism 8 Selector cable
2 Counterbalance 9 Body seal
3 Selector cable adjustment mechanism 10 Shift cable mounting
4 Shift cable 11 Shift cable mounting point on the gearshift lever
5 Gear lever housing 12 Reverse gear switch
6 Shift lever 13 Transmission vent
7 Selector cable mounting point on the gearshift lever
The transaxle uses a cable-shift mechanism designed to provide a smooth and positive gearshift action, while also isolating the lever from
any powertrain vibration. Cable adjustment is provided at the transaxle end of the cables at the abutment brackets. Damper weights
incorporated behind the cable adjusters suppress cable vibration.
There are no adjustment capabilities within the gear selector mechanism.
The cables are color coded and attached at both ends with ball connections incorporating a button release.
Reverse gear is selected by pulling-up the ring below the gear knob and then moving the lever to the reverse position.
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Manual Transmission/Transaxle External Controls - External Controls
Mechanical
Visibly damaged or worn
Loose or missing screws or nuts
step.
3.
4. If the concern is not visually evident, verify the symptom and refer to the
REFER to: Manual Transmission and Clutch (308-00 Manual Transmission/Transaxle and Clutch - General Information, Diagnosis
and Testing).
4.
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Manual Transmission/Transaxle External Controls - Gearshift CablesVehicles With:
Special Tool(s)
HTJ1200-2
Removal
1. Remove the center console right-hand side panel.
2. NOTE: Press the button to release the cable fitting before disconnecting
the cable.
Disconnect the gearshift selector cables.
3. Disconnect the gearshift selector cables.
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4. Remove the instrument panel center mount bracket.
5. Remove the center air duct retaining screw.
6. Reposition the center air duct upwards.
7. Detach the gearshift selector cable grommet.
toSection 100-02 Jacking and Lifting.
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9. Detach the exhaust heat shield.
10. CAUTION: Using the powertrain assembly jack, support the rear
of the subframe.
Remove the subframe reinforcement plate retaining bolts.
Loosen the subframe rear mount retaining bolt.
12. NOTE: Press the button to release the cable fitting before
disconnecting the cable.
Detach the gearshift selector cables.
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13. NOTE: Press the button to release the cable fitting before
disconnecting the cable.
Remove the gearshift selector cable.
Installation
2. Tighten to 60 lb/in.
3. Check and adjust the gearshift cables. For additional information, refer
toSection 308-00 Manual Transmission/Transaxle and Clutch - General
Information.
4. Tighten the subframe rear mount retaining bolt.
Tighten to 142 Nm.
5. Tighten the front subframe reinforcement plate retaining bolts.
Tighten to 35 Nm.
6. Carry out front subframe alignment procedure. For additional
information, refer toSection 502-00 Uni-Body, Subframe and Mounting
System.
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Manual Transmission/Transaxle External Controls - Gearshift CablesVehicles With:
Removal
1. Remove the gearshift lever.
For additional information, refer to: Gearshift Lever - Vehicles With:
6-Speed Manual Transaxle - MMT6 (308-06 Manual
Transmission/Transaxle External Controls, Removal and Installation).
2. Remove the center air duct retaining screw.
3. Reposition the center air duct upwards.
4. Detach the gearshift cable grommet.
5. Detach the gearshift cables from the transmission selector mechanism.
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6. Detach the gearshift cables from the transmission retaining bracket.
8. Reposition the exhaust mounting for access to the exhaust heat shield.
9. Reposition the exhaust heat shield for access to the gearshift cables.
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10. Reposition the gearshift cables from the subframe.
11. CAUTION: Make sure the gearshift cables are fed through the
vehicle floor pan individually. Failure to follow this instruction may result
NOTE: Remove the gearshift cables from inside the vehicle.
Remove the gearshift cables.
Installation
Tighten to 10 Nm.
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Manual Transmission/Transaxle External Controls - Gearshift LeverVehicles With:
Removal
1. Remove the gearshift lever knob.
3. NOTE: Press the button to release the cable fitting before disconnecting
the cable.
Disconnect the gearshift selector cables.
4. Remove the gearshift lever surround.
1. Detach the reverse gear selector rods.
2. Remove the gearshift lever surround.
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6. NOTE: Right-hand shown, left hand similar.
Remove the center console right-hand side trim panel.
1. Remove the gearshift lever mounting retaining nuts.
Installation
1. Tighten to 60 lb-ft.
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Manual Transmission/Transaxle External Controls - Gearshift LeverVehicles With:
Removal
1. Remove the gearshift lever knob.
Remove the gearshift lever spring.
2. Remove the restraints control module (RCM).
For additional information, refer to: Restraints Control Module (RCM)
3. Remove the floor console mounting bracket.
4. NOTE: Left -hand shown, right-hand similar.
Remove the floor console sound absorbing foam.
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6. Detach the gearshift lever assembly to allow access to the gearshift
cables.
7. Disconnect the gearshift cables.
Remove the gearshift lever assembly.
Installation
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Transfer Case -
Capacities
Description Liters
Transfer case lubricant, drain and refill 0.50
Torque specifications
Description Nm Lb - ft Lb - in
M8 pinion housing studs 35 26 -
M8 pinion housing bolts 35 26 -
Engine anti-roll restrictor mounting bracket top retaining bolts 55 41 -
Engine anti-roll restrictor mounting bracket side retaining bolts 35 26 -
Engine anti-roll restrictor mounting bracket bottom retaining nuts 35 26 -
Engine anti-roll restrictor mount retaining bolt 55 41 -
Transfer case support bracket top retaining bolts 25 18 -
Transfer case support bracket bottom retaining bolt 47 35 -
Transfer case retaining bolts* 80 59 -
Transfer case fill plug 20 15 -
Exhaust front pipe retaining clamp 55 41 -
Catalytic converter to catalytic converter mount bracket retaining bolts 25 18 -
*On vehicles prior to VIN J25640, if you are re-using fixings, tighten to 90 Nm.
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Transfer Case - Transfer Case
1 Transfer case
2 Transfer case fill plug
3 Transfer case retaining bolt
4 Transfer case air cooling duct
5 Transfer case Y bracket retaining bolt
6 Transfer case Y bracket
7 Engine anti-roll restrictor mounting bracket retaining bolts
8 Engine anti-roll restrictor mounting bracket
9 Engine anti-roll restrictor mounting bracket retaining nuts
10 Companion flange retaining nut
11 Companion flange
The transfer case system consists of a power transfer unit, rear driveshaft, coupling device and rear axle. The power transfer unit is a
gearbox that attaches to the transaxle. The right hand halfshaft engages to the transfer case link shaft which engages to the differential
side gears as in a normal 4x2 application. The transfer case provides power to the driveshaft through a helical gear spline coupled to the
transaxle differential case, a helical gear drop (idler gear) and hypoid/helical ring gear assembly and pinion set. Repair of the transfer case
is limited to seals and gaskets. If any of the geared components, tappered roller bearings, case cover or internal shafts fail, a new transfer
case must be installed. The transfer case is sealed from the transaxle and has its own sump. The transfer case uses SAE 75W140 synthetic
gear lubricant. The fill plug is located on the top of the transfer case, under the engine anti roll restrictor mounting bracket.
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Transfer Case - Transfer Case Draining and Filling
General Procedures
Special Tool(s)
Flange holding tool
205-053
Flange remover/installer
204-068A
Flange remover/installer boss
204-266
204-295
Seal extractor
308-375
Slide hammer
100-012
Slide hammer adapter
100-012-01
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flange.
4. Detach the engine roll restrictor.
Remove the engine roll restrictor retaining bolt.
5. Detach the driveshaft from drive pinion flange.
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6. Using suitable tie straps, secure the outer casing of the driveshaft
universal joint.
7. CAUTION: Make sure that the driveshaft does not hang on the
center universal joint. Failure to follow this instruction may result in
damage to the driveshaft.
Using suitable tie straps, secure the driveshaft to the subframe.
8. Mark the position of the retaining nut in relation to the companion
flange and the companion flange in relation to the output shaft.
9. Install the special tool to the companion flange.
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10. NOTE: Make a note of the complete number of turns required to
remove the companion flange retaining nut.
NOTE: Make a note of the number of degrees past the last complete
rotation required to remove the companion flange retaining nut.
Remove the companion flange retaining nut.
11. Install the special tool to the output shaft.
12. Install special tool 204-266 to special tool 204-068A.
Install the six retaining bolts. J
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14. Remove the companion flange.
Rotate the special tool counter-clockwise.
15. Using the special tools remove the pinion oil seal.
16. NOTE: Make sure the vehicle is completely level when draining the
transfer case.
Allow the oil to fully drain into a suitable container.
17. Using the special tool 204-264 fully seat the new oil seal.
18. Install the companion flange to the output shaft.
Lubricate the companion flange splines with SAE 75W140 lubricant.
Install the companion flange making sure that the flange and
output shaft marks are aligned.
Install special tool 204-295 to the companion flange.
Install special tool 204-266.
Using the special tools install the companion flange to the output
shaft by 10mm.
20. Using a suitable solvent/cleaner, remove all traces of oil from the
transfer case rear output flange and exposed threads of the output
shaft.
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21. Apply sealant (C2S 12099) to the area of transfer case rear output
flange where securing nut seats.
23. Apply sealant (C2S 12099) to the mating face of the transfer case rear
output flange securing nut.
24. Install the companion flange securing nut.
Start the nut at the noted number of degrees before the start of
the first full rotation.
Tighten to the noted full number of rotations.
Make sure that the original marks between the companion flange,
securing nut and output shaft are aligned.
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Cut and remove the tie straps securing the outer casing of the driveshaft
universal joint.
26. Cut and remove the tie straps securing the outer casing of the
driveshaft universal joint.
27. Connect the driveshaft to the transfer case.
28. Attach the driveshaft universal joint.
Tighten to 44 Nm.
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29. Attach the engine roll restrictor.
Tighten to 80 Nm.
NOTE: The lower lip of the sill must be 540mm from the floor.
Raise and support the left hand side of the vehicle.
Remove the vehicle from the lift.
Raise the vehicle using two jacks.
31. Fill the transfer case with 400ml of oil.
Tighten the filler plug to 20Nm.
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Transfer Case - Halfshaft Seal RH
In-vehicle Repair
Removal
1. Remove the right-hand halfshaft seal.
For additional information, refer to Transfer Case in this section.
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Transfer Case - Transfer Case Rear Output Shaft Seal
In-vehicle Repair
Special Tool(s)
Flange holding tool
205-053
204-068A
Flange remover/installer boss
204-266
204-295
Seal extractor
308-375
Slide hammer
100-012
100-012-01
Removal
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flange.
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universal joint.
Using suitable tie straps, secure the driveshaft to the subframe.
8. Mark the position of the retaining nut in relation to the companion
flange and the companion flange in relation to the output shaft.
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10. NOTE: Make a note of the complete number of turns required to
remove the companion flange retaining nut.
NOTE: Make a note of the number of degrees past the last complete
rotation required to remove the companion flange retaining nut.
Remove the companion flange retaining nut.
11. Install the special tool to the output shaft.
12. Install special tool 204-266 to special tool 204-268A.
Install the six retaining bolts. J
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14. Remove the companion flange.
Rotate the special tool anti-clockwise.
15. Using the special tools remove the pinion oil seal.
16. NOTE: Make sure the vehicle is completely level when draining the
transfer case.
Allow the oil to fully drain into a suitable container.
Installation
1. Using the special tool 204-268 fully seat the new oil seal.
2. Install the companion flange to the output shaft.
Lubricate the companion flange splines with SAE 75W140 lubricant.
Install the companion flange making sure that the flange and
output shaft marks are aligned.
Install special tool 204-295 to the companion flange.
Install special tool 204-266.
Using the special tools install the companion flange to the output
shaft by 10mm.
4. Using a suitable solvent/cleaner, remove all traces of oil from the
transfer case rear output flange and exposed threads of the output
shaft.
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5. Apply sealant (C2S 12099) to the area of transfer case rear output
flange where securing nut seats.
7. Apply sealant (C2S 12099) to the mating face of the transfer case rear
output flange securing nut.
8. Install the companion flange securing nut.
Start the nut at the noted number of degrees before the start of
the first full rotation.
Tighten to the noted full number of rotations.
Make sure that the original marks between the companion flange,
securing nut and output shaft are aligned.
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universal joint.
Tighten to 44 Nm.
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Tighten to 80 Nm.
NOTE: The lower lip of the sill must be 540mm from the floor.
Raise and support the left hand side of the vehicle.
Remove the vehicle from the lift.
Raise the vehicle using two jacks.
15. Fill the transfer case with 400ml of oil.
Tighten the filler plug to 20Nm.
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Removal
Special Tool(s)
100-012-03
Slide hammer
100-012
100-012-02
Slide hammer shaft
307-442
307-443
Link shaft limiter bracket
307-446
Link shaft oil seal remover
308-208
Torque adaptor
303-1069
Removal
All vehicles
1. Position the front wheels in a straight ahead position and centralize the
steering wheel.
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3. Loosen the shock absorber and spring assembly securing nuts.
4. Remove the right-hand front wheel and tire.
6. Remove the front pipe.
7. Remove the muffler inlet pipe.
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8. Remove the selector lever cable shield.
9. Detach the selector lever cable bracket.
10. Disconnect the selector lever cable.
12. Drain the transmission fluid. For additional information, refer to:
(308-03 Manual Transmission/Transaxle)
Transmission - MT75 (General Procedures),
Transmission - MT75 (General Procedures).
All vehicles
13. NOTE: Mark the position of the driveshaft in relation to the drive
pinion flange.
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universal joint.
Using suitable tie straps, secure the driveshaft to the subframe
21. Remove the right-hand front subframe rear mount retaining bolt.
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22. Loosen the left-hand front subframe rear mount retaining bolt.
23. CAUTION: Make sure the constant velocity (CV) joint boot is
protected. Failure to follow this instruction may result in damage to the CV
joint boot.
Detach the lower arm from the wheel knuckle.
3. Reposition the wheel knuckle.
24. CAUTIONS:
To prevent damage to the transfer box internal seal, make sure that
the link shaft is not retracted further than 200 mm (7.87 inches) from the
transfer case.
Using the special tools, detach the halfshaft.
1. Align the special tools to the halfshaft.
2. Detach the halfshaft.
Remove and discard the halfshaft seal.
Support the halfshaft.
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27. Remove the transfer case support bracket.
28. Remove the catalytic converter mount bracket retaining bolts.
29. Remove the catalytic converter mount bracket to transfer case
retaining bolt.
30. Remove the catalytic converter mount bracket retaining bolt.
31. Using the special tool, loosen the catalytic converter mount bracket,
top left-hand retaining bolt.
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32. Remove the catalytic converter mount bracket.
33. Remove the engine anti-roll restrictor bracket retaining bolts.
34. Remove the engine anti-roll restrictor bracket retaining nuts.
35. Remove the engine anti-roll restrictor bracket.
make sure that the link shaft is not retracted further than 200 mm (7.87
inches) from the transfer case.
Using the special tools, detach the transfer case link shaft from the
transfer case.
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make sure that the link shaft is not retracted further than 200 mm (7.87
inches) from the transfer case.
Using the special tool, retract the transfer case link shaft.
38. CAUTION: Make sure there is no loss of fluid from the transfer
case. Failure to follow this instruction may result in damage to the
transfer case.
With the aid of an assistant remove the transfer case.
transfer case.
transfer case.
Remove and discard O-ring seal.
transfer case.
Remove and discard the link shaft snap ring.
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transfer case.
Remove the link shaft from the transfer case.
transfer case.
Using the special tool, remove the link shaft seal.
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Installation
Special Tool(s)
Link shaft limiter bracket
307-446
Torque adapter
303-1069
205-115
Installation
All vehicles
transfer case.
NOTE: Using a suitable solvent clean the seal face on the housing before
fitting a new seal.
Using the special tool, install the link shaft oil seal.
If any transfer case fluid is lost during installation carry out drain
and refill.
For additional information, refer to: Transfer Case Draining and
Filling (308-07 Transfer Case, General Procedures).
transfer case.
Install the link shaft into the transfer case.
transfer case.
Install a new link shaft snap ring.
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transfer case.
transfer case.
transfer case.
With the aid of an assistant install the transfer case.
Tighten to 80 Nm.
If any transfer case fluid is lost during installation carry out drain
and refill.
For additional information, refer to: Transfer Case Draining and
Filling (308-07 Transfer Case, General Procedures).
NOTE: On vehicles prior to VIN J25640, if you are re-using transfer case fixings, tighten to 90 Nm.
Engage the link shaft into the transfer case.
8. NOTE: Do not tighten the engine anti-roll restrictor bracket top
retaining bolt at this stage.
Install the engine anti-roll restrictor bracket.
Install the engine anti-roll restrictor bracket top retaining bolt.
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9. NOTE: Do not tighten the engine anti-roll restrictor bracket retaining
nuts at this stage.
Install the engine anti-roll restrictor bracket retaining nuts.
10. NOTE: Do not tighten the engine anti-roll restrictor bracket retaining
Install the engine anti-roll restrictor bracket side retaining bolts.
11. NOTE: Do not tighten the catalytic converter mount bracket retaining
12. Using the special tool, tighten the catalytic converter mount bracket,
top left-hand retaining bolt.
Use the calculation in step 13 to produce the correct torque to
apply to the retaining bolt.
13. Using the special tool and a torque wrench, tighten the catalytic
converter mount bracket, top left-hand retaining bolt.
To make sure the catalytic converter mount bracket, top left-hand
retaining bolt is torqued to the correct specification the following
calculation steps must be used.
wrench (1).
Tighten the catalytic converter mount bracket, top left-hand
retaining bolt to the torque given by the calculation.
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Tighten to 55 Nm.
15. Tighten the catalytic converter mount bracket retaining bolt.
Tighten to 55 Nm.
16. Install the catalytic converter mount bracket to transfer case retaining
bolt.
Tighten to 25 Nm.
17. Tighten the engine anti-roll restrictor bracket top retaining bolt.
Tighten to 55 Nm.
18. Tighten the engine anti-roll restrictor bracket retaining nuts.
Tighten to 35 Nm.
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19. Tighten the engine anti-roll restrictor bracket side retaining bolts.
Tighten to 35 Nm.
20. Install the catalytic converter to catalytic converter mount bracket
retaining bolts.
Tighten to 25 Nm.
21. NOTE: Alternator cooling duct shown removed for clarity.
Install transfer case support bracket.
Tighten to 47 Nm.
22. Install transfer case support bracket top retaining bolts.
Tighten to 25 Nm.
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Remove the halfshaft support strap.
26. CAUTION: Make sure the CV joint splines are located fully. Do
not use excessive force when engaging the CV joint into the link shaft.
Tighten to 83 Nm.
28. Loosley install the right-hand front subframe rear mount retaining bolt.
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Tighten to 142 Nm.
M8 to 35 Nm.
M10 to 70 Nm.
universal joint.
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2. Install new driveshaft retaining bolts
Tighten to 44 Nm.
Install the engine roll restrictor retaining bolt.
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Tighten to 80 Nm
39. Fill the manual transmission to the correct oil level. For additional
information, refer to: (308-03 Manual Transmission/Transaxle)
Transmission - MT75 (General Procedures),
Transmission - MT75 (General Procedures).
40. Connect the selector lever cable.
41. Attach the selector lever cable bracket.
Tighten to 10 Nm.
42. Fill the automatic transmission to the correct oil level.
(307-01A Automatic Transmission/Transaxle - Vehicles With: 5-Speed
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Automatic Transaxle - JATCO, General Procedures).
43. Install the selector lever cable shield.
Tighten to 10 Nm.
All vehicles
44. Install the muffler inlet pipe.
45. Install the front pipe.
Tighten to 55 Nm.
46. Install the fender splash shield access panel.
47. Install the right-hand front wheel and tire.
48. Tighten the shock absorber and spring assembly securing nuts.
Tighten to 25 Nm.
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49. NOTE: Install a new steering column lower retaining bolt.
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Exhaust System -
Catalytic converter retaining studs - vehicles without diesel engines 9 - 80
Catalytic converter to exhaust manifold retaining nuts - vehicles without diesel engines A - -
Catalytic converter - right-hand - to transfer case mounting bracket retaining bolts - vehicles without diesel engines 25 18 -
Catalytic converter - left-hand - to support bracket retaining bolts - vehicles without diesel engines 25 18 -
Muffler and tailpipe clamp retaining nut - all vehicles 48 35 -
Front muffler to muffler inlet pipe retaining nuts - vehicles without diesel engines 48 35 -
Muffler inlet pipe to front pipe retaining nut and bolt - vehicles without diesel engines 48 35 -
Exhaust hanger to front muffler retaining bolt - all vehicles 25 18 -
Heated oxygen sensor (HO2S) - vehicles without diesel engines 40 30 -
Catalyst monitor sensor - vehicles without diesel engines 40 30 -
Exhaust hanger to body retaining bolts - all vehicles 25 18
Exhaust heat shield retaining bolts - vehicles without diesel engines 10 - 89
Catalytic converter heat shield retaining bolts - vehicles without diesel engines 10 - 89
Air cleaner bracket retaining nuts - vehicles without diesel engines 6 - 53
Catalytic converter to turbocharger retaining nuts - vehicles with diesel engines 48 35 -
Catalytic converter retaining bolts - vehicles with diesel engines 48 35 -
Turbocharger heat shield retaining nuts - vehicles with diesel engines 8 - 71
Turbocharger heat shield retaining bolts - vehicles with diesel engines 8 - 71
Exhaust flexible pipe to catalytic converter retaining nuts - vehicles with diesel engines 48 35 -
Front muffler to exhaust flexible pipe retaining nuts - vehicles with diesel engines 48 35 -
Exhaust flexible pipe to diesel particulate filter retaining nuts - vehicles with di esel engines 48 35 -
Diesel particulate filter to muffler inlet pipe retaining nuts - vehicles with diesel engines 48 35 -
Diesel particulate filter pressure sensor mounting bracket retaining nuts - vehicles with diesel engines 5 - 44
Catalytic converter temperature sensor - vehicles with diesel engines 35 26 -
Diesel particulate filter temperature sensor - vehicles with diesel engines 35 26 -
A = refer to the procedure for the correct torque sequence
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Exhaust System - Exhaust System
Vehicles with 2.0L petrol engine
1 - Exhaust hanger
2 - Exhaust hanger isolator
4 - Exhaust hanger
5 - Exhaust hanger
7 - Catalytic converter - R/H
8 - Catalytic converter - L/H
9 - Front pipe
10 - Muffler inlet pipe
11 - Front muffler
12 - Muffler and tailpipe
13 - Exhaust hanger
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1 Exhaust manifold - R/H
2 Muffler and tailpipe assembly
3 Exhaust hanger
4 Exhaust hanger isolator
6 Exhaust hanger
7 Front muffler
10 Front muffler to muffler inlet pipe gasket
11 Muffler inlet pipe
12 Catalytic converter - L/H, support bracket
13 Catalytic converter - L/H
14 Exhaust manifold - L/H
15 Front pipe
16 Catalytic converter - R/H
Vehicles with Diesel Engine
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1 Catalytic converter
2 Exhaust flexible pipe
4 Front muffler
6 Muffler and tailpipe
9 Exhaust hanger
Vehicles with Diesel Particulate Filter (DPF)
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1 Catalytic converter
2 Exhaust hanger
3 DPF
5 Rear pipe
7 Muffler
9 Exhaust flexible pipe
All petrol vehicles are fitted with a stainless steel exhaust system consisting of:
catalytic converter(s)
front pipe
muffler inlet pipe
front muffler assembly
muffler and tailpipe assembly
The exhaust system is designed to meet the rising standards of vehicle emissions, complying with LEV (USA) and stage three (Europe)
emission legislation; effective from January 2001.
The exhaust system is supported at the front by the two catalytic converters which are retained directly to the exhaust manifolds by studs
and nuts. The remainder of the exhaust system is supported by four rubber hanger isolators. On 2.0L and diesel vehicles there are three
attached to the front muffler assembly and one attached to the rear muffler. On 2.5L and 3.0L vehicles there is one attached to the front
muffler and three attached to the rear muffler and tail pipe assembly.
A flexible coupling, which is part of the front muffler, is fitted to isolate the exhaust system from engine movement and vibration.
For 2.5L and 3.0L vehicles the rear exhaust muffler and tail pipe assembly is manufactured in one section which consists of a 'Y' pipe joined
to the two rear muffler and tail pipes. A service fix is provided for replacement of the rear mufflers and tail pipes. For 2.0L and diesel
vehicles there is a single rear muffler assembly which is attached to the left-hand side of the vehicle.
Three Way Catalytic Converters
The catalytic converters each contain two bricks coated with palladium/rhodium. These elements are utilized to control the emissions of
hydrocarbons (HC), carbon monoxide (CO) and oxides of nitrogen (NOx) from the engine.
Oxidation Catalytic Converter
The catalytic converter contains a brick coated with platinum. This element is utilized to control the emissions of hydrocarbons (HC), carbon
monoxide (CO) and particles of matter from the engine.
Diesel Particulate Filter
The Diesel Particulate Filter (DPF) system reduces diesel particulate emissions to negligible levels (0.005 g/km) to meet current local
European City clear air requirements.
The particulate emissions are the black fumes emitted from the diesel engine under certain load conditions. The emissions are a complex
mixture of solid and liquid components with the majority of the particulates being carbon micro-spheres on which hydrocarbons from the
engine's fuel and lubricant condense.
The DPF filter system consists of the following components:
DPF
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DPF control software incorporated into the engine control module (ECM)
Differential pressure sensor
The DPF reduces the pollution generated by diesel vehicles by filtering soot particles out of the exhaust gases.
The DPF is located in the exhaust system, downstream of the catalytic converter. A major feature of the DPF is its ability for regeneration.
Regeneration is the burning of particulates trapped by the filter to prevent obstruction to the free flow of exhaust gasses. The regeneration
process takes place at calculated intervals and is not noticeable by the driver of the vehicle.
Regeneration is most important, since an overfilled filter can damage the engine through excessive exhaust back-pressure and can its self
be damaged or destroyed. The material trapped in the filter is in the most part carbon particles with some absorbed hydrocarbons.
A - Front face showing alternate closed cells
B - Side view showing exhaust gas flow through the filter and particulate build up
C - Rear face showing alternate closed cells
The DPF uses a filter technology based on a filter with a catalytic coating. The DPF is made from silicon carbide housed in a steel container
and has excellent thermal shock resistance and thermal conductivity properties. The DPF is designed for the engine's operating requirements
to maintain the optimum back-pressure requirements.
The porous surface of the filter consists of hundreds of small parallel channels positioned in the longitudinal direction of the exhaust
system. Adjacent channels in the filter are alternately plugged at the end. This design forces the exhaust gasses to flow through the porous
filter walls, which act as the filter medium. Particulate matter, which are too big to pass through the porous surface are collected and stored
in the channels.
The collected particulate matter, if not removed, can create an obstruction to exhaust gas flow. The particles are removed by a regeneration
process, which incinerates the particles.
Two processes are used to regenerate the DPF, passive and active.
Passive Regeneration
Passive regeneration requires no special engine management intervention and occurs during normal engine operation. The passive
regeneration involves a slow conversion of the particulate matter deposited in the DPF into carbon dioxide. This process is active when the
DPF temperature reaches 250C (482F) and is a continuous process when the vehicle is being driven at higher engine loads and speeds.
During passive regeneration, only a portion of the particulate matter is converted into carbon dioxide. This is due to the chemical reaction
process, which is only effective within the normal operating temperature range of 250C to 500C (482F to 932F).
Above this temperature range the conversion efficiency of the particulates into carbon dioxide increases as the DPF temperature is raised.
These temperatures can only be achieved using the active regeneration process.
Active Regeneration
Active regeneration starts when the particulate loading of the DPF reaches a threshold as monitored or determined by the DPF control
software. The threshold calculation is based on driving style, distance traveled and back-pressure signals from the differential pressure
sensor.
Active regeneration generally occurs every 370 to 1250 miles (600 to 2000km) although this is dependant on how the vehicle is driven. For
example, if the vehicle is driven at low loads in urban traffic regularly, active regeneration will occur more often. This is due to the rapid
build-up of particulates in the DPF than if the vehicle is driven at high speeds when passive regeneration will have occurred.
The DPF software incorporates an additional trigger, which is used as backup for active regeneration. If active regeneration has not been
initiated by a back-pressure signal from the differential pressure sensor, regeneration is requested based on estimated cumulative
particulate emissions since the last active regeneration event.
Active regeneration of the DPF is commenced when the temperature of the DPF is increased to the combustion temperature of the particles.
The DPF temperature is raised by increasing the exhaust gas temperature. This is achieved by:
Retarding the main injection timing
Reducing intake boost pressure levels
Activation of the inlet throttle
Introducing post-injection of fuel after the pilot and main fuel injections have occurred.
Control of the post-injection is determined by the DPF software monitoring the signals from the two DPF temperature sensors to establish
the temperature of the DPF. Depending on the DPF temperature, the DPF software requests the ECM to perform either 1 or 2 post-injections
of fuel:
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The first post-injection of fuel burns inside the cylinder, which increases the temperature of the exhaust gas
The second post-injection of fuel is injected late in the power stroke cycle. The fuel partly combusts in the cylinder, but some
un-burnt fuel also passes into the exhaust where it creates an exothermic event within the catalytic converter, further increasing the
temperature of the DPF
The active regeneration process takes approximately 20 minutes to complete. The first phase increases the DPF temperature to 200C
(392F). The second phase further increases the DPF temperature to 600C (1112F), which is the optimum temperature for particle
combustion. This temperature is then maintained for 15-20 minutes to ensure complete incineration of the particles within the DPF. The
incineration process converts the carbon particles to carbon dioxide and water.
The active regeneration temperature of the DPF is closely monitored by the DPF software to maintain a target temperature of 600C
(1112F) at the DPF inlet. The temperature control ensures that the temperatures do not exceed the operational limits of the turbocharger
and the catalytic converter. The turbocharger inlet temperature must not exceed 760C (1400F) and the catalytic converter brick
temperature must not exceed 800C (1472F) and the exit temperature must remain below 750C (1382F).
During the active regeneration process the following ECM controlled events occur:
The turbocharger is maintained in the fully open position. This minimizes heat transmission from the exhaust gas to the turbocharger
and reduces the rate of exhaust gas flow allowing optimum heating of the DPF. If the driver demands an increase in engine torque,
the turbocharger will respond by closing the vanes as necessary
The throttle is closed as this assists in increasing the exhaust gas temperature and reduces the rate of exhaust gas flow which has
the effect of reducing the time for the DPF to reach the optimum temperature
The exhaust gas re-circulation (EGR) valve is closed. The use of EGR decreases the exhaust gas temperature and therefore prevents
the optimum DPF temperature being achieved
The glow plugs are occasionally activated to provide additional heat to assist in raising the DPF temperature
If, due to vehicle usage and/or driving style, the active regeneration process cannot take place or is unable to regenerate the DPF, the
dealer can force regenerate the DPF. This is achieved by either driving the vehicle until the engine is at its normal operating temperature
and then driving for a further 20 minutes at speeds of not less than 30 mph (48 km/h) or by connecting the Jaguar approved diagnostic
system to the vehicle, which will perform an automated static regeneration procedure to clean the DPF.
Diesel Particulate Filter Control
The DPF requires constant monitoring to ensure that it is operating at its optimum efficiency and does not become blocked. The ECM
contains DPF software, which controls the monitoring and operation of the DPF system and also monitors other vehicle data to determine
regeneration periods and service intervals.
The DPF software can be divided into 3 separate control software modules; a DPF supervisor module, a DPF fuel management module and a
DPF air management module.
These 3 modules are controlled by a fourth software module known as the DPF co-ordinator module. The co-ordinator module manages the
operation of the other modules when an active regeneration is requested. The DPF supervisor module is a sub-system of the DPF
co-ordinator module.
DPF Fuel Management Module
The DPF fuel management module controls the following functions:
Timing and quantity of the 4 split injections per stroke (pilot, main and 2 post injections)
Injection pressure and the transition between the 3 different calibration levels of injection
The above functions are dependant on the condition of the catalytic converter and the DPF.
The controlled injection determines the required injection level in addition to measuring the activity of the catalytic converter and the DPF.
The fuel management calculates the quantity and timing for the 4-split injections, for each of the 3 calibration levels for injection pressure,
and also manages the transition between the levels.
The 2 post injections are required to separate the functionality of increasing in-cylinder gas temperatures and the production of
hydrocarbons. The first post injection is used to generate the higher in-cylinder gas temperature while simultaneously retaining the same
engine torque output produced during normal (non-regeneration) engine operation. The second post injection is used to generate
hydrocarbons by allowing un-burnt fuel into the catalytic converter without producing increased engine torque.
DPF Air Management Module
The DPF air management module controls the following functions:
EGR control
Turbocharger boost pressure control
Exhaust Air Fuel Ratio (AFR) control
During active regeneration, the EGR operation is disabled and the closed-loop activation of the turbocharger boost controller is calculated.
The air management module controls the air in the intake manifold to a predetermined level of pressure. This control is required to achieve
the correct in-cylinder conditions for stable and robust combustion of the post-injected fuel.
The module controls the exhaust AFR by actuating the EGR throttle.
DPF Co-ordinator Module
The DPF co-ordinator module reacts to a regeneration request from the supervisor module by initiating and co-ordinating the following DPF
regeneration requests:
EGR cut-off
Turbocharger boost pressure control
Engine load increase
Control of air pressure in the intake manifold
Fuel injection control
When the supervisor module issues a regeneration request, the co-ordinator module manages the change over to the regeneration specific
settings. The change over occurs during an accelerator pedal release manoeuver from the driver or after a calibrated waiting time.
Pressure Differential Sensor
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1 - High pressure connection
2 - Low pressure connection
The differential pressure sensor is located in the engine compartment, on the lower RH side of the bulkhead. The sensor is located on 2
studs and secured with nuts.
The differential pressure sensor is used by the DPF software to monitor the condition of the DPF. Two pipe connections on the sensor are
connected by pipes to the inlet and outlet ends of the DPF. The pipes allow the sensor to measure the inlet and outlet pressures of the
DPF.
As the amount of particulates trapped by the DPF increases, the pressure at the inlet side of the DPF increases in comparison to the DPF
outlet. The DPF software uses this comparison, in conjunction with other data, to calculate the accumulated amount of trapped particulates.
By measuring the pressure difference between the DPF inlet and outlet and the DPF temperature, the DPF software can determine if the DPF
is becoming blocked and requires regeneration.
Differential Particulate Filter Temperature Sensors
Two temperature sensors are used in the DPF system. One is located in the catalyst inlet and the second sensor is located in the DPF inlet.
The sensors measure the temperature of exhaust gas exiting the turbocharger and before it passes through the DPF and provides the
information needed to calculate the DPF temperature.
The information is used, in conjunction with other data, to estimate the amount of accumulated particulates and to control the DPF
temperature.
Instrument Cluster Indications
When the engine is at it's normal operating temperature and the vehicle is driven at moderate speeds, 30 mph (48 km/h), or more, a
regeneration of the DPF takes place automatically. This means that the exhaust particles collected in the filter are burned away and the
filter is emptied.
For drivers who make regular short journeys at low speeds, it may not be possible to efficiently regenerate the DPF. In this case, the DPF
software will detect a blockage of the DPF from signals from the differential pressure sensor and will alert the driver by displaying a warning
message 'DPF FULL' in the message center, plus either a RED or AMBER warning lamp.
CAUTION: If the warning message with the RED warning lamp is displayed, a Jaguar dealer/authorized repairer must be contacted as
soon as possible before damage to the DPF occurs.
When the message is displayed with an AMBER priority warning lamp, regeneration is required.
CAUTION: If the vehicle continues to be driven with the AMBER warning lamp illuminated without regenerating the DPF, the RED
warning lamp will illuminate.
NOTE: Once triggered, the warning lamp and message will remain on until the ignition is switched to the 'OFF' position. Even though
regeneration is still required, the warning lamp and message will only re-appear after 255 seconds of driving and sufficient pressure has
built up in the DPF.
For more information, refer to the Owners Handbook.
Diesel Particulate Filter Side Effects
The following section details some side effects caused by the active regeneration process.
Engine Oil Dilution
Engine oil dilution can occur due to small amounts of fuel entering the engine crankcase during the post-injection phases. This has made it
necessary to introduce a calculation based on driving style to reduce oil service intervals if necessary. The driver is alerted to the oil service
by a message in the instrument cluster.
The DPF software monitors the driving style, the frequency of the active regeneration and duration. Using this information a calculation can
be made on the engine oil dilution. When the DPF software calculates the engine oil dilution has reached a predetermined threshold (fuel
being 7% of engine oil volume) a service message is displayed in the instrument cluster.
Depending on driving style, some vehicles may require an oil service before the designated interval. If a service message is displayed, the
vehicle will be required have a full service and the service interval counter will be reset.
Fuel consumption
During the active regeneration process of the DPF, there will be an increase in fuel consumption. When active regeneration is operating,
there will be a 100% increase in fuel consumption.
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Exhaust System - Exhaust System
Overview
For information on the description and operation of the diesel particulate filter (DPF) and catalytic converter systems:
REFER to: Exhaust System (309-00 Exhaust System, Description and Operation).
1. Verify the customer concern.
Confirm the illumination of any DPF warning lamps (red or amber) and any message center information.
Once the ignition is turned off, the warnings will disappear, but will reappear after 255 seconds of driving, or once sufficient
pressure has built up in the DPF.
1.
Visual inspection
Mufflers and pipes
Catalytic converter
Diesel particulate filter (DPF)
Exhaust gas recirculation (EGR) valve
Turbocharger
Exhaust gas temperature sensors
Injectors
Differential pressure sensor and circuits
Exhaust gas recirculation (EGR) valve and circuits
Turbocharger and circuits
Glow plugs
step.
3.
4.
Symptom chart
Condition Possible source Action
Engine oil dilution Fuel entering the
crankcase during
post-injection
Note that depending on driving style and use, some vehicles may require
engine oil changes at less than usual service intervals. Check the message
center and service history. Change the engine oil and reset the counter as
necessary.
Excessive fuel
consumption/poor
performance
Damaged/blocked exhaust
pipe and/or muffler(s)
Blocked catalytic
converter(s)
Inspect the exhaust system for damage. Disconnect the exhaust system from
the catalytic converter(s) and check for restricted flow. Remove the catalytic
converter(s) and inspect internally for damage. Install new components as
necessary.
REFER to: Exhaust System (309-00 Exhaust System, Description and
Operation).
Note that the fuel consumption increases while active regeneration is in
operation, but as this happens infrequently there is only a slight increase in
overall consumption.
Knocks/rattles from
underside
Exhaust system
components
insecure/damaged
Catalytic converter(s)
damaged
Inspect the exhaust system for damage. Check the security of the system
fittings. Tap the sides of the catalytic converter(s) with a soft-faced hammer
and listen for movement inside the converter. Install new components as
necessary.
Operation).
Noise/fumes in vehicle Exhaust system
components
insecure/damaged
Leakage from joints
Inspect the exhaust system for damage. Check the security of the system
fittings. In a well-ventilated area, close off the tailpipe(s) and check for
evidence of leakage. Seal any leaks as necessary.
Operation).
DTC index
NOTE: For a full list of Engine Control Module (ECM) DTCs:
P0544 Exhaust gas temperature sensor
circuit, right-hand bank, upstream
sensor
sensor circuit: short circuit
to ground
sensor circuit: open circuit
to power
sensor fault
Refer to the approved diagnostic system for a guided
diagnostic routine. Check the exhaust gas temperature sensor
and circuits. Refer to the electrical guides. Rectify as
circuit low, right-hand bank,
upstream sensor
to ground
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sensor fault
circuit high, right-hand bank,
upstream sensor
to power
sensor fault
P1403 Differential pressure feedback
sensor hoses reversed
Diesel Particulate Filter
(DPF) delta pressure sensor
crossed hose fault
Check the correct connection of the hoses to the pressure
sensor. Rectify as necessary. Clear the DTCs, test for normal
operation.
temperature sensor circuit, sensor
2
to ground
to power
sensor fault
temperature sensor circuit low,
sensor 2
to ground
sensor fault
temperature sensor circuit high,
sensor 2
to power
sensor fault
range/performance, sensor 1
to ground
to power
sensor fault
sensor circuit: intermittent
high resistance
sensor fault
sensor circuit: intermittent
high resistance
sensor fault
P242F Diesel particulate filter
(DPF)restriction - ash accumulation
DPF blocked Install a new DPF as necessary.
REFER to: Diesel Particulate Filter (DPF) (309-00 Exhaust
P244ADiesel particulate filter
(DPF)differential pressure too low
DPF leaking Install a new DPF as necessary.
REFER to: Diesel Particulate Filter (DPF) (309-00 Exhaust
P244BDiesel particulate filter
(DPF)differential pressure too high
DPF overloaded Carry out the regeneration procedure. Clear the DTCs, test for
normal operation.
P244CExhaust temperature too low for
particulate filter regeneration
Insufficient mileage/speed
for regeneration
Carry out the regeneration procedure. Clear the DTCs, test for
normal operation.
P2452 Diesel particulate filter
(DPF)pressure sensor A circuit
DPF delta pressure sensor
circuit fault
fault
Check the DPF delta pressure sensor and circuits. Refer to the
electrical guides. Rectify as necessary.
P2453 Diesel particulate filter
(DPF)pressure sensor A circuit
range/performance
hose fault
fault
diagnostic routine. Check the condition and fitment of the DPF
delta pressure sensor and hoses. Rectify as necessary.
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Exhaust System - Catalytic Converter2.0L Duratorq-TDCi/2.2L Duratorq-TDCi
Removal
4. Remove the turbocharger heatshield.
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5. Remove the catalytic converter to turbocharger retaining nuts.
6. Disconnect the catalytic converter temperature sensor electrical
connector.
8. Remove the turbocharger outlet pipe retaining bolt.
9. Detach the turbocharger outlet pipe.
1. Loosen the retaining clip.
2. Reposition the pipe.
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Remove the securing bolt.
Installation
converter.
NOTE: Coat the catalytic converter studs with anti-seize grease.
Install the catalytic converter.
Loosely install the catalytic converter retaining bolt.
3. Install the catalytic converter to turbocharger retaining nuts.
Tighten to 46 Nm.
5. Tighten the catalytic converter retaining bolt.
Tighten to 46 Nm.
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6. Attach the turbocharger outlet pipe.
1. Reposition the pipe.
2. Tighten the retaining clip.
Tighten to 4 Nm.
7. Install the turbocharger outlet pipe retaining bolt.
Tighten to 46 Nm.
9. Connect the catalytic converter temperature sensor electrical connector.
10. Install the turbocharger heatshield.
Tighten to 8 Nm.
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Exhaust System - Catalytic Converter LH2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L
NA V6 - AJ27
Removal
.
refer to
.
5. Remove the catalyst to support bracket retaining bolt.
Detach the muffler inlet pipe.
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7. Remove the front pipe.
8. Remove the thermostat housing to oil cooler coolant pipe.
9. Remove the catalytic converter heat shield lower retaining bolt.
11. Detach and reposition the wiring harnesses.
12. Remove the air cleaner retaining bracket.
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13. Detach and reposition the radiator inlet coolant pipe.
14. Remove the catalytic converter heat shield.
Discard the retaining nuts.
16. Remove the HO2S.
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18. Remove and discard the sealing ring.
Installation
converter.
Install a new sealing ring.
Tighten to 9 Nm.
4. NOTE: Make sure that the retaining nuts are tightened twice in the
sequence shown.
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6. Tighten to 6 Nm.
Tighten to 55 Nm.
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Exhaust System - Catalytic Converter RH2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L
NA V6 - AJ27
Removal
1. Remove the front subframe. For additional information, refer to
.
Disconnect the catalyst monitor sensor electrical connector.
Disconnect the heated oxygen sensor (HO2S) electrical connector.
Remove the exhaust heat shield.
Remove the catalytic converter retaining bolts.
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7. Remove and discard the retaining studs.
8. Remove the HO2S.
9. Remove and discard the sealing ring.
Installation
converter.
Install a new sealing ring.
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3. Install new retaining studs.
Tighten to 9 Nm.
NOTE: Make sure that the retaining nuts are tightened twice in the
sequence shown.
Tighten to 25 Nm.
Tighten to 10 Nm.
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Exhaust System - Diesel Particulate Filter (DPF)
Removal
2. Disconnect the diesel particulate filter temperature sensor electrical
connector.
3. NOTE: Note the orientation of the diesel particulate filter high-pressure
and low-pressure hoses and make sure they are installed in the same
position.
Detach the diesel particulate filter low-pressure hose.
4. NOTE: Note the orientation of the diesel particulate filter high-pressure
and low-pressure hoses and make sure they are installed in the same
position.
Detach the diesel particulate filter high-pressure hose.
5. Detach the diesel particulate filter support isolator.
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6. Remove the diesel particulate filter to flexible pipe retaining nuts.
Remove and discard the gasket and nuts.
7. Remove the diesel particulate filter.
Installation
Tighten to 46 Nm.
Install a new gasket and nuts.
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Install a new gasket and nuts.
www.JagDocs.com
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Exhaust System - Diesel Particulate Filter (DPF) Differential Pressure Sensor
Removal
2. NOTE: Note the orientation of the retaining clip.
Detach the diesel particulate filter (DPF) high-pressure and low-pressure
hoses.
4. Detach the DPF differential pressure sensor retaining bracket.
5. Disconnect the DPF differential pressure sensor electrical connector.
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the same position.
Disconnect the DPF differential pressure sensor high-pressure and
low-pressure hoses.
7. Remove the DPF differential pressure sensor.
Installation
Tighten to 5 Nm.
2. Tighten to 4 Nm.
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Exhaust System - Exhaust Flexible Pipe2.0L Duratorq-TDCi/2.2L Duratorq-TDCi
Removal
2. Detach the exhaust flexible pipe support isolator.
3. Remove the exhaust flexible pipe retaining nuts.
4. CAUTION: Over bending of the exhaust flexible pipe may result in
Remove the exhaust flexible pipe.
Installation
1. CAUTION: Over bending of the exhaust flexible pipe may result in
Install a new exhaust flexible pipe gasket and nuts.
Tighten to 46 Nm.
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Exhaust System - Front Muffler2.0L Duratorq-TDCi/2.2L Duratorq-TDCi
Removal
2. Loosen the rear muffler exhaust clamp nut.
3. Remove the front muffler retaining nuts.
4. Detach the front muffler exhaust hanger isolator bracket.
Detach the front muffler hanger isolators.
Discard the gasket.
Installation
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1. CAUTION: The exhaust hanger isolators are constructed of a
special material. Use only the correct specification exhaust hanger
isolators.
NOTE: Check the exhaust hanger isolators for damage or fatigue. Install
new exhaust hanger isolators if required.
NOTE: Make sure the front muffler does not foul the underside of the
vehicle.
Tighten to 25 Nm.
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Exhaust System - Front Muffler2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 -
AJ27
Removal
All vehicles
For additional information, refer to Section 100-01 Identification Codes.
3. Detach the front muffler exhaust hanger isolator bracket.
5. Detach the front muffler exhaust hanger isolator.
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6. Detach the front muffler hanger isolators.
Loosen the front muffler clamp retaining nuts.
Installation
isolators.
vehicle.
Tighten to 55 Nm.
2. Tighten bolt to 25 Nm.
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isolators.
vehicle.
Tighten to 55 Nm.
All vehicles
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Exhaust System - Muffler and Tailpipe2.0L Duratorq-TDCi/2.2L Duratorq-TDCi
(110kW/150PS) - Puma, 2.0L
Removal
2. CAUTION: Before removing the rear muffler assembly, make a
note of the location between the rear muffler and the rear muffler inlet
pipe. Failure to install the rear muffler in the correct position could cause
an acoustic vibration inside the vehicle.
Loosen the muffler and tailpipe clamp retaining nut.
3. Remove the rear muffler assembly.
Detach the muffler and tailpipe support isolator.
Installation
isolators. Failure to follow this instruction may result in damage to the
component.
NOTE: Install the muffler and tailpipe in the same position that was
noted in the removal procedure. If installing a new rear muffler make sure
that there is no torsional stress in the exhaust system, and that the
exhaust system is free of the underbody of the vehicle.
Tighten to 55 Nm.
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Exhaust System - Muffler and Tailpipe2.5L NA V6 - AJV6/3.0L NA V6 - AJ27
Removal
Cut the rear muffler 'Y' pipe in front of the welded joint.
Remove the muffler and tailpipe.
Remove the exhaust hanger and isolator.
Installation
isolators. Failure to follow this instruction may result in damage to the
component.
NOTE: Make sure the rear muffler 'Y' pipe does not have any burrs.
NOTE: Make sure the muffler and tailpipe is central to the bumper
aperture.
Install the muffler and tailpipe.
Tighten to 55 Nm.
Tighten to 25 Nm.
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Exhaust System - Muffler Inlet Pipe2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 -
AJ27
Removal
All vehicles
1. Remove the front wheel and tire. For additional information, refer to
Section 204-04 Wheels and Tires.
2. Detach and reposition the heat shield.
3. Loosen the muffler inlet pipe exhaust clamp nut.
4. Detach the front muffler.
5. Loosen the muffler inlet pipe exhaust clamp nut.
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6. Detach the muffler.
Slacken the muffler retaining clamp nuts.
All vehicles
Remove the muffler inlet pipe.
Remove the exhaust heat shield.
Installation
All vehicles
Tighten to 10 Nm.
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Tighten to 55 Nm.
Tighten to 55 Nm.
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Exhaust System - Muffler Inlet PipeVehicles With: Diesel Particulate Filter (DPF)
Removal
3. Remove the muffler inlet pipe to diesel particulate filter retaining nuts.
Detach the muffler inlet pipe support isolators.
Installation
1. NOTE: Check the exhaust support isolators for damage or fatigue.
Install new exhaust support isolators if required.
Tighten to 46 Nm.
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Fuel System - General Information -
Item Specification
Fuel tank capacity 61.5 ltrs
Fuel tank sender unit lock rings 70 52 -
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Fuel System - General Information - Fuel System
1 Fuel tank filler pipe
2 Inertia fuel shutoff (IFS) switch
3 Fuel pump
4 Fuel filter
5 Fuel tank
The mechanical returnless fuel system utilized has the following advantages:
Reduces the build up of fuel pressure on starting the engine
Holds the pressure in the fuel lines to aid engine hot starts
Smooths out pulsations and reduces fuel pump noise
The fuel tank is constructed of high density polythylene and is located underneath the vehicle below the rear passenger seat. The tank is
retained by two support straps fixed to the vehicle's underbody, with the underside of the tank being protected by a fitted heatshield.
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The electric turbine fuel pump, which operates in a fuel reservoir, has an integral top plate for the external pipe work and electrical
connectors. The pump is secured to the fuel tank by a screw-on plastic closure ring.
Two roll over valves are connected by a hose which allows air to circulate in the tank which prevents the build up of high pressure vapor
areas which may be created during fuel tank filling on gradients or when the vehicle is in motion.
Fuel is pumped from the tank to the fuel rail at a constant pressure of 4.5 bar, regardless of the amount of fuel being injected into the
engine. Fuel pressure is constantly maintained by the fuel pump's integral mechanical pressure regulator which returns excess fuel to the
fuel tank via a T-piece positioned directly after the fuel filter.
2 Inertia fuel shutoff (IFS) switch
3 Fuel pump module
4 Fuel filter
5 Fuel tank
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6 Fuel transfer pump (jet pump) module
The electronic returnless fuel system utilized has the following advantages:
reduced fuel tank vapor.
requires less electrical power.
does not require a fuel return line.
The intelligence of this system is contained within the engine control module (ECM).
The ECM determines the required fuel flow and communicates this information to the fuel pump controller. The fuel pump controller has the
fuel pump driver functions fully integrated into the microprocessor. The ECM calculates the frequency and determines the current required by
the fuel pump to maintain the correct fuel pressure at the fuel injectors.
The fuel tank is of a saddle design which incorporates two sender units. The right-hand side houses the fuel pump module. The left-hand
side houses the transfer pump (jet pump) module.
Fuel is supplied at high pressure to the injectors via a fuel rail which incorporates a fuel pressure and a fuel temperature sensor. The ECM
increases the fuel pressure to minimize fuel vapor formation to maintain fuel flow across the injectors. An inertia type fuel cut-off switch
will cut power to the fuel pump module in the event of an accident.
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1 - Fuel tank filler pipe
2 - Fuel filter
3 - Sender unit
4 - Fuel tank
The fuel tank is constructed of high density polythylene and is located underneath the vehicle below the rear passenger seat. The tank is
retained by two support straps fixed to the vehicle's underbody, with the underside of the tank being protected by a fitted heatshield.
The fuel sender unit uses a resistor tile and float rod system to supply information to the instrument cluster of the fuel level. The fuel
system has a run dry strategy which leaves four litres of unusable fuel in the tank. If fuel runout occurs no system priming/bleeding is
required.
function, which utilizes a ball valve operated by a bimetallic strip. When the temperature is less than 15 C (59 F), the ball valve allows
the warm fuel in the fuel return system to pass back through the fuel filter to the fuel pump to improve cold running. Once the temperature
exceeds 31 C (88 F) a bimetallic strip closes the ball valve in the fuel filter and all of the fuel in the fuel return system is directed back to
the fuel tank.
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*
*
*
*
*
*
*
*
*
*
*
*
*
*
Fuel System - General Information - Fuel System
step.
3.
4. If the concern is not visually evident, refer to the Symptom Chart. 4.
Symptom Chart
P1233, P1235, Fuel Pump Primary
Circuit Failure
Damaged harness.
Connector loose or corroded.
Connector pin(s) bent or tracking between connections.
Damaged GROUND.
'Popped' inertia switch.
GO to Pinpoint
Test A.
B1201, P0460, Fuel Sender Circuit
Failure
Worn or damaged sensor tracks.
Damaged Harness.
Connector loose or corroded.
Connector pin(s) bent or tracking between connections.
Fuel level sensor to instrument cluster circuits intermittent short or open
circuit or high resistance.
Fuel level sensor failure.
Instrument cluster fault (incorrect fuel level data).
GO to Pinpoint
Test B.
Fuel Pump Harness Connector
1 Fuel level sensor signal supply Yellow/white
2 Fuel pump voltage supply Pink/black
3 Fuel level sensor GROUND supply Pink/orange
4 Fuel pump GROUND supply Black
Transfer Pump Fuel Level Sensor Harness Connector
1 Fuel level sensor signal supply Yellow/white
3 Fuel level sensor GROUND supply Pink/orange
Fuel Pump Controller Harness Connector
1 engine control module (ECM) control input Brown
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1
2
3
4
1
2
1
2
1
1
2
3
4
1
1
2
1
1
2 Ground Black
3 Fuel pump ground Yellow
4 Throttle screen Black/green
5 Fuel pump screen White
7 ECM monitor output White
9 Battery positive Brown/green
10 Fuel pump positive Red
PINPOINT TEST A : P1233, P1235FUEL PUMP PRIMARY CIRCUIT FAILURE
TEST
CONDITIONS
A1: CHECK THE POSITIVE SUPPLY TO THE FUEL PUMP
Switch the ignition to the RUN position.
Measure the pulse width modulation voltage between the fuel pump electrical connector FT002 pin 2, (KB) and
GROUND.
Is there a 1 second, 12 volts voltage signal after the ignition is switched on?
Yes
GO to A2.
No
GO to A5.
A2: CHECK THE GROUND SUPPLY TO THE FUEL PUMP
Measure the resistance between the fuel pump electrical connector FT002 pin 4, (B) and GROUND.
Is the resistance less than 0.5 Ohm?
Yes
INSTALL a new fuel pump. CLEAR DTC. TEST the system for normal operation.
No
GO to A7.
A3: CHECK THE POSITIVE SUPPLY TO THE FUEL PUMP CONTROLLER
Measure the voltage at the fuel pump controller CA105 pin 9.
Is the voltage less than 10.5 Volts?
Yes
GO to A4.
No
GO to A10.
A4: CHECK THE FUEL PUMP CONTROLLER VOLTAGE SUPPLY FUSE
Measure the voltage at the fuel pump controller supply fuse.
Yes
GO to A12.
No
REPAIR the circuit between the central electrical junction box (CEJB) and the fuel pump controller. CLEAR DTC. TEST
A5: CHECK THE VOLTAGE OUTPUT AT THE FUEL PUMP CONTROLLER
Disconnect the fuel pump controller electrical connector CA105.
Measure the pulse width modulation voltage between the fuel pump controller electrical connector CA105 pin 10 and
GROUND.
Is there a 1 second 12 volts voltage signal after the ignition is switched on?
Yes
GO to A6. .
No
GO to A3. .
A6: CHECK THE CONTINUITY BETWEEN THE FUEL PUMP CONTROLLER AND THE FUEL PUMP
Measure the resistance between the fuel pump controller connector CA105 pin 10, (R) and fuel pump electrical
connector FT002 pin 2, (KB).
Yes
INSTALL a new fuel pump controller. CLEAR DTC. TEST the system for normal operation.
No
REPAIR the circuit between the fuel pump controller CA105 pin 10, (R) and the fuel pump electrical connector FT002
pin 2, (KB). CLEAR DTC. TEST the system for normal operation.
A7: CHECK THE GROUND SUPPLY AT THE FUEL PUMP CONTROLLER
Measure the resistance between the fuel pump controller electrical connector CA105 pin 3, (Y) and GROUND.
Yes
GO to A8. .
No
GO to A9. .
A8: CHECK THE CONTINUITY BETWEEN THE FUEL PUMP AND THE FUEL PUMP CONTROLLER
Measure the resistance between the fuel pump connector FT002 pin 4, (B) and the fuel pump controller connector
CA105 pin 3 (Y).
Is the resistance less than 0.5 Ohms?
Yes
GO to A9.
No
REPAIR the circuit between the fuel pump FT002 pin 4, (B) and the fuel pump controll er CA105 pin 3, (Y). CLEAR DTC.
A9: CHECK THE GROUND SUPPLY TO THE FUEL PUMP CONTROLLER
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Measure the resistance between the fuel pump controller CA105 pin 2, and GROUND.
Yes
REPAIR the circuit between the fuel pump controller CA105 pin 2, (B) and GROUND. CLEAR DTC. TEST the system for
normal operation.
No
A10: CHECK THE SWITCHABLE SUPPLY TO THE FUEL PUMP CONTROLLER
Disconnect the fuel pump controller electrical connector CA105.
Measure the pulse width modulation frequency between the fuel pump controller electrical connector CA105 pin 1, (N)
and GROUND.
Is the frequency 250 Hz, 1-50% duty?
Yes
No
GO to A11.
A11: CHECK THE CONTINUITY BETWEEN THE FUEL PUMP CONTROLLER AND THE ECM
Measure the resistance between the fuel pump controller electrical connector CA105 pin 1, (N) and the ECM electrical
connector EN106 pin 27, (N).
Yes
INSTALL a new ECM. CLEAR DTC. TEST the system for normal operation.
No
REPAIR the circuit between the fuel pump controller electrical connector CA105 pin 1, (N) and the ECM electrical
connector EN106 pin 27, (N). CLEAR DTC. TEST the system for normal operation.
A12: CHECK THE POSITIVE SUPPLY TO THE IGNITION RELAY
Disconnect the central electrical junction box (CEJB) electrical connector IP003.
Measure the voltage between the CEJB electrical connector IP003 pin 1, (GU) and GROUND.
Yes
GO to A13.
No
INSTALL a new ignition relay R18. CLEAR DTC. TEST the system for normal operation.
A13: CHECK THE POSITIVE SUPPLY TO THE INERTIA SWITCH
Disconnect the inertia switch electrical connector IP132.
Measure the voltage between the inertia switch electrical connector IP132 pin 3, (GO) and GROUND.
Yes
GO to A14.
No
GO to A15.
A14: CHECK THE INERTIA SWITCH VOLTAGE SUPPLY AT THE IGNITION SWITCH
Remove the ignition switch electrical connector IP018.
Measure the voltage between the ignition switch electrical connector IP018 pin 1 and GROUND.
Yes
INSTALL a new ignition switch. CLEAR DTC. TEST the system for normal operation.
No
REPAIR the circuit between the ignition switch and the inertia switch. CLEAR DTC. TEST system for normal operation.
A15: CHECK THE CONTINUITY BETWEEN THE CEJB AND THE INERTIA SWITCH
Switch the ignition switch to the OFF position.
Measure the resistance between the CEJB electrical connector IP003 pin 1, (GU) and the inertia switch electrical
connector IP132 pin 1, (GU).
Yes
INSTALL a new inertia switch. CLEAR DTC. TEST the system for normal operation.
No
REPAIR the circuit between the CEJB electrical connector IP003 pin 1, (GU) and the inertia switch electrical connector
IP132 pin 1, (GU). CLEAR DTC. TEST the system for normal operation.
PINPOINT TEST B : B1201, P0460FUEL SENDER CIRCUIT FAILURE
TEST
CONDITIONS
B1: CHECK THE VOLTAGE SUPPLY TO THE FUEL TANK ELECTRICAL CONNECTOR
Disconnect the fuel tank electrical connector CA005.
Measure the voltage at the fuel tank electrical connector between:
CA005 pin 1, (WU) and GROUND
CA005 pin 2, (WB) and GROUND
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Yes
GO to B2.
No
GO to B3.
B2: CHECK THE GROUND SUPPLY TO THE FUEL TANK ELECTRICAL CONNECTOR
Measure the resistance at the fuel tank electrical connector between CA005 pin 3, (B) and GROUND.
Is the resistance less than 0.5 Ohms?
Yes
GO to B4.
No
GO to B5.
B3: CHECK THE VOLTAGE SUPPLY FROM THE INSTRUMENT CLUSTER
Switch the ignition switch to the RUN position.
Measure the voltage at the instrument cluster connector between:
IP010 pin 8 and GROUND
IP010 pin 7 and GROUND
Yes
REPAIR the relevant circuit. CLEAR DTC. TEST the system for normal operation.
No
INSTALL a new instrument cluster. CLEAR DTC. TEST the system for normal operation.
B4: CHECK THE RESISTANCE AT THE FUEL LEVEL SENSORS
Remove the fuel tank. For additional information, refer to Section 310-01 Fuel Tank and Lines.
Disconnect the fuel sensor electrical connectors:
FT002
FT003
Measure the resistance between the sensor electrical connectors:
FT002 pin 1 and FT002 pin 3
FT003 pin 1 and FT003 pin 3
Is the resistance between 16 and 160 Ohms?
Yes
REPAIR the relevant circuit. CLEAR DTC. TEST the system for normal operation.
No
INSTALL the relevant new fuel level sensor. CLEAR DTC. TEST the system for normal operation.
B5: CHECK THE GROUND SUPPLY FROM THE INSTRUMENT CLUSTER
Measure the resistance at the instrument cluster between IP010 pin 9 and GROUND.
Yes
REPAIR the circuit between the instrument cluster IP010 pin 9, (B) and the fuel tank electrical connector CA005 pin
3, (B). CLEAR DTC. TEST the system for normal operation.
No
INSTALL a new instrument cluster. CLEAR DTC. TEST the system for normal operation.
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Fuel System - General Information - Fuel System Pressure Check
General Procedures
NOTE: This procedure is for the installation of the adaptor into the fuel line due to the removal of the schraeder valve from the fuel line.
1. WARNINGS:
Place the vehicle in a quarantined area and arrange "No
Smoking/Petrol Fumes" signs about the vehicle.
Before any work is carried out on the fuel system, ground the vehicle
to earth and maintain the ground connection until the work is complete.
vapors are always present and may ignite. Failure to follow these
Do not carry or operate cellular phones when working on or near any
fuel related components. Highly flammable vapors are always present and
may ignite. Failure to follow these instructions may result in personal
injury.
The fuel system remains pressurized for a long time after the
ignition is switched off. The fuel pressure must be relieved before
attempting any repairs. Failure to follow these instructions may result in
personal injury.
After carrying out repairs, the fuel system must be checked visually
for leaks. Failure to follow these instructions may result in personal injury.
3. Detach the power steering fluid reservoir and reposition.
4. Disconnect the fuel rail feed pipe.
5. NOTE: Make sure the special tool is fully seated to the fuel pipe
connections.
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6. Install the fuel pressure gauge.
8. Carry out the fuel system pressure check.
For additional information, refer to: Fuel Charging and Controls - 2.0L
NA V6 - AJV6 (303-04A Fuel Charging and Controls - 2.0L NA V6 -
AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27, Diagnosis and Testing).
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Fuel System - General Information - Fuel System Pressure Release
General Procedures
Release
1. WARNINGS:
Do not smoke, carry lighted tobacco or an open flame of any type
ignition is switched off. The fuel pressure must be released before
attempting any repairs. Failure to follow this instruction may result in
personal injury.
Remove the fuel pump fuse.
2. Start the engine and allow to idle until the engine stalls.
3. Crank the engine for approximately five seconds to make sure the fuel
injection supply manifold pressure has been released.
4. Install the fuel pump fuse.
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Fuel System - General Information - Fuel Tank Draining2.0L Duratorq-TDCi/2.2L
General Procedures
Special Tool(s)
Fuel supply line adaptor
310-131
1. WARNINGS:
Place the vehicle in a quarantined area and arrange No Smoking
signs about the vehicle.
injury.
3. Disconnect the supply line.
4. Install the special tool to the fuel supply line.
5. Using suitable draining equipment, connect the draining equipment to
the special tool and drain the fuel tank. Follow the manufactures
operating instructions.
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Fuel System - General Information - Fuel Tank Draining2.0L NA V6 - AJV6/2.5L NA V6
- AJV6/3.0L NA V6 - AJ27
General Procedures
Special Tool(s)
Remove/Refit fuel pump/sender locking nut
310-072A
2.0L vehicle
1. WARNINGS:
injury.
Disconnect the battery ground cable. For additional information, refer to
2. Remove the fuel filler cap.
3. Using suitable draining equipment, drain the fuel tank. Follow the
manufactures operating instructions.
2.5L and 3.0L vehicles
1. WARNINGS:
The fuel tank on the 2.5L and 3.0L vehicles can not be drained in
vehicle. Due to the heavy weight, make sure that the fuel tank is securely
attached to the lowering equipment when removing.
injury.
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2. Remove the fuel tank. For additional information, refer to Section
310-01 Fuel Tank and Lines.
5. Using the special tool, remove the locking ring.
6. CAUTION: Make sure the float or arm are not damaged while
removing the fuel transfer pump.
Detach the fuel transfer pump.
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7. Remove the fuel transfer pump.
Disconnect the cross over pipes
10. Disconnect the fuel supply pipe.
11. Using the special tool, remove the locking ring.
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removing the fuel pump module.
Guide the fuel pump module through the aperture.
13. CAUTION: Make sure damage to the fuel cross over pipes does
not occur.
Guide the cross over pipes through the aperture.
14. Remove the fuel pump module and cross over pipes.
15. Using the fuel pump access holes to gain access to the fuel, remove
the fuel from the fuel tank using suitable fuel tank draining equipment.
Follow the manufactures operating instructions.
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Fuel System - General Information - Quick Release Coupling - Push Connect
General Procedures
Disconnect
1. WARNINGS:
Smoking/Fuel Vapors" signs about the vehicle.
injury.
personal injury.
2. Relieve the fuel pressure.
For additional information, refer to: Fuel System Pressure Release.
3. Disconnect the fuel line quick release coupling.
1. Press the fuel line quick release coupling locking tangs.
1. Pull the fuel line quick release coupling locking tang.
2. Push the clip through the fuel line quick release coupling to
release the fuel line.
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1. Press the fuel line quick release coupling locking tangs.
Press the fuel line quick release coupling buttons and pull the fuel
line to disconnect.
7. Release the fuel tank vent line quick release coupling.
Press the fuel tank vent line quick release coupling locking release
collar.
8. Disconnect the fuel tank vent line quick release coupling.
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9. Release the fuel line quick release coupling.
Press the fuel line quick release coupling locking release collar.
11. Using a suitable Flat-bladed screwdriver release the fuel line quick
release coupling secondary locking tang.
12. Operate the fuel line quick release coupling primary locking tang.
Push the fuel line quick release coupling primary locking tang into
from the fuel line quick release coupling.
13. Disconnect the fuel line from the fuel line quick release coupling.
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Connect
WARNINGS:
After carrying out repairs, the fuel system must be checked visually for leaks. Failure to follow these instructions may result in
personal injury.
1. Install the fuel line to the fuel line quick release coupling.
2. CAUTION: Make sure the quick release coupling primary locking
tang clicks into place when installing.
Insert the fuel line quick release coupling secondary locking tang into
the fuel line quick release coupling.
3. CAUTION: After installation, to make sure that the fuel line is fully
seated, pull on the line.
Install the fuel line quick release coupling.
4. CAUTION: After installation, to make sure that the vent line is
fully seated, pull on the line.
Install the fuel tank vent line quick release coupling.
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5. CAUTION: Make sure the fuel line clicks into place when installing
the line. To make sure that the fuel line is fully seated, pull on the line.
6. NOTE: Make sure the collar on the fuel line is inserted fully into the fuel
line quick release coupling.
line quick release coupling before the locking tang is locked.
1. Install the fuel line quick release coupling locking tang.
2. Rotate the fuel line quick release coupling locking tang into
position.
line quick release coupling before the locking tang is locked.
1. Install the fuel line quick release coupling.
2. Press the fuel line quick release coupling locking tang into
position.
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Fuel System - General Information - Spring Lock Couplings
General Procedures
Special Tool(s)
Spring Lock Coupler Tool or Equivalent
23-040
Disconnection
1. WARNINGS:
fuel related components. Highly flammable vapours are always present
and may ignite. Failure to follow these instructions may result in personal
injury.
personal injury.
2. Relieve the fuel pressure.
.
3. Remove the safety clip from the spring lock coupling.
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4. Install the spring lock coupling tool.
Place suitable absorbent material below the pipe to collect fuel
spillage
5. Close and push the spring lock coupling tool into the open side of the
cage.
6. Separate the fitting.
7. Remove the spring lock coupling tool.
Connection
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1. Inspect and clean both coupling ends. Install new O-rings and garter
springs if necessary.
2. Fit the male fitting into the female end and push until the garter spring
snaps over the flared end of the male fitting.
3. Make sure the coupling is engaged by pulling on the lines.
4. Install the safety clip.
Remove the absorbent material below the pipe
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Fuel Tank and Lines -
Fuel tank support strap retaining bolts 25 18 -
Fuel pump module locking ring - vehicles with 2.5L or 3.0L engine (non federal market vehicles) 70 52 -
Fuel pump module locking ring - vehicles with 2.5L or 3.0L engine (federal market vehicles) 120 89 -
Fuel pump module locking ring - vehicles with 2.0L or diesel engine 85 63 -
Transfer pump locking ring (non federal market vehicles) 70 52 -
Transfer pump locking ring ( federal market vehicles) 120 89 -
Fuel tank filler pipe to fuel tank hose retaining clip 3 - 27
Fuel tank filler pipe retaining nuts 4 - 35
Fuel filter bracket retaining nuts - vehicles with 2.0L, 2.5L or 3.0L engine 4 - 35
Axle assembly rear retaining bolt 110 81 -
Axle assembly front retaining bolts 90 66 -
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Fuel Tank and Lines - Fuel Tank and Lines
1 - Fuel pump module
2 - Fuel tank
3 - Lower fuel tank filler pipe retaining nut
4 - Upper fuel tank filler pipe retaining nut
6 - Fuel tank filler pipe breather hose
7 - Fuel tank heat shield
8 - Fuel tank heat shield retaining clips
9 - Fuel tank support straps
10 - Fuel tank support straps retaining bolts
11 - Fuel tank support strap insulator
12 - Fuel filter
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1 - Fuel level sensor
2 - Fuel tank
4 - Fuel tank filler pipe breather hose
5 - Fuel tank heat shield
6 - Fuel tank support straps
7 - Fuel tank support strap insulator
8 - Fuel filter
NOTE: Federal market vehicle shown, non federal market vehicle similar.
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1 Fuel filler cap
3 Fuel transfer pump
4 Fuel tank
5 Fuel tank support straps
6 Fuel filter
7 Fuel pump module
8 Fuel tank pressure sensor (Federal market vehicles only)
Fuel Tank
The fuel tank is of a plastic construction and is retained to the vehicle by two steel support straps. The fuel tank support straps are
mounted onto the underside of the vehicle chassis towards the rear of the fuel tank and retained by bolts to the vehicle towards the front of
the fuel tank. Fuel tank ventilation is achieved through two fuel tank roll-over valves into an evaporative emission canister which absorbs
fuel tank vapor. The fuel tank roll-over valves are integral to the fuel tank and will prevent fuel loss from the fuel tank if the vehicle
becomes inverted. A fuel level valve is also incorporated into the fuel tank to prevent fuel overfilling, this allows the fuel tank to maintain
adequate space for expansion of the fuel.
For additional information, refer to: Evaporative Emissions (303-13 Evaporative Emissions, Description and Operation).
Federal market vehicles only are fitted with leak check diagnostics which detect leaks in the fuel vapor system using signals from a vapor
pressure sensor mounted in the evaporative emission canister purge vapor line.
Fuel Filter - Vehicles with 2.0L, 2.5L or 3.0L engine
The fuel filter is of a conventional construction being that of a paper element seal ed within a steel canister. The fuel filter is located in front
of the fuel tank, on the right-hand side of the floor pan.
Fuel Filter - Vehicles with diesel engine
function, which utilizes a ball valve operated by a bimetallic strip. When the temperature is less than 15C (59F), the ball valve allows the
warm fuel in the fuel return system to pass back through the fuel filter to the fuel pump to improve cold running. Once the temperature
exceeds 31C (88F) a bimetallic strip closes the ball valve in the fuel filter and all of the fuel in the fuel return system is directed back to
the fuel tank.
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Fuel Tank Filler Pipe
The fuel tank filler pipe is of a steel construction and is retained to the vehicle by means of three retaining nuts, one retaining the filler
neck to the body and two nuts retaining the filler pipe to the vehicle chassis. The fuel tank filler pipe is fitted with a screw turn filler cap,
which seals the system.
Inertia Fuel Shutoff (IFS) Switch
The inertia fuel shutoff (IFS) switch is designed to cut power to the fuel pump in the event of an accident. The shutoff switch is located
behind the right-hand cowl side trim panel.
Fuel pump - Vehicles with 2.0L, 2.5L or 3.0L engine
On all wheel drive vehicles, the fuel is pumped by a transfer pump and an electric turbine pump. Both pumps are fitted with fuel level
sender units which are serviced separately. On two wheel drive vehicles, the fuel is pumped by a single electric turbine pump which is fitted
with a separately serviced fuel level sender. The fuel pumps are fixed to the fuel tank by means of a locking ring and seal, which can only
be accessed by removing the fuel tank.
On 2.0L vehicles the fuel tank is of a conventional design, a fuel pump module with mechanical pressure regulator and a local returnless
circuit through the fuel filter is incorporated.
On 2.5L and 3.0L vehicles the fuel tank is of a saddle design, incorporating a fuel pump module and a transfer pump module. The transfer
pump module (jet pump), located in the left-hand saddle, transfers low pressure fuel (high flow) to the right-hand saddle of the tank. The
fuel pump module located in the right-hand saddle, supplies high pressure fuel (low flow) to the fuel pump on the engine.
Fuel Pump - Vehicles with diesel engine
For additional information, refer to: Fuel Charging and Controls (303-04B Fuel Charging and Controls - 2.0L Duratorq-TDCi/2.2L
Duratorq-TDCi (110kW/150PS) - Puma, Description and Operation).
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Fuel Tank and Lines - Fuel Tank and Lines
Visual inspection, vehicles with petrol engines
Fuel line(s)
Push connect fittings
Fuel leak(s)
Fuel filler cap
Fuel tank filler pipe
Fuel filter
Fuel tank
Fuel tank roll-over valve
Damaged or corroded wiring harness
Fuel pump module
Fuel transfer pump
Fuse(s)
Visual inspection, vehicles with diesel engines
Fuel line(s)
Fuel leak(s)
Fuel filler cap
Fuel tank filler pipe
Fuel filter
Fuel tank
Fuel tank roll-over valve
WARNINGS:
Vehicles with diesel engine only. Do NOT carry out any work on the fuel system with the engine running. The fuel pressure within
the system can be as high as 1600 bar (23,206 lb/in). Failure to follow this instruction may result in personal injury.
Eye protection must be worn at all times when working on or near any fuel related components. Failure to follow this instruction may
Vehicles with diesel engine only. The fuel system remains pressurized after the ignition is switched off. If communications with a
suitable tester (able to read fuel rail pressure and temperature) can be established, wait until the tester indicates pressure of less than 20
bar (290 lb/in), and temperature of less than 35 C (95 F) before working on the system. If communications with a suitable tester cannot
be established, the fuel system must NOT be worked on for a period of fifteen minutes following the ignition being switched off. Failure to
Vehicles with diesel engine only. After carrying out repairs, the fuel system must be checked visually for leaks. This should be done
after the engine has been run, but with the engine switched OFF. Failure to follow this instruction may result in personal injury.
If fuel is taken internally, DO NOT induce vomiting. Seek immediate medical attention. Failure to follow this instruction may result in
personal injury.
If fuel contacts the eyes, flush the eyes with cold water or eyewash solution and seek medical attention. Failure to follow this
Wash hands thoroughly after handling, as prolonged contact may cause irritation. Should irritation develop, seek medical attention.
CAUTIONS:
Vehicles with diesel engine only. Before disconnecting any part of the system, it is imperative that all dust, dirt and debris is
removed from around components to prevent ingress of foreign matter into the fuel system. Failure to follow this instruction may result in
Vehicles with diesel engine only. The fuel pipes between the injectors and the rail must be discarded after each use, and new pipes
installed. Failure to follow this instruction may result in damage to the vehicle.
Vehicles with diesel engine only. It is essential that absolute cleanliness is observed when working with these components. Always
install blanking plugs to any open orifices or lines. Failure to follow this instruction may result in damage to the vehicle.
Vehicles with diesel engine only. Make sure that the workshop area in which the vehicle is being worked on is as clean and dust-free
as possible. Areas in which work on clutches, brakes or where welding or machining are carried out are not suitable in view of the risk of
contamination to the fuel system. Failure to follow this instruction may result in damage to the vehicle.
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Vehicles with diesel engine only. Do not interchange fuel injectors. Improper injector installation can cause misfires, poor running
and severe engine damage.
Make sure that any protective clothing worn is clean and made from lint-free non-flocking material. Failure to follow this instruction
may result in damage to the vehicle.
Make sure that any protective gloves worn are new and are of the non-powdered latex type. Failure to follow this instruction may
result in damage to the vehicle.
Vehicles with diesel engine only. Make sure that clean, non-plated tools are used. Clean tools using a new brush that will not lose
it's bristles and fresh cleaning fluid prior to starting work on the vehicle. Failure to follow this instruction may result in damage to the
vehicle.
Use a steel-topped work bench and cover it with clean, lint-free, non-flocking material. Failure to follow this instruction may result in
When probing connectors to take measurements in the course of the pinpoint tests, use the adaptor kit, part number 3548-1358-00.
scantool may be used to access these PIDs, all of which give information, and some of which can be used to both read information and to
NOTE: Vehicles with diesel engine only. As well as carrying out its normal function the glow plug indicator also acts as an engine check
lamp which will flash continuously when a hard diagnostic trouble code (DTC) is detected by the ECM. Soft DTCs are also stored by the ECM
but will only be identified if the system is checked for DTCs using the Jaguar approved diagnostic system.
concerns.
NOTE: Vehicles with diesel engine only. If the fuel level in the fuel tank drops below approximately four liters, rough running will occur.
This is to signal to the driver that the vehicle requires refuelling in order to prevent the fuel system from running dry.
step.
3.
Symptom chart (vehicles with petrol engine only)
Engine cranks, but does
not start
IFS switch
Low/contaminated fuel
ECM malfunction
Check that the IFS switch is in the 'down' position, check the fuel level and
condition, GO to Pinpoint Test F. Check for DTCs indicating fuel pump inactive.
For ECM tests,
REFER to: Electronic Engine Controls - 2.0L NA V6 - AJV6 (303-14A Electronic
Difficult to start Low/contaminated fuel
Purge valve
Fuel pump
Engine coolant
temperature (ECT) sensor
Ignition system
Battery/charging system
Check the fuel level and condition, GO to Pinpoint Test F. For evaporative
emission system tests,
REFER to: Evaporative Emissions - 2.0L NA V6 - AJV6 (303-13 Evaporative
Emissions, Diagnosis and Testing).
and/or
REFER to: Evaporative Emissions - 2.5L NA V6 - AJV6/3.0L NA V6 - AJ27 (303-13
Evaporative Emissions, Diagnosis and Testing).
Check for fuel pump DTCs, refer to DTC table. For engine coolant temperature
sensor tests,
and/or
REFER to: Electronic Engine Controls - 2.5L NA V6 - AJV6/3.0L NA V6 - AJ27, VIN
Range: E96603->J28492 (303-14A Electronic Engine Controls - 2.0L NA V6 -
For ignition system tests,
REFER to: Engine Ignition - 2.0L NA V6 - AJV6 (303-07A Engine Ignition - 2.0L
and/or
For charging system tests,
REFER to: Battery (414-01 Battery, Mounting and Cables, Diagnosis and
Testing).
and/or
REFER to: Generator (414-02 Generator and Regulator, Diagnosis and Testing).
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Difficult to start hot Injector leak
IAT sensor
MAF sensor
Engine coolant
Purge valve
Fuel pump
Ignition system
For fuel injector tests,
REFER to: Fuel Charging and Controls - 2.0L NA V6 - AJV6 (303-04A Fuel
Charging and Controls - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27,
and/or
REFER to: Fuel Charging and Controls - 2.5L NA V6 - AJV6/3.0L NA V6 - AJ27,
VIN Range: E96603->J28492 (303-04A Fuel Charging and Controls - 2.0L NA V6 -
For sensor tests,
and/or
For evaporative emission system tests,
REFER to: Evaporative Emissions - 2.0L NA V6 - AJV6 (303-13 Evaporative
and/or
Check for fuel pump DTCs, refer to DTC table. For ignition system tests,
and/or
For EGR system tests,
REFER to: Engine Emission Control (303-08 Engine Emission Control - 2.0L
Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) - Puma, Diagnosis and
Testing).
Engine stalls soon after
start
Breather system
disconnected/restricted
ECM relay
MAF sensor
Engine coolant
Ignition system
Fuel rail pressure sensor
Air filter restricted
Air leakage
Check the fuel level and condition, GO to Pinpoint Test F. For breather system
tests,
Testing).
For ECM relaly and sensor tests,
and/or
and/or
For fuel rail pressure sensor tests,
REFER to: Fuel Charging and Controls - 2.5L NA V6 - AJV6/3.0L NA V6 - AJ27,
VIN Range: E96603->J28492 (303-04A Fuel Charging and Controls - 2.0L NA V6 -
Check the air filter element and intake system.
Engine hesitates/poor
acceleration/pre-
detonation at high
engine speeds
Restricted pedal travel
(carpet, etc)
Fuel pump
No fuel pump commands
Throttle sensors
APP sensor
HO2 sensors
(ECM)
Ignition system
Air leakage
Fuel starvation
Check the fuel level and condition, GO to Pinpoint Test F. Check the accelerator
pedal for full travel. Check for fuel pump and related DTCs. For sensor and ECM
tests,
and/or
and/or
For EGR system tests,
Testing).
Check the air intake system for leakage. For fuel starvation tests, GO to Pinpoint
Test E.
Difficulty in fuelling
vehicle
Customer using incorrect
filling procedure
Service station equipment
Obstructions in/damage to
filler neck/pipe
Blockage in vent system
Canister close valve
blockage
Purge valve malfunction
Water ingress into carbon
Refer to owner's handbook. Check if filling difficulty is consistent, or
intermittent. Check for obstructions/damage at filler neck. Check the vent
system (this will vary dependent on market). Check for DTCs indicating an
evaporative emissions system valve malfunction. For evaporative emissions
system tests,
Check the condition of the carbon canister.
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canister
Snow or ice pack around
the canister outlet or filter
Fuel smells in/around
the vehicle
Filler cap incorrectly fitted
Leaks from joints
Leaks from module seals
Leak from inlet/outlet
pipes at purge valve
Inoperative purge valve
Check that the filler cap is correctly fitted and secure (the filler cap must be
tightened to at least three 'clicks'). Inspect the pipes and joints for evidence of
leakage, using an HC detector. Inspect the fuel tank for evidence indicating a
leak from the module seals. If such evidence is found, the fuel tank should be
removed to check the seals. Check for DTCs indicating an evaporative emissions
system purge valve malfunction. For evaporative emissions system tests,
Engine stops with fuel
indicated on the gauge
Fuel transfer malfunction
(2.5/3.0 L only)
Level sensor malfunction
Transfer pipes split/kinked
(2.5/3.0 L only)
Blocked transfer pump
module jet (2.5/3.0 L only)
Non fuel-related fault
Check for DTCs indicating a failure to transfer fuel, refer to the DTC index. For
fuel transfer test, GO to Pinpoint Test C. Check the internal transfer pipes for
damage/kinking. Check the 2mm hole as detailed in bulletin A310-01. Check for
DTCs indicating a non fuel-related fault. For a full list of DTCs,
Fuel pump noise Fuel pump module
malfunction
For a basic noise test, GO to Pinpoint Test D.
Symptom chart (vehicles with diesel engine only)
Engine cranks, but
does not start
IFS switch
Blocked fuel filter
Low pressure circuit fault
Fuel metering valve
Pump failure
Check that the inertia switch has not tripped. Check fuel level/condition. For
fuel system tests,
REFER to: Fuel Charging and Controls (303-04B Fuel Charging and Controls -
2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) - Puma, Diagnosis and
Testing).
Difficult to start Low/contaminated fuel
Blocked fuel filter
Fuel metering valve
Injector(s)
failure/programming
Check fuel level/condition. For fuel system tests,
Testing).
Check the injector programming using the Jaguar approved diagnostic system.
Rough idle Low/contaminated fuel
Blocked fuel filter
Fuel metering valve
Injector(s)
failure/programming
Testing).
Check the injector programming using the Jaguar approved diagnostic system.
Lack of power when
accelerating
Catalyst blocked
Low fuel pressure
EGR valve fault
Turbocharger fault
For fuel system tests,
Testing).
For exhaust system tests,
REFER to: Exhaust System (309-00 Exhaust System, Diagnosis and Testing).
For EGR tests,
Testing).
For turbocharger tests,
REFER to: Turbocharger (303-04C Fuel Charging and Controls - Turbocharger,
Engine stops/stalls Low/contaminated fuel
Fuel metering valve
Fuel metering valve leak
High pressure leak
Testing).
Engine judders Low/contaminated fuel
Fuel metering valve
High pressure leak
Pump fault
Testing).
Excessive fuel
consumption
Fuel temperature sensor leak
High pressure leak
Injector(s)
failure/programming
Testing).
DTC index (for a full list of DTCs for both petrol and diesel engines, refer to sections 303.14 A or B)
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1
2
3
P0441 Evaporative emissions system,
incorrect purge flow
Canister purge pipe; restricted, leaking or
disconnected
Canister vent restricted
Canister purge pipes to engine; restricted,
leaking or disconnected
Canister purge valve failure
For evaporative emissions system tests,
REFER to: Evaporative Emissions - 2.0L NA V6
- AJV6 (303-13 Evaporative Emissions,
Evaporative Emissions - 2.5L NA V6 -
AJV6/3.0L NA V6 - AJ27 (303-13 Evaporative
P0444 Evaporative emissions system
canister purge valve circuit; open
circuit
Canister purge valve disconnected
Canister purge valve to ECM drive circuit;
open circuit, high resistance
P0445 Evaporative emissions system
canister purge valve circuit; short
circuit
Canister purge valve to ECM drive circuit;
P0460 Fuel level sensor range/performance ECM software level
Fuel level sensor
Fuel level sensor circuit
Instrument cluster
Refer to technical bulletin A310-02. For fuel
level sensor circuit tests, GO to Pinpoint Test
A.
P1234 No fuel pump commands received
by ECM
ECM to fuel pump control module and/or
feedback circuits: open circuit, short
For fuel pump module circuit tests, GO to
Pinpoint Test B.
P1236 Fuel pump not activated when
requested by the ECM
Pinpoint Test B.
P1338 Fuel pump feedback circuit high/low
voltage
Pinpoint Test B.
B1202Fuel level sensor 1 circuit fault Fuel level sensor 1 circuit; open circuit For fuel level sensor circuit tests, GO to
Pinpoint Test A.
B1204Fuel level sensor 1 circuit fault Fuel level sensor 1 circuit; short circuit to
ground
For fuel level sensor circuit tests, GO to
Pinpoint Test A.
B2627Fuel level sensor 2 circuit fault Fuel level sensor 1 circuit; open circuit For fuel level sensor circuit tests, GO to
Pinpoint Test A.
B2628Fuel level sensor 2 circuit fault Fuel level sensor 1 circuit; short circuit to
ground
For fuel level sensor circuit tests, GO to
Pinpoint Test A.
B2879Failure to transfer fuel Transfer pump malfunction
Internal transfer system
Carry out fuel transfer test, GO to Pinpoint
Test C. Refer to bulletin A310-01.
Pinpoint tests
PINPOINT TEST A : P0460, B1202, B1204, B2627, B2628: FUEL LEVEL SENSORS
NOTE: In the event of a fault with the level sensors, only the relevant module should be replaced. There is no requirement to replace the
fuel tank.
TEST
CONDITIONS
A1: CHECK THE FUEL LEVEL SENSOR GROUND CIRCUITS
Disconnect the fuel level sensor connector(s):
Vehicles with 2.5/3.0 L engine, ROW;
FT02 and FT03.
Vehicles with 2.5/3.0 L engine, USA;
FT06.
Vehicles with 2.0 L petrol engine;
CA415.
Vehicles with 2.0/2.2 L diesel engines;
CA415.
FT02, pin 03 (B) and GROUND.
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2
1
1
1
Vehicles with 2.0 L petrol;
CA415, pin 04 (B) and GROUND.
Vehicles with 2.0 /2.2 L diesel engines;
CA415, pin 04 (B) and GROUND.
Yes
REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC, test the
No
GO to A2.
A2: CHECK THE FUEL LEVEL SENSOR SIGNAL CIRCUIT FOR HIGH RESISTANCE
Disconnect the Instrument cluster connector, IP10.
Measure the resistance between IP10, pin 07 (WU) and:
FT02, pin 01 (WU).
FT06, pin 03 (WU).
Vehicles with 2.0 L petrol;
CA415, pin 02 (WB).
CA415, pin 02 (WB).
Yes
No
GO to A3.
A3: CHECK THE FUEL LEVEL SENSOR SIGNAL CIRCUIT FOR SHORT CIRCUIT TO GROUND
Measure the resistance between;
FT02, pin 01 (WU) and GROUND.
FT06, pin 03 (WU) and GROUND.
CA415, pin 02 (WB) and GROUND.
CA415, pin 02 (WB) and GROUND.
Yes
REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC, test the system for
normal operation.
No
GO to A4.
A4: CHECK THE FUEL LEVEL SENSOR (2) SIGNAL CIRCUIT FOR HIGH RESISTANCE
NOTE: Vehicles with 2.0 L petrol or 2.0/2.2 L diesel engines are only fitted with one sensor.
Measure the resistance between IP10 pin 08 (WB) and:
FT03, pin 01 (WB).
F06, pin 05 (WB).
Yes
No
GO to A6.
A5: CHECK THE FUEL LEVEL SENSOR (2) SIGNAL CIRCUIT FOR SHORT CIRCUIT TO GROUND
Measure the resistance between;
FT03, pin 01 (WB) and GROUND.
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1
1
2
3
1
1
2
F06, pin 05 (WB) and GROUND.
Yes
normal operation.
No
GO to A6.
A6: CHECK THE FUEL LEVEL SENSOR RANGE
Pins 01 and 03 of the fuel pump module at FT02.
Pins 03 and 04 of the fuel pump module.
Pins 02 and 04 of the fuel pump module/level sensor.
Vehicles with 2.0/2.2 L diesel engine;
Pins 02 and 04 of the fuel pump module/level sensor.
Is the resistance between 11 ohms and 165 ohms?
Yes
Vehicles with 2.0 L petrol or 2.0/2.2 L diesel engines, Reflash the engine control module using the Jaguar
approved diagnostic system, Vehicles with 2.5/3.0 L engineGO to A7.
No
REFER to: Fuel Level Sensor - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) - Puma (310-01 Fuel Tank and
Lines, Removal and Installation).
INSTALL a new fuel pump module,
REFER to: Fuel Pump Module - 2.0L NA V6 - AJV6 (310-01 Fuel Tank and Lines, Removal and Installation) /
Fuel Pump Module - 2.5L NA V6 - AJV6/3.0L NA V6 - AJ27 (310-01 Fuel Tank and Lines, Removal and Installation) /
Fuel Pump Module - 2.0L NA V6 - AJV6 (310-01 Fuel Tank and Lines, Removal and Installation).
CLEAR the DTC, test the system for normal operation.
A7: CHECK THE FUEL LEVEL SENSOR (2) RANGE
NOTE: Vehicles with 2.0 L petrol or 2.0/2.2 L diesel engines are only fitted with one sensor.
Pins 01 and 03 of the fuel level sensor at FT03.
Pins 02 and 05 of the fuel level sensor.
Is the resistance between 11 ohms and 165 ohms?
Yes
Reflash the engine control module using the Jaguar approved diagnostic system.
No
INSTALL a new fuel transfer pump module,
REFER to: Fuel Transfer Pump (310-01 Fuel Tank and Lines, Removal and Installation).
PINPOINT TEST B : P1234, P1236, P1338: FUEL PUMP CONTROL MODULE
TEST
CONDITIONS
B1: CHECK THE POWER SUPPLY TO THE FUEL PUMP MODULE
Disconnect the fuel pump module connector, CA105.
Measure the voltage between CA105, pin 09 (NG) and GROUND.
Yes
GO to B2.
No
REPAIR the circuit between CA105 pin 09 (NG) and the ignition switch. This circuit i ncludes the passenger junction box
(fuse 17), ignition relay, and the inertia switch. For additional information, refer to the wiring diagrams. CLEAR the
DTC, test the system for normal operation.
B2: CHECK THE GROUND CIRCUIT TO THE FUEL PUMP MODULE
Measure the resistance between CA105, pin 02 (B) and GROUND.
Yes
No
GO to B3.
B3: CHECK THE SIGNAL GROUND CIRCUIT TO THE FUEL PUMP MODULE
Measure the resistance between CA105, pin 04 (BG) and GROUND.
Yes
REPAIR the high resistance circuit. This circuit includes the ECM. For additional information, refer to the wiring
diagrams. CLEAR the DTC, test the system for normal operation.
()
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2
3
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1
2
1
2
3
4
5
6
7
8
1
No
GO to B4.
B4: CHECK THE POWER SUPPLY CIRCUIT TO THE FUEL PUMP
Reconnect the fuel pump module connector, CA105.
Disconnect the fuel pump connector:
FT02.
FT06.
FT02, pin 02 (R) and GROUND.
FT06, pin 06 (R) and GROUND.
Yes
Fuel Pump Module - 2.5L NA V6 - AJV6/3.0L NA V6 - AJ27 (310-01 Fuel Tank and Lines, Removal and Installation).
No
GO to B5.
B5: CHECK THE SIGNAL GROUND CIRCUIT FOR CONTINUITY
Disconnect the fuel pump module connector, CA105.
Measure the resistance between CA105, pin 03 (Y) and:
FT02, pin 04 (Y).
FT06, pin 01 (Y).
Yes
No
PINPOINT TEST C : FUEL TRANSFER TEST
WARNING: Use extreme care when carrying out the fuel transfer test not to endanger other road users or infringe any road traffic
regulations. Ideally, this should be carried out away from public roads.
NOTE: Make sure the fuel tank is between one quarter and half full as indicated by the fuel gauge before beginning this test.
NOTE: If the 'F2****' value in step 6 of this test is '255', suspect an open or short circuit through the level sensor.
TEST
CONDITIONS
C1: CHECK THE 'F2****' VALUES
Depress the trip button on the indicator stalk and turn the ignition switch to the ON position.
Continue to hold the trip button in until 'TEST' appears on the instrument cluster display.
Release the trip button.
Press the trip button repeatedly until 'F2****' is displayed (this is the sender value of the transfer fuel pump
module).
Start the engine and drive the vehicle in a tight right-hand circle to transfer fuel from the fuel pump module side of
the fuel tank to the transfer pump module side.
Monitor the 'F2****' value (with assistance, if necessary), and once the value is greater than 60, bring the vehicle
to rest.
Monitor the 'F2****' value over approximately 3 minutes.
Does the 'F2****' value decrease steadily?
Yes
If the 'F2****' value decreases steadily, this indicates that fuel is transferring.
No
If the 'F2****' value does not decrease, or increases, return to the symptom chart and follow the actions listed for
'engine stops with fuel indicated on the gauge'.
PINPOINT TEST D : FUEL PUMP NOISE (VEHICLES WITH 2.5/3.0L ENGINES ONLY)
NOTE: A certain amount of 'swishing' from the fuel tank is normal as fuel is transferred around the fuel modules.
TEST
CONDITIONS
D1: VERIFY THAT THE FUEL PUMP IS THE SOURCE OF THE NOISE
Apply the parking brake.
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2
3
4
1
2
3
4
5
1
2
Make sure the gear selector is in the NEUTRAL position for vehicles fitted with manual transmission, PARK position
for vehicles fitted with automatic transmission.
Start the engine and allow to idle.
While the engine is idling, disconnect the main tank harness and monitor the noise (the engine will continue to run
briefly to allow this test to be performed).
Does the noise continue?
Yes
The noise is not caused by the fuel pumps. Clear any DTCs, recheck the system.
No
INSTALL a new fuel pump module,
Installation).
CLEAR any DTCs, test the system for normal operation.
PINPOINT TEST E : FUEL STARVATION
TEST
CONDITIONS
E1: CHECK FUEL PRESSURE
NOTE: Petrol vehicles only.
WARNING: This procedure involves fuel handling. Be prepared for fuel spillage at all times and always observe fuel
handling precautions. Failure to follow these instructions may result in personal injury.
NOTE: Vehicles built to Vin: D86654. The fuel pressure can be tested using the Jaguar approved diagnostic system
datalogger facility, or by the use of a suitable gauge from the schraeder connector on the fuel rail.
NOTE: Vehicles built from Vin: D86655. The fuel pressure can be tested using the Jaguar approved diagnostic system
datalogger facility, or by the use of a suitable gauge from the schraeder connector on the special tool fitted to the fuel
rail.
REFER to: Fuel System Pressure Check (310-00 Fuel System - General Information, General Procedures).
NOTE: The fuel pressure should rise to nominal pressure (320 - 380 Kpa [46 - 55 lb/in]) within 2 seconds of starting.
Install the fuel pressure gauge to the fuel Schraeder valve.
Apply the parking brake.
Make sure the gear selector is in the NEUTRAL position for vehicles fitted with manual transmission, PARK position
for vehicles fitted with automatic transmission.
Start the engine.
Make sure there are no leaks from the gauge connections
Hold the engine at a steady light throttle and monitor the fuel pressure.
Does the fuel pressure decrease as the throttle is held steady?
Yes
CHECK the following; Visual inspections from this sectionSender function, GO to Pinpoint Test A. If this fails to
resolve the issue, install a new fuel pump module,
and transfer pump,
REFER to: Fuel Transfer Pump (310-01 Fuel Tank and Lines, Removal and Installation).
Clean and flush any heavy contamination from the fuel tank. Clear any DTCs, test the system for normal operation.
No
CHECK the ECM for DTCs indicating another cause for the problem.
PINPOINT TEST F : FUEL CONTAMINATION
TEST
CONDITIONS
F1: CHECK FOR THE PRESENCE OF CONTAMINANTS IN THE FUEL
Extract approximately 1 liter of fuel from the rail into a suitable clear container.
Allow to settle for 2 minutes and check for separation of the fuel into layers.
Is there visible separation of the fuel?
Yes
REMOVE the fuel tank. Drain off the fuel. Clean and flush the fuel tank and lines. Refill with fresh fuel. Clear any
DTCs, test the system for normal operation.
No
CHECK the ECM for DTCs indicating another cause for the problem.
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Fuel Tank and Lines - Fuel Filter2.0L Duratorq-TDCi/2.2L Duratorq-TDCi
Special Tool(s)
Hand Pressure Pump with Adapter Kit
310-110
Removal
WARNINGS:
flammable mixtures are always present and can ignite. Failure to follow these instructions may result in personal injury.
CAUTIONS:
cleanliness is observed when working with these components. Always fit blanking plugs to any open orifices or lines.
Always carry out the cleaning process before carrying out any repairs to the fuel injection system components. Failure to follow these
instructions may result in foreign matter ingress to the fuel injection system.
1. CAUTION: The generator must be protected from contamination.
Failure to follow this instruction may cause premature failure of the
generator.
Protect the generator with lint-free material to prevent contamination.
2. Disconnect the fuel pump to fuel filter fuel return line from the fuel
filter.
Procedures).
3. Disconnect the fuel tank to fuel filter fuel supply line from the fuel
filter.
Procedures).
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4. Disconnect the fuel filter to fuel pump fuel supply line from the fuel
filter.
Procedures).
Install a blanking plug to the fuel pump fuel supply line.
5. Remove the fuel filter
1. Detach the fuel filter retaining clip.
2. Remove the fuel filter.
Installation
1. WARNINGS:
mixtures are always present and can ignite. Failure to follow these
CAUTION: Diesel fuel injection equipment is manufactured to very
precise tolerances and fine clearances. It is therefore essential that
absolute cleanliness is observed when working with these components.
Always fit blanking plugs to any open orifices or lines.
NOTE: Make sure that the fuel filter is fully installed into the fuel filter
retaining bracket.
Install the fuel filter.
1. Install the fuel filter.
2. Attach the fuel filter retaining clip.
2. Connect the fuel pump to fuel filter fuel supply and fuel return lines to
the fuel filter.
Procedures).
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3. NOTE: Make sure that the hand primer arrow indicating the fuel flow is
pointing towards the fuel filter.
Install the hand pressure pump special tool between the fuel filter and
the fuel filter fuel supply line.
4. NOTE: Once the hand pressure pump special tool bellow has become
firm hold the pressure for five minutes.
Operate the hand pressure pump special tool until fuel starts to flow
through the fuel filter and the special tool becomes firm.
5. Remove the hand pressure pump special tool.
6. Connect the fuel tank to fuel filter fuel supply line to the fuel filter.
Procedures).
7. Remove the lint-free material from the generator.
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Fuel Tank and Lines - Fuel Filter2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 -
AJ27
Removal
1. WARNINGS:
injury.
2. De-pressurize the fuel system. For additional information, refer to
Section 310-00 Fuel System - General Information.
4. Disconnect the fuel line quick release couplings. For additional
information, refer to Section 310-00 Fuel System - General Information.
5. Remove the fuel filter and bracket assembly.
1. Loosen the fuel filter bracket retaining bolt.
2. Remove the retaining bracket nuts.
3. Remove the fuel filter and bracket assembly.
6. Remove the fuel filter.
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Installation
1. WARNINGS:
injury.
NOTE: Observe the direction of the flow arrow.
Tighten to 4 Nm.
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Fuel Tank and Lines - Fuel Level Sender2.0L NA V6 - AJV6
Removal
WARNINGS:
1. Remove the fuel pump module.
For additional information, refer to: Fuel Pump Module - 2.0L NA V6 -
AJV6 (310-01 Fuel Tank and Lines, Removal and Installation).
2. NOTE: Note the position of the tie straps securing the harness to the
fuel pipes.
Remove the tie straps.
3. NOTE: Vehicle with single electrical connector shown, vehicles with
multiple electrical connectors similar.
Disconnect the electrical connector from the fuel pump module flange.
4. Disconnect the electrical connector from the fuel pump.
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5. Remove the fuel level sender.
Installation
WARNINGS:
CAUTION: Make sure the float or arm are not damaged while installing the fuel pump module.
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Fuel Tank and Lines - Fuel Level Sender2.0L Duratorq-TDCi/2.2L Duratorq-TDCi
Removal
WARNINGS:
1. Remove the fuel level sensor.
For additional information, refer to: Fuel Level Sensor - 2.0L Duratorq-
TDCi/2.2L Duratorq-TDCi (110kW/150PS) - Puma (310-01 Fuel Tank and
Lines, Removal and Installation).
2. NOTE: Note the position of the tie straps securing the harness to the
fuel pipes.
3. NOTE: Vehicle with single electrical connector shown, vehicles with
multiple electrical connectors similar.
Disconnect the electrical connector from the fuel level sensor flange.
Installation
WARNINGS:
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Fuel Tank and Lines - Fuel Level Sender LH2.5L NA V6 - AJV6/3.0L NA V6 - AJ27
Removal
WARNINGS:
1. NOTE: All vehicles.
Remove the transfer pump.
For additional information, refer to: Fuel Transfer Pump (310-01 Fuel
Tank and Lines, Removal and Installation).
Disconnect the fuel level sender electrical connector.
Remove the fuel level sender.
NOTE: Note the position of the tie straps securing the harness to the
fuel pipes.
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Remove the fuel level sender and harness.
Installation
WARNINGS:
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Fuel Tank and Lines - Fuel Level Sender RH2.5L NA V6 - AJV6/3.0L NA V6 - AJ27
Removal
WARNINGS:
AJV6/3.0L NA V6 - AJ27 (310-01 Fuel Tank and Lines, Removal and
Installation).
2. Disconnect the fuel level sender electrical connector.
Installation
WARNINGS:
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Fuel Tank and Lines - Fuel Level Sensor2.0L Duratorq-TDCi/2.2L Duratorq-TDCi
Special Tool(s)
Remove/Install fuel pump/transfer pump locking
ring
310-127
Removal
WARNINGS:
1. Remove the fuel tank.
For additional information, refer to: Fuel Tank - 2.0L Duratorq-TDCi/2.2L
Duratorq-TDCi (110kW/150PS) - Puma (310-01 Fuel Tank and Lines,
Procedures).
3. NOTE: Note the orientation of the fuel level sensor before removal.
Using the special tool, remove the locking ring.
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4. Detach the top of the fuel level sensor.
removing the fuel level sensor.
Remove the fuel level sensor.
1. Rotate the lower part of the fuel level sensor.
2. Remove the fuel level sensor.
Installation
1. WARNINGS:
Do not smoke or carry lighted tobacco or an open flame of any type
injury.
CAUTION: Make sure the float or arm are not damaged while
installing the fuel level sensor.
NOTE: Install a new seal.
NOTE: Make sure the fuel level sensor is correctly orientated.
Tighten to 85 Nm.
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Fuel Tank and Lines - Fuel Pump Module2.0L NA V6 - AJV6
Special Tool(s)
Remove/Install fuel pump/transfer pump locking
ring
310-072A
Removal
WARNINGS:
1. Remove the fuel tank.
For additional information, refer to: Fuel Tank - 2.0L NA V6 - AJV6
(310-01 Fuel Tank and Lines, Removal and Installation).
Procedures).
3. NOTE: Note the orientation of the fuel pump module before removal.
4. Detach the top of the fuel pump module.
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Remove the fuel pump module.
1. Rotate the lower part of the fuel pump module.
Installation
1. WARNINGS:
injury.
CAUTION: Make sure the float or arm are not damaged while
installing the fuel pump module.
NOTE: Make sure the fuel pump module is correctly orientated.
Install a new seal.
Tighten to 85 Nm.
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Fuel Tank and Lines - Fuel Pump Module2.5L NA V6 - AJV6/3.0L NA V6 - AJ27
Special Tool(s)
Remove/Install fuel pump/transfer pump
locking ring (Non federal market vehicles
only)
310-072A
locking ring (Federal market vehicles only)
310-147
Removal
WARNINGS:
Place the vehicle in a quarantined area and arrange "No Smoking/Petrol Fumes" signs about the vehicle.
Before any work is carried out on the fuel system, ground the vehicle to earth and maintain the ground connection until the work is
complete.
The fuel system remains pressurized for a long time after the ignition is switched off. The fuel pressure must be relieved before
attempting any repairs. Failure to follow these instructions may result in personal injury.
personal injury.
If taken internally do not induce vomiting, seek immediate medical attention. Failure to follow these instructions may result in
personal injury.
If fuel contacts the eyes, flush the eyes with cold water or eyewash solution and seek medical attention.
Remove the fuel transfer pump.
For additional information, refer to: Fuel Transfer Pump (310-01 Fuel
Tank and Lines, Removal and Installation).
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Disconnect the fuel supply pipe.
Procedures).
NOTE: Note the orientation of the fuel pump module before removal.
NOTE: Non federal market vehicles only.
Guide the fuel pump module through the aperture.
7. CAUTION: Make sure damage to the fuel crossover pipes does not
occur.
Guide the crossover pipes through the aperture.
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Remove the fuel pump module and crossover pipes.
Remove the fuel supply pipe.
Procedures).
NOTE: Note the orientation of the fuel pump module before removal.
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Detach the fuel pump module flange from the fuel pump module base.
16. Detach the fuel crossover pipe from the fuel pump module base.
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Disconnect the fuel crossover pipe from the fuel pump module base.
Remove the fuel pump module base from the fuel tank.
Installation
WARNINGS:
complete.
personal injury.
personal injury.
NOTE: Federal market vehicles, refer to step 1.
NOTE: Non federal market vehicles, refer to step 2.
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Tighten to 120 Nm.
2. CAUTIONS:
Make sure the float or arm are not damaged while installing the fuel
pump module.
Make sure the fuel cross over pipes are not damaged while installing
the fuel pump module.
Tighten to 70 Nm.
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Fuel Tank and Lines - Fuel Tank2.0L NA V6 - AJV6
Removal
WARNINGS:
Place the vehicle in a well ventilated, quarantined area and arrange No Smoking/Petrol Fumes signs about the vehicle.
complete.
1. De-pressurize the fuel system.
3. Detach the wiring harness grommet.
5. Drain the fuel tank.
For additional information, refer to: Fuel Tank Draining - 2.0L NA V6 -
AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27 (310-00 Fuel System -
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7. Disconnect the fuel filter line quick release coupling.
Procedures).
Procedures).
9. Disconnect the evaporative emission canister hose.
Procedures).
10. Detach the breather hose from the fuel tank.
11. NOTE: Note the orientation of the fuel tank filler pipe to fuel tank
hose retaining clip before loosening.
Loosen the fuel tank filler pipe to fuel tank hose retaining clip.
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12. NOTE: An assistant will be required to remove the fuel tank.
Installation
WARNINGS:
1. NOTE: An assistant will be required to install the fuel tank.
NOTE: Make sure the fuel filler pipe hose is connected to the fuel tank
as it is installed.
Tighten to 25 Nm.
2. NOTE: Make sure the fuel tank filler pipe to fuel tank hose retaining clip
Tighten to 3 Nm.
3. Attach the breather hose from the fuel tank.
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4. Connect the evaporative emission canister hose.
Procedures).
5. Connect the fuel filter line quick release coupling.
Procedures).
6. Connect the fuel filter line quick release coupling.
Procedures).
8. Fill the fuel tank with fuel.
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10. Attach the wiring harness grommet.
11. Install the rear seat cushion.
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Fuel Tank and Lines - Fuel Tank2.0L Duratorq-TDCi/2.2L Duratorq-TDCi
Removal
WARNINGS:
Place the vehicle in a well ventilated, quarantined area and arrange No Smoking signs about the vehicle.
Do not smoke or carry lighted tobacco or an open flame of any type when working on or near any fuel related components. Failure to
complete. Failure to follow this instruction may result in personal injury.
After carrying out repairs, the fuel system must be checked for leaks. Failure to follow this instruction may result in personal injury.
4. Drain the fuel tank.
For additional information, refer to: Fuel Tank Draining - 2.0L Duratorq-
TDCi/2.2L Duratorq-TDCi (110kW/150PS) - Puma (310-00 Fuel System -
5. Disconnect the fuel return line.
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6. Detach the breather hose from the fuel tank.
7. NOTE: Note the orientation of the fuel tank filler pipe to fuel tank hose
retaining clip before loosening.
8. NOTE: An assistant will be required to remove the fuel tank.
Installation
WARNINGS:
Place the vehicle in a well ventilated, quarantined area and arrange No Smoking signs about the vehicle.
Do not smoke or carry lighted tobacco or an open flame of any type when working on or near any fuel related components. Failure to
complete.
After carrying out repairs, the fuel system must be checked for leaks. Failure to follow this instruction may result in personal injury.
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1. NOTE: An assistant will be required to install the fuel tank.
as it is installed.
Tighten to 25 Nm.
2. NOTE: Make sure the fuel tank filler pipe to fuel tank hose retaining clip
Tightyen to 3 Nm.
3. Attach the breather hose to the fuel tank.
4. Connect the fuel return line.
5. Connect the fuel supply line.
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7. Fill the fuel tank with fuel.
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Fuel Tank and Lines - Fuel Tank2.5L NA V6 - AJV6/3.0L NA V6 - AJ27
Special Tool(s)
HTJ1200-2
Removal
WARNINGS:
Place the vehicle in a well ventilated, quarantined area and arrange No Smoking/Petrol Fumes signs about the vehicle.
complete.
NOTE: Non federal market vehicles, refer to steps 29 and 32.
NOTE: Federal market vehicles, refer to steps 23, 24, 28 and 31.
1. NOTE: All vehicles
3. De-pressurize the fuel system.
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8. Using a suitable suction device drain the fuel tank filler pipe.
9. NOTE: To prevent the vehicle becoming unstable when the fuel tank has
been removed, install the vehicle tie down straps.
12. Using the special tool, support the axle assembly.
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14. Remove the axle assembly front retaining bolts.
15. Using the special tool, lower the axle assembly approximately 75 mm
(2.95 inches).
16. Install the chain supplied with the special tool HTJ1200-2 to the axle
assembly front support bracket.
17. Install the securing strap supplied with the special tool HTJ1200-2 to
the axle assembly.
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18. Attach the securing strap supplied with the special tool HTJ1200-2 to
the rear towing eye thread and support the rear of the axle assembly.
20. NOTE: Note the orientation of the fuel tank filler pipe to fuel tank
hose retaining clip before loosening.
21. Disconnect the evaporative emission canister purge hose quick release
coupling.
Procedures).
Procedures).
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Disconnect the evaporative emission canister close valve electrical
connector.
Detach the evaporative emission canister purge hose from the fuel tank
retaining clips.
25. CAUTION: Use packing blocks supplied with the special tool
HTJ1200-2 to prevent damage to the underside of the fuel tank. Failure to
follow this instruction may result in damage to the fuel tank.
NOTE: All vehicles
Using the special tool, support the fuel tank.
26. Remove the fuel tank support straps retaining bolts.
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Using the special tool, lower the fuel tank approximately 100 mm (3.94
inches).
Using the special tool, lower the fuel tank approximately 75 mm (2.95
inches).
Install the securing strap supplied with the special tool HTJ1200-2 to
secure the fuel tank to the special tool.
emission canister.
emission canister.
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NOTE: All vehicles
Using the special tool, remove the fuel tank.
Installation
WARNINGS:
NOTE: Non federal vehicles, refer to steps 2 and 3.
NOTE: Federal vehicles, refer to steps 1, 4, 10 and 11.
Using the special tool, position the fuel tank approximately 100 mm
(3.94 inches) lower than the fully installed position.
Using the special tool, position the fuel tank approximately 75 mm (2.95
inches) lower than the fully installed position.
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emission canister.
emission canister.
Remove the securing strap from the fuel tank and the special tool.
6. NOTE: Remove the blanking plugs from the fuel tank and fuel filler pipe
hose.
as it is installed.
Using the special tool, install the fuel tank.
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8. Install the fuel tank support straps retaining bolts.
Tighten to 25 Nm.
Attach the evaporative emission canister purge hose to the fuel tank
retaining clips.
Connect the evaporative emission canister close valve electrical
connector.
Connect the fuel filter line quick release coupling.
Procedures).
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13. Connect the evaporative emission canister purge hose quick release
coupling.
Procedures).
14. NOTE: Make sure the fuel tank filler pipe to fuel tank hose retaining
clip is correctly orientated.
Tighten to 3 Nm.
15. Using the special tool, support the axle assembly.
16. Detach the securing strap from the rear towing eye thread.
17. Remove the securing strap from the axle assembly.
Discard the axle assembly rear retaining bolt.
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18. Remove and discard the axle assembly washer.
19. Install a new axle assembly washer.
20. Remove the chain from the axle assembly front support bracket.
21. Using the special tool, install the axle assembly.
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23. Loosely install a new axle assembly rear retaining bolt.
29. NOTE: Remove the the vehicle tie down straps.
Lower the vehicle.
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34. Fill the fuel tank with the fuel drained from the fuel filler pipe.
35. Install the fuel filler cap.
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Fuel Tank and Lines - Fuel Tank Filler Pipe
Removal
1. WARNINGS:
injury.
4. Remove the rear subframe. For additional information, refer to Section
5. Detach the fuel tank filler pipe.
6. Detach the fuel tank filler pipe hose from the fuel tank.
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7. Remove the fuel tank filler pipe and hose.
1. Remove the retaining nuts.
2. Remove the fuel tank filler pipe and hose.
Installation
1. WARNINGS:
injury.
Tighten to 4 Nm.
2. Tighten to 4 Nm.
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Fuel Tank and Lines - Gas Fuel Tank Pressure Sensor
Removal
NOTE: The fuel tank pressure sensor is fitted to federal market vehicles only.
1. WARNINGS:
instructions can result in personal injury.
injury.
2. NOTE: The fuel tank pressure sensor is supplied as an assembly with
the evaporative emission hoses.
Remove the fuel tank pressure sensor assembly.
3. Remove the fuel tank pressure sensor assembly.
Installation
1. WARNINGS:
instructions can result in personal injury.
injury.
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Fuel Tank and Lines - Fuel Transfer Pump
Special Tool(s)
locking ring (Non federal market vehicles
only)
310-072A
locking ring (Federal market vehicles only)
310-147
Removal
WARNINGS:
complete.
personal injury.
personal injury.
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NOTE: Note the orientation of the fuel transfer pump before removal.
Detach the fuel transfer pump from the fuel tank.
Remove the fuel transfer pump.
Disconnect the fuel crossover pipes.
AJV6/3.0L NA V6 - AJ27 (310-01 Fuel Tank and Lines, Removal and
Installation).
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NOTE: Note the orientation of the fuel transfer pump before removal.
Detach the fuel transfer pump from the fuel tank.
Remove the fuel transfer pump and fuel crossover pipes.
Installation
WARNINGS:
complete.
personal injury.
personal injury.
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NOTE: Federal market vehicles, refer to step 1.
NOTE: Non federal market vehicles, refer to step 2.
NOTE: Make sure the fuel transfer pump is correctly orientated.
Tighten to 120 Nm.
2. CAUTIONS:
Make sure the float or arm are not damaged while installing the fuel
pump module.
Make sure the fuel crossover pipes are not damaged while installing
the fuel pump module.
NOTE: Make sure the fuel transfer pump is correctly orientated.
Tighten to 70 Nm.
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Fuel Tank and Lines - Inertia Fuel Shutoff (IFS) Switch
Removal
1. Remove the cowl side trim panel. For additional information, refer to
Section 501-05 Interior Trim and Ornamentation.
3. Remove the inertia fuel shutoff (IFS) switch.
Installation
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Published: 24-Mar-2011
Fuel Tank and Lines - Fuel Tank Filler Pipe Hose
Removal
1. WARNINGS:
injury.
.
5. NOTE: Subframe shown removed for clarity.
Remove the fuel filler neck link hose.
Release the two band clamps.
Remove the fuel filler neck nut.
Installation
1. WARNINGS:
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injury.
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Acceleration Control -
Accelerator pedal 9 - 80
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Acceleration Control - Acceleration Control
2 Accelerator pedal (left-hand drive vehicles)
3 Throttle body
4 Accelerator pedal (right-hand drive vehicles)
The acceleration control consists of the pedal and shaft assembly, accelerator cable and accelerator cable bracket.
WARNING: Make sure surrounding components such as wiring, hoses, sound insulation and floor carpeting are not contacting the
sliding inner cable or the accelerator pedal and shaft. Failure to follow these instructions may result in personal injury.
The throttle is controlled by an accelerator cable attached to the accelerator pedal and shaft. The accelerator pedal and shaft should travel
smoothly from the idle to the wide-open throttle positions. Hesitation on return or prevention of return to the idle position must not occur.
Vehicles with 2.5L, 3.0L or diesel engine
The accelerator pedal demand sensor provides an analogue voltage to the ECM which is proportional to the accelerator pedal position. A
throttle position sensor provides a signal to the ECM which monitors throttle plate position.
After receiving these signals and monitoring the wheel speed signal output, coolant temperature, rotary switch status (automatic
transmission) and inertia switch confirmation, the ECM then issues a throttle request signal. A motor within the throttle body rotates the
throttle plate to a position which is relative to the position demanded.
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* *
* *
* *
* *
* *
* *
* *
Acceleration Control - Acceleration Control
step.
3.
4. If the concern is not visually evident, use a fault code reader to retrieve the fault codes before proceeding to the Symptom Chart. 4.
Symptom Chart
DTC P1240, P1241,
P1242
Accelerator pedal power supply
circuit out of range
DTC P1122, P1123,
P1215, P1216, P1344
Accelerator pedal demand sensor
output circuit out of range
DTC P0121, P0122,
P0123
Throttle position sensor circuit
out of range
DTC P1251, P1658,
P1631, P1657
Throttle motor relay failure GO to Pinpoint Test D.
DTC P1243 Accelerator pedal demand sensor
ground; open circuit
DTC P1506, P1507,
P1611, P1633
failure
INSTALL a new ECM. For additional information, refer toSection 303-14A
Electronic Engine ControlsSection 303-14B Electronic Engine Controls.
DTC P1254, P1250 Throttle limp home spring
malfunction.
INSTALL a new throttle motor. For additional information refer toSection
303-14A Electronic Engine ControlsSection 303-14B Electronic Engine
Controls.
Accelerator Pedal Demand Sensor Electrical Connector (PA1, Harness Side)
1 Sensor Ground Black/Green
3 Output Signal Red
4 Sensor Power Supply (5 volts) Orange/Yellow
5 Sensor Power Supply (5 volts) Yellow
6 Output Signal Yellow
Engine Control Module (ECM) Electrical Connector (EN16, Harness Side)
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1
2
3
1
2
3
4
1
2
12 Output (5 volts) Orange/Yellow
13 Output (5 volts) Yellow
19 Ground Black/Green
20 Ground Black/Green
52 Throttle Relay Ground Green/Red
75 Input Purple
76 Input Yellow
80 Throttle motor Green
102 Input Red
103 Input Yellow
106 Throttle motor Red
134 Power Supply (12 volts) Red/White
Throttle Position Sensor Electrical Connector (EN13, Harness Side)
2 Output Signal Yellow
3 Output Signal Purple
4 Sensor Power Supply (5 volts) Orange/Yellow
Throttle Motor Electrical Connector (EN10, Harness Side)
80 Throttle motor Green
106 Throttle motor Red
PINPOINT TEST A : DTC P1240, P1241, P1242
TEST
CONDITIONS
A1: CHECK THE POWER SUPPLY TO THE ACCELERATOR PEDAL DEMAND SENSOR
TURN the ignition switch to the RUN position.
Measure the voltage between electrical connector PA1-5 and ground.
Measure the voltage between electrical connector PA1-4 and ground.
Yes
GO to A2. .
No
DIAGNOSE the electronic engine control system. For additional information, refer toSection 303-14A Electronic Engine
ControlsSection 303-14B Electronic Engine Controls.
A2: CHECK CONTINUITY OF THE ACCELERATOR PEDAL DEMAND SENSOR POWER SUPPLY CIRCUIT
Disconnect the ECM electrical connector EN16 and the accelerator pedal electrical connector PA1.
Measure the resistance between EN16-13 and PA1-5.
Yes
GO to A3. .
No
REPAIR the power supply circuit from the ECM to the accelerator pedal. CLEAR the DTC. TEST the system for normal
operation.
A3: CHECK THE ACCELERATOR PEDAL DEMAND SENSOR POWER SUPPLY FOR A SHORT CIRCUIT TO GROUND
Measure the resistance between PA1-5 and ground.
Measure the resistance between PA1-4 and ground.
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1
2
3
1
2
3
1
2
3
1
2
3
1
2
1
2
3
1
Yes
No
REPAIR the power supply circuit from the ECM to the accelerator pedal. CLEAR the DTC. TEST the system for normal
operation.
PINPOINT TEST B : DTC P1122, P1123, P1215, P1216, P1344
TEST
CONDITIONS
B1: CHECK THE ACCELERATOR PEDAL DEMAND SENSOR OUTPUT
Measure the voltage between electrical connector PA1-6 and ground with the accelerator pedal released and with the
accelerator pedal at full throttle.
Measure the voltage between electrical connector PA1-3 and ground with the accelerator pedal released and with the
accelerator pedal at full throttle.
Does the voltage vary between 0.3 volts and 5 volts?
Yes
GO to B4. .
No
GO to B2. .
B2: CARRY OUT AN ACCELERATOR PEDAL POSITION SENSOR COMPONENT CHECK
Remove the accelerator pedal. For additional information, refer to Pedal.
Measure the resistance between pin 1 and pin 6 of the accelerator pedal.
Measure the resistance between pin 2 and pin 3 of the accelerator pedal.
Is the resistance between pin 1 and pin 6 between 546 and 1134 ohms, and between pin 2 and pin 3 between 975 and
2025 ohms?
Yes
GO to B3. .
No
INSTALL a new accelerator pedal. For additional information, refer to Pedal. CLEAR the DTC. TEST the system for
normal operation.
B3: CHECK THE ACCELERATOR PEDAL DEMAND SENSOR CIRCUIT FOR A SHORT TO GROUND
Measure the resistance between electrical connector PA1-6 and ground.
Measure the resistance between electrical connector PA1-3 and ground.
Yes
GO to B4. .
No
REPAIR the accelerator pedal demand sensor circuit from the ECM to the accelerator pedal. CLEAR the DTC. TEST the
B4: CHECK THE ACCELERATOR PEDAL DEMAND SENSOR CIRCUIT FOR OPEN CIRCUIT
Yes
No
REPAIR the accelerator pedal demand sensor circuit from the ECM to the accelerator pedal. CLEAR the DTC. TEST the
PINPOINT TEST C : DTC P0121, P0122, P0123
TEST
CONDITIONS
C1: CHECK THE POWER SUPPLY TO THE THROTTLE POSITION SENSOR
Turn the ignition switch the to the RUN position.
Measure the voltage between the throttle position sensor electrical connector EN13-4 and ground.
Yes
GO to C2. .
No
GO to C4. .
C2: CHECK THE THROTTLE POSITION SENSOR POWER SUPPLY CIRCUIT FOR OPEN CIRCUIT
Disconnect the ECM electrical connector EN16 and the throttle position sensor electrical connector EN13.
Measure the resistance between EN16-12 and EN13-4.
Yes
GO to C3. .
No
REPAIR the throttle position sensor power supply circuit from the ECM to the throttle position sensor. CLEAR the
C3: CHECK THE THROTTLE POSITION SENSOR POWER SUPPLY CIRCUIT FOR A SHORT TO GROUND
Measure the resistance between EN13-4 and ground.
Yes
No
REPAIR the throttle position sensor power supply circuit from the ECM to the throttle position sensor. CLEAR the
C4: CHECK THE THROTTLE POSITION SENSOR GROUND CIRCUIT
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1
2
3
1
2
1
2
1
2
1
2
1
1
1
2
3
1
1
2
Disconnect the throttle position sensor electrical connector EN13.
Yes
GO to C6. .
No
GO to C5. .
C5: CHECK THE THROTTLE POSITION SENSOR GROUND WIRE FOR OPEN CIRCUIT
Disconnect the ECM electrical connector EN16 and the throttle position sensor electrical connector EN13.
Yes
GO to C6. .
No
REPAIR the throttle position sensor ground circuit from the ECM to the throttle posi tion sensor. CLEAR the DTC. TEST
C6: CHECK THE THROTTLE POSITION SENSOR
Are the resistor values the same?
Yes
GO to C7. .
No
INSTALL a new throttle position sensor. For additional information refer toSection 303-14A Electronic Engine
C7: CHECK CONTINUITY OF THE THROTTLE POSITION SENSOR OUTPUT CIRCUIT
Yes
GO to C8. .
No
REPAIR the circuit from the ECM to the throttle position sensor. CLEAR the DTC. TEST the system for normal
operation.
C8: CHECK THE THROTTLE POSITION SENSOR OUTPUT CIRCUIT FOR A SHORT TO GROUND
Yes
No
REPAIR the circuit from the ECM to the throttle position sensor. CLEAR the DTC. TEST the system for normal
operation.
PINPOINT TEST D : DTC P1251, P1658, P1631, P1657
TEST
CONDITIONS
D1: CHECK THE THROTTLE MOTOR RELAY
Does the throttle relay make an audible click?
Yes
GO to D2. .
No
GO to D8. .
D2: CHECK THE ECM POWER SUPPLY FROM THE THROTTLE MOTOR RELAY
Measure the voltage between the throttle motor relay connector JB34-138 and ground.
Yes
GO to D3. .
No
GO to D4. .
D3: CHECK CONTINUITY OF THE ECM POWER SUPPLY WIRE FROM THE THROTTLE MOTOR RELAY
Disconnect the ECM electrical connector EN16 and remove the throttle motor relay.
Measure the resistance between the throttle motor relay electrical connector JB34-138 and the ECM electrical
connector EN16-134.
Yes
No
REPAIR the ECM power supply wire from the throttle motor relay. CLEAR the DTC. TEST the system for normal
operation.
D4: CHECK FUSE 33 IN THE ENGINE COMPARTMENT FUSE BOX.
Check the fuse.
Is the fuse OK?
Yes
GO to D5. .
No
GO to D6. .
D5: CHECK THE THROTTLE MOTOR RELAY POWER SUPPLY CIRCUIT
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1
1
2
1
2
1
1
2
1
2
1
2
3
Yes
REPAIR the throttle motor relay power supply circuit. CLEAR the DTC. TEST the system for normal operation.
No
INSTALL a new throttle motor relay. CLEAR the DTC. TEST the system for normal operation.
D6: CHECK FUSE 33 FOR A SHORT TO GROUND
Measure the resistance between fuse 33 and ground.
Yes
No
REPAIR short to ground between engine compartment fuse box and the throttle motor relay. INSTALL a new fuse.
D7: CHECK FUSE 36 IN THE ENGINE COMPARTMENT FUSE BOX
Check the fuse.
Is the fuse OK?
Yes
GO to D7. .
No
GO to D10. .
D8: CHECK THE POWER SUPPLY CIRCUIT TO THE THROTTLE MOTOR RELAY COIL
Yes
GO to D11. .
No
GO to D9. .
D9: CHECK CONTINUITY OF THE POWER SUPPLY CIRCUIT TO THE THROTTLE MOTOR RELAY COIL
Disconnect the ECM electrical connector EN16 and remove the throttle motor relay.
connector EN16-52.
Yes
GO to D11. .
No
REPAIR the throttle motor relay coil power supply circuit from the engine compartment fuse box. CLEAR the DTC.
D10: CHECK FUSE 36 OF THE PASSENGER COMPARTMENT FUSE BOX FOR A SHORT TO GROUND
Measure the resistance between fuse 36 of the passenger compartment fuse box and ground.
Yes
REPAIR short to ground between the engine compartment fuse box and the throttle motor relay coil. CLEAR the DTC.
No
D11: CHECK CONTINUITY OF THE THROTTLE MOTOR RELAY COIL
Remove the throttle motor relay (if not already removed).
Measure the resistance between terminal 1 and terminal 2 of the throttle motor relay.
Yes
GO to D12. .
No
INSTALL a new throttle motor relay. CLEAR the DTC. TEST the system for normal operation.
D12: CHECK CONTINUITY OF THE THROTTLE MOTOR RELAY GROUND CIRCUIT
connector EN16-52.
Yes
No
REPAIR the throttle motor relay ground circuit from the ECM to the engine compartment fuse box. CLEAR the DTC.
PINPOINT TEST E : DTC P1254, P1250
TEST
CONDITIONS
E1: CHECK THE ACCELERATOR PEDAL DEMAND SENSOR GROUND CIRCUIT
Yes
No
REPAIR the accelerator pedal demand sensor ground circuit from the accelerator pedal to the ECM. CLEAR the DTC.
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Acceleration Control - Accelerator Cable Adjustment2.0L NA V6 - AJV6
General Procedures
1. Remove the primary cable retaining clip.
2. NOTE: Make sure the accelerator cable is seated fully in the retaining
bracket.
Fully depress the accelerator pedal and hold down.
3. NOTE: Make sure the throttle actuator is in the fully open position.
4. Release the accelerator pedal.
5. Fully depress the accelerator pedal and hold down.
6. If the accelerator actuator is not in the fully open position, repeat the
above procedure.
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Acceleration Control - Accelerator Cable2.0L NA V6 - AJV6
Removal
and Cables.
1. Position the accelerator actuator to the fully open position.
3. Detach the outer accelerator cable.
4. Detach the accelerator cable from the accelerator pedal.
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6. Remove the accelerator cable.
Detach the accelerator cable grommet.
Installation
2. Tighten to 5 Nm.
3. Adjust the accelerator cable.
For additional information, refer to Accelerator Cable Adjustment-2.0L in
this section.
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Acceleration Control - Accelerator Pedal
Removal
1. Position the accelerator actuator to the fully open position.
3. Disconnect the accelerator pedal electrical connector.
All vehicles
4. NOTE: Vehicles with 2.5L, 3.0L or diesel engine shown, 2.0L similar.
Remove the accelerator pedal retaining nuts.
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5. Remove the accelerator pedal.
Installation
1. NOTE: Vehicles with 2.5L, 3.0L or diesel engine shown, 2.0L similar.
Tighten to 9 Nm.
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Speed Control -
Cruise control switch retaining screws 3 - 27
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Speed Control - Speed Control
2.0L vehicles
2 Cruise control switch
3 Handbrake switch
4 Cruise control module
5 Throttle body
6 Instrument cluster (IC)
7 - Speed control deactivator switch (brake pedal position primary switch, black)
8 - Speed control deactivator switch (brake pedal position secondary switch)
9 - Speed control deactivator switch (clutch pedal position switch, red, vehicles fitted with manual transmission)
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2 Cruise control switch
3 Throttle body
4 Instrument cluster (IC)
5 Speed control deactivator switch (brake pedal position secondary switch, green)
6 Speed control deactivator switch (brake pedal position primary switch, black)
7 Speed control deactivator switch (clutch pedal position switch, red, vehicles fitted with manual transmission)
System operation
The speed control system operates between the following speeds:
On vehicles with 2.0L engine the speed range is 40km/h (25mile/h) and 192km/h (120mile/h). On vehicles with 2.5L, 3.0L or diesel
engine the speed range is 40km/h (25mile/h) and 180km/h (112mile/h).
The speed control system is designed to maintain a selected vehicle speed between these two parameters.
Any of the deactivator switches operated by the handbrake, footbrake or clutch pedal (vehicles fitted with manual transmission) or by
information sent by the engine control module (ECM) to the cruise control module will interrupt the speed control operation. This will allow
the system to go into STANDBY mode. Operating the RESUME switch with the system in STANDBY mode will allow the vehicle to accelerate
until the last set speed is resumed, providing the vehicle speed remains between the upper and lower operating limits of the speed control
system.
Any of the deactivator switches operated by the brake or clutch pedal (vehicles fitted with manual transmission) will interrupt the speed
control operation by switching the signal to the ECM. This will allow the system to go into STANDBY mode. Operating the RESUME switch
with the system in STANDBY mode will allow the vehicle to accelerate until the last set speed is resumed, providing the vehicle speed
remains between the upper and lower operating limits of the speed control system.
Vehicle Speed Signal
The vehicle speed signal for the speed control system comes from the anti-lock control system (ABS) through the control area network
(CAN) via the (EMS).
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Actuator Switches
ON Switch
When the ON switch is operated the speed control system is activated and providing the vehicle is travelling at a speed greater than
40km/h (25mile/h), the speed control system will accept the speed inputs. The instrument cluster (IC) will inform the driver that the speed
control has been activated.
OFF Switch
When the OFF switch is operated the speed control system is deactivated and the speed setting stored in the ECM memory will be erased.
The speed control warning in the IC will be extinguished.
RESUME Switch
When the RESUME switch is operated with the system in STANDBY mode, providing the vehicle speed is above, 40km/h (25mile/h) the
vehicle will accelerate until the last set speed is reached.
The RESUME switch will not function if:
The OFF switch has been operated.
The ignition switch has been turned to the OFF position.
The vehicle speed is below 40km/h (25mile/h).
There is a loss of drive between the driveline system and the road wheels.
The diagnostic system has detected a fault with the speed control system.
CANCEL Switch
When the CANCEL switch is operated with the vehicle speed control system active, the system will enter STANDBY mode.
SET Switch
When the SET switch is operated, providing the vehicle is travelling above 40km/h (25mile/h) the system allows the vehicle speed to be
maintained to 2km/h (1 mile/h). When the vehicle speed control system is active, operating the SET switch will increase or decrease the
vehicle speed respectively until the switch is released. If the SET switch is operated momentarily, the vehicle speed will increase or
decrease in 2km/h (1 mile/h) increments.
Handbrake switch (vehicles with 2.0L engine only)
If the handbrake is operated when the speed control system is active, the cruise control module will receive a signal from the handbrake
position switch via the (EMS). This will put the system into STANDBY mode and allow the vehicle to return to a speed demanded by the
throttle pedal position.
Brake Pedal Position Switches
If the brake pedal is operated when the speed control system is active, the cruise control module will receive a signal from the brake pedal
position primary and secondary switches. This will put the system into STANDBY mode and allow the vehicle to return to a speed demanded
by the throttle pedal position.
If the brake pedal is operated when the speed control system is active, the ECM will receive a signal from the brake pedal position primary
and secondary switches. This will put the system into STANDBY mode and allow the vehicle to return to a speed demanded by the throttle
pedal position.
The brake pedal position primary switch is also used to operate the stop lamps.
Clutch Pedal Position Switch (vehicles fitted with manual transmission)
If the clutch pedal is operated when the speed control system is active, the cruise control module will receive a signal from the clutch pedal
position (CPP) switch. This will put the system into STANDBY mode and allow the vehicle to return to a speed demanded by the throttle
pedal.
If the clutch pedal is operated when the speed control system is active, the ECM will receive a signal from the clutch pedal position (CPP)
switch. This will put the system into STANDBY mode and allow the vehicle to return to a speed demanded by the throttle pedal.
Throttle Body
The throttle body moves the throttle plate to a position demanded by the throttle pedal or the speed control system.
Cruise control module (vehicles with 2.0L engine only)
The cruise control module receives information from the sensors and the ECM, which enables it to hold the throttle lever in a set position,
this is achieved via a cable which is attached to the throttle lever. The cruise control actuator cable is permanently attached to the cruise
control module and cannot be replaced or adjusted.
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Speed Control - Speed Control2.0L NA V6 - AJV6
The complexity of the electronics involved with the vehicle speed control system and the communication network which is connected to the
system, preclude the use of workshop general electrical test equipment. For diagnosis and testing of the vehicle speed control system, refer
to the Jaguar approved diagnostic system.
Throttle body mechanism Module
Switch(es)
Instrument cluster
step.
3.
electrical guides are available, the speed control system can only be accurately diagnosed using the Jaguar approved diagnostic
5.
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Speed Control - Speed Control2.5L NA V6 - AJV6/3.0L NA V6 - AJ27
The complexity of the electronics involved with the vehicle speed control system and the communication network which is connected to the
system, preclude the use of workshop general electrical test equipment. For diagnosis and testing of the vehicle speed control system, refer
to the Jaguar approved diagnostic system.
The Jaguar approved diagnostic system tests and analyses all functions of the vehicle speed control system. The following DTCs may be
tested using a suitable meter.
Throttle body mechanism Throttle body actuator
Module
Switch(es)
Instrument cluster
step.
3.
P0568Speed control input signal low/high resistance,
open circuit.
Speed control switches internal steering wheel circuit, open
circuit, high resistance.
Cassette reel open circuit, high resistance.
Cassette reel to engine control module (ECM) circuit, open
GO to Pinpoint
Test A.
P0565Speed control ON/OFF switch fault. Speed control switches internal steering wheel circuit, short
to ground.
Cassette reel short to ground.
Cassette reel to ECM circuit short to ground.
ON/OFF switch failure. (Stuck on)
GO to Pinpoint
Test B.
P0566Speed control CANCEL switch fault. Speed control switches internal steering wheel circuit, short
to ground.
Cassette reel to ECM circuit short to ground
CANCEL switch failure. (Stuck on).
GO to Pinpoint
Test C.
P0567Speed control RESUME switch fault. Speed control switches internal steering wheel circuit, short
to ground.
RESUME switch failure. (Stuck on)
GO to Pinpoint
Test D.
P0569Speed control SET/- switch fault. Speed control switches internal steering wheel circuit, short
to ground.
SET/- switch failure.
GO to Pinpoint
Test E.
P0570Speed control SET/+ switch fault. Speed control switches internal steering wheel circuit, short
to ground.
SET/+ switch failure.
GO to Pinpoint
Test F.
P0831Clutch cancel switch, low voltage. (Switch
normally closed).
Switch supply open circuit.
Switch to ECM circuit open circuit or high resistance.
Switch failure.
GO to Pinpoint
Test G.
P0832Clutch cancel switch, high voltage. (Switch
normally closed).
Switch short circuit to battery.
Switch failure.
GO to Pinpoint
Test G.
P0834Clutch pedal safety switch, low voltage.
(Switch normally open).
Clutch pedal safety switch supply circuit open circuit.
Clutch pedal safety switch to ECM circuit open circuit/high
resistance.
Switch failure.
GO to Pinpoint
Test H.
P0835Clutch pedal safety switch, high voltage.
(Switch normally open).
Clutch pedal safety switch to ECM circuit short circuit to
battery.
Switch failure.
GO to Pinpoint
Test H.
P1571Brake ON/OFF switch, brake cancel switch
malfunction.
Brake ON/OFF switch to ECM circuit open circuit, short circuit
to ground, high resistance.
Brake ON/OFF switch power supply circuit open circuit.
Brake ON/OFF switch failure.
Brake cancel switch to ECM circuit open circuit, short circuit
GO to Pinpoint
Test I.
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1
2
3
1
1
2
3
1
2
1
2
1
1
2
1
to ground, high resistance.
Brake cancel switch power supply circuit open circuit.
Brake cancel switch failure.
Pinpoint Tests
PINPOINT TEST A : P0568. CHECK SPEED CONTROL INPUT WIRE FOR OPEN CIRCUIT/HIGH RESISTANCE
TEST
CONDITIONS
A1: CHECK INTERNAL STEERING WHEEL CIRCUIT FOR OPEN CIRCUIT/HIGH RESISTANCE (INPUT)
Disconnect steering wheel internal connector, SW5.
Disconnect steering wheel connector, SW4.
Measure the resistance between SW5, pin 4 (YR) and SW4, pin 1 (YR).
Yes
GO to A3.
No
INSTALL a new steering wheel assembly.
A2: CHECK INTERNAL STEERING WHEEL CIRCUIT FOR OPEN CIRCUIT/HIGH RESISTANCE (SIGNAL)
Measure the resistance between SW5, pin 2 (B) and SW4, pin 3.
Yes
GO to A3.
No
INSTALL a new steering wheel assembly.
A3: CHECK STEERING WHEEL CASSETTE FOR OPEN CIRCUIT/HIGH RESISTANCE (INPUT)
Disconnect steering wheel Cassette connector, IP34.
Reconnect steering wheel internal connector, SW5.
Measure the resistance between SW5, pin 4 (YR) and IP34, pin 8 (YR).
Yes
GO to A4.
No
INSTALL a new steering wheel Cassette assembly.
A4: CHECK STEERING WHEEL CASSETTE FOR OPEN CIRCUIT/HIGH RESISTANCE (SIGNAL)
Disconnect steering wheel cassette connector, IP34.
Measure the resistance between SW5, pin 2 (B) and IP34, pin 6 (YG).
Yes
GO to A5.
No
INSTALL a new steering wheel cassette assembly.
A5: CHECK INPUT LEAD FROM ECM TO STEERING WHEEL CASSETTE FOR OPEN CIRCUIT/HIGH RESISTANCE
Measure the resistance between IP34, pin 8 (YR) and EN16, pin 47 (YR).
Yes
GO to A6.
No
Repair the circuit between EN16, pin 47 and IP34, pin 8. For additional information, refer to wiring diagrams. CLEAR
A6: CHECK SIGNAL LEAD FROM ECM TO STEERING WHEEL CASSETTE FOR OPEN CIRCUIT/HIGH RESISTANCE
Measure the resistance between IP34, pin 6 (YG) and EN16, pin 48 (YG).
Yes
GO to B1.
No
Repair the circuit between EN16, pin 48 and IP34, pin 6. For additional information, refer to wiring diagrams. CLEAR
PINPOINT TEST B : P0565. SPEED CONTROL ON/OFF SWITCH MALFUNCTION
B1: CHECK SWITCH FUNCTION OF ON/OFF SWITCH
Connect an Ohmmeter between pins 1 and 3 of the Speed Control switchpack.
Set the switch to the ON position.
Does the resistance vary by 2200 ohms?
Yes
GO to B2.
No
INSTALL a new switchpack.
REFER to Speed Control Switch in this section.
B2: CHECK SWITCH FUNCTION OF ON/OFF SWITCH
Set the switch to the OFF position.
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1
2
1
2
1
2
1
2
1
2
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1
2
3
Yes
No electrical fault in switchpack. RECHECK DTCs.
No
PINPOINT TEST C : P0566. SPEED CONTROL CANCEL SWITCH MALFUNCTION
C1: CHECK SWITCH FUNCTION OF CANCEL SWITCH
Operate the Cancel switch.
Yes
No
PINPOINT TEST D : P0567. SPEED CONTROL RESUME SWITCH MALFUNCTION
D1: CHECK SWITCH FUNCTION OF RESUME SWITCH
Operate the Resume switch.
Yes
No
PINPOINT TEST E : P0569. SPEED CONTROL SET/- SWITCH MALFUNCTION
E1: CHECK SWITCH FUNCTION OF SET/- SWITCH
Operate the Set /- switch.
Yes
No
PINPOINT TEST F : P0570. SPEED CONTROL SET/+ SWITCH MALFUNCTION
F1: CHECK SWITCH FUNCTION OF SET/+ SWITCH
Operate the Set /+ switch.
Yes
No
PINPOINT TEST G : P0831, P0832. CLUTCH CANCEL SWITCH, HIGH/LOW VOLTAGE
TEST
CONDITIONS
G1: CHECK THE POWER SUPPLY CIRCUIT TO THE CLUTCH CANCEL SWITCH
Disconnect the clutch cancel switch electrical connector, PA4.
Measure the voltage between PA4, pin 1 (RW) and GROUND.
Yes
GO to G2.
No
REPAIR the circuit between the clutch cancel switch electrical connector, PA4, pin 1 (RW) and the ignition switch. For
(This circuit includes the ignition relay and the inertia switch)
G2: CHECK THE POWER SUPPLY CIRCUIT TO THE CLUTCH CANCEL SWITCH FOR SHORT CIRCUIT TO BATTERY
Disconnect the clutch cancel switch electrical connector, PA4.
Yes
Repair the short circuit. For additional information, refer to wiring diagrams. CLEAR the DTC. TEST the system for
normal operation.
No
GO to G3.
G3: CHECK THE SWITCH ACTION OF THE CLUTCH CANCEL SWITCH
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4
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1
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1
2
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1
2
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1
2
1
2
3
4
5
1
2
3
Connect an ohmmeter between pins 1 and 3 of the clutch cancel switch.
Operate the clutch pedal up and down, while observing the resistance reading.
Yes
GO to G4.
No
INSTALL a new clutch cancel switch. CLEAR the DTC. TEST the system for normal operation.
G4: CHECK THE SWITCH ACTION OF THE CLUTCH CANCEL SWITCH
Reconnect the clutch cancel switch electrical connector, PA4.
Connect a voltmeter between ECM electrical connector EN16, pin 33 (WG) and GROUND.
Operate the clutch pedal up and down, while observing the voltage reading.
Does the voltage switch between 0 volts and battery voltage as the pedal is operated?
Yes
Before replacing a ECM, contact Dealer technical support. CLEAR the DTC. TEST the system for normal operation.
No
GO to G5.
G5: CHECK THE CLUTCH CANCEL SWITCH SIGNAL WIRE FOR CONTINUITY
Disconnect clutch cancel switch electrical connector, PA4.
Measure the resistance between clutch cancel switch electrical connector PA4, pin 3 (W) and ECM electrical connector
EN16, pin 33 (WG).
Yes
No electrical fault in circuit. RECHECK DTCs.
No
REPAIR the circuit between clutch cancel switch electrical connector PA4, pin 3 (W) and ECM electrical connector EN16,
pin 33 (WG). For additional information, refer to wiring diagrams. CLEAR the DTC. TEST the system for normal
operation.
PINPOINT TEST H : P0834, P0835. CLUTCH PEDAL SAFETY SWITCH, HIGH/LOW VOLTAGE
TEST
CONDITIONS
H1: CHECK THE POWER SUPPLY CIRCUIT TO THE CLUTCH PEDAL SAFETY SWITCH
Disconnect the clutch pedal safety switch electrical connector, PA5.
Yes
GO to H3.
No
REPAIR the circuit between the clutch pedal safety switch electrical connector, PA5, pin 1 (RW) and the ignition
switch. For additional information, refer to wiring diagrams. CLEAR the DTC. TEST the system for normal operation.
H2: CHECK THE POWER SUPPLY CIRCUIT TO THE CLUTCH PEDAL SAFETY SWITCH FOR SHORT CIRCUIT TO BATTERY
Yes
normal operation.
No
GO to H3.
H3: CHECK THE SWITCH ACTION OF THE CLUTCH PEDAL SAFETY SWITCH
Connect an ohmmeter between pins 1 and 2 of the clutch pedal safety switch.
Operate the clutch pedal up and down, while observing the resistance reading.
Yes
GO to H4.
No
INSTALL a new clutch pedal safety switch. CLEAR the DTC. TEST the system for normal operation.
H4: CHECK THE SWITCH ACTION OF THE CLUTCH PEDAL SAFETY SWITCH
Reconnect the clutch pedal safety switch electrical connector, PA5.
Connect a voltmeter between ECM electrical connector EN16, pin 31 (B) and GROUND.
Operate the clutch pedal up and down, while observing the voltage reading.
Does the voltage switch between 0 volts and battery voltage as the pedal is operated?
Yes
No
GO to H5.
H5: CHECK THE CLUTCH PEDAL SAFETY SWITCH SIGNAL WIRE FOR CONTINUITY
Measure the resistance between clutch pedal safety switch electrical connector PA5, pin 2 (W) and ECM electrical
connector EN16, pin 31 (B).
Yes
No electrical fault in circuit. RECHECK DTCs.
No
REPAIR the circuit between clutch pedal safety switch electrical connector PA5, pin 2 (W) and ECM electrical connector
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2
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1
2
1
2
1
1
1
2
3
1
2
3
1
2
1
EN16, pin 31 (B). For additional information, refer to wiring diagrams. CLEAR the DTC. TEST the system for normal
operation.
PINPOINT TEST I : P1571. BRAKE ON/OFF SWITCH / BRAKE CANCEL SWITCH MALFUNCTION
TEST
CONDITIONS
I1: CHECK THE POWER SUPPLY CIRCUIT TO THE BRAKE ON/OFF SWITCH
Disconnect the brake ON/OFF switch electrical connector, PA3.
Yes
GO to I2.
No
REPAIR the circuit between the brake ON/OFF switch electrical connector, PA3, pin 3 (NR) and the ignition switch. For
(This circuit icludes the inertia switch, ignition relay, and the central junction fuse box)
I2: CHECK THE POWER SUPPLY CIRCUIT TO THE BRAKE ON/OFF SWITCH FOR SHORT CIRCUIT TO BATTERY
Yes
normal operation.
No
GO to I3.
I3: CHECK THE BRAKE ON/OFF SWITCH SIGNAL WIRE FOR CONTINUITY
Measure the resistance between the ECM electrical connector, EN16, pin 8 (GO) and brake ON/OFF switch electrical
connector PA3, pin 1 (GW).
Yes
GO to I4.
No
REPAIR the circuit between the ECM electrical connector, EN16, pin 8 (GO) and brake ON/OFF switch electrical
connector PA3, pin 1 (GW). For additional information, refer to wiring diagrams. CLEAR the DTC. TEST the system for
normal operation.
I4: CHECK THE SWITCH ACTION OF THE BRAKE ON/OFF SWITCH
Measure the resistance between pins 1 and 3 of the brake ON/OFF switch, with the brake pedal at rest.
Is the switch open circuit?
Yes
GO to I5.
No
INSTALL a new brake ON/OFF Switch. CLEAR the DTC. TEST the system for normal operati on.
I5: CHECK THE SWITCH ACTION OF THE BRAKE ON/OFF SWITCH
Measure the resistance between pins 1 and 3 of the brake ON/OFF switch, with the brake pedal depressed.
Yes
No
INSTALL a new brake ON/OFF switch. CLEAR the DTC. TEST the system for normal operation.
I6: CHECK THE POWER SUPPLY CIRCUIT TO THE BRAKE CANCEL SWITCH
Disconnect the brake cancel switch electrical connector, PA2.
Yes
GO to I7.
No
REPAIR the circuit between the brake cancel switch electrical connector, PA2, pin 2 (NR) and the Ignition Switch. For
(This circuit includes the inertia switch, ignition relay, and the central junction fuse box)
I7: CHECK THE POWER SUPPLY CIRCUIT TO THE BRAKE CANCEL SWITCH FOR SHORT CIRCUIT TO BATTERY
Disconnect the brake cancel switch electrical connector, PA2.
Yes
normal operation.
No
GO to I8.
I8: CHECK THE BRAKE CANCEL SWITCH SIGNAL WIRE FOR CONTINUITY
Measure the resistance between the ECM electrical connector, EN16, pin 9 (U) and brake cancel switch electrical
connector PA2, pin 1 (U).
Yes
GO to I9.
No
REPAIR the circuit between the ECM electrical connector, EN16, pin 9 (U) and brake cancel switch electrical connector
PA2, pin 1 (U). For additional information, refer to wiring diagrams. CLEAR the DTC. TEST the system for normal
operation.
I9: CHECK THE SWITCH ACTION OF THE BRAKE CANCEL SWITCH
Measure the resistance between pins 1 and 2 of the brake cancel switch, with the brake pedal at rest.
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1
Is the switch open circuit?
Yes
GO to I10.
No
INSTALL a new brake cancel switch. CLEAR the DTC. TEST the system for normal operation.
I10: CHECK THE SWITCH ACTION OF THE BRAKE CANCEL SWITCH
Measure the resistance between pins 1 and 2 of the brake cancel switch, with the brake pedal depressed.
Yes
No
INSTALL a new brake cancel switch. CLEAR the DTC. TEST the system for normal operation.
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Speed Control - Speed Control Deactivator Switch
Removal
1. Disconnect the speed control deactivator switch electrical connector.
2. Remove the speed control deactivator switch.
Turn the speed control deactivator switch 45 degrees counter
clockwise.
Installation
1. NOTE: Operate the brake pedal to allow the speed control deactivator
switch plunger to remain in the fully extended position during installation.
NOTE: Releasing and then pulling back on the brake pedal until the
pedal reaches the stop in the brake booster, will adjust the speed control
de-activator switch plunger to the required setting.
Install the speed control deactivator switch.
Turn the speed control deactivator switch 45 degrees clockwise.
2. Connect the speed control deactivator switch electrical connector.
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Speed Control - Speed Control Module
Removal
1. Remove the speed control module cable retaining tie strap.
2. Detach the inner cable.
3. Detach the outer cable.
2. Turn the coolant expansion tank counter clockwise.
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6. Remove the module retaining bolt.
7. Remove the module.
Installation
2. Tighten to 4 Nm.
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3. Tighten to 3 Nm.
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Speed Control - Speed Control Switch
Removal
For additional information, refer to: Steering Wheel (211-04 Steering
Column, Removal and Installation).
2. Remove the steering wheel finisher trim panel.
3. Disconnect the speed control switch electrical connector.
4. Remove the speed control switch.
Installation
Tighten to 4 Nm.
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Climate Control System - General Information -
Item Specification
Refrigerant HFC 134a
Compressor oil Polyalkyleneglycol
System oil quantityTotal system oil quantity = 160ml. New compressor supplied with 90ml, plus additonal 70ml of oil added online = 160ml
Refridgerant oil adding capacities for replacment parts.
NOTE: Rotate the A/C compressor shaft at least 6 to 8 turns when draining the refrigerant oil.
Item Specification
Air conditioning compressor 1. Drain old Air conditioning (A/C) compressor. With drain plug removed and ports uncapped, rotate shaft to
remove A/C compressor oil and measure the amount of oil captured. 2. Drain new A/C compressor into a
clean vessel. With drain plug removed and ports uncapped, rotate shaft to remove oil. Then add back a
quantity of the new oil that is identical to the quantity of oil removed from the ol d A/C compressor.
However, if this quantity is less than 30ml, then make it up to 30ml.
Air conditioning condenser Add30 ml.
Accumulator/dehydrator Transfer the oil from the accumulator/dehydrator being removed to a measuring cylinder. Fill the new
accumulator with the same quantity of fresh oil plus 90 ml.
Air conditioning lines, if air
conditioning has been
operational.
Add 10 ml per AC line.
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Climate Control System - General Information - Climate Control System
The purpose of the air distribution system is to route air to the designated registers. This is accomplished when air enters the plenum
through the fresh/recirculated air inlet and is routed to the desired outlets by the use of air distribution doors.
The air distribution system contains the heater core, A/C evaporator core, blower motor, and all of the distribution doors. All of the air is
mixed and distributed inside of the plenum assembly, depending on the distribution door positions.
For additional information on the air distribution and filtering system, refer to Section 412-01 Air Distribution and Filtering.
Heating/Defrosting
The heater system is a blended air system, receiving outside air through the air inlet, which is connected to the upper cowl. Air is directed
through and/or around the heater core and mixed and discharged through outlets in the plenum assembly to the floor, panel or defrost
nozzles, as desired.
For additional information on heating and defrosting, refer toSection 412-02A Heating and VentilationSection 412-02B Auxiliary Heating.
Heater Core
The heater core consists of a number of fins and tubes in an arrangement to extract heat from the engine coolant and transfer that heat to
the air that passes through the heater core.
Blower motor
The blower motor pulls air from the air inlet and forces it into the plenum assembly where it is mixed and distributed. The blower motor is
controlled electronically by the NAV/EATC controller.
Air Conditioning
The R-134a air conditioning system uses a hydrofluorocarbon (HFC) non-CFC based refrigerant, R-134a requires the use of Jaguar refrigerant
oil or equivalent meeting Jaguar specification. Do not use R-12 tools and equipment when repairing a R-134a system unless specified in the
workshop manual. Never mix R-12 and R-134a refrigerants and oils. They are not compatible.
A/C System
The A/C system is a multi-piece, single case design, with an integral blower. The system allows the operator to control the temperature by
delivering heated or cooled air to maintain a constant temperature. In addition, during A/C operation, it reduces the relative humidity of air
inside the vehicle. Controls are provided to adjust the temperature and system functions, included blower motor speeds for desired airflow.
Outside air is drawn from the cowl air inlet just below the windshield during all system operations except for MAX A/C cooling (when
recirculated air is used) and OFF. For additional information on the air conditioning, refer toSection 412-03 Air Conditioning.
Control System Inputs
The climate control system inputs are selected from the climate control head.
Control System Outputs
The air distribution and air temperature blend doors are all controlled by electronic stepper motors. For additional information, refer
toSection 412-04 Control Components.
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Climate Control System - General Information - Climate Control System
REFER to: Climate Control System (412-00 Climate Control System - General Information, Description and Operation).
CAUTION: Diagnosis by substitution from a donor vehicle is NOT acceptable. Substitution of control modules does not guarantee
confirmation of a fault, and may also cause additional faults in the vehicle being tested and/or the donor vehicle.
NOTE: All Climate Control System tests should be run in an ambient temperature of at least 10c (50F)
Refrigerant circuit (fill level, leakage, flow restriction)
Condenser air flow (obstructions)
Evaporator air flow (obstructions)
air distribution housing condensate drain hose (not trapped)
Pollen filter (restricted flow)
Drive belt damage
Heater control flaps
Air conditioning compressor
Air outlet ducts (obstructions)
Battery condition (fully charged and correctly connected)
Fuse(s)
Blower motor
Cooling fan motor
step.
3.
DTC Index
3548-1358-00
NOTE: If the refrigerant compressor or Climate Control ECU is suspect and the vehicle remains under manufacturer warranty, refer to the
Warranty Policy and Procedures manual (section B1.2), or determine if any prior approval programme is in operation, prior to the installation
of a new component.
B1200Climate Control
Pushbutton Circuit
Failure
This DTC is logged when a
Climate Control bezel
button is pressed
continuously for more than
5 minutes when the
ignition is on
Check for objects pressing against the control buttons. Check for
contamination of the buttons which could cause them to stick. (E.g.: spilt
food or drink) If there are no apparent external reasons for a button to stick
- then suspect an internal fault and install a new combined Climate Control
panel / electronic control unit as required. Clear the DTC and recheck
operation of system to ensure the DTC does not reset after 5 minutes
B1239Air Flow Blend Door
Driver Circuit Failure
NOTE: Fault is checked for whilst
the motor is running.
Short circuit (to ground or
power) on any of the motor
control lines
Open circuit on any of the
motor control lines
Short to ground on the
motor supply wire
NOTE: check that the blend door is not mechanically jammed by a foreign
body inside the air distribution housing
Refer to the electrical circuit diagrams and check the integrity of the wiring
between the blend door actuator motor and the climate control ECU. Check
the motor power feed line for short to ground. Check the four control lines
for open/short circuits. If no wiring defects are found install a new actuator
motor. Clear the DTC and recheck that the DTC does not reset by operating
the system
B1242Air Flow
Recirculation Door
Driver Circuit Failure
NOTE: Fault is checked for when
the motor is not running.
Open circuit or short circuit
to ground or power on
either drive line
NOTE: check that the recirculation door is not mechanically jammed by a
foreign body inside the air distribution housing
Refer to the electrical circuit diagrams and check the integrity of the wiring
between the recirculation door actuator motor and the climate control ECU.
Check both control lines for open/short circuits. If no wiring defects are
found install a new actuator motor. Clear the DTC and recheck that the DTC
does not reset by operating the system
B1251Air Temperature
Internal Sensor
Circuit Open
In car temp sensor feed
open circuit
Refer to the relevant circuit diagram and check the integrity of the wiring
between the air temperature internal sensor and the Climate Control System
ECU. Check for open circuits on the Incar Sensor Input and Sensor Ground
lines between the sensor and the Climate Control ECU. If no wiring defects
are found install a new Air Temperature Internal Sensor. Clear the DTC and
operate the system to check that the DTC does not reset.
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Internal Sensor
Circuit Short to
Ground
In car temp sensor feed
short to ground
between the air temperature internal sensor and the Climate Control System
ECU. Check for short circuits to ground on the Incar Sensor Input line
between the sensor and the Climate Control ECU. If no wiring defects are
found install a new Air Temperature Internal Sensor. Clear the DTC and
operate the system to check that the DTC does not reset.
External Sensor
Circuit Open
Ambient temp sensor feed
open circuit
between the air temperature external sensor and the Climate Control System
ECU. Check for open circuits on the Ambient Sensor line and the Sensor
Ground line between the sensor and the Climate Control ECU. If no wiring
defects are found install a new Ambient Temperature External Sensor. Clear
the DTC and operate the system to check that the DTC does not reset.
External Sensor
Circuit Short To
Ground
Ambient sensor feed short
to ground
between the air temperature external sensor and the Climate Control System
ECU. Check for shorts to ground on the Ambient Sensor line between the
sensor and the Climate Control ECU. If no wiring defects are found install a
new Ambient Temperature External Sensor. Clear the DTC and operate the
system to check that the DTC does not reset.
B1261Solar Radiation
Sensor Circuit Short
To Ground
Sunload sensor short This component is not fitted after 2005 model year. The circuit should be
open in vehicles after 2005my
B1262Servo Motor Defrost
Circuit Failure
the motor is running
control lines
motor control lines
motor supply wire
NOTE: check that the defrost door is not mechanically jammed by a foreign
between the Defrost Door Servo motor and the Climate Control System ECU.
Check the Defrost Power line for a short to ground. Check each of the four
control lines for open circuits, or shorts to power or ground. If no wiring
defects are found install a new Defrost Door actuator motor. Clear the DTC
and operate the system to check that the DTC does not reset.
B1263Panel Door Circuit
Failure
the motor is running
control lines
motor control lines
motor supply wire
NOTE: check that the panel door is not mechanically jammed by a foreign
between the Panel Door Servo motor and the Climate Control System ECU.
Check the Panel/Floor Power line for a short to ground. Check each of the
four control lines for open circuits, or shorts to power or ground. If no wiring
defects are found install a new Panel/floor actuator motor. Clear the DTC
and operate the system to check that the DTC does not reset.
B1342ECU is Faulted DTC set when ECU fails
EEPROM checksum test
DTC set when ECU fails
EEPROM write test
DTC set when ECU fails
EEPROM / ROM matching
software revision check
Check the battery is fully charged and the supply leads are correctly
connected. Refer to the relevant circuit diagram and check the integrity of
the wiring between the Climate Control ECU and Power and ground
distribution components. Check the power supply lines and fuses for open
circuits and volt drops. Check the ground connections for open circuits and
volt drops. Repair power supply and ground connections as required. Clear
the DTC and operate the system to check if the DTC does reset. If the DTC
is reset install a new Climate Control ECU.
B1676Battery Pack Voltage
Out Of Range
battery voltage outside 9 -
16 volts range
Check the battery is fully charged and the supply leads are correctly
connected. Refer to the relevant circuit diagram and check the integrity of
the wiring between the Climate Control ECU and the Front Power Distribution
Box and ground distribution components. Check the power supply lines and
fuses for open circuits and volt drops. Check the ground connections for open
circuits and volt drops. Repair power supply and ground connections as
required.
B2672Discharge Air
Temperature Sensor
Circuit Open
Discharge Air Temperature
Sensor Open Circuit
between the discharge air temperature sensor and the Climate Control
System ECU. Check for open circuits on the Discharge Sensor line and the
sensor ground line between the sensor and the Climate Control ECU. If no
wiring defects are found install a new Discharge Air Temperature Sensor.
Clear the DTC and operate the system to check that the DTC does not reset.
B2673Discharge Air
Temperature Sensor
Circuit Short to
Ground
Discharge Air Temperature
Sensor Circuit Short to
Ground
between the discharge air temperature sensor and the Climate Control
System ECU. Check for short circuits on the Discharge Sensor line between
the sensor and the Climate Control ECU. If no wiring defects are found
install a new Discharge Air Temperature Sensor. Clear the DTC and operate
the system to check that the DTC does not reset.
B2308Interior Air
Temperature Inlet
Motor Failure
motor stalled
motor open or short circuit
Check the air inlet path is clear and no foreign objects are present in the air
intake orifice. Check the integrity of the wiring between the Interior Air
Temperature Sensor Aspirator Motor and the power distribution components.
Refer to the appropriate wiring diagram and inspect fuses and relays to
confirm power is present at the motor. Check the aspirator motor ground
connection to the climate control ECU for open circuits. If no wiring faults are
found replace the interior air temperature sensor. Clear the DTC and operate
the system to check that the DTC does not reset.
B2516Blower Motor Failure NOTE: This DTC is only relavent
to the ATC version of the climate
control system.
motor stalled
motor open or short circuit
Validate the fault on the car. Check the blower motor is not stalled by a
foreign object. Refer to the relevant circuit diagram and check the integrity
of the wiring between the blower motor and the power distribution
components. Check the fuses and relay which supply the motor. Check the
motor supply lines between the Passenger Junction Box and motor for open
or short circuits to ground. Check the motor ground lines to the ground point
on the cross car beam for open circuits. Repair harness faults using approved
repair kit. replace blower motor if there are no harness faults
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B1946Climate Control A/C
Post Evaporator
Sensor Circuit
Failure
Evaporator temperature
sensor feed open circuit
between the Climate Control A/C Post Evaporator Sensor and the Climate
Control System ECU. Check for open circuits on the Evap Sensor line between
the sensor and the Climate Control ECU. Check the sensor ground line for
open circuits. If no wiring defects are found install a new Climate Control
A/C Post Evaporator Sensor. Clear the DTC and operate the system to check
that the DTC does not reset.
B1947Climate Control A/C
Post Evaporator
To Ground
Evaporator sensor feed
short to ground
between the Climate Control A/C Post Evaporator Sensor and the Climate
Control System ECU. Check for short circuits to ground on the Evap Sensor
line between the sensor and the Climate Control ECU. If no wiring defects
are found install a new Climate Control A/C Post Evaporator Sensor. Clear
the DTC and operate the system to check that the DTC does not reset.
U1900CAN Communication
Bus Fault - Receive
Error
Communication on CAN
network fault
Refer to the relevant wiring diagram and check the CAN bus wiring for open
circuits, shorts to power or ground. Check termination resistance is correct.
Repair harness as required using approved harness repair kit
B2477Module
Configuration Failure
'Configuration never
programmed' or
'Configuration write failure'
Not used on X400 or set on delivered modules
Auxiliary Heaters
There are two types of auxilliary heater fitted to diesel powered vehicles according to it's intended market. An electric booster heater, which
is a standard fitment, or a fuel fired booster heater which is fitted for specific extreme cold climate markets.
The electric booster heater uses 3 glowplugs mounted in a housing connected into the coolant circuit, the glowplugs are controlled
automatically by the engine management system.
The fuel fired booster heater uses a separate combustion housing and heat exchanger to heat the coolant by burning diesel drawn from the
vehicle fuel tank. The fuel fired booster heater is controlled automatically by an electronic control unit which also uses data from the engine
management system.
CAUTION: Diagnosis by substitution from a donor vehicle is NOT acceptable. Substitution of control modules does not guarantee
confirmation of a fault, and may also cause additional faults in the vehicle being tested and/or the donor vehicle.
Air inlet ducting to fuel burning heater free of obstructions
Exhaust outlet from fuel burning heater free of obstructions
Fuel supply lines to fuel burning heater not damaged (leaks,
blockages)
Coolant hoses correctly connected
Cooling system filled and bled correctly
Battery condition (fully charged and correctly
connected)
Fuse(s) and relay(s)
auxilliary water pump functional
step.
3.
DTC Index
3548-1358-00
NOTE: If the Fuel Burning Heater is suspect and the vehicle remains under manufacturer warranty, refer to the Warranty Policy and
Procedures manual (section B1.2), or determine if any prior approval programme is in operation, prior to the installation of a new
component.
B2462Aux. Heater
Flame Out
Fault
Fuel supply lines to
the auxilliary heater
crushed, blocked,
leaking
Internal fault within
auxilliary heater unit
Check fuel supply lines to the auxilliary heater are free from damage, leaks or air
ingress.Rectify any restrictions, leaks of air ingress. Clear DTC and test the system to
verify the repair.
B1317Battery
voltage high
Charging system
fault
Check charging system
REFER to: Charging System - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) -
Puma (414-00 Battery and Charging System - General Information, Diagnosis and
Testing).
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B1318Battery
Voltage Low
Battery discharged
Charging system
fault
Check battery is fully charged. Using the appropriate circuit diagrams: Check power
supply circuits from front power distribution box to the fuel fired heater unit. Using the
appropriate circuit diagrams: check ground connections to the fuel fired heater unit.
Repair any wiring faults using the approved harness repair kit. Clear the DTC and test the
system to verify the repair. Check charging system
REFER to: Charging System - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) -
Puma (414-00 Battery and Charging System - General Information, Diagnosis and
Testing).
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Climate Control System - General Information - Air Conditioning (A/C) Compressor
Leak Detection
General Procedures
1. Remove the A/C compressor from the vehicle. For additional
information, refer to Section 412-03 Air Conditioning.
2. Install A/C pressure test adaptor to the A/C compressor using the
existing manifold bolt.
3. Connect the high and low pressure lines of R-134a manifold gauge set
to the fittings on A/C pressure test adaptor.
4. Attach the center hose of R-134a manifold gauge set to a refrigerant
container standing in an upright position.
5. Hand rotate the compressor shaft ten revolutions to distribute the oil
inside the A/C compressor.
6. Open the low and high pressure gauge valves and the valve on the
refrigerant container to allow the refrigerant vapor to flow into the A/C
compressor.
7. Use R-134a automatic calibration halogen leak detector to check for
leaks at the compressor shaft seal and the compressor center seal.
8. If a shaft seal leak is found, install a new shaft seal. If a leak is found
at the compressor center seal, install a new A/C compressor.
9. When the leak test is finished, close the manifold gauge valves and the
valve on the refrigerant container.
10. Slowly remove the gauge set hoses from A/C pressure test adapter.
Allow the refrigerant in the compressor to escape.
11. Install the A/C compressor on the vehicles. For additional information,
refer to Section 412-03 Air Conditioning
12. Evacuate, charge and leak test the system.
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Climate Control System - General Information - Air Conditioning (A/C) System
Flushing
General Procedures
1. WARNING: Use extreme care and observe all safety precautions
related to the use of refrigerants. Warning: Due to refrigerant hazards,
always wear safety goggles and non-penetrable gloves when working on or
flushing A/C systems. Failure to follow this instruction may result to
personal injury.
CAUTIONS:
The A/C refrigerant analyzer must be used before the recovery of
any vehicle's A/C refrigerant. Failure to do so puts shop bulk refrigerant at
risk of contamination. If the vehicle A/C refrigerant is contaminated, refer
the customer to return to the repair facility that performed the last A/C
repair. If the customer wishes to pay the additional cost, use the A/C
recovery equipment that is designated for recovering contaminated A/C
refrigerant. All contaminated A/C refrigerant must be disposed of as
hazardous waste. For all equipment, follow the equipment manufacturers
procedures and instructions. Failure to follow this instruction may result to
personal injury.
Suction accumulator/drier, muffler, hoses, thermal expansion valve,
and fixed orifice tube should be removed when flushing the A/C system.
Internal plumbing of these devices makes it impossible to correctly remove
any residual flushing agent. Except for the hoses, these components are
typically discarded after A/C system contamination. Hoses can normally be
reused unless they are clogged with debris. The flushing solvent and filter
used in the A/C Flusher are intended for use on one vehicle only. They may
be used to flush both the A/C condenser core and the A/C evaporator core
on an individual vehicle, but under no circumstances should they be used
on more than one vehicle.
NOTE: Prior to using A/C Flusher for the first time, review its operating
instructions. Failure to follow this instruction may result to personal injury.
This procedure allows the specified components to be cleaned and
flushed while installed in their normal in-vehicle location. The types of
contamination flushed include particle matter that results from A/C
compressor and/or desiccant failure within the suction accumulator/drier
and gummy residue that may form when refrigerant oil is overheated
during A/C compressor seizure. The flushing process is a two-step
procedure that involves the use of an A/C Flusher to:
Circulate the flushing solvent through the heat exchanger in the
reverse direction of normal refrigerant flow (back-flushing).
Particulate matter picked up during flushing is filtered from the
returning solvent before the solvent is returned to the reservoir for
continued circulation.
Remove the flushing solvent from the heat exchanger. In this step
of the procedure, pressurized air 621-862 kPa (90-125 psi) is used
to push and/or evaporate any remaining flush solvent from the heat
exchanger.
2. Reclaim the refrigerant. For additional information, refer to Discharging
and Recovery.
3. Disconnect refrigerant lines from the heat exchanger(s) to be flushed.
For additional information, refer to Section 412-03 Air Conditioning
4. Connect A/C flusher and A/C flusher fitting kit to the heat exchanger to
be flushed. Do not flush through the A/C evaporator core orifice,
mufflers or lines. Internal plumbing and material make-up of these
components make it impossible to correctly remove debris and/or
residual flushing solvent.
5. Use flushing solvent to flush the heat exchanger for a minimum of 15
minutes. The flush solvent may be used for one or both heat exchangers
in the A/C system. However, the flush solvent is intended for one
vehicle only. The filter used on the flushing unit is also intended for use
on one vehicle only.
6. Flush component for a minimum of 15 minutes.
7. Apply 621-862 kPa (90-125 psi) pressurized air to the component for a
minimum of 30 minutes. The 30 minute purge time is required to force
and/or evaporate all residual flush solvent from the A/C system
component. Failure to successfully remove all residual solvent within the
component can result in system damage when reconnected and
operated. Dispose of used flush solvent and filter in accordance with
local, state and federal ordinances.
8. NOTE: A/C system filtering as described in this section is optional if
system flushing is performed. However, filter kit use is recommended after
flushing if A/C system contamination is extensive.
Install new suction accumulator/drier and A/C evaporator core orifice on
any vehicle being repaired for A/C compressor or desiccant failure.
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9. Install new refrigerant lines if clogged with debris.
10. Reconnect the heat exchanger being flushed.
11. Add additional refrigerant oil as required. For additional information,
refer to Refrigerant Oil Adding.
12. Evacuate, charge and leak test A/C system.
13. Check A/C system for correct operation.
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Climate Control System - General Information - Air Conditioning (A/C) System
Recovery, Evacuation and Charging
General Procedures
1. WARNINGS:
A/C refrigerant can be extremely hazardous and failure to follow the
equipment manufacturers instructions may result in personal injury.
Jaguar Cars Limited recommend the use of a charging station to
carry out recover, evacuation and charging of the refrigerant system.
Follow the manufactures equipment procedures and instructions. Failure to
CAUTIONS:
The A/C refrigerant analyzer must be used before the recovery of
the customer to return to the repair facility that carried out the last A/C
procedures and instructions.
Do not add R-12 refrigerant to an A/C system that requires the use
of R-134a refrigerant. These two types of refrigerant should never be
mixed. Doing so may cause damage to the A/C system.
Connect the charging station. For additional information, refer to the
manufactures equipment instructions.
2. Recover the refrigerant. For additional information, refer to the
3. Carry out the required repair procedure.
For additional information, refer to Section 412-03 Air Conditioning.
4. Add the required amount of oil to the A/C system depending on the
repair procedure.
For additional information, refer to Refrigerant Oil Adding - in this
section.
5. Evacuate the A/C system. For additional information, refer to the
6. Check the A/C system for a sufficient vacuum. For additional
information, refer to the manufactures equipment instructions.
7. Charge the A/C system with refrigerant.
8. Check the A/C system for correct operation.
9. Carry out a leak detection test.
For additional information, refer to Leak Detection - in this section.
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Climate Control System - General Information - Contaminated Refrigerant Handling
General Procedures
1. If contaminated refrigerant is detected DO NOT recover the refrigerant
into your R-134a OR R-12 recovery/recycling equipment. Take the follow
actions:
1. Repeat the test to verify contaminated refrigerant is present.
2. Advise the customer of the contaminated A/C system and any
additional cost to repair the system. The customer may wish
to return to the repair facility performing the last A/C repair.
3. Recover the contaminated refrigerant using suitable recovery
only equipment designed for capturing and storing
contaminated refrigerant. This equipment must only be used
to recover contaminated refrigerant to prevent the spread to
other vehicles. As an alternative, contact an A/C repair facility
in your area with the proper equipment to perform the repair.
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Climate Control System - General Information - Discharging and Recovery
General Procedures
related to the use of refrigerants. Failure to follow this instruction may
CAUTIONS:
If a refrigerant recovery or recycling station is used, the following
general procedures should be observed in addition to the operating
instructions provided by the equipment manufacturers. Failure to follow
this instruction may result in personal injury.
The A/C Refrigerant Analyzer must be used before the recovery of
the customer to return to the repair facility that performed the last A/C
procedures and instructions. Failure to follow this instruction may result in
personal injury.
NOTE: Hoses should have shut off devices or check valves within 305mm
(12 in) of the hose end to minimize the introduction of non-condensable
gases (air) into the recovery station, as well as to minimize the amount of
refrigerant released when the hoses are disconnected.
NOTE: Follow the equipment manufacturers procedures and instructions.
Connect R-134a A/C refrigerant center hose(s) to the vehicle gauge ports
and R-134a A/C refrigerant center inlet fittings.
2. Turn on the power to R-134a A/C refrigerant center to start the recovery
process. Allow R-134a A/C refrigerant center to recover refrigerant from
the system until the station pressure goes into a vacuum. On some
equipment, the pump will be shut off automatically by a low-pressure
switch in the electrical system. On other units, it may be necessary to
manually turn off the pump.
3. Once R-134a A/C refrigerant center has recovered the vehicle A/C
system refrigerant, close R-134a A/C refrigerant center inlet valve (if
equipped). Then switch off the power supply.
4. Allow the vehicle A/C system to remain closed for about two minutes.
Observe the system vacuum level as shown on the gauge. If the
pressure does not rise, disconnect R-134a A/C refrigerant center
hose(s).
5. If the system pressure rises, repeat Steps 2-4 until the vacuum level
remains stable for two minutes.
6. Carry out the required operations, then evacuate and recharge the A/C
system. For additional information, refer to Evacuation and Charging.
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Climate Control System - General Information - Electronic Leak Detection
General Procedures
1. WARNING: Good ventilation is necessary in the area where A/C
leak testing is to be carried out. If the surrounding air is contaminated
with refrigerant gas, the leak detector will indicate this gas all the time.
Odors from other chemicals such as antifreeze, diesel fuel, disc brake
cleaner, or other cleaning solvents can cause the same problem. A fan,
even in a well ventilated area, is very helpful in removing small traces of
contamination from the air that might affect the leak detector. Failure to
Attach R-134a manifold gauge set to the service gauge port valves.
Leave both R-134a manifold gauge set valves closed.
Both gauges should indicate 413-551 kPa (60-80 psi) at 24C
(75F) with the engine off.
If little or no pressure is indicated, charge the refrigerant system.
For additional information, refer to Discharging and Recovery.
2. Use R134-a Automatic calibration halogen leak detector to leak test the
refrigerant system. Follow the instructions included with leak detector
for handling and operation techniques.
3. If a leak is found, reclaim the refrigerant. For additional information,
refer to Discharging and Recovery.
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Climate Control System - General Information - Inspection and Assembly
Requirements
General Procedures
1. NOTE: Any time a hose or component connection leak is observed, the
component and fitting must be separated, cleaned and a new O-ring and
connector should be lubricated.
O-ring seal surfaces must be free of dirt, lint, burrs and scratches. The
O-ring and connector should be lubricated.
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Climate Control System - General Information - Leak Detection
General Procedures
1. NOTE: On vehicles with R-134a Leak Trace Dye incorporated into the
A/C system. The exact location of leaks can be pinpointed by the bright
yellow-green glow of the tracer dye. Since more than one leak may exist,
always inspect each component. If it is necessary to add dye, use Dye
Injector. A/C systems require 7.39 ml (0.25 oz.) of Fluoro-Light/P
Fluorescent Tracer Dye 164-R3712.
NOTE: Some vehicles may have signs of refrigerant oil at the spring lock
couplers. This may be caused from the assembly process which applies to
the fittings before installation to aid in assembly. When a spring lock
coupler is suspected of leaking,always wipe the fitting clean and verify the
leak with R-134a Automatic Calibration Halogen Leak Detector.
Check for leaks using 120 Watt UV Spot Lamp.
2. Scan all components, fittings and lines of the A/C system.
3. After the leak is repaired, remove any traces of leak dye with a general
purpose oil solvent.
4. Verify the repair by operating the system for a short time and
inspecting with the UV lamp.
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Climate Control System - General Information - Refrigerant Oil Adding
General Procedures
1. A new replacement A/C compressor contains 150 ml (5 oz.) refrigerant
oil. If the amount of oil drained from the removed A/C compressor is
between 90 and 150 ml (3 to 5 oz.), pour the same amount plus 28 ml
(1 oz.) of clean oil into the new A/C compressor. If the amount of oil
drained from the old A/C compressor is greater than 150 ml (5 oz.), pour
only 150 ml (5 oz.) of clean refrigerant oil into the new A/C compressor.
If the amount of refrigerant oil drained from the old A/C compressor is
less than 90 ml (3 oz.), pour 90 ml (3 oz.) of clean refrigerant oil into
the new compressor.
When replacing components of the air conditioning refrigerant
system, add oil to the replacement components.
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Climate Control System - General Information - Refrigerant System Tests
General Procedures
related to the use of refrigerants. The A/C refrigerant analyzer must be
used before the recovery of any vehicle's A/C refrigerant. Failure to do so
puts shop bulk refrigerant at risk of contamination. If the vehicle A/C
refrigerant is contaminated, refer the customer to return to the repair
facility that carried out the last A/C repair. If the customer wishes to pay
the additional cost, use the A/C recovery equipment that is designated for
recovering contaminated A/C refrigerant. All contaminated A/C refrigerant
must be disposed of as hazardous waste. For all equipment, follow the
equipment manufacturers procedures and instructions. Failure to follow
NOTE: Jaguar Cars Ltd supports the efficient usage, recovery and
recycling of the refrigerant used in passenger car air conditioners. Jaguar
Cars Ltd recommends the use of UL-approved recovery/recycling device
such as R-134a A/C refrigerant center (which meets SAE Standard J 1991)
during any A/C system repair and recharge procedure which requires that
the system be evacuated.
Use R-134a A/C refrigerant centre to evacuate and recover the A/C
system.
Follow the equipment manufacture procedures and instructions for
use of equipment.
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Air Distribution and Filtering - Air Distribution and Filtering
1 Left-hand side register
2 Center register
3 Right-hand side register
4 Right-hand side front floor duct
5 Right-hand side rear floor duct
6 Left-hand side rear floor duct
7 Left-hand side front floor duct
The purpose of the air distribution system is to route air to the designated registers. This is accomplished when air enters the plenum
through the fresh/recirculated air inlet and is routed to the desired outlets by use of distribution doors. The incoming stream of fresh air is
passed through a pollen filter.
The air distribution system consists of the heater core, air conditioning (A/C) evaporator core, A/C blower motor and all of the distribution
doors. All of the air is mixed and distributed inside of the plenum chamber, dependi ng on the distribution door positions.
Air ducts route air to specified areas of the air distribution system. These areas are the floor ducts, side window registers, windshield
demister, instrument panel vents and instrument panel center registers.
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Air Distribution and Filtering - Air Distribution and Filtering
For additional information, refer toSection 412-00 Climate Control System - General Information
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Air Distribution and Filtering - Center Registers
Removal
1. Remove the instrument panel veneer trim.
2. Remove the center registers.
Remove the center register retaining screws.
Installation
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Air Distribution and Filtering - Driver Side Register
Removal
1. Remove the instrument panel veneer trim.
2. Remove the instrument panel surround.
Remove the instrument panel surround retaining screws.
3. Remove the driver side register.
Remove the driver side register retaining screws.
Installation
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Air Distribution and Filtering - Front Footwell Duct LH
Removal
1. Detach the footwell lamp.
2. Detach the floor register.
Remove the floor register retaining screws
3. Detach the front of the center consul side trim.
4. Remove the register.
Installation
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Air Distribution and Filtering - Front Footwell Duct RH
Removal
1. Detach the footwell lamp.
2. Detach the floor register.
Remove the floor register retaining screws.
3. Detach the front of the center consul side trim.
4. Remove the register.
Installation
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Air Distribution and Filtering - Passenger Side Register
Removal
1. WARNING: To avoid accidental deployment and possible personal
injury, the back up power supply must be depleted before repairing or
replacing any airbag supplemental restraint system (SRS) components. To
deplete the back up power supply energy, disconnect the battery ground
cable and wait for one minute. Failure to follow this instruction may result
in personal injury.
2. CAUTION: The passenger side air bag door is retained to the air
bag by a securing strap.
Detach the passenger side air bag door.
3. Remove the passenger side register.
Remove the passenger side register retaining screws.
Installation
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Air Distribution and Filtering - Pollen Filter
Removal
2. Remove the pollen filter.
Installation
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Heating and Ventilation -
Specification
In vehicle cross beam bonding WSKM2G379-A1
In vehicle cross beam solvent wipe WSKM14J251-A1
Evaporator core housing to in vehicle cross beam retaining bolts. 5 - 44
Blower motor housing to in vehicle cross beam retaining bolt. 7 - 62
In vehicle cross beam to vehicle body retaining bolts. 25 18 -
Evaporator core housing nut and washer assembly. 1 - 9
Pollen filter housing retaining nuts. 7 - 52
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Heating and Ventilation - Heating and Ventilation
The heating and defrosting system is a blended air system and consists of a heater core, a blower motor, distribution doors and an
evaporator core.
Air is directed through the heater core for heating and around for cooling, mixed and discharged through outlets in the plenum assembly to
the floor, instrument panel registers or defrost nozzles as required
The heating and defrosting system:
controls the vehicle air temperature and, during A/C operation, reduces the relative humidity of the air inside the vehicle.
delivers heated or cooled air to maintain the vehicle interior temperature and comfort level.
controls the A/C blower motor speed.
The blower motor draws outside air through the air inlet filter and duct during all system operations except for MAX A/C cooling (when
recirculated air is used).
1 Heater core
2 Evaporator core
3 Blower motor
Heater Core
The heater core consists of fins and tubes arranged to extract heat from the engine coolant and transfer it to air passing through the heater
core. Air passing through the heater core is then directed to the relevant register.
Blower Motor
The HVAC blower motor pulls air from the air inlet and forces it into the evaporator housing and plenum assembly which is attached to the
instrument panel where it is mixed and distributed.
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Heating and Ventilation - Heating and Ventilation
For additional information, refer to Section 412-00 Climate Control System - General Information.
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Heating and Ventilation - Blower Motor
Removal
1. Remove the blower motor lower cover.
3. Remove the blower motor.
Remove the blower motor retaining screws.
Installation
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Heating and Ventilation - Evaporator Core Housing
Removal
2. Recover the refrigerant. For additional information, refer to Section
412-00 Climate Control System - General Information.
4. Disconnect the drain tube from the heater core.
5. Disconnect the heater hose from the heater core.
8. Remove the refrigerant line retaining clip.
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9. Using a suitable tool disconnect the refrigerant line.
10. Remove the refrigerant line retaining clip.
11. Using a suitable tool disconnect the refrigerant line.
12. Remove the evaporator core housing lower securing nut.
13. Remove the instrument panel. For additional information, refer to
Section 501-12 Instrument Panel and Console.
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14. Remove the center register air duct.
1. On manual A/C only.
2. All vehicles.
17. Remove the glove box mounting frame.
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Remove the earth lead retaining bolt.
23. Using a suitable tool cut the bonding on the in vehicle cross beam.
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24. Detach the center of the in vehicle cross beam.
25. Remove the in vehicle cross beam retaining bolts.
26. Remove the in vehicle cross beam and the evaporator core housing.
Installation
1. NOTE: Remove the PU bonding from the in vehicle cross beam.
NOTE: Clean the in vehicle cross beam locator and the vehicle body
locating pegs with a solvent wipe, part number WSKM14J251-A1.
NOTE: Apply the PU bonding, part number WSKM2G379-A1 to the in
vehicle cross beam locating pegs.
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Heating and Ventilation - Heater Core
Removal
1. NOTE: If a leak is suspected, the heater core must be leak tested in the
vehicle before removal. For additional information, refer to Section 412-00
Climate Control System - General Information.
Drain the cooling system. For additional information, refer to Section
2. Disconnect the drain tube from the heater core.
6. Position the heater core air duct up.
1. Remove the heater core air duct retaining screw.
2. Position the heater core air duct up.
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7. Remove the heater core air duct housing.
1. Remove the heater core air duct housing retaining screws.
2. Remove the heater core air duct housing.
Release the retaining tabs.
Right-hand side shown, left-hand side similar.
8. Remove the heater core housing retaining clips.
9. Remove the heater core housing
Release the heater core housing retaining tabs.
10. Remove the seal.
11. Remove the heater core retaining screw.
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12. Remove the heater core.
Installation
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Heating and Ventilation - Evaporator Core Housing
Disassembly
1. Remove the evaporator core housing. For additional information, refer to
Evaporator Core Housing.
2. Detach the blower motor from the in vehicle cross beam..
3. Remove the evaporator core housing from the in vehicle cross beam.
4. Remove the heater core retaining clips.
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5. Release the heater core housing retaining tabs.
6. Remove the heater core housing.
7. Remove the rubber seal.
8. Remove the heater core retaining bolt.
9. Remove the heater core.
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10. Remove the blower motor.
Remove the blower motor retaining screws.
11. Remove the manual control blower motor resistor.
Remove the manual control blower motor resistor retaining screw.
13. Remove the evaporator core retaining screw.
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14. Remove the evaporator core upper housing.
15. Remove the evaporator core.
Assembly
1. To assemble, reverse the disassembly procedure.
2. Tighten to 7 Nm.
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3. Tighten to 5 Nm.
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Auxiliary Heating -
Electric booster heater retaining nuts 10 - 89
Heating element electrical connector retaining nuts 4 - 35
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Auxiliary Heating - Electric Booster Heater
Due to the high-efficiency of the diesel engine, there is insufficient waste-heat available to the heater core. An auxiliary electrical booster
heater is installed as standard. When the specified operating conditions are met, the heater is activated to raise the temperature of the
coolant before it enters the heater core.
The heater is located at the lower left-hand side of the bulkhead and is integral to the cooling system.
The heater comprimises of an aluminum housing into which three glow-plug elements are located. Each element has a heating capability of
300 Watts.
1 - Coolant inlet hose
2 - Coolant outlet hose
The powertrain control module (PCM) determines which (if any) of the elements within the auxiliary heater are activated depending on the
following:
cylinder head temperature (CHT)
air charge temperature (ACT)
load condition of the generator
The auxiliary heater will:
not activate should the ACT be greater than 5C
only be activated when the CHT is below 75C and the ACT is below 5C
be de-activated should the CHT rise above 75C
not activate if the generator saturation is above 90%
1 - PCM
2 - Relay 1
3 - Relay 2
4 - Heater
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5 - TMAP sensor
6 - CHT sensor
7 - Generator
Provided the temperature conditions are satisfied and depending on the load condition of the generator, the PCM will cause one of the
following to occur:
activation of relay 1
activation of relay 2
activation of both relays
no activation of either relay
The PCM software includes a calibrated map, which is used in conjunction with generator load to define the heater switching-points relative
to actual generator speed.
At all times during heater operation, the system is designed to allow as manyglow-pl ug elements as possible to be activated, without
causing the generator to become saturated.
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Auxiliary Heating - Fuel Fired Booster Heater
For markets that experience extremely low temperatures, a fuel fired booster heater is installed in place of the electrical booster heater.
The fuel fired booster heater only operates when the engine is running. The fuel fired booster heater is located at the lower left-hand side
of the bulkhead and is integral to the cooling system.
The fuel fired booster heater provides the following:
automatic operation
quickly boosts the engine up to it's optimum operating temperature range
reduces engine wear by keeping the engine at its optimum operating temperature
helps to create a warm and comfortable vehicle interior
provides greater heat levels for quicker defrosting of glass
compact design and engine compartment mounting.
Fuel Fired Booster Heater System
The system consists of a fuel fired booster heater unit and fuel pump.
The fuel fired booster heater takes its coolant feed from the engine exhaust gas recirculation (EGR) system.
The fuel fired booster heater fuel pump is located above the heater and connected to the engine fuel-return line. The pump delivers metered
quantities of fuel into the combustion chamber. A pressure-regulating valve is installed between the fuel intake and the pump to reduce the
fuel pressure down to below 0.2 bar.
The fuel fired booster heater incorporates an electronic control module, this unit controls the operation of the fuel fired booster heater.
1 - Fuel pump
2 - Regulating valve
3 - Fuel feed pipe
4 - Exhaust
5 - Air intake
7 - Coolant inlet pipe
8 - Coolant outlet pipe
Fuel Fired Booster Heater Unit Components
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1 - Combustion air fan
2 - Burner housing
3 - Electronic control module
4 - Heat exchanger
5 - Burner insert
6 - Exhaust
7 - Coolant inlet
8 - Glow plug / flame sensor
9 - Evaporator
10 - Fuel inlet
11 - Coolant outlet
12 - Air intake
Combustion Air Fan
The combustion air fan uses a permanent magnet motor with a fan wheel, which is driven by a pulse width modulated (PWM) voltage
supply.
The combustion air fan delivers and regulates the flow of air into the fuel fired booster heater to support combustion of the fuel supplied by
the fuel fired booster heater fuel pump. The combustion air fan is also used to purge and cool the fuel fired booster heater unit. A canister
type muffler in the air inlet supply line is used to reduce operating noise.
Burner Housing
The burner housing incorporates the burner insert connections for the coolant ports and exhaust pipe. Exhaust gases are directed to
atmosphere through a pipe and muffler.
Burner Insert
The burner insert incorporates the fuel combustion chamber, heat exchanger, evaporator and combined glow plug and flame sensor. Fuel
from the fuel fired booster heater pump is supplied to a venturi, where it enters the combustion chamber to mix with air from the
combustion air fan.
When commanded by the fuel fired booster heater electronic control module the glow plug supplies a temperature of approximately 1500 C
to provide the ignition source for the fuel/air mixture. The fuel fired booster heater electronic control module establishes combustion by
monitoring the flame sensor. It measures the heat from the flame by converting the resistance value of the glow plug into a voltage signal.
Heat Exchanger
The heat exchanger transfers the heat generated by the combustion process into the vehicles coolant.
Two sensors located in the heat exchanger provide the fuel fired booster heater electronic control module with temperature values for the
heat exchangers casing temperature and coolant temperature.
The values from the sensors are used for fuel fired booster heater system adaptation between full-load, part-load and stand-by.
Electronic Control Module
The electronic control module controls and monitors the combustion operation. The module is ventilated by a hose routed from the air
storage compartment of the burner.
Temperature Sensor
The temperature sensor located in the heat exchanger provides an electrical resistance signal to the electronic control module to indicate
the coolant temperature status.
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Overheat Protection
Overheat protection is controlled by a temperature resistor located in the heat exchanger. This protects against excessive operating
temperatures. Overheat protection responds at a coolant temperature in excess of 125 C and switches the fuel fired booster heater from
stand-by to OFF.
Fuel Pump
The fuel fired booster heater electronic control module outputs a PWM voltage signal to activate the pump. When the pump is de-energized
it provides a positive shut-off of the fuel supply.
Fuel Fired Heater Operation
The powertrain control module (PCM) determines the ignition of the heater by a solid-state relay, which switches battery voltage to the
heater control module as appropriate.
An electronic control module incorporated into the fuel fired booster heater controls the operation of the fuel fired booster heater system.
The module monitors the ambient air temperature sensor and cylinder head temperature sensor. Two further sensors located in the heat
exchanger provide the module with an input of the heat exchangers casing temperature and coolant temperature.
Ambient air temperature sensor
The values from the sensors are used for fuel fired booster heater system adaptation between full-load, part-load and stand-by.
To minimize drain on the battery, the fuel fired booster heater switches from full-load to part-load, on the coolant reaching 87 C. The fuel
fired booster heater will not operate if the battery voltage is below 10.2 volts.
Part-load operation offers the following benefits:
Low noise output
Low power operation
Low fuel consumption
Switch On / Starting
During engine startup the fuel fired booster heater goes into stand-by. If the coolant circuit temperature is below 87 C and the ambient
temperature is below 5 C the fuel fired booster heater starting sequence commences.
The glow plug is activated and after a delay the fuel pump commences operation and the fuel is ignited.
The combustion air fan operation is then initiated. The combustion air fan speed is increased in two ramps to nearly full-load operation.
After a stabilization phase the combustion air fan speed is again increased to full-load and the glow plug is deactivated.
After these events have been completed the fuel fired booster heater enters Automatic Heating Operation.
Automatic Heating Operation
During automatic heating operation the glow plug functions as the flame sensor to monitor the flame condition. In the event of a no flame
condition, a restart is automatically initiated.
If the no flame condition persists, fuel delivery is stopped and the fuel fired booster heater enters an error lockout with a timed shutdown
of the combustion air fan to cool the fuel fired booster heater unit.
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Auxiliary Heating - Auxiliary Heater
There are two types of auxiliary heater, the electric booster heater, which is fitted as standard, and the fuel fired booster heater, which
is an option. For additional information on the fuel fired booster heater.
REFER to: Fuel Fired Booster Heater (412-02B Auxiliary Heating, Diagnosis and Testing).
The electric booster heater functions in the following way:
Automatic activation occurs if:
The ambient temperature is below five degrees C (41 degrees F)
The cylinder head temperature is below 71 degrees C (160 degrees F)
The engine is running
The generator is charging
The coolant is heated by three glowplugs mounted in their own housing through which the coolant passes as it circulates.
Depending on the conditions detected, the control module will activate the appropriate number of glowplugs to achieve the desired level of
heating.
The system will deactivate once the cylinder head temperature reaches 85 degrees C (185 degrees F), but will automatically reactivate if
the temperature drops below 71 degrees C (160 degrees F) for whatever reason.
Visual inspection chart
Coolant level
Heater unit and connections
Fuses
Relays
Harnesses
Connectors
ECM
Cylinder head temperature (CHT) sensor
Charging system
4. If the cause is not visually evident, verify the symptom and refer to the diagnostic trouble code (DTC) index. 4.
Diagnostic Trouble Code (DTC) index
DTC Description Possible causes Action
P0380 Auxiliary heater
circuit(s)
Auxiliary heater relay circuit
Auxiliary heater control circuit
For auxiliary heater circuit tests. GO to Pinpoint Test A.
P1543 Auxiliary heater 1
circuit
Auxiliary heater 1 relay circuit
Auxiliary heater 1 control circuit
For auxiliary heater 1 circuit tests. GO to Pinpoint Test B.
P1544 Auxiliary heater 2
circuit
Auxiliary heater 2 relay circuit
Auxiliary heater 2 control circuit
For auxiliary heater 2 circuit tests. GO to Pinpoint Test C.
B2449Auxiliary heater short
circuit
Auxiliary heater circuit: short
circuit to ground
For auxiliary heater circuit tests. GO to Pinpoint Test A. GO to
Pinpoint Test B. GO to Pinpoint Test C.
B2450Auxiliary heater
interrupted
Auxiliary heater circuit: open
circuit
For auxiliary heater circuit tests. GO to Pinpoint Test A. GO to
Pinpoint Test B. GO to Pinpoint Test C.
Pinpoint Tests
concerns.
PINPOINT TEST A : AUXILIARY HEATER RELAY 1
A1: CHECK THE AUXILIARY HEATER RELAY CIRCUIT FOR SHORT CIRCUIT TO POWER
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1
2
3
1
2
Auxiliary heater 1 fuse connector
Circuit Pin
Auxiliary heater relay 1 output 01
Auxiliary heater 1 control 02
Auxiliary heater 1 connector
Circuit Pin
Auxiliary heater relay 1 control 01
Junction box connector
Circuit Pin
Engine control module connector
Circuit Pin
Key off.
Auxiliary heater fuse removed.
Auxiliary heater fuse connector Vehicle battery
Auxiliary heater 1 control, pin 02 Positive post
Yes
GO to A3.
No
GO to A2.
A2: CHECK WHETHER THE SHORT CIRCUIT TO POWER IS IN THE HARNESS OR THE AUXILIARY HEATER UNIT
Auxiliary heater 1 connector disconnected.
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1
2
1
2
3
4
1
1
2
3
4
1
1
2
3
4
5
6
7
1
Yes
SUSPECT:- Auxiliary heater 1 assembly
No
diagrams.
A3: CHECK THE AUXILIARY HEATER 1 CIRCUIT CONTINUITY
Auxiliary heater 1 connector disconnected.
Auxiliary heater 1 control, pin 02 Negative post
Is the resistance between 0.5 ohms and 10 ohms?
Yes
GO to A6.
No
GO to A4.
A4: CHECK THE AUXILIARY HEATER CONTROL CIRCUIT FOR SHORT CIRCUIT TO GROUND
Key off.
Auxiliary heater connector disconnected.
Key on, engine off.
Auxiliary heater 1 fuse connector Vehicle battery
Yes
GO to A5.
No
diagrams.
A5: CHECK THE AUXILIARY HEATER 1 CIRCUIT(S) FOR OPEN CIRCUIT IN THE HARNESS
Auxiliary heater 1 fuse
connector
Auxiliary heater 1 assembly connector, harness
side
Auxiliary heater 1 control, pin 02 Auxiliary heater 1 control, pin 01
Yes
SUSPECT:- Auxiliary heater 1 assembly- Auxiliary heater 1 ground
No
diagrams.
A6: CHECK THE AUXILIARY HEATER 1 CONTROL LINE 'ON' STATE
Access the ECM and control the auxiliary heater 1 relay PID.
Activate the auxiliary heater 1.
Auxiliary heater relay 1 output, pin 01 Negative post
Is the voltage between 9 volts and 15 volts?
Yes
GO to A10.
No
GO to A7.
A7: CHECK THE AUXILIARY HEATER 1 CONTROL LINE FOR SHORT TO GROUND
Yes
GO to A8.
No
diagrams.
A8: CHECK THE ECM CONTROL LINE 'ON' STATE
Key off.
Junction box connector disconnected.
Key on, engine off.
Junction box harness connector, component side Vehicle battery
Auxiliary heater relay 1 control, Pin 38 Negative post
Yes
SUSPECT:- Short circuit to power in the harness between the junction box
harness and the fuse box connectors- Open circuit in the harness between the
junction box harness and the fuse box connectors- Fusebox assembly
No
GO to A9.
A9: CHECK THE ECM CONTROL LINE FOR SHORT CIRCUIT TO POWER
Junction box harness connector, component side Vehicle battery
Auxiliary heater relay 1 control, Pin 38 Positive post
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1
2
3
4
1
2
3
4
1
1
2
3
4
1
2
3
Yes
GO to A14.
No
GO to A13.
A10: CHECK THE AUXILIARY HEATER 1 CONTROL LINE 'OFF' STATE
NOTE: It is assumed the ignition is still on from the previous step, if not, please make sure the ignition is returned to the 'key on engine
off' state.
De-activate the auxiliary heater 1.
Auxiliary heater relay 1 output, pin 01 Positive post
Yes
the circuit, suspect the following component(s):- Fuse- ECM connector- Fusebox
assembly- ECM
No
GO to A11.
A11: ELIMINATE THE ECM FROM THE POSSIBLE CAUSES
Key off.
Key on, engine off.
Yes
SUSPECT:- ECM
No
GO to A12.
A12: CHECK THE ECM CONTROL LINE FOR SHORT CIRCUIT TO GROUND
ECM connector, harness side Vehicle battery
Engine coolant heater relay 1 control, pin 61 Negative post
Yes
SUSPECT:- Fusebox assembly
No
diagrams.
A13: CHECK WHETHER THE SHORT CIRCUIT TO POWER IS IN THE ECM HARNESS OR THE MODULE
Key off.
Key on, engine off.
Junction box connector, harness side Vehicle battery
Engine coolant heater relay 1 control, pin 38 Positive post
Yes
SUSPECT:- ECM
No
diagrams.
A14: CHECK THE ECM CONTROL LINE FOR CONTINUITY
Key off.
Junction box connector, harness side ECM connector, harness side
Auxiliary heater relay 1 control, pin 38 Auxiliary heater relay 1 control, pin 61
Yes
SUSPECT:- ECM connector- ECM
No
REPAIR the open circuit, For additional information, refer to the wiring
diagrams.
PINPOINT TEST B : AUXILIARY HEATER RELAY 2
B1: CHECK THE AUXILIARY HEATER 2 CONTROL LINE 'ON' STATE
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1
2
3
4
5
6
7
1
2
3
4
1
Auxiliary heater connector
Circuit Pins
Auxiliary heater control 03/05
Auxiliary heater relay 2 connector
Circuit Pin
Ignition supply 01
Engine control module connector
Circuit Pin
Key off.
Key on, engine off.
Access the ECM and control the auxiliary heater relay 2 PID.
Auxiliary heater connector, harness side Vehicle battery
Auxiliary heater 2 control, pins 03 and 05 Negative post
Yes
GO to B7.
No
GO to B2.
B2: CHECK THE AUXILIARY HEATER 2 CONTROL LINE FOR SHORT CIRCUIT TO GROUND
Key off.
Auxiliary heater 2 relay connector disconnected.
Key on, engine off.
Auxiliary heater 2 control, pins 03 and 05 Negative post
Yes
GO to B3.
No
diagrams.
B3: CHECK THE AUXILIARY HEATER 2 CONTROL LINE FOR CONTINUITY
Auxiliary heater connector, harness
side
Auxiliary heater 2 relay connector,
harness side
Auxiliary heater 2 control, pins 03 and
05
Auxiliary heater 2 control, pin 05
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Yes
GO to B4.
No
diagrams.
B4: CHECK THE SUPPLIES TO THE AUXILIARY HEATER 2 RELAY
Key off.
Auxiliary heater 2 relay connector, harness side Vehicle battery
Permanent 12 volt supply, pin 03 Negative post
Key on, engine off.
Ignition supply, pin 01 Negative post
Are the voltages between 9 volts and 15 volts?
Yes
GO to B5.
No
NO supply to the auxiliary heater 2 circuit. For additional information, refer to
the wiring diagrams.
B5: CHECK THE ECM CONTROL LINE 'ON' STATE
Access the ECM and control the auxiliary heater relay 2 PID.
Auxiliary heater relay 2 control, pin 02 Negative post
Yes
SUSPECT:- Auxiliary heater 2 relay connector- Auxiliary heater 2 relay
No
GO to B6.
B6: CHECK THE ECM CONTROL LINE FOR SHORT CIRCUIT TO POWER
Auxiliary heater relay 2 control, pin 02 Positive post
Yes
GO to B12.
No
GO to B11.
B7: CHECK THE AUXILIARY HEATER 2 CONTROL LINE 'OFF' STATE
NOTE: It is assumed the ignition is still on from the previous step, if not, please make sure the ignition is returned to the 'key on engine
off' state.
Access the ECM and control the auxiliary heater heater relay 2 PID.
De-activate the auxiliary heater 2.
Auxiliary heater 2 control, pins 03 and 05 Positive post
Yes
the circuit, suspect the following component(s):- Auxiliary heater ground circuit-
Auxiliary heater
No
GO to B8.
B8: CHECK THE AUXILIARY HEATER 2 CIRCUIT FOR SHORT CIRCUIT TO POWER IN THE HARNESS
Key off.
Auxiliary heater relay 2 connector disconnected.
Key on, engine off.
Auxiliary heater relay 2 connector, harness side Vehicle battery
Yes
GO to B9.
No
diagrams.
B9: CHECK THE ECM CONTROL LINE FOR SHORT CIRCUIT TO GROUND
Yes
SUSPECT:- Auxiliary heater relay 2
No
GO to B10.
B10: CHECK WHETHER THE SHORT CIRCUIT TO GROUND IS IN THE ECM HARNESS OR THE MODULE
Key off.
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2
3
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2
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Key on, engine off.
Yes
SUSPECT:- ECM
No
diagrams.
B11: CHECK WHETHER THE SHORT CIRCUIT TO POWER IS IN THE ECM HARNESS OR THE MODULE
Key off.
Key on, engine off.
Yes
SUSPECT:- ECM
No
diagrams.
B12: CHECK THE ECM CONTROL LINE FOR CONTINUITY
Key off.
Auxiliary heater relay 2 connector, harness side ECM connector, harness side
Auxiliary heater 2 control, pin 02 Auxiliary heater 2 control, pin 62
Yes
SUSPECT:- ECM connector- ECM
No
diagrams.
PINPOINT TEST C : AUXILIARY HEATER CIRCUIT TESTS
C1: CHECK THE AUXILIARY HEATER CIRCUITS FOR SHORT CIRCUIT TO POWER
Auxiliary heater fuse connector
Circuit Pin
Auxiliary heater relay output 01
Auxiliary heater control 02
Circuit Pin
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Auxiliary heater connector
Circuit Pin
Auxiliary heater relay connector
Circuit Pin
Auxiliary heater relay control 02
ECM relay controlled 12 volt supply 01
Auxiliary heater relay output 05
Key off.
Auxiliary heater fuse removed.
Key on, engine off.
Auxiliary heater fuse connector, harness side Vehicle battery
Auxiliary heater control, pin 02 Positive post
Yes
GO to C3.
No
GO to C2.
C2: CHECK WHETHER THE SHORT CIRCUIT TO POWER IS IN THE HARNESS OR THE AUXILIARY HEATER
Auxiliary heater control, pin 02 Positive post
Yes
SUSPECT:- Auxiliary heater assembly
No
diagrams.
C3: CHECK THE AUXILIARY HEATER CIRCUIT CONTINUITY
Auxiliary heater control, pin 02 Negative post
Is the resistance between 0.5 ohms and 10 ohms?
Yes
GO to C6.
No
GO to C4.
C4: CHECK THE AUXILIARY HEATER CIRCUIT FOR SHORT CIRCUIT TO GROUND
Auxiliary heater control, pin 02 Negative post
Yes
GO to C5.
No
diagrams.
C5: CHECK THE AUXILIARY HEATER CIRCUIT(S) FOR OPEN CIRCUIT IN THE HARNESS
Auxiliary heater connector, harness
side
Auxiliary heater fuse connector, harness
side
Auxiliary heater control, pin 01 Auxiliary heater control, pin 02
Yes
SUSPECT:- Auxiliary heater assembly- Auxiliary heater assembly ground
No
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diagrams.
C6: CHECK THE AUXILIARY HEATER CONTROL LINE 'ON' STATE
Access the ECM and control the auxiliary heater control PID.
Activate the auxiliary heater.
Glow plug relay output, pin 01 Negative post
Yes
GO to C12.
No
GO to C7.
C7: CHECK THE AUXILIARY HEATER CONTROL LINE FOR SHORT CIRCUIT TO GROUND
Key off.
Auxiliary heater relay connector disconnected.
Key on, engine off.
Auxiliary heater relay output, pin 01 Negative post
Yes
GO to C8.
No
INSTALL a new front power distribution box.
C8: CHECK THE AUXILIARY HEATER CONTROL LINE FOR CONTINUITY
Auxiliary heater fuse connector,
harness side
Auxiliary heater relay connector,
harness side
Auxiliary heater relay output, pin 01 Auxiliary heater relay output, pin 05
Yes
GO to C9.
No
diagrams.
C9: CHECK THE SUPPLIES TO THE AUXILIARY HEATER RELAY
Auxiliary heater relay connector, harness side Vehicle battery
ECM relay controlled 12 volt supply, pin 01 Negative post
Permanent 12 volt supply, pin 03 Negative post
Are the voltages between 9 volts and 15 volts?
Yes
GO to C10.
No
REPAIR the supply to the auxiliary heater. For additional information, refer to
the wiring diagrams.
C10: CHECK THE ECM CONTROL LINE 'ON' STATE
Access the ECM and control the auxiliary heater PID.
Activate the auxiliary heater.
Auxiliary heater relay control, pin 02 Negative post
Yes
SUSPECT:- Auxiliary heater connector- Auxiliary heater assembly
No
GO to C11.
C11: CHECK THE ECM CONTROL LINE FOR SHORT CIRCUIT TO POWER
Yes
GO to C17.
No
GO to C16.
C12: CHECK THE AUXILIARY HEATER CONTROL LINE 'OFF' STATE
Access the ECM and control the auxiliary heater PID.
De-activate the auxiliary heater.
Auxiliary heater relay output, pin 01 Positive post
Yes
the circuit, suspect the following component(s):- Auxiliary heater fuse
connector- Auxiliary heater fuse
No
GO to C13.
C13: CHECK THE AUXILIARY HEATER CIRCUIT FOR SHORT CIRCUIT TO POWER IN THE HARNESS
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Key off.
Auxiliary heater relay connector disconnected.
Key on, engine off.
Auxiliary heater relay output, pin 01 Positive post
Yes
GO to C14.
No
INSTALL a new front power distribution box.
C14: CHECK THE ECM CONTROL LINE FOR SHORT CIRCUIT TO GROUND
Yes
SUSPECT:- Auxiliary heater relay
No
GO to C15.
C15: CHECK WHETHER THE SHORT CIRCUIT TO GROUND IS IN THE ECM HARNESS OR THE MODULE
Key off.
Key on, engine off.
Yes
SUSPECT:- ECM
No
diagrams.
C16: CHECK WHETHER THE SHORT CIRCUIT TO POWER IS IN THE ECM HARNESS OR THE MODULE
Key off.
Key on, engine off.
Auxiliary heater relay control, pin 02 Positive post
Yes
SUSPECT:- ECM
No
diagrams.
C17: CHECK THE ECM CONTROL LINE FOR CONTINUITY
Key off.
Auxiliary heater relay connector, harness side ECM connector, harness side
Auxiliary heater relay control, pin 02 Auxiliary heater control, pin 20
Yes
SUSPECT:- ECM- ECM connector
No
diagrams.
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The fuel fired booster heater is available as an option in place of the electric version, and is likely to be more common in extreme climates.
The system performs the same function as the electric booster heater, and functions in the following way:
Automatic activation occurs if:
The ambient temperature is below five degrees C (41 degrees F)
The coolant temperature is below 75 degrees C (167 degrees F)
The engine is running
The generator is charging
When these operating conditions are detected by the control module, the glow plug preheats the heater chamber and the fuel fired heater
pump supplies fuel.
The fuel is ignited and the heater continues to operate until:
The system deactivates automatically when the coolant temperature reaches 85 degrees C (185 degrees F), or when a malfunction is
detected.
The system will shut down if:
There is no ignition for the fuel injected by the fuel fired heater pump within 90 seconds
The flame is extinguished during operation and a new ignition attempt fails
The internal sensor indicates an overheat condition
The operating voltage falls below 9 volts or above 15 volts
A circuit fault is detected
The air flow is blocked
Fuel supply
Coolant level
Pipework
Heater unit for damage, etc
Blockages/Restrictions to the air flow
Fuses
Connectors
Harness
Control module
Charging system
Fuel fired heater pump
4. If the cause is not visually evident, verify the symptom and refer to the symptom chart. 4.
Diagnostic Trouble Code (DTC) index
DTC Description Possible causes Action
P1937Fuel fired heater control
circuit
Fuel fired heater circuit(s): open circuit
Fuel fired heater circuit(s): short circuit to
power
Fuel fired heater circuit(s): short circuit to
ground
For fuel fired heater circuit tests, GO to Pinpoint
Test A.
Pinpoint Tests
concerns.
PINPOINT TEST A : FUEL FIRED HEATER CONTROL CIRCUIT
A1: CHECK THE FUEL FIRED HEATER CONTROL RELAY SUPPLY
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Fuel fired heater module connector
Circuit Pin
Fuel fired heater module ground 02
Fuel fired heater module ignition supply 04
Fuel fired heater module power 01
Fuel fired heater module signal 05
Fuel fired heater module relay connector
Circuit Pin
Fuel fired heater module signal 05
Fuel fired heater module relay signal 01
Fuel fired heater module relay power 03
Engine Control Module (ECM) connector
Circuit Pin
Fuel fired heater module relay signal 80
Fuel fired heater relay connector disconnected.
Key on, engine off.
Fuel fired heater relay connector, harness side Vehicle battery
Fuel fired heater module relay power, pin 03 Negative post
Yes
GO to A2.
No
NO supply to the fuel fired heater module relay. REPAIR the circuit as
necessary. For additional information, refer to the wiring diagrams.
A2: CHECK THE CONTROL LINE FOR SHORT CIRCUIT TO GROUND
Fuel fired heater module relay signal, pin 01 Negative post
Is the resistance greater than 100 Kohms?
Yes
GO to A4.
No
GO to A3.
A3: CHECK WHETHER THE SHORT CIRCUIT TO GROUND IS IN THE FUEL FIRED HEATER MODULE RELAY HARNESS OR CONTROL
MODULE
Key off.
Key on, engine off.
Fuel fired heater module relay signal, pin 01 Negative post
Yes
SUSPECT:- ECM
No
diagrams.
A4: CHECK THE CONTROL LINE FOR SHORT CIRCUIT TO POWER
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Fuel fired heater module relay signal, pin 01 Positive post
Yes
GO to A6.
No
GO to A5.
A5: CHECK WHETHER THE SHORT CIRCUIT TO POWER IS IN THE FUEL FIRED HEATER MODULE RELAY HARNESS OR CONTROL
MODULE
Key off.
Key on, engine off.
Fuel fired heater module relay signal, pin 01 Positive post
Yes
SUSPECT:- ECM
No
diagrams.
A6: CHECK THE FUEL FIRED HEATER MODULE SIGNAL LINE FOR SHORT CIRCUIT TO GROUND
Fuel fired heater module signal, pin 05 Negative post
Yes
GO to A8.
No
GO to A7.
A7: CHECK WHETHER THE SHORT CIRCUIT TO GROUND IS IN THE HARNESS OR THE FUEL FIRED HEATER ASSEMBLY
Key off.
Fuel fired heater assembly connector disconnected.
Key on, engine off.
Yes
INSTALL a new fuel fired heater assembly.
No
diagrams.
A8: CHECK THE FUEL FIRED HEATER MODULE SIGNAL LINE FOR SHORT CIRCUIT TO POWER
Yes
GO to A10.
No
GO to A9.
A9: CHECK WHETHER THE SHORT CIRCUIT TO POWER IS IN THE HARNESS OR THE FUEL FIRED HEATER ASSEMBLY
Key off.
Key on, engine off.
Fuel fired heater module signal, pin 05 Positive post
Yes
INSTALL a new fuel fired heater assembly.
No
diagrams.
A10: CHECK THE FUEL FIRED HEATER SIGNAL LINE FOR OPEN CIRCUIT
Key off.
Key on, engine off.
Fuel fired heater relay connector, harness
side
Fuel fired heater connector, harness
side
Fuel fired heater module signal, pin 05 Fuel fired heater module signal, pin 05
Yes
GO to A11.
No
diagrams.
A11: CHECK THE POWER TO THE FUEL FIRED HEATER MODULE
Fuel fired heater connector, harness side Vehicle battery
Fuel fired heater module power, pin 01 Negative post
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Yes
GO to A12.
No
NO supply to the fuel fired heater module circuit. REPAIR the circuit as
A12: CHECK THE IGNITION SUPPLY TO THE FUEL FIRED HEATER MODULE
Key on, engine off.
Fuel fired heater module ignition supply, pin 04 Negative post
Yes
GO to A13.
No
NO ignition supply to the fuel fired heater module circuit. REPAIR the circuit as
A13: CHECK THE FUEL FIRED HEATER MODULE GROUND CIRCUIT
Fuel fired heater module ground, pin 02 Negative post
Yes
GO to A14.
No
diagrams.
A14: CHECK THE CONTROL LINE FOR CONTINUITY
Fuel fired heater relay connector,
harness side ECM connector, harness side
Fuel fired heater module relay signal, pin 01 Fuel fired heater module relay signal,
pin 80
Yes
the circuit, suspect the following component(s):- Fuel fired heater relay- Fuel
fired heater assembly- ECM
No
diagrams.
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Auxiliary Heating - Electric Booster Heater
Removal
4. NOTE: Clamp the hoses to minimize coolant loss.
Disconnect the coolant hoses.
5. Remove the electric booster heater.
Installation
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Tighten to 10 Nm.
2. Tighten to 4 Nm.
3. Check and top up the coolant if necessary.
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Removal
2. Disconnect the fuel fired booster heater electrical connector.
3. Disconnect the fuel fired booster heater fuel line.
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8. Remove the fuel fired booster heater.
Installation
1. Install the fuel fired booster heater.
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2. Install the retaining bolts.
Remove the hose clamp.
6. Connect the fuel fired booster heater fuel line.
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7. Connect the fuel fired booster heater electrical connector.
9. Check and top up the coolant if necessary.
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Air Conditioning -
Air conditioning (A/C) clutch retaining nut 26 19 -
A/C compressor retaining bolts 25 18 -
A/C compressor manifold and tube retaining bolt 20 15 -
A/C condenser core retaining bolts 7 - 62
Item Specification
A/C clutch air gap 0.35 mm 0.75 mm (0.014 in 0.03 in)
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Air Conditioning - Air Conditioning
The air conditioning (A/C) system is a clutch cycling, fixed orifice tube type.
The A/C compressor is driven by the engine. The A/C compressor primes the gaseous refrigerant out of the suction accumulator and
compresses it. The refrigerant heats up and is passed to the condenser core under hi gh pressure.
At this point heat is drawn from the refrigerant by the air being forced past the cooling fins. Because of this heat loss, the refrigerant
liquefies and leaves the condenser core.
An evaporator core orifice, which separates the refrigerant at high pressure from that at low pressure, is located between the condenser
core and the evaporator core. This evaporator core orifice slows down the flow of the refrigerant from the A/C compressor, so that the
pressure builds up in the condenser core.
After passing through the evaporator core orifice the liquid refrigerant expands in the circuit to the evaporator core. In the evaporator core
the liquid refrigerant converts back into the gaseous state and this causes heat to be extracted from the air coming into the vehicle. The air
therefore cools down and the moisture it contained is given up at the evaporator core. The refrigerant enters the suction accumulator and is
primed up again by the A/C compressor.
The system is protected by the pressure transducer. The pressure transducer is used to control over pressure in the high side of the A/C
system.
A/C Compressor and Clutch Assembly
NOTE: Internal A/C compressor components are not serviced separately. The A/C scroll compressor is serviced only as an assembly.
The compressor has a variable capacity via an internal valve, which can by-pass volume through the compressor when required. Compressor
output varies from 100% to 30% depending on refrigerant demand, the variation being governed by the internal valve within the compressor
housing. The compressor has protection in the form of a pressure relief valve and a sensing element for over temperature conditions.
1 A/C clutch field coil
2 Field coil snap ring
3 A/C clutch pulley
4 Pulley snap ring
5 A/C clutch hub spacer
6 A/C clutch
7 A/C clutch nut
The magnetic A/C clutch has the following characteristics:
It drives the compressor shaft.
When battery positive voltage is applied to the A/C clutch field coil, the clutch di sc and hub assembly is drawn toward the A/C clutch
pulley.
The magnetic force locks the clutch disc and hub assembly and the A/C clutch pulley together as one unit, causing the compressor
shaft to rotate.
When battery positive voltage is removed from the A/C clutch field coil, springs in the clutch disc and hub assembly move the clutch
disc away from the A/C clutch pulley.
A/C Condenser Core
The A/C condenser core has the following characteristics:
It is an aluminum fin and tube design heat exchanger located in front of the vehicle radiator.
It cools compressed refrigerant gas by allowing air to pass over fins and tubes to extract heat and by condensing gas to liquid
refrigerant as it is cooled.
A/C Evaporator Core
The A/C evaporator core is mounted within the passenger compartment and is situated with the heater core in a single housing.
Suction/Accumulator
The suction/accumulator is mounted under the right-hand front wheel arch liner.
The suction/accumulator is connected to the low pressure side of the A/C system and is used to make sure only refrigerant gas is passed to
the compressor and not liquid.
The suction/accumulator also removes moisture from the refrigerant.
A/C Pressure transducer
The pressure transducer is used to control over pressure in the high side of the A/C system.
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Fixed orifice tube
The fixed orifice tube system allows the compressed liquid to expand, by metering the liquid into the low pressure area of the evaporator.
The low pressure being created by the restriction of the fixed orifice tube and the suction of the scroll type compressor.
The liquid begins to change state by transferring from a high pressure liquid into a low pressure gas immediately it leaves the fixed orifice
tube.
Service Gauge Port Valves
The service gauge port valves are located on the right-hand side at the rear of the engine bay.
The fitting is an integral part of the refrigerant line or component.
Special couplings are necessary for both the high side and low side service gauge ports.
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Air Conditioning - Air Conditioning
For additional information refer toSection 412-00 Climate Control System - General Information.
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Air Conditioning - Air Conditioning (A/C) Compressor2.0L NA V6 - AJV6/2.5L NA V6 -
Removal
1. Reclaim the refrigerant. For additional information, refer toSection
1. Using the special tool, rotate the belt tensioner counter
clockwise.
2. Detach the accessory drivebelt
5. NOTE: Seal the tube and the compressor with plugs
Detach the compressor supply and return tubes.
6. Remove and discard the compressor O-rings.
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7. Remove the compressor.
Installation
NOTE: Coat the refrigerant line O-ring seals in clean refrigerant oil prior
to installation.
NOTE: 5oz of oil are contained in the new compressor. The air
conditioning system requires a total of 7oz of oil.
Tighten to 25 Nm.
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Air Conditioning - Air Conditioning (A/C) Compressor2.0L Duratorq-TDCi/2.2L
Special Tool(s)
303-676
Removal
3. Loosen the A/C compressor supply and return tubes retaining bolt.
5. Detach the engine wiring harness from the retaining bracket.
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7. NOTE: Road wheel shown removed for clarity.
Remove the right-hand wheel arch liner access panels.
9. Detach the exhaust flexible pipe support isolator.
10. CAUTION: Make sure that the exhaust flexible pipe is positioned
below the diesel partciculate filter (DPF) flange. Failure to follow this
instruction may result in damage to exhaust flexible pipe.
Release the exhaust flexible pipe from the diesel particulate filter (DPF).
Remove the exhaust flexible pipe retaining nuts.
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11. CAUTION: Care must be taken to avoid damaging components
when positioning the block.
Displace the engine approximately 40mm rearwards.
Remove the roll restrictor rear retaining bolt.
With assistance displace the engine and support in an appropriate
position using a suitable block.
12. NOTE: Seal the tube and the suction accumulator with plugs.
Detach the suction accumulator pipe.
Install blanking plugs to the exposed ports.
13. NOTE: Remove and discard the O-ring seals if the old A/C compressor
is to be refitted.
Install blanking plugs to the exposed ports.
Displace the A/C tubes to a position above the A/C compressor.
14. Remove the A/C compressor.
Installation
1. Add refrigerant oil to the new A/C compressor.
For additional information, refer to: Refrigerant Oil Adding (412-00
Climate Control System - General Information, General Procedures).
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2. NOTE: If installing the old A/C compressor, install new O-ring seals.
NOTE: If installing a new A/C compressor, make sure that new O-ring
seals are already installed.
NOTE: Coat the A/C compressor O-ring seals in clean refrigerant oil prior
to installation.
Tighten to 25 Nm.
With assistance remove the engine support block.
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Air Conditioning - Air Conditioning (A/C) Pressure Transducer
Removal
1. Remove the front wheel and tire. For additional information, refer to
Section 204-04 Wheels and Tires.
2. Detach the wheel arch liner.
4. Remove the pressure transducer.
Installation
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Air Conditioning - Clutch and Clutch Field Coil2.0L NA V6 - AJV6/2.5L NA V6 -
Special Tool(s)
Pulley Replacer
412-109
Wrench Strap-Universal
303-D055
Crankshaft Damper Remover
303-D121
Removal
1. Remove the air conditioning (A/C) compressor.
For additional information, refer to: Air Conditioning (A/C) Compressor -
2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27 (412-03 Air
Conditioning, Removal and Installation).
2. Using the special tool, loosen the A/C clutch retaining nut.
3. Remove the A/C clutch.
Remove the A/C clutch retaining nut.
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4. Remove the A/C clutch shim.
5. Remove the A/C clutch pulley circlip.
6. CAUTION: Do not use air tools. Failure to follow this instruction
may result in damage to the component.
Using the special tool, remove the A/C clutch pulley.
7. Remove the A/C sensor retaining plate.
8. Detach the A/C sensor.
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9. Remove the A/C clutch and clutch field coil circlip.
10. Remove the A/C clutch and clutch field coil.
Installation
1. Install the A/C clutch and clutch field coil.
2. CAUTION: Make sure the circlip is installed and seated correctly.
Install the A/C clutch and clutch field coil circlip.
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3. Attach the A/C temperature sensor.
4. Install the A/C temperature sensor retaining plate.
Tighten to 6 Nm.
5. NOTE: The A/C clutch bearing and pulley is a slip fit on the compressor.
If correctly aligned it should slip on easily. If difficulty is experienced on
installation, use the special tool and gently tap the A/C clutch pulley.
Using the special tool, install the A/C clutch pulley.
6. CAUTION: Make sure the circlip is installed and seated correctly.
Install the A/C clutch pulley circlip.
7. Install the A/C clutch shim.
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8. Install the A/C clutch.
Install the A/C clutch retaining nut.
9. Using the special tool, tighten the A/C clutch retaining nut.
Tighten to 26 Nm.
10. Measure and adjust the A/C clutch air gap by removing or installing
A/C clutch shims.
A/C clutch air gap to be set between 0.35 mm (0.014 in) and 0.75
mm (0.03 in).
11. Install the A/C compressor.
For additional information, refer to: Air Conditioning (A/C) Compressor -
2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27 (412-03 Air
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Air Conditioning - Condenser Core
Removal
1. Reclaim the refrigerant. For additional information, refer to Section
2. Remove the front bumper cover. For additional information, refer to
Section 501-19 Bumpers.
3. NOTE: Seal the tube and the condenser with plugs
Detach the air conditioning tube.
4. NOTE: Seal the tube and the condenser with plugs
Detach the air conditioning tube.
5. Detach the condenser.
7. Remove the condenser.
Installation
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2. Tighten 7 Nm.
3. NOTE: Coat the refrigerant line O-ring seals in clean refrigerant oil prior
to installation.
to installation.
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Air Conditioning - Evaporator Core
Removal
1. Remove the in vehicle cross beam and evaporator core housing. For
additional information, refer to Section 412-02A Heating and
VentilationSection 412-02B Auxiliary Heating.
2. Detach the blower motor housing from the in vehicle cross beam..
3. Remove the evaporator core housing from the in vehicle cross beam.
4. Remove the air inlet blend door actuator.
Remove the retaining screws.
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6. Remove the evaporator core support bracket.
Remove the retaining screw.
7. Remove the evaporator core housing.
8. Remove the evaporator core.
Installation
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Air Conditioning - Evaporator Core Orifice
Removal
2. Detach the evaporator core orifice refrigerant tube.
3. Disconnect the refrigerant line.
4. Using a suitable tool. Remove the evaporator core orifice.
Installation
to installation.
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Air Conditioning - Suction Accumulator
Removal
2. Remove the washer resevoir. For additional information, refer to Section
501-16 Wipers and Washers.
3. NOTE: Seal the tube and the suction accumulator with plugs.
Detach the suction accumulator pipe.
4. Remove the suction accumulator pipe retaining clip.
5. Detach the suction accumulator pipe.
6. Using a suitable tool detach the suction accumulator pipe.
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7. Remove the suction accumulator.
Installation
to installation.
to installation.
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Control Components - Control Components
1 Air inlet blend door actuator
2 Air discharge temperature sensor
3 Defrost vent/register blend door actuator
4 Temperature blend door actuator
5 Footwell vent/duct blend door actuator
Automatic climate control with touch screen
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1 Touch screen switch
2 Recirculated air switch
3 Increase set temperature switch
4 Decrease set temperature switch
5 Temperature/clock display
6 Automatic operation switch
7 Fan speed switch
8 Climate control select switch
Automatic climate control with liquid crystal display (LCD)
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1 Fan speed and ON/OFF switch
2 Recirculated air switch
3 Screen display
4 Celsius/Fahrenheit select switch
5 Automatic operation switch
6 Air distribution switches
7 Increase set temperature switch
8 Decrease set temperature switch
Manual climate control
1 Climate control assembly
1 Sunload sensor
This vehicle is fitted with one of the following climate control systems:
manual climate control
automatic climate control with a liquid crystal display (LCD) screen
automatic climate control with a touch screen
Each system has a unique control panel located in the center console above the radio and audio controls.
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Control Components - Control Components
For additional information, refer to Section 412-00 Climate Control System - General Information.
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Control Components - Air Discharge Temperature Sensor
Removal
1. Remove the lower vent.
1. Detach the bulb holder.
2. Disconnect the air discharge temperature sensor electrical connector.
3. Remove the air discharge temperature sensor.
Installation
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Control Components - Ambient Air Temperature Sensor
Removal
CAUTION: Make sure the ignition switch is in the off position before disconnecting the ambient air temperature sensor.
1. Detach the ambient air temperature sensor from the power assisted
steering cooler bracket.
2. Remove the ambient air temperature sensor.
Installation
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Control Components - Climate Control Assembly
Removal
Vehicles with automatic transaxle
1. NOTE: To aid removal of the climate control assembly place the J-gate
selector in the neutral position.
Remove the J-gate surround.
Vehicles with manual transaxle
All vehicles
5. Remove the ashtray.
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6. Remove the climate control assembly mounting bracket upper retaining
screws cover.
7. Remove the climate control assembly mounting bracket upper retaining
screws.
8. Remove the climate control assembly mounting bracket lower retaining
screws.
9. Disconnect the hazard lamp switch assembly electrical connectors.
10. Remove the hazard lamp switch assembly.
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11. Disconnect the climate control assembly electrical connectors.
12. Remove the climate control assembly retaining screws.
13. Remove the climate control assembly.
1. Remove the retaining screws.
2. Remove the climate control assembly.
Installation
1. NOTE: Make sure the climate control assembly is correctly located into
the audio unit.
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Control Components - Defrost Vent/Register Blend Door Actuator
Removal
2. Disconnect the defrost vent/register blend door actuator electrical
connector.
3. Remove the defrost vent/register blend door actuator.
Installation
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Control Components - Footwell Vent/Duct Blend Door Actuator
Removal
2. Disconnect the footwell vent/duct blend door actuator electrical
connector.
3. Remove the footwell vent/duct blend door actuator.
Installation
1. NOTE: Make sure the drive gear is fully meshed with the driven gear
before tightening the retaining screws.
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Control Components - Sunload Sensor
Removal
1. Remove the instrument cluster and vent finish panel.
2. Remove the instrument cluster finish panel.
3. Remove the side air vent.
4. Disconnect the sunload sensor electrical connector.
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5. Remove the sunload sensor.
Installation
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Control Components - Temperature Blend Door Actuator
Removal
2. Disconnect the temperature blend door actuator electrical connector.
3. Remove the temperature blend door actuator.
Installation
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Instrument Cluster and Panel Illumination - Instrument Cluster and Panel Illumination
The complexity of the electronics involved with the instrument cluster preclude the use of workshop general electrical test equipment.
Therefore, reference should be made to the Jaguar Approved Diagnostic System for detailed instructions on testing the instrument cluster.
The Jaguar Approved Diagnostic System tests and analyses, in detail, all functions of the instrument cluster.
Where a fault involving the instrument cluster is indicated by the Jaguar Approved Diagnostic System, some basic diagnostic methods may
be necessary to confirm that connections are good and that the wiring is not damaged, before installing new components.
Fluid level(s)
Accessory installations
Bulb(s)/LED(s)
Fuse(s)
Engine/engine compartment or underbody components
Instrument cluster
step.
3.
4. If the cause is not visually evident, verify the sympton and refer to the Jaguar Approved Diagnostic System. 4.
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Instrument Cluster - Instrument Cluster
Vehicles With 2.0L, 2.5L And 3.0L Engines
1 Engine temperature gauge
2 Left hand direction indicator
3 Door ajar warning
4 Low exterior temperature warning
5 Tachometer
6 Powertrain malfunction
7 Engine malfunction
8 Front fog lamps
9 Main beam
10 Side (Parking) lamps
11 Rear fog lamps
12 Speedometer
13 Overspeed warning (Gulf coast countries only)
14 Right hand direction indicator
15 Fuel level gauge
16 Low fuel remainder lamp
17 Parking/Low brake fluid indicator/EBD system failure
18 Safety belt indicator
19 Trip odometer
20 Cruise (speed) control activated
21 Low washer fluid level
22 Airbag warning indicator
23 Traction control/Dynamic Stability Control (DSC) indicator
24 Anti-lock Brake System (ABS) warning indicator
25 Charge warning indicator
26 Oil pressure warning indicator
27 High engine temperature warning
Vehicles With 2.0L, 2.5L And 3.0L Engines
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3 Door ajar warning
5 Tachometer
6 Powertrain malfunction
8 Front fog lamps
9 Main beam
11 Rear fog lamps
12 Speedometer
15 Fuel level gauge
19 Trip odometer
Vehicles With 2.0L Diesel Engine
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3 Door ajar warning
4 Glow plug warning lamp
6 Tachometer
8 Front fog lamps
9 Main beam
11 Rear fog lamps
12 Speedometer
15 Fuel level gauge
19 Trip odometer
The instrument cluster provides the driver with information, indicators and warning indicators on the vehicle systems.
The gauges and warning indicators may use the outputs from common sensors to carry out their respective functions.
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For a detailed description of the instrument cluster, refer to the relevant Description and Operation sections in the workshop manual. REFER
to: Instrument Cluster (413-01 Instrument Cluster, Description and Operation).
The complexity of the electronics involved with the instrument cluster, preclude the use of workshop general electrical test equipment.
Therefore, reference should be made to the approved Jaguar diagnostic system for detailed instructions on testing the instrument cluster
circuits.
Where a fault involving the instrument cluster is indicated by the approved Jaguar diagnostic system, some basic diagnostic methods may
be necessary to confirm that connections are good and that wiring is not damaged, before installing new component .
Visual Inspection
Engine oil filter
Oil pump
Engine oil level
Oil pressure switch
Engine coolant level
Coolant thermostat
Fuel gauge
Door adjustment
Fuse(s)
Bulb(s)
LED(s)
Wiring harness
Sensor(s)
Instrument cluster
Instrument cluster printed circuit
step.
NOTE: If all of the following systems are not operating correctly this may indicate a concern with the GEM. If one or more of the
following systems operate correctly this may indicate an instrument cluster concern.
3.
3.
4. Verify the following systems are working correctly by operating the system.
Charging
Turn signals
Headlamps
4.
5. If the concern is not visually evident, refer to the approved Jaguar diagnostic system for detailed instructions on testing the
instrument cluster.
5.
DTC Index
3548-1358-00
module/component.
B1202Fuel sender circuit
failure
Instrument cluster, fuel sender
circuit open
Carry out any pinpoint tests associated with this DTC using the
manufacturer approved diagnostic system. Refer to electrical circuit
diagrams, notes and check the rear electronic module, fuel sender
circuit for open circuit.
B1204Fuel sender circuit short
to ground
Instrument cluster, fuel sender
diagrams, notes and check the rear electronic module, fuel sender
circuit for short to ground.
B1205EIC switch-1 assembly
circuit failure
Instrument cluster, auxiliary
lighting switch pack - circuit fault
Refer to electrical circuit diagrams, notes and check instrument
cluster, auxiliary lighting switch pack for circuit fault
B1213Anti-theft number of
programmed keys is
below minimum
Number of programmed keys
below minimum (2 keys
minimum)
Count number of stored keys using the manufacturer approved
diagnostic system. Add keys as required.
B1317Battery voltage high Instrument cluster, power supply
voltage above high limit,
generator voltage is regulated by
the engine control module.
Refer to electrical circuit diagrams, notes, and check instrument
cluster, power supply for voltage fault.
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Removal
1. CAUTION: Do not leave the instrument cluster face down for any
length of time.
Lower and extend the steering column to its maximum rearward
position.
4. Remove the instrument cluster finish panel.
5. Detach the instrument cluster.
6. Remove the instrument cluster.
Installation
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Horn - Horn
Vehicles With 2.0L, 2.5L And 3.0L engines
1 Horn switch
2 Power distribution box
3 Horn
The horn system consists of the following:
Power distribution box fuse 38 (20A)
Power distribution box with integral relay
Horn
Air bag sliding contact
Wiring harness
Horn switch
Generic electronic module
Vehicles with 2.0L Diesel Engine
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1 Horn switch
2 Horn relay
3 Horn
The horn system consists of the following:
Power distribution box fuse 3 (20A)
Power distribution box relay 2
Horn
Air bag sliding contact
Wiring harness
Horn switch
Generic electronic module
The horn system is designed to sound the horn when the horn switch is operated. The horn relay is supplied voltage at all times through
power distribution box. Operating the horn switch provides a ground circuit to the coil side of the horn relay. In turn, the switch side of the
horn relay is closed, allowing voltage to be supplied to the horn.
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Horn - Horn
Switch
Horn
Relay(s)
Fuse(s)
Damaged or corroded Wiring harness
step.
3.
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Horn - Horn
Removal
2. Detach the horn.
3. Remove the horn.
1. Disconnect the horn electrical connector.
2. Remove the horn.
Installation
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Horn - Horn Switch
Removal
1. Remove the driver air bag module.
For additional information, refer to: Driver Air Bag Module (501-20B
2. Disconnect the horn switch electrical connector.
3. Remove the horn switch.
Remove the horn switch retaining screws.
Installation
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Information and Message Center - Information and Message Center
1 Instrument Cluster
2 Red Warning Lamp
3 Amber Warning Lamp
4 Driver's Information/Message Center
The driver's information/message center has a dot matrix LCD (liquid crystal display) and is located in the lower area of the speedometer.
The message center displays messages in text form for the driver, including odometer readings and trip computer data. It can also provide
information normally covered by conventional warning lamps or typically indicate that a feature such as the cruise control is operating.
Located above the message center are two lamps, red for warning and amber for caution. When a message is displayed, the appropriate
lamp will illuminate to attract the driver's attention and to signify the importance of the message.
On 2.2L Diesel vehicles from 2009MY using the AW F21 transmission, when 'Sport' mode is selected using the selector lever, 'S' is displayed
and when in Jaguar Sequential Shift mode the selected gear (1, 2, 3, 4, 5, or 6) is displayed.
Trip Computer
The trip computer can be accessed by pressing the trip computer button located on the end of the LH (left-hand) steering column
multifunction switch. Pressing the trip button displays trip data on the message center. Warning and information messages have priority
over trip data. If a driver information message is displayed prior to activation of the trip computer, the trip data will appear for 10 seconds
only, before being replaced by the original message.
Each successive press of the trip button causes the computer to continually cycle through the stored data which is then displayed on the
message center.
The trip computer button is only enabled while the trip computer output is displayed. Refer to the Drivers Handbook for full operating
instructions.
Service Interval Indicator - Vehicles with Diesel Particulate Filter (DPF)
The Service Interval Indicator informs the driver that the engine requires an engine oil change due to excessive build-up of fuel within the
engine oil. This is due to the Diesel Particulate Filter (DPF) regeneration process where additional fuel quantities are added to increase
exhaust gas temperatures. As a result small quantities of unburnt fuel remain in the combustion chamber and bypass the piston rings into
the engine oil.
The amount of excessive fuel is calculated by the ECM (engine control module). The ECM monitors the engine operating conditions and the
values from the exhaust gas temperature sensor during the DPF regeneration process and calculates the amount of fuel in the oil. If the fuel
content exceeds the permitted level, the ECM will illuminate the service interval indicator in the instrument cluster message center.
After the engine oil has been changed, a service indicator reset procedure must be carried out.
For additional information, refer to: Oil Change Indicator Reset (413-09 Warning Devices, General Procedures).
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Information and Message Center - Information and Message Center
Electrical
Fuse(s)
Engine/engine compartment or underbody components
Instrument cluster
step.
3.
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Information and Message Center - Message Center
1. The information and message center is built integral to the
speedometer. For additional information, refer to Section 413-01
Instrument Cluster.
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Information and Message Center - Message Center Switch
1. The trip computer switch is built integral to the headlamp switch. For
additional information, refer to Section 417-01 Exterior Lighting.
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Warning Devices - Warning Devices
4-door
1 Door actuator
2 Safety belt buckle
4 J Gate (Automatic only)
5 Engine compartment switch - visual warning only
6 Headlamp switch
7 Ignition switch
8 Luggage compartment switch - visual warning only
9 Generic electronic module (GEM)
Wagon
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1 Door actuator
2 Safety belt buckle
4 J Gate (Automatic only)
5 Engine compartment switch - visual warning only
6 Headlamp switch
7 Ignition switch
8 Liftgate switch - visual warning only
9 Liftgate window glass switch - visual warning only
The driver warning chime provides the driver with an audible warning:
when the key is in the ignition and the driver door is open (North American vehicles only).
when the headlamps are on and the driver door is open with the ignition off.
when the engine is running and the safety belt is not engaged (driver side only).
The driver will also be provided with a visual warning or visual message displayed in the information message center (if fitted). The system
uses a number of inputs to provide the driver with audible and visual warnings.
Instrument Cluster
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The instrument cluster acts as a system monitor for the visual warnings. It receives inputs from switches and sensors directly or through the
multiplex link from another module and triggers the necessary visual warning
Ignition Switch Lock Cylinder (North America Only)
A warning chime will sound continuously when the driver door is open and the key is in the ignition, on removal of the key the warning will
cease. The switch is an integral part of the ignition lock cylinder and therefore can only be installed with the lock cylinder.
Door Ajar Switches
The door ajar switches (within the latch) activate the system to provide a visual warning when the ignition is in the RUN position and any of
the doors are open/ajar.
Luggage Compartment Switch - 4 Door Vehicles
The luggage compartment switch activates the system to provide a visual warning when the ignition is in the RUN position and the luggage
compartment is open/ajar.
Liftgate Switch - Wagon
The liftgate switch (within the liftgate latch) activates the system to provide a visual warning when the ignition is in the RUN position and
the liftgate is open/ajar.
Liftgate Opening Window - Wagon
The liftgate opening window switch (within the liftgate window glass latch) activates the system to provide a visual warning when the
ignition is in the RUN position and the liftgate window glass is open/ajar.
Engine Compartment Switch
The engine compartment switch activates the system to provide a visual warning when the ignition is in the RUN position and the hood is
open/ajar.
Headlamp Switch
A warning chime will sound continuously when the driver door is open/ajar and the vehicle lamps are on. This warning is provided only with
the ignition off and will cease after 30 minutes, when the lamps are switched off or when the door is closed.
Safety Belt Switch (North America, Japan, Mexico and Dominican Republic Only)
A warning chime will sound continuously for approximately six seconds when the driver turns the ignition to the RUN position and the safety
belt is not engaged. The warning chime will cease if the safety belt is engaged. The switch is an integral part of the driver safety belt
buckle and therefore can only be installed with a safety belt buckle. A visual warni ng will also be provided on the instrument cluster.
Cooling Over Temperature
Engine temperatures above 120C activate the system to provide a visual warning in the instrument cluster. The temperature warning light
is illuminated constantly and a HIGH ENGINE TEMPERATURE is displayed in the message center (if fitted).
Air Bag Malfunction Chime
If a fault is detected with the air bag visual indication circuit five short warning chimes will be generated and repeated five times. This
sequence is repeated every 30 minutes.
J Gate (Automatic vehicles only)
A warning chime will sound if the J Gate selector is not in PARK and the ignition is turned from RUN to ACC. The chime continues for 10
seconds or until the selector is placed in PARK.
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Warning Devices - Warning Devices
The complexity of the electronics involved with the instrument cluster and general electronic module (GEM), of which the message center is
a part, and the multiplexed communication network which are connected to it preclude the use of workshop general electrical test
equipment. Therefore, reference should be made to the Jaguar Approved Diagnostic System for detailed instructions on testing the message
center.
The Jaguar Approved Diagnostic System tests and analyses, in detail, all functions of the message center.
Where a fault involving the message center is indicated by the Jaguar Approved Diagnostic System, some basic diagnostic methods may be
necessary to confirm that connections are good and that the wiring is not damaged, before installing new components.
Safety belt buckle and pretensioner Fuse(s)
Headlamp switch Wiring harness
Fuel gauge Electrical connector(s)
Switch(es)
Sensor(s)
step.
3.
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Warning Devices - Oil Change Indicator Reset
General Procedures
1. NOTE: Steps 2 to 5 must be completed within 3 seconds for successful
service mode resetting.
NOTE: Ignition key in the OFF position.
Press and hold down the trip computer RESET button.
2. Continue to hold down the trip computer RESET button and turn the
ignition switch to the ON position.
3. Release the trip computer RESET button.
4. Press and hold down the trip computer TRIP button located on the
left-hand steering column multifunction switch.
5. Continue to hold down the trip computer TRIP button and press and
hold down the trip computer RESET button.
6. Continue to hold down the trip computer TRIP and RESET buttons,
RESETTING SERVICE MODE will display in the information and
message center if steps 2 to 5 are completed successfully.
7. After 10 seconds the information and message center will then display
SERVICE MODE RESET once the process is complete.
8. NOTE: If the information and message center does NOT display
SERVICE MODE RESET, steps 1 to 8 must be repeated.
Release the trip computer TRIP and RESET buttons and turn the
ignition switch to the OFF position.
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Warning Devices - Low Washer Fluid Warning Indicator Switch
Removal
3. Remove the reservoir fluid level switch.
1. Disconnect the reservoir fluid level electrical connector.
2. Remove the reservoir fluid level switch.
Installation
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Parking Aid - Parking Aid
1 Parking aid switch
2 Front parking aid speaker
3 Front parking aid sensor
4 Rear outer parking aid sensor
5 Rear centre parking aid sensor
6 Parking aid module
7 Rear parking aid speaker
The function of the parking aid is to provide an audible warning to the driver of the distance to obstacles near the bumpers of the vehicle
when parking. The system provides an assistance to the driver when parking in order to help avoid collision with obstacles.
The sensor range at the rear of the vehicle is 1.8 meters (5.9 ft). This extends the full width of the rear bumper and reduces to 0.6 meters
(2 ft.), at the vehicle corners. The vertical range is adequate to protect the highest and lowest points of the vehicle. The system will detect
curbs with heights of at least 18 cm (7.1 inches). Obstacles, such as curbs, that are low enough to pass under the vehicle until they make
contact with the tires will not be detected.
The sensor range at the front of the vehicle is 0.8 meters (2.6 ft). This extends the full width of the front bumper and reduces to 0.6 meters
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(2 ft), at the vehicle corners. The vertical range is adequate to protect the highest and lowest points of the front of the vehicle. The system
will detect curbs with heights of at least 18 cm (7.1 inches). Obstacles, such as curbs, that are low enough to pass under the vehicle until
they make contact with the tires will not be detected.
The system activates a specific speaker at the front or the rear of the vehicle with a tone signifying the distance to the obstacle. The tone
consists of a beep and defined space ratio which varies depending on the calculated distance. When the distance to the obstacle is less
than 20 cm (7.8 inches) the speaker tone is continuous.
The parking aid system comprises of:
a module mounted in the spare wheel well just rearward of the spare tire.
four rear bumper mounted sensors of which the two inner sensors have a 90 angled electrical connector, and the two outer sensors
have a straight electrical connector plug.
four front bumper mounted sensors all with a 90 angled electrical connector.
two audible speakers, the rear mounted on the rear parcel shelf on 4-door vehicles or behind the left hand loadspace trim on wagon,
and the front mounted above the audio unit.
a cancellation switch that is mounted into the roof console. This is fitted for the driver to disable the system when in slow moving
traffic. This stops the front parking aid continuously monitoring the vehicle in front.
NOTE: On vehicles from 2009MY, smaller parking aid sensors are fitted in the rear bumper. There is no change to system functionality.
The overhead console switch contains a Light Emitting Diode (LED) to inform the driver of the system status:
LED ON - System Active
LED OFF - System Inactive
LED FLASHING - System Fault
The reverse parking aid is active when reverse gear is selected, unless towing (with a Jaguar approved towbar) when the system
automatically switches off. If the parking aid system develops a fault the tone will sound continuously for three seconds when the ignition
is switched on or when the reverse gear is selected, and the overhead console switch LED will flash.
The front parking aid remains inactive after the ignition is switched to the ON position until the overhead console switch is pressed or
reverse gear is selected. The system will then remain active up to 15 kph (9.5 mph) in a forward gear, or until the overhead console switch
is pressed. The front parking aid system becomes inactive if the overhead console switch is pressed while the system is active, or at all
forward speeds above 15 kph (9.5 mph).
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Parking Aid - Parking Aid
For a detailed description of the parking aid, refer to the relevant Description and Operation sections in the workshop manual. REFER to:
Parking Aid (413-13 Parking Aid, Description and Operation).
Parking Aid
Relay(s)
Speaker
Reverse lamp switch
Obstructions or damage to the sensors
Parking sensor face obstructed (e.g. snow, ice, dirt, flies etc)
Sensor(s)
Parking aid module
step.
3.
DTC Index
DTC Index
3548-1358-00
NOTE: If the control module/component is suspect and the vehicle remains under warranty, refer to the warranty policy and procedures
manual (section B1.2) or determine if any prior approval program is in operation, prior to the installation of a new module/component.
C1699Left Rear Outer
to Vbat
Wiring harness concern Refer to electrical circuit diagrams. Check if data line is short circuit to
power. Repair wiring harness using approved methods and materials,
clear DTC and retest system to confirm correct operation.
Sensor Circuit Failure
or Blockage
Wiring harness concern Refer to electrical circuit diagrams. Check if data line is open circuit or
short circuit to ground. Repair wiring harness using approved methods
and materials, clear DTC and retest system to confirm correct
operation.
Sensor Circuit Fault
Sensor fault Check sensor for correct mounting and cleanliness, renew sensor as
required. Clear DTC and retest system to confirm correct operation.
C1702Right Rear Outer
to Vbat
C1704Right Rear Outer
C1705Left Rear Center
to Vbat
operation.
C1708Right Rear Center
to Vbat
operation.
C1711Left Front Sensor
Circuit Short to Vbat
Circuit Failure
operation.
Circuit Fault
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C1714Right Front Sensor
Circuit Short to Vbat
Circuit Failure
operation.
Circuit Fault
C1717Left Front Center
to Vbat
operation.
C1742Rear Sounder Circuit
Failure
Wiring harness concern This fault is detected when speaker is off, refer to electrical circuit
diagrams. Check if rear sounder circuit is open circuit or short circuit to
ground. Repair wiring harness using approved methods and materials,
C1743Rear Sounder Circuit
Short to Vbatt
Wiring harness concern This fault is detected when the speaker is on, refer to electrical circuit
diagrams. Check if rear sounder circuit is short circuit to power. Repair
wiring harness using approved methods and materials, clear DTC and
retest system to confirm correct operation.
C1744Front Sounder Circuit
Failure
Wiring harness concern This fault is detected when speaker is off, refer to electrical circuit
diagrams. Check if front sounder circuit is open circuit or short circuit to
C1745Front Sounder Circuit
Short to Vbatt
Wiring harness concern This fault is detected when the speaker is on, refer to electrical circuit
diagrams. Check if front sounder circuit is short circuit to power. Repair
wiring harness using approved methods and materials, clear DTC and
retest system to confirm correct operation.
C1920Led #1 Circuit Failure LED circuit fault Refer to electrical circuit diagrams. Check if LED circuit is short to
B1299Power Supply Sensor
Circuit Short To
Ground
Parking aid module, parking
distance sensor (rear) power
Refer to electrical circuit diagrams, check parking aid module rear
sensor power circuit for short to ground. Repair wiring harness using
approved methods and materials, clear DTC and retest system to
confirm correct operation.
B1342ECU Is Faulted Parking aid module memory
failure (RAM)
Suspect faulty module, check and install as required, refer to the new
module installation note at the top of the DTC index
B2207ECU ROM Checksum
Error
Parking aid module - memory
failure (ROM)
Suspect faulty module, check and install as required, refer to the new
module installation note at the top of the DTC index
B2373LED #1 Circuit Short
to Battery
Parking aid module, parking aid
status (roof console LED) circuit
- short to power or open circuit
Refer to electrical diagrams, check parking aid status LED circuit for
short to power or open circuit. Repair wiring harness using approved
methods and materials, clear DTC and retest system to confirm correct
operation.
B2477Module Configuration
Failure
Parking aid module -
configuration failure (EEPROM
error during power up)
Reconfigure. If this fails suspect faulty module, check and install as
required. Refer to new module installation note at the top of the DTC
index
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Parking Aid - Front Parking Aid Sensor
Removal
1. Remove the front bumper cover.
3. CAUTION: Make sure excessive pressure or tools are not used
when removing the front parking aid sensor from the parking aid sensor
housing.
Remove the front parking aid sensor.
Detach the front parking aid sensor from the parking aid sensor
housing.
Installation
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Parking Aid - Front Parking Aid Speaker
Removal
All vehicles
2. NOTE: To aid removal of the navigation module and audio unit place the
transmission selector lever in the 'D' position.
Remove the transmission selector lever surround.
All vehicles
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5. Remove the ashtray
Remove the ashtray.
6. Remove the switch pack trim cover.
7. Remove the retaining screw cover plate.
8. Remove the display mounting bracket upper retaining screws.
9. Remove the display mounting bracket lower retaining screws.
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11. Remove the display module and audio unit.
1. Disconnect the electrical connectors and the fibre optic
connector.
12. Disconnect the front parking aid speaker electrical connector.
13. Remove the front parking aid speaker.
Installation
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Parking Aid - Parking Aid Module4-Door
Removal
2. Remove the spare wheel.
4. Remove the parking aid control module.
Installation
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Parking Aid - Parking Aid ModuleWagon
Removal
1. Raise the loadspace floor covering.
2. Remove the loadspace floor covering.
3. Remove the centre loadspace stowage compartment.
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7. Remove the parking aid module.
Installation
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Parking Aid - Rear Parking Aid Sensor
Removal
1. Detach the bumper lower black out panel.
3. CAUTION: Make sure excessive pressure or tools are not used
when removing the sensor from the sensor housing.
Remove the sensor.
Unclip the sensor from the sensor housing.
Installation
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Parking Aid - Rear Parking Aid Speaker4-Door
Removal
1. Remove the rear parcel shelf. For additional information, refer to
3. Remove the speaker.
Remove and discard the rivets.
Installation
1. NOTE: Install new rivets.
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Parking Aid - Rear Parking Aid SpeakerWagon, VIN Range: D86655->E43419
Removal
2. Remove the loadspace stowage compartment trim panel.
3. Remove the loadspace stowage compartment.
4. Disconnect the rear parking aid speaker electrical connector.
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5. Remove the rear parking aid speaker.
Installation
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Parking Aid - Rear Parking Aid SpeakerWagon, VIN Range: E43420->V99999
Removal
1. NOTE: The liftgate weatherstrip must be replaced once removed.
Remove and discard the liftgate opening weatherstrip.
2. Remove both C-pillar trim panels.
For additional information, refer to: C-Pillar Trim Panel - Wagon (501-05
3. Remove both D-pillar trim panels.
For additional information, refer to: D-Pillar Trim Panel (501-05 Interior
Trim and Ornamentation, Removal and Installation).
4. Remove the rear grab handles.
Reposition the screw covers.
Remove the screws.
5. Remove both luggage net retaining clips.
6. Detach the headliner.
7. CAUTION: Make sure the headliner is not creased or folded. Failure
to follow this instruction may result in damage to the vehicle.
Lower the rear of the headliner to gain access to the rear parking aid
speaker.
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8. Disconnect rear parking aid speaker electrical connector.
9. Remove the rear parking aid speaker.
Remove the 2 screws.
Installation
Install a new liftgate opening weatherstrip.
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Battery and Charging System - General Information - Charging System
Vehicles with 2.0L, 2.5L or 3.0L engines
The charging system consists of a 120 amp output generator and regulator assembly which generates current to supply the vehicle electrical
system with electricity when the engine is running and maintain the battery in a charged condition.
The generator is belt driven by the accessory drive belt.
For additional information, refer to: Accessory Drive (303-05 Accessory Drive, Description and Operation).
When the engine is started, the generator begins to generate alternating current (AC) which is converted to direct current (DC) internally.
The DC current and voltage is controlled by the voltage regulator, (located inside the generator), and then supplied to the battery through
the main battery positive cable.
The generator is solidly mounted to the engine timing cover and is driven at 2.8 times the engine speed.
Vehicles fitted with manual transmission have a one way clutch fitted to the drive pulley, which prevents torsional vibrations from the
engine being transmitted to the generator.
The engine control module (ECM) can switch the voltage regulator between two voltages to optimize the charging of the battery.
The low voltage regulator setting is 13.6 volts and the high voltage regulator setting is 15.3 volts, measured with the generator at 25C
(77F) and charging at a rate of 5 amps. These values decrease with a rise in temperature or current flow.
The ECM determines the voltage setting of the voltage regulator. The high voltage setting is always selected by the ECM once the vehicle
has started. The ECM determines the period of time that the high voltage setting is selected for.
There are three different time periods selected by the ECM which is dependent upon the vehicle conditions when the vehicle is started:
The longest time period is selected if the ECM determines that the vehicle has been 'soaking' for sufficient time to allow the engine
coolant temperature (ECT) and the intake air temperature (IAT) to fall within 3C (37F) of each other.
The intermediate time period is selected when the ECT and the IAT is below 5C (41F).
The shortest time period is the default time and is used to provide a short period of boost charge.
At the end of these time periods the voltage is always set to the low voltage setting to prevent the battery from being overcharged.
The time periods are variable depending upon the temperature and the battery voltage. The target voltage of the battery varies between 14
volts and 15 volts depending upon the ambient temperature and the vehicle operating conditions. Once this target voltage has been
achieved, providing the vehicle has been operating for at least the shortest time period, the ECM will reduce the voltage regulator to the
minimum setting of 13.6 volts.
There are three wires connected to the generator from the ECM by connector EN16:
EN49-1; RG wire, is the voltage regulator request setting from the ECM to the generator.
EN49-3; OG wire, is a pulse width modulated signal (PWM) from the generator to the ECM which enables the ECM to monitor the
generator load on the engine.
EN49-4; U wire, is the charge warning lamp signal wire from the generator to the ECM.
If the voltage request signal wire (EN 49-1) is open circuit or short to battery positive, the generator will charge the battery at a setting of
15.3 volts. If the wire is short circuit to ground, the generator will charge the battery at a setting of 13.6 volts.
A fault in the wiring or the connections from the generator to the ECM, will cause a fault code to be generated and stored in the ECM and
the charge warning indicator lamp to be displayed in the instrument cluster (IC) after a short time.
The charge warning indicator lamp is operated by the IC after receiving a signal from the ECM through the control area network (CAN).
With the ignition switch in the RUN position the charge warning indicator lamp will be displayed in the IC when the generator is not
generating power.
If a fault is detected with the generator a fault code will be generated and stored by the ECM. The charge warning indicator lamp will also
be displayed in the IC.
Units should be repaired as an assembly and not dismantled for repair.
For additional information, refer to: Generator - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27 (414-02 Generator and Regulator,
Vehicles with 2.0L and 2.2L diesel engine
The diesel charging system differs from that used in petrol-engined variants in that it incorporates a 'smartcharge' function.
This function is capable of supplying infinitely variable voltages to the battery, depending on the temperature and on the current
requirements of the battery.
The system continuously monitors the battery voltage and temperature (via the ambient air temperature sensor), and uses a map of both to
deliver the optimum charge to the battery.
Another feature of this system is that it uses a 'wake-up' and 'sleep' strategy, initiated by the ignition switch position and ECM, rather than
being constantly active, to avoid current drain.
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Battery and Charging System - General Information - Battery Care
12V LEAD ACID BATTERY CARE MANUAL FOR DEALER / RETAILER USE
1. INTRODUCTION
2. GENERAL RULES FOR BATTERY CARE
3. EQUIPMENT (MINIMUM STANDARD)
4. HEALTH AND SAFETY PRECAUTIONS
5. DETERMINING BATTERY CONDITION
6. BATTERY CHARGING AND MAINTENANCE
7. CHARGING SYSTEM TEST AND DIAGNOSIS
8. VEHICLE QUIESCENT CURRENT TESTING
APPENDIX A: BATTERY TEST PROCESS
APPENDIX B: BATTERY REPORT FORM - IN SERVICE BATTERIES ONLY
1. INTRODUCTION
This publication sets out, for the benefit of dealers / retailers worldwide, requirements for the care and maintenance of batteries, from the
vehicles hand-over to the dealer / retailer to the handover to the customer or in the case of a spare part battery from is delivery to the
dealer / retailer to its fitment to a customer vehicle.
It applies to all types of 12 volt Lead Acid Batteries used, whether they are conventional flooded technology or Absorbed Glass Mat (AGM)
technology and also applies to both Primary and Secondary or Auxiliary Batteries.
The clearly laid out and illustrated sections guide dealers / retailers through each stage of the vehicles or spare parts receipt, storage,
pre-delivery and customer hand-over. This publication can be used as a guide to the handling and care of batteries in service. It is vital to
appreciate that unless each process is rigorously applied on all vehicles, the customer will receive a vehicle with a battery or a spare part
battery which will not provide a satisfactory service life.
It is very important that all tests quoted throughout this publication are adhered to. If they are applied incorrectly batteries could be
scrapped unnecessarily. Refer to the battery testing section for detailed information.
It is equally important therefore to note the following key points:
Most new vehicles leave the factory with either a transit relay installed and/or have a transit mode programmed into the vehicle
control modules. The transit relay must be removed and the transit mode disabled (where applicable) using an approved diagnostic
system, NOT MORE THAN 24 HOURS before the customer takes delivery.
12 Volt Lead Acid Batteries rely on internal chemical processes to create a voltage and deliver current. These processes and the
internal chemical structure of the battery can be damaged if the battery is allowed to discharge over a number of weeks / months, or
is left in a discharged state for a lengthy time period. For this reason the battery must be tested / re-charged if necessary every
month, and MUST BE re-charged after every three month period of storage. Refer to the vehicle storage manual and update the
vehicle history sheet.
Under no circumstances should the battery be disconnected with the engine running because under these conditions the alternator
can give a very high output voltage. This high transient voltage will damage the electronic components in the vehicle. Loose or
incomplete battery connections may also cause high transient voltage.
On vehicles with conventional ignition keys, these must not be left in the ignition lock barrel when the transit relay has been
removed, otherwise quiescent current will increase and the battery will discharge more rapidly.
Two types of Lead acid batteries are used; standard Flooded type and AGM (Absorbed Glass Mat) or VRLA (Valve regulated Lead
Acid) types. AGM batteries offer improved resistance to cycling as seen in stop start applications. AGM Batteries are fully sealed and
cannot have the electrolyte level topped up.
Dealers and retailers involved in the storage, handling of vehicles and spare parts batteries have a responsibility to ensure that only
vehicles and spare parts having a fully satisfactory battery may be processed further through the distribution selling chain.
NOTE: It is very important that test processes quoted throughout this publication are adhered to.
If they are not adhered to correctly batteries could be scrapped unnecessarily or a battery with an issue remains in use. Refer to the battery
testing section for detailed information.
2. GENERAL RULES FOR BATTERY CARE
Frequency of Battery Condition Checks.
Any battery in storage whether it is in a vehicle or in spare parts inventory must have its charge status checked every 30 days as described
in Appendix A, and must be recharged every 90 days as described in the "Battery Charging and Maintenance" section of this manual.
Dealer Demonstration Vehicles
Due to the high depth of discharge a dealer demonstration vehicle battery may experience, batteries that are fitted to vehicles used as
dealer demonstration vehicles must be connected to a power supply / charger capable of delivering 50 Amps or more whilst the vehicle is
being demonstrated and the engine is not running. This will prevent the battery from being damaged from "energy throughput " wear out
during a demonstration.
Software Reflash, SDD work or Ignition On related Workshop Activities.
Due to the high electrical current demand and high depth of Discharge that can occur during vehicle software re-flash activities, SDD work or
ignition on related work in the workshop, vehicles that are undergoing such activities MUST have the electrical system on the vehicle
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supported with a power supply / charger / vehicle maintainer capable of delivering 50 Amps or more.
Jump Starting New vehicles Before They Have Been Delivered to the Customer.
It is the dealer / retailers responsibility to ensure the battery is not allowed to go flat by following the instructions and processes
defined in this manual.
However if circumstances dictate that a new vehicle must be jump started due to a fl at battery whilst the vehicle is in the dealer /
retailers care, the battery on this vehicle must be replaced with a new one prior to delivery to the customer at the dealer / retailers
liability.
The vehicle should also undergo investigation as to why the battery went flat.
Do not connect the jump starting cable to the negative (-) terminal of the battery. Always connect to the recommended earthing
point. As defined in the owners handbook or service documentation for that vehicle.
Jump Starting or Boost Charging Vehicles in Service
Do not connect the jump starting cable to the negative (-) terminal of the battery. Always connect to the recommended earthing point. As
defined in the owners handbook or service documentation for that vehicle.
Charging AGM Batteries
AGM batteries must not be charged with voltages above 14.8 Volts. Doing so will damage them.
Testing AGM Batteries
Midtronics 393, 394, 493 and 494 testers are not capable of testing AGM batteries. Doing so can give an incorrect result.
When it is necessary to test an AGM battery use the Midtronics EXP1080 tester or the GR1 Diagnostics Charger.
3. EQUIPMENT (MINIMUM STANDARD) (pictures are for illustration only)
Traction Battery Charger (or similar stand-alone charger)
Midtronics EXP1080 Hand-Held Tester
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Digital Multi-Meter or Digital Volt-Ohm Meter (DVOM)
Midtronics GR-1 Diagnostic Charger
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4. HEALTH AND SAFETY PRECAUTIONS
WARNINGS:
BATTERY CELLS CONTAIN SULPHURIC ACID AND EXPLOSIVE MIXTURES OF HYDROGEN AND OXYGEN GASES. IT IS THEREFORE
ESSENTIAL THAT THE FOLLOWING SAFETY PRECAUTIONS ARE OBSERVED.
Batteries emit highly explosive hydrogen at all times, particularly during charging. To prevent any potential form of ignition occurring
when working in the vicinity of a battery:
Do not smoke when working near batteries.
Avoid sparks, short circuits or other sources of ignition in the battery vicinity.
Switch off current before making or breaking electrical connections.
Ensure battery charging area is well ventilated.
Ensure the charger is switched off when: a) connecting to a battery; b) disconnecting from the battery.
Always disconnect the ground cable from the battery terminal first and reconnect it last.
Batteries contain poisonous and highly corrosive acid. To prevent personal injury, or damage to clothing or the vehicle, the following
working practices should be followed when topping up, checking electrolyte specific gravity, removal, refitting or carrying batteries:
Always wear suitable protective clothing (an apron or similar), safety glasses, a face mask and suitable gloves.
If acid is spilled or splashed onto clothing or the body, it must be neutralized immediately and then rinsed with clean water. A
solution of baking soda or household ammonia and water may be used as a neutralizer.
In the event of contact with the skin, drench the affected area with water. In the case of contact with the eyes, bathe the affected
area with cool clean water for approximately 15 minutes and seek urgent medical attention.
If battery acid is spilled or splashed on any surface of a vehicle, it should be neutralized and rinsed with clean water.
Heat is generated when acid is mixed with water. If it becomes necessary to prepare electrolyte of a desired specific gravity,
SLOWLY pour the concentrated acid into water (not water into acid), adding small amounts of acid while stirring. Allow the
electrolyte to cool if noticeable heat develops. With the exception of lead or lead-lined containers, always use non-metallic
receptacles or funnels. Do not store acid in excessively warm locations or in direct sunlight.
Due to their hazardous contents, the disposal of batteries is strictly controlled. When a battery is scrapped, ensure it is disposed of
safely, complying with local environmental regulations. If in doubt, contact your local authority for advice on disposal facilities.
5. DETERMINING BATTERY CONDITION
The tools used for determining the condition of the battery will depend upon whether it is installed in a vehicle or in spare parts inventory.
Concerning an installed battery, procedures will vary if the vehicle is new, or already in service with a customer.
NOTE: The term `New Vehicle' refers to a vehicle at any part of the delivery process from leaving the factory to arriving at a port of entry,
dealership, retailer, including any storage facilities en route or a vehicle being stored prior to sale at dealership / retailer.
NOTE: Midtronics 393, 394. 493 and 494 testers must not be used to test AGM batteries as these testers are not capable of correctly
testing AGM batteries and can give an incorrect result. For AGM battery testing use the EXP1080 tester or the GR1 Diagnostics charger.
NEW VEHICLES
A Midtronics tester should be used to assess the condition of the battery for new vehicles. The test results should be recorded on the
Storage History Sheet (see Vehicle Storage manual).
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Scenario 1 - Dealership / Retailer (Responsibility: Dealer / Retailer)
1. Within 24 hours of arrival at the dealer / retailer proceed as follows:
Perform a Midtronics battery test (See Appendix A.)
Carry out the recommended actions accordingly.
2. If the Midtronics result is "Good Battery" the vehicle may be stored.
For all new vehicles in storage the transit relay MUST be fitted, or the Transit Mode enabled where used. For vehicles without a
transit relay or a Transit Mode, the battery negative cable MUST BE DISCONNECTED from the battery.
3. The battery must be tested and/or re-charged every month and MUST be re-charged after every three month period.
4. Record your test results on the Storage History Sheet (see Vehicle Storage Manual) to indicate when a re-charge will be necessary.
Scenario 2 - Delivery to the Customer (Responsibility: Dealer / Retailer)
NOTE: It is essential that the following actions are conducted in the 24 hours prior to the agreed hand over time:
1. Perform a Midtronics Battery test (See Appendix A).
2. Carry out the recommended actions accordingly.
3. The vehicle should only be released to the customer if Midtronics has tested the battery as "Good Battery"
Spare Part Batteries
Lead acid batteries will, as a result of natural chemical processes, slowly self discharge themselves over a period of time (even when open
circuit and no electrical load applied).
In the case of spare parts batteries, a Midtronics tester should be used to assess the condition of new spare parts batteries.
The batteries must be stored such that they cannot get wet and are not in direct sunlight.
Any batteries which are dropped must be scrapped. This applies even if no external damage is apparent.
Scenario 1 - Spare Part Batteries Within Dealer Stock But Not Yet Fitted To A Vehicle (Responsibility: Dealer /
Retailer)
1. For a battery in the Dealer parts or in ready to use stock but not yet fitted to a vehicle the following rules must be followed:
Check the battery condition on receipt by performing a Midtronics battery test (See Appendix A).
Batteries should only be returned to storage if the Midtronics tester indicates "Good Battery".
The battery condition should be rechecked every 30 days by performing a Midtronics battery test (See Appendix A).
If required batteries should be recharged as described in the "Battery Charging and Maintenance" section of this manual.
2. 2 All batteries must be controlled via a FIFO (First In First Out) process to ensure aged batteries are not held and the batteries are not
allowed to age unnecessarily.
VEHICLES IN SERVICE
The Midtronics hand-held tester or the Midtronics Diagnostic Charger are the preferred tools to assess battery condition for vehicles in
service. The test results should be recorded on the In-Service Battery Report Form (See Appendix B).
Midtronics Testing - In-Service Testing Only
NOTE: The battery surface charge must be removed before this test in accordance with the procedure in Appendix A. Ensure that the
battery terminal connectors are clean. When connecting the Midtronics testing equipment, connect the RED clip to the positive (+) battery
terminal first, and then connect the BLACK clip to the negative (-) battery terminal. Rock the clips backward and forward to ensure a good
connection to the battery.
1. Perform a Midtronics battery test (See Appendix A).
2. Carry out the recommended actions accordingly.
6. BATTERY CHARGING AND MAINTENANCE
BATTERY CHARGING
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It is essential that a suitably ventilated defined area exists in each dealership / retailer for battery charging. Likewise, an area should be
allotted for scrap batteries, and clearly indicated as such. It is recommended that dealers / retailers always have fully charged batteries
ready for use. However the battery MUST BE tested and charged if necessary every month, and charged after three months irrespective of
any test.
CAUTIONS:
Batteries must be re-charged after a maximum of 3 months storage (see Storage History sheet in the New Vehicle Storage Manual).
It is very important that when charging batteries using the traction charger or other stand-alone chargers that the charger is set for
the correct type of battery before charging commences. If the wrong switch is selected the result would be a battery that is not charged
fully and / or overheating can occur. Follow the manufacturers operating instructions.
Do not charge AGM batteries with voltages over 14.8 volts as this will damage the battery.
To bring a serviceable but discharged battery back to a fully charged condition proceed as follows:
Check and if necessary top-up the battery electrolyte level.
Charge the battery using the Midtronics Diagnostic Charger (USA) or Traction Charger (all other markets) following the manufacturers
operating instructions.
NOTE: When using the Midtronics Diagnostic Charger, automatic mode must always be used. After charging and analysis, the charger may
display Top-Off Charging, press STOP to end. Do not stop charging until the current falls to 5A or less, otherwise the battery will not be
fully charged.
POST-CHARGE TEST METHODS
New Batteries, Batteries in Storage and In-Service Batteries
The purpose of this test is to ensure that the charging process has fully charged the battery.
NOTE: IT IS RECOMMENDED THAT THIS TEST IS CONDUCTED AT LEAST 24 HOURS AFTER THE CHARGE CYCLE IS COMPLETED.
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CAUTION: DO NOT connect the tester to any other circuit or chassis point.
1. Attach the Midtronics Tester to the battery.
2. Follow the instructions on the tester to test the battery. Ensure the correct battery type and size is selected.
3. Perform the action based on the tester results (see the tester results chart in the Vehicles in Service sub -section of Determining Battery
Condition Section).
4. Enter the readings and test code obtained on the In Service Battery Report Form.
BATTERY REPLACEMENT
If it is determined that a battery requires replacement, always refer to the appropriate section of the workshop manual for instructions on
removing and installing the battery from the vehicle.
On in service vehicles fitted with a Battery Monitoring System (BMS), the BMS module must be reset following the installation of a new
battery. The BMS module reset procedure must be performed using an approved diagnostic system.
CHECK/TOP-UP BATTERY ELECTROLYTE Only Applicable to certain Flooded Types of Battery.
WARNINGS:
AGM TECHNOLOGY BATTERIES ARE FULLY SEALED FOR LIFE AND NO ATTEMPT SHOULD BE MADE TO CHECK OR TOP UP THE
ELECTROLYTE LEVEL.
BEFORE CHECKING AND TOPPING-UP THE BATTERY ELECTROLYTE, REFER TO THE HEALTH AND SAFETY PRECAUTIONS SECTION.
Check to ensure the battery is of a type suitable for topping up. These types of batteries will have cell plugs visible on the top face of the
battery or a removable access panel to allow access to the cells.
On batteries with a clear or opaque case and level marks, check the electrolyte level by visual inspection of the maximum level indicator
mark on the battery casing indicating adequate level above the battery separators.
On batteries with black cases, remove the cell plugs or access panel and ensure the electrolyte level is level with the indicator in the cell
hole. A flashlight may be required to see the electrolyte level on this type of battery.
CAUTION: DO NOT overfill.
If the electrolyte level is low, top-up using distilled water.
Maintenance free and Valve Regulated (AGM) batteries are sealed and therefore cannot be topped up.
CHARGING SYSTEM TEST AND DIAGNOSIS
For all vehicles, refer to the Charging System - Diagnosis and Testing in section 414-00 of the Workshop Manual.
VEHICLE QUIESCENT CURRENT TESTING
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NOTE: On vehicles fitted with a Battery Monitoring System (BMS), the diagnostic routine for quiescent drain testing in the approved
diagnostic system should be utilized.
NOTE: If a customer complains of a vehicle battery that discharges continuously or when left for a prolonged period of time, it is
recommended that a quiescent drain test is performed as described below.
NOTE: The battery drain should be measured using an approved diagnostic system or a Digital Multi-Meter (DVOM).
The vehicle should be in the locked/armed state (for example vehicle alarm fully armed), all doors, engine and luggage compartment lids are
open and latched (so as to appear closed from an electrical point of view). The test should take place after the vehicle has entered
shutdown mode. The time taken for this to occur after the ignition is switched off varies according to model - Refer to Quiescent Drain in
section 414-00 of the Workshop Manual.
NOTE: When the vehicle is armed, the effect of the security system Light Emitting Diode (LED) flashing is to cause a pulsation in the
measured current drain. In this case, either the average current should be taken (using a Digital Multi- Meter (DVOM) with an averaging
system) or the current reading taken, ignoring the brief high current peaks.
EQUIPMENT
Approved diagnostic system with current probe or Digital Multi-Meter (DVOM) with current probe.
METHOD OF MEASUREMENT
Using an Approved Diagnostic System
1. Switch off all electrical loads and ensure that the ignition is off.
2. Connect the current probe to the approved diagnostic system.
3. Calibrate the probe.
4. Install a clamp around the battery lead/junction box lead.
5. Go to the Quiescent Current Testing section.
Using a Digital Multi-Meter (DVOM)
NOTE: Do not use an in-line DVOM to measure the quiescent drain on vehicles fitted with an electronic throttle. The current exceeds the
maximum amount the fuse in the DVOM is capable of handling.
1. Switch off all electrical loads and ensure that the ignition is off.
2. Connect the current probe to the DVOM.
3. Calibrate the probe.
4. Install a clamp around the battery lead/junction box lead.
5. Go to the following Quiescent Current Testing section.
QUIESCENT CURRENT TESTING
1. Switch ignition to on or select ignition mode in keyless vehicles and switch to off (do not crank).
2. Remove key from ignition switch (where applicable).
3. Open and latch all doors, hood and luggage compartment lid.
4. Lock the vehicle using the remote function on the remote handset. (Single lock only to avoid volumetric alarm arming).
5. Remove any other potential electrical drains such as accessories plugged into accessory sockets.
6. Record the amperage readings after the shutdown period. The model specific Amperage readings for quiescent drain are referenced in
Quiescent Drain in section 414-00 of the Workshop Manual
7. Record the final reading on the battery report form Appendix B.
NOTE: The preferred method of testing following an excessive current consumption figure is to use a current probe around individual
junction box leads to the various suspected circuits to identify a potential cause. This is in preference to the old method of removing fuses
for the following reasons:
Many modules take a considerable time to power down. Each time a fuse is removed and re-fitted, the quiescent drain current may
take an extended period of time to return to normal (typically up to 45 minutes).
The drain may be caused by a module remaining active and preventing the quiescent drain from reducing to normal levels.
The drain may be caused by a relay winding that is activated. Pulling the fuse can allow this to reset and the drain will be lost and
go un-diagnosed.
APPENDIX A BATTERY TEST PROCESS
It is recommended that this test is conducted at least 24 hours after the vehicle engine has been run or the battery charged to avoid the
need of surface charge removal or if this time constraint is unacceptable due to circumstances, then conduct the charge strip removal
process.
Part 1 - Surface Charge Removal
NOTE: Before carrying out a battery test you must ensure that there is no battery surface charge present.
NOTE: The battery may be tested either on a bench or on the vehicle.
In the case of on-vehicle testing, the battery must be isolated from the vehicle by removal of the battery negative (-) cable from the
battery terminal before the measurement is taken unless the vehicle has a transit relay fitted or is in transit mode.
A vehicle which has had its battery charged or been driven in a 24 hour period before the test, must have its surface charge removed using
one of the following methods:
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1. If 24 hours have passed since the last time the engine was run or the battery charged, proceed to `Part 2 - Battery Test'.
2. Turn on the ignition. Switch on the headlamps on high beam for a minimum 3 minutes.
3. Switch off the headlamps. For vehicles tested after the transit relay has been removed, disconnect the battery by removal of the negative
(-) cable. Vehicles with a transit relay fitted or with a low current transport mode enabled do not need to have the battery disconnected.
4. Wait a maximum of 5 minutes before recording test results for any battery measurements.
Part 2 - Battery Test
NOTE: The battery surface charge must be removed before this test in accordance with the procedure in Part 1 above. Ensure that the
battery terminal connectors are clean. When connecting the Midtronics testing equipment, connect the RED clip to the positive (+) battery
terminal first, and then connect the BLACK clip to the negative (-) battery terminal. Rock the clips backward and forward to ensure a good
connection to the battery.
CAUTION: DO NOT connect the tester to any other circuit or chassis point other than the battery negative terminal.
1. Attach the Midtronics tester to the battery.
2. Follow the instructions on the tester to test the battery. Ensure the correct battery type and size is selected.
3. Perform the action based on the tester results (see table below).
4. Enter the readings and test code obtained on the Battery Report Form (Appendix B) or equivalent which records as a minimum the
technician's name, Vehicle Identification Number (VIN), Date of check, Midtronics code and Battery Voltage from the Midtronics tester.
At the end of the test, the battery negative (-) cable should be re-attached to the battery terminal.
TESTER RESULTS ACTION
GOOD BATTERY Return to service.
GOOD RE-CHARGE Fully charge battery and return to service.
CHARGE AND RE-TEST Fully charge battery. Remove surface charge. Re-test battery. If same result replace battery.
REPLACE BATTERY OR BAD
CELL BATTERY
Verify surface charge removed. Disconnect battery from vehicle and re-test. If result repeats after surface
charge removal, replace battery. DO NOT RECHARGE.
UNABLE TO DO TEST Disconnect battery from vehicle and re-test.
APPENDIX B : BATTERY REPORT FORM - IN SERVICE BATTERIES ONLY
NOTE: Fields marked with * are mandatory and must be completed.
General Information
YES /
NO
YES /
NO
Customer Name: Dealer/Retailer Code: *
Repair Order Number: * Battery Date Code: *
Repair Order Date: * Number of Times Battery
Charged:
*
Repair Order Date: Technicians Name: *
Vehicle Identification Number (VIN): * Technicians Signature: *
Give a detailed description of the symptoms experienced by the customer (attach a separate sheet if necessary)
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-
-
Diagnostics (Battery Testing)
1: Loose battery clamps Yes * No *
2: Loose hold down clamps Yes No
3: Corroded terminal posts Yes * No *
4: Physical damage/leaks Yes No
5: Low electrolyte Yes * No *
6: FEAD belt tension OK * Not OK *
7: Surface charge removed Yes * No *
8: Voltage (appendix A) Yes * No *
9: Quiescent Drain mA *
10: Vent tube correctly installed Yes No
11: Midtronics test
Code before charging *
If Midtronics indicates that the battery needs re-charging, charge the battery for 24
hours

Code after charge *
Result after charge *
If "good and re-charge" charge the battery for an additional 24 hours.
If "charge and re-test" for both before and after 24 hours charge renew the battery
Only renew the battery if "renew battery", "bad cell" or charge and re-test has been
displayed twice.

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Published: 28-Sep-2011
Battery and Charging System - General Information - Quiescent Drain
QUIESCENT DRAIN - TYPICAL VALUES
NOTE: The quiescent drain after the initial shutdown period should not exceed the value shown in the table.
Jaguar Quiescent Drain Values
MODEL SHUT DOWN PERIOD (minutes) TYPICAL VALUES BATTERY DRAIN (mA)
XJS 3.2 60 <30
Sovereign 3.2 60 <37.3
XJ6 4.0 60 <38.6
XJS 60 <43.9
XJ6 (X300) (1995MY) 60 <43
XJ8 (X300) 60 <30
XK8 (X100) 60 <30
S-Type (X200) 60 <30
X-Type (X400) 30 <30
XJ6 (X350) 40 <30
XJ8 (X350) 40 <30
XK (X150) 3 (after lock/arm condition) <30
33 (unlocked) <30
XF (X250) 3 (after lock/arm condition) <30
33 (unlocked) <30
XJ (X351) 3 (afterlock/arm condition) <30
33 (unlocked) <30
NOTE:
1. The total current drain will be higher if certain approved accessories are fitted (for example: tracker, trailer module, etc.)
2. Applies to vehicles without Tire Pressure Monitoring System (TPMS). Vehicle shut-down period with TPMS is approximately 15 minutes.
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Battery and Charging System - General Information - Charging System2.0L NA V6 -
AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27
Drive belt
Drive belt tensioner
Generator
Generator pulley (vehicles fitted with manual transmission)
Battery
Generator
Fuse
Circuit
Electrical connectors
Warning lamp operation
step.
3.
Symptom chart
Charging system faults/codes and related causes
DTC P1146 Low input from the Engine control
module (ECM) on the voltage regulator request
signal wire
Circuit.
Generator.
ECM.
DTC P1244 Generator overcharging Generator.
Circuit.
Battery.
DTC P1629 Generator load monitoring signal
failure
Circuit.
Generator.
ECM.
DTC P1632 Charging system failure Fuse 82 (20A).
Circuit.
Generator.
Battery.
ECM.
The charging system warning indicator is on,
intermittent or flickers with the engine running
Accessory drive belt.
Fuse 82 (20A).
Circuit.
Generator.
Generator pulley (vehicles fitted
with manual transmission).
Battery.
ECM.
Instrument cluster (IC).
Control area network (CAN).
CHECK the accessory drive belt tension. For
additional information, refer to Section 303-05
Accessory Drive .
Generator not charging, battery keeps going flat Accessory drive belt.
Fuse 82 (20A).
Circuit.
Generator.
Battery.
CHECK drive belt tension. For additional information,
refer to Section 303-05 Accessory Drive .
Generator noisy Accessory drive belt.
Accessory drive belt tensioner.
CHECK the accessory drive belt and tensioner. For
additional information, refer to Section 303-05
Accessory Drive .
Radio interference Circuit.
Generator.
Generator Electrical Connector (EN49, Harness Side)
1 Voltage Request Input Signal from ECM Red/Green
2 Power Supply (12 volts) from Fuse 82 of the Passenger Compartment Fuse Box Green/Red
3 PWM Output Signal to ECM Orange/Green
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4 Generator Charge Warning Indicator Lamp Output Signal to ECM Blue
Engine Control Module (ECM) Electrical Connector (EN16, Harness Side)
53 Voltage Request Output Signal to Generator Red/Green
65 PWM Input Signal from Generator Orange/Green
79 Generator Charge Warning Indicator Lamp Input Signal from Generator Blue
PINPOINT TEST A : LOW INPUT ON THE VOLTAGE REGULATOR REQUEST SIGNAL WIRE FROM THE ECM (P1146)
TEST
CONDITIONS
A1: CHECK THE VOLTAGE REGULATOR REQUEST SIGNAL WIRE FOR A SHORT TO GROUND
Disconnect the ECM electrical connector EN16 and the generator electrical connector EN49.
Measure the resistance between electrical connector EN49-1 and ground.
Yes
REPAIR short to ground between the generator and the ECM. CLEAR the DTC. TEST the system for normal operation.
No
GO to A2. .
A2: CHECK THE VOLTAGE REGULATOR REQUEST SIGNAL WIRE FOR OPEN CIRCUIT
Measure the resistance between electrical connector EN49-1 and the ECM electrical connector EN16-53.
Yes
REPAIR the circuit from the ECM to the generator. CLEAR the DTC. TEST the system for normal operation.
No
GO to A3. .
A3: CHECK THE OPERATION OF THE GENERATOR CHARGE WARNING INDICATOR LAMP
Connect the ECM electrical connector EN16 and the generator electrical connector EN49.
Clear the DTC. START and RUN the engine at 1500 RPM with no electrical load applied.
Does the generator charge warning indicator lamp illuminate within 30 seconds of the engine being started?
Yes
INSTALL a new generator. CLEAR the DTC. TEST the system for normal operation. If the DTC is repeated, INSTALL a
new ECM. For additional information, refer to Section 303-14A Electronic Engine ControlsSection 303-14B Electronic
Engine Controls .
No
GO to A4. .
A4: CHECK THE OPERATION OF THE GENERATOR CHARGE WARNING INDICATOR LAMP AFTER 15 MINUTES
RUN the engine at idle for 15 minutes and then increase the engine speed to 1500 RPM for one minute with no
electrical load applied.
Does the generator charge warning indicator lamp illuminate or is the DTC repeated?
Yes
Engine Controls .
No
DIAGNOSE the ECM. For additional information, refer to Section 303-14A Electronic Engine ControlsSection 303-14B
Electronic Engine Controls .
PINPOINT TEST B : GENERATOR OVERCHARGING (P1244)
TEST
CONDITIONS
B1: CHECK THE VOLTAGE REGULATOR REQUEST SIGNAL WIRE FOR A SHORT TO BATTERY POSITIVE
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Measure the resistance between electrical connector EN49-1 and the generator battery positive cable.
Yes
REPAIR short to the generator battery positive cable. CLEAR the DTC. TEST the system for normal operation.
No
GO to B2. .
B2: CHECK THE VOLTAGE REGULATOR REQUEST SIGNAL WIRE FOR OPEN CIRCUIT
Yes
No
Engine Controls .
PINPOINT TEST C : CHARGING SYSTEM FAILURE (P1632)
TEST
CONDITIONS
C1: CHECK THE BATTERY VOLTAGE WITH THE ENGINE RUNNING AND NO ELECTRICAL LOADS APPLIED
START and RUN the engine at 1500 RPM with no electrical load applied.
Measure the battery voltage.
Yes
GO to C2. .
No
INSTALL a fully charged battery.GO to C4. .
C2: CHECK CONTINUITY OF THE VOLTAGE REGULATOR REQUEST SIGNAL WIRE
Yes
REPAIR the circuit from the ECM to the generator. Clear the DTC. TEST the system for normal operation.
No
GO to C3. .
C3: CHECK THE VOLTAGE REGULATOR REQUEST SIGNAL WIRE FOR A SHORT GROUND
Yes
REPAIR the circuit from the ECM to the generator. Clear the DTC. TEST the system for normal operation.
No
Engine Controls .
C4: CHECK THE GENERATOR CHARGE WARNING INDICATOR LAMP AND COOLING FAN OPERATION WITH THE ENGINE RUNNING
AT IDLE SPEED
START and RUN the engine at idle speed for 15 minutes with no electrical load applied.
Is the generator charge warning indicator lamp illuminated and the cooling fans operating at maximum speed?
Yes
GO to C6. .
No
GO to C5. .
C5: CHECK THE GENERATOR CHARGE WARNING INDICATOR LAMP AND COOLING FAN OPERATION WITH THE ENGINE RUNNING
FOR A FURTHER MINUTE AT 1500 RPM.
Increase the engine speed to 1500 RPM for one minute with no electrical load applied.
Is the generator charge warning indicator lamp illuminated?
Yes
Engine Controls .
No
INSTALL a fully charged slave battery. CLEAR the DTC. TEST the system for normal operation.
C6: CHECK FOR A SHORT TO BATTERY POSITIVE CABLE
Yes
No
Engine Controls .
PINPOINT TEST D : GENERATOR LOAD MONITORING SIGNAL FAILURE (P1629)
TEST
CONDITIONS
D1: CHECK THE SIGNAL WIRE FOR OPEN CIRCUIT
Yes
GO to D2. .
No
D2: CHECK THE SIGNAL WIRE FOR A SHORT TO BATTERY POSITIVE
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Yes
REPAIR short to the generator battery positive cable. CLEAR the DTC. TEST the system for normal operation.
No
GO to D3. .
D3: CHECK THE SIGNAL WIRE FOR A SHORT TO GROUND
Measure the resistance between electrical connector EN49-3 and ground.
Yes
No
Engine Controls .
PINPOINT TEST E : THE GENERATOR CHARGE WARNING INDICATOR LAMP IS ON WITH THE ENGINE RUNNING
TEST
CONDITIONS
E1: CHECK THE BATTERY VOLTAGE
Yes
Charge the battery.GO to E2. .
No
GO to E3. .
E2: CHECK THE BATTERY
Carry out a Battery Condition Test.
Is the battery OK?
Yes
GO to E3. .
No
INSTALL a new battery. TEST the system for normal operation.
E3: CHECK THE BATTERY VOLTAGE WITH THE ENGINE RUNNING AND NO ELECTRICAL LOADS APPLIED
START and RUN the engine at 1500 RPM. Measure the battery voltage.
Yes
For vehicles fitted with manual transmissionGO to E4. . For vehicles fitted with automatic transmissionGO to E5. .
No
GO to E11. .
E4: CHECK THE GENERATOR DRIVE PULLEY (VEHICLES FITTED WITH MANUAL TRANSMISSION)
REMOVE the accessory drive belt. For additional information, refer to Section 303-05 Accessory Drive .
ROTATE the generator pulley by hand.
Does the alternator rotor shaft rotate with the pulley?
Yes
GO to E5. .
No
INSTALL a new generator. TEST the system for normal operation.
E5: CHECK THE GENERATOR OUTPUT VOLTAGE AT THE GENERATOR BATTERY POSITIVE CABLE TERMINAL, WITH THE ENGINE
RUNNING AND NO ELECTRICAL LOADS APPLIED
START and RUN the engine at 1500 RPM. Measure the voltage between the generator battery positive cable
electrical connector; ST4 and ground.
Yes
GO to E6. .
No
REPAIR the permanent live supply circuit from the battery to the generator. TEST the system for normal operation.
E6: CHECK THE GENERATOR GROUND CIRCUIT
Measure the resistance between the generator casing and the battery ground terminal.
Yes
GO to E7. .
No
REPAIR the ground circuit between the generator and the battery ground terminal. TEST the system for normal
operation.
E7: CHECK IGNITION SUPPLY VOLTAGE TO THE GENERATOR
Turn the ignition switch to the RUN position. Measure the voltage between the generator ignition supply terminal,
EN49-2 and ground.
Yes
GO to E8. .
No
E8: CHECK FUSE 82 IN THE PASSENGER COMPARTMENT FUSE BOX
Check the fuse.
Is the fuse OK?
Yes
GO to E9. .
No
GO to E10. .
E9: CHECK FOR IGNITION SUPPLY VOLTAGE AT FUSE 82 OF THE PASSENGER COMPARTMENT FUSE BOX
Turn the ignition switch to the RUN position. Measure the voltage between the passenger compartment fuse box;
JB51-14 and ground.
Yes
REPAIR the circuit between the passenger compartment fuse box and the ignition relay. TEST the system for normal
operation.
No
REPAIR the circuit between the passenger compartment fuse box and the generator. TEST the system for normal
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operation.
E10: CHECK FUSE 82 OF THE PASSENGER COMPARTMENT FUSE BOX FOR A SHORT TO GROUND
Measure the resistance between electrical connector JB51-14 of the passenger compartment fuse box and ground.
Yes
REPAIR short to ground between the passenger compartment fuse box and the generator. INSTALL a new fuse.
No
INSTALL a new fuse. TEST the system for normal operation.
E11: CHECK THE CONTINUITY OF THE GENERATOR CHARGE WARNING INDICATOR LAMP SIGNAL WIRE
Disconnect the ECM electrical connector; EN16 and the generator electrical connector; EN49.
Yes
Refer to the approved Jaguar diagnostic system.
No
REPAIR the circuit from the ECM to the generator. TEST the system for normal operation.
PINPOINT TEST F : GENERATOR NOT CHARGING BATTERY KEEPS GOING FLAT
TEST
CONDITIONS
F1: CHECK THE CHARGE WARNING LAMP IS ILLUMINATED WITH THE ENGINE RUNNING
START and RUN the engine at 1500 RPM. INSPECT the generator charge warning indicator lamp.
Is the warning lamp illuminated?
Yes
GO to F2. .
No
GO to F4. .
F2: CHECK THE BATTERY VOLTAGE WITH IGNITION OFF AND NO ELECTRICAL LOADS APPLIED
Yes
Charge the battery.GO to F3. .
No
GO to F4. .
F3: CHECK THE BATTERY
Carry out a Battery Condition Test.
Is the battery OK?
Yes
GO to F4. .
No
INSTALL a new battery. TEST the system for normal operation.
F4: CHECK THE BATTERY VOLTAGE WITH THE ENGINE RUNNING AND NO ELECTRICAL LOADS APPLIED
START and RUN the engine at 1500 RPM. Measure the battery voltage.
Yes
For vehicles fitted with manual transmissionGO to F5. . For vehicles fitted with automatic transmissionGO to F6. .
No
GO to F10. .
F5: CHECK THE GENERATOR DRIVE PULLEY (VEHICLES FITTED WITH MANUAL TRANSMISSION)
REMOVE the accessory drive belt. For additional information, refer to Section 303-05 Accessory Drive .
Does the alternator rotor shaft rotate with the pulley?
Yes
GO to F6. .
No
F6: CHECK THE GENERATOR OUTPUT VOLTAGE AT THE GENERATOR MAIN TERMINAL WITH THE ENGINE RUNNING AND NO
ELECTRICAL LOADS APPLIED
START and RUN the engine at 1500 RPM. Measure the voltage between the generator main output electrical
connector; ST4 and ground.
Yes
GO to F7. .
No
REPAIR the permanent live supply circuit from the battery to the generator. TEST the system for normal operation.
F7: CHECK FUSE 82 IN THE PASSENGER COMPARTMENT FUSE BOX
Check the fuse.
Is the fuse OK?
Yes
GO to F9. .
No
GO to F8. .
F8: CHECK FUSE 82 OF THE PASSENGER COMPARTMENT FUSE BOX FOR A SHORT TO GROUND
Measure the resistance between electrical connector JB51-14 of the passenger compartment fuse box and ground.
Yes
REPAIR short to ground between the passenger compartment fuse box and the generator. INSTALL a new fuse. TEST
No
INSTALL a new fuse. TEST the system for normal operation.
F9: CHECK FOR IGNITION SUPPLY VOLTAGE AT FUSE 82 OF THE PASSENGER COMPARTMENT FUSE BOX
Turn the ignition switch to the RUN position. Measure the voltage between the passenger compartment fuse box;
JB51-14 and ground.
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Yes
REPAIR the circuit between the passenger compartment fuse box and the ignition relay. TEST the system for normal
operation.
No
REPAIR the circuit between the passenger compartment fuse box and the generator. TEST the system for normal
operation.
F10: CHECK THE CONTINUITY OF THE GENERATOR CHARGE WARNING INDICATOR LAMP SIGNAL WIRE
Yes
Refer to the approved Jaguar diagnostic system.
No
REPAIR the circuit from the ECM to the generator. TEST the system for normal operation.
PINPOINT TEST G : GENERATOR NOISY
TEST
CONDITIONS
G1: CHECK GENERATOR FOR SECURITY
INSPECT the generator fixings.
Is the generator loose?
Yes
TIGHTEN generator fixings. TEST the system for normal operation.
No
GO to G2. .
G2: CHECK THE ACCESSORY DRIVE BELT
REMOVE and INSPECT the accessory drive belt. For additional information, refer to Section 303-05 Accessory Drive .
Is the accessory drive belt OK?
Yes
GO to G3. .
No
INSTALL a new accessory drive belt. TEST the system for normal operation.
G3: CHECK THE ACCESSORY DRIVE BELT TENSIONER
REMOVE and INSPECT the accessory drive belt tensioner. For additional information, refer to Section 303-05 Accessory
Drive .
Is the accessory drive belt tensioner OK?
Yes
GO to G4. .
No
INSTALL a new accessory drive belt tensioner. For additional information, refer to Section 303-05 Accessory Drive .
G4: CHECK GENERATOR FOR MECHANICAL NOISE
Does the generator rotor shaft rotate smoothly?
Yes
For vehicles fitted with manual transmissionGO to G5. . For vehicles fitted with automatic transmissionGO to G6. .
No
G5: CHECK GENERATOR DRIVE PULLEY (VEHICLES FITTED WITH MANUAL TRANSMISSION)
ROTATE the generator pulley quickly by hand.
Stop the generator pulley from spinning by holding the pulley.
Does the generator rotor shaft continue to rotate?
Yes
GO to G6. .
No
G6: CHECK THE ACCESSORY DRIVE BELT IDLER PULLEYS
ROTATE the accessory drive belt idler pulleys by hand.
Do the accessory drive belt idler pulleys rotate smoothly?
Yes
GO to G7. .
No
INSTALL new accessory drive belt pulleys as necessary. TEST the system for normal operation.
G7: CHECK GENERATOR FOR ELECTRICAL NOISE
INSTALL the accessory drive belt. For additional information, refer to Section 303-05 Accessory Drive .
START and RUN the engine at 1500 RPM. APPLY a high electrical load to the battery.
Is the noise only heard with the high electrical load applied?
Yes
GO to G8. .
No
CHECK the air conditioning compressor. For additional information, refer to Section 412-03 Air Conditioning . CHECK
the power steering pump. For additional information, refer to Section 211-02 Power Steering . TEST the system for
normal operation.
G8: ELIMINATE THE GENERATOR AS THE CAUSE OF ELECTRICAL NOISE
REMOVE fuse 82 from the passenger compartment fuse box.
START and RUN the engine at 1500 RPM.
Is the noise still present?
Yes
CHECK the air conditioning compressor. For additional information, refer to Section 412-03 Air Conditioning . CHECK
the power steering pump. For additional information, refer to Section 211-02 Power Steering . TEST the system for
normal operation.
No
PINPOINT TEST H : RADIO INTERFERENCE
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TEST
CONDITIONS
H1: CHECK THE GENERATOR FOR THE CAUSE OF RADIO INTERFERENCE
TURN the radio switch to the ON position.
Is radio interference present?
Yes
GO to H3. .
No
GO to H2. .
H2: CHECK THE GENERATOR FOR THE CAUSE OF RADIO INTERFERENCE WITH A HIGH ELECTRICAL LOAD APPLIED TO THE
BATTERY
START and RUN the engine at 1500 RPM
APPLY a high electrical load to the battery.
Is radio interference present?
Yes
GO to H3. .
No
DIAGNOSE the entertainment system. For additional information, refer to Section 415-00 Information and
Entertainment System - General Information .
H3: ELIMINATE THE GENERATOR AS THE CAUSE OF RADIO INTERFERENCE
REMOVE fuse 82 from the passenger compartment fuse box.
Is radio interference still present?
Yes
Diagnose the Entertainment System. For additional information, refer to Section 415-00 Information and
Entertainment System - General Information .
No
CLEAN and TIGHTEN all mounting points, positive and ground cable connections. INSTALL fuse 82 in the passenger
compartment fuse box. TEST the system for normal operation. If interference is still present, INSTALL a new
generator.
Base Voltage Test
NOTE: Prior to running this test, turn the headlamps on for 30 seconds to remove any surface charge from the battery. Wait until the
voltage stabilizes before carrying out the base voltage test.
1. With the ignition switch in the OFF position and no electrical loads applied to the battery, connect the negative lead of a digital
multimeter to the battery ground cable clamp.
1.
2. Connect the positive lead of the digital multimeter to the battery positive terminal cable clamp. 2.
3. Read and record the battery voltage shown on the digital multimeter. This is called base voltage and will be used in later tests. 3.
No-Load Test
1. Connect the digital multimeter leads across the battery terminals. 1.
2. Read the voltage (base voltage). If the battery voltage is less than 12 volts. Charge the battery before test. 2.
3. Start the engine. 3.
4. Run the engine to 1500 RPM with no electrical load applied to the battery. 4.
5. Read the voltage. If the voltage increase is less than 0.5 volts above the base voltage, carry out the Battery Condition Test. If
there is no voltage increase, diagnose the charging system. For additional information refer to the symptom chart.
5.
Battery Condition Test
WARNINGS:
Batteries contain sulphuric acid and explosive mixtures of Hydrogen and Oxygen gasses; protective clothing should be worn to avoid
the risk of personal injury.
Avoid sparks and all sources of ignition when working on the battery.
CAUTIONS:
Do not carry out this test if the battery voltage is below 12.5 volts.
Do not carry out this test for longer than 15 seconds or damage to the battery may occur.
NOTE: Make sure that the high rate discharge tester is capable of applying a load of 300 Amps to the battery.
1. Connect the high rate discharge tester to the battery. 1.
2. Observe and record the voltage reading of the battery. 2.
3. Turn the switch to the ON position for 15 seconds. 3.
4. Observe and record the minimum voltage reading of the battery. 4.
5. Turn the switch to the OFF position. 5.
6. Observe the voltage reading of the battery. 6.
The battery should recover to the original voltage when the test is complete.
The battery voltage should not fall below 9.6 volts at a temperature of 21C (70F)
when carrying out the test.
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Battery and Charging System - General Information - Charging System2.0L Duratorq-
TDCi/2.2L Duratorq-TDCi (110kW/150PS) - Puma
The diesel charging system differs from that used in petrol-engined variants in that it incorporates a 'smartcharge' function.
This function is capable of supplying infinitely variable voltages to the battery, depending on the temperature and on the current
requirements of the battery.
The system continuously monitors the battery voltage and temperature (via the ambient air temperature sensor), and uses a map of both to
deliver the optimum charge to the battery.
Another feature of this system is that it uses a 'wake-up' and 'sleep' strategy, initiated by the ignition switch position and engine control
module (ECM) to avoid current drain.
3. Check the vehicle battery condition and state of charge before condemning any of the charging system components. For additional
information, refer to the battery care manual.
3.
Generator
Drive belt
Drive belt tensioner
Generator pulley
Check the security of the generator fittings
Generator
Battery
Charging system warning light function (ignition ON, engine OFF)
Fuse 36 (7.5A) front power distribution box (battery voltage sense)
Engine/Generator ground connection
Circuit(s)
step.
4.
5. If the cause is not visually evident and the Jaguar approved diagnostic system is not available, use a scan tool to retrieve the
fault codes before proceeding to the symptom chart.
5.
3548-1358-00.
Symptom Chart
NOTE: For a full list of DTCs,
P0622Generator monitor circuit fault Generator monitor circuit: open
circuit, high resistance, short circuit
to B+, short circuit to ground
Generator regulator failure
ECM fault
For generator monitor circuit tests, GO to Pinpoint Test C.
P0623Generator warning light circuit
fault
Generator warning light circuit: open
circuit, short circuit
For generator warning light circuit tests,
REFER to: Electronic Engine Controls (303-14B Electronic
Engine Controls - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi
(110kW/150PS) - Puma, Diagnosis and Testing).
P1632Generator communications
circuit fault
Generator communications circuit:
open circuit, high resistance, short
circuit to B+, short circuit to ground
Generator regulator failure
ECM fault
For generator communications circuit tests, GO to
Pinpoint Test D.
None The battery warning light is
on, intermittent, or flickers
with the engine running
Battery, low voltage
Accessory drive belt tension
Generator failure
ECM
Instrument cluster (IC) fault
Check the battery condition and state of charge. Refer to
the battery care manual. Check the accessory drive belt
tension,
REFER to: Accessory Drive Belt Tensioner - 2.0L Duratorq-
TDCi/2.2L Duratorq-TDCi (110kW/150PS) - Puma (303-05
Accessory Drive, Removal and Installation).
Check the generator output, GO to Pinpoint Test B. and
GO to Pinpoint Test A. . For CAN circuit tests,
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2
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1
1
1
2
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1
2
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1
None The battery keeps discharging Battery fault
Battery cables
Battery quiescent drain
Generator failure
Generator pulley fault
Check the battery condition and state of charge. Refer to
the battery care manual. Check the volt drop across the
charging circuit, GO to Pinpoint Test G. Check the
accessory drive belt tension,
Check the generator output, GO to Pinpoint Test B. and
GO to Pinpoint Test A. Check that the generator pulley
does not turn independently of the generator.
None Generator noisy Generator failure
Accessory drive belt
Accessory drive belt tensioner
For generator mechanical tests, GO to Pinpoint Test E.
Check the accessory drive belt and tensioners,
None Radio interference Generator
Wiring harness
For interference tests, GO to Pinpoint Test F.
Pinpoint tests
PINPOINT TEST A : CHECK THE GENERATOR OUTPUT UNDER LOAD AT IDLE
TEST
CONDITIONS
A1: CHECK THE GENERATOR OUTPUT AT IDLE
Turn the headlights ON.
With the engine idling, measure the voltage between the battery positive terminal and GROUND over ten seconds.
Was the average voltage greater than 12.85 volts?
Yes
GO to A2.
No
Check the volt drop across the charging circuit, GO to Pinpoint Test G. . If the volt drop is within limits, install a
new generator.
REFER to: Generator.
A2: CHECK THE GENERATOR OUTPUT AT IDLE FOR OVERCHARGE
With the engine idling and headlights still ON, measure the voltage between the battery positive terminal and
GROUND over ten seconds.
Was the average voltage greater than 15.25 volts?
Yes
The generator is overcharging. INSTALL a new generator.
No
Charging system is within limits.
PINPOINT TEST B : CHECK THE GENERATOR OUTPUT UNDER LOAD
NOTE: Before beginning this test, make sure the warning light function is normal without the engine running (see visual inspection table).
TEST
CONDITIONS
B1: CHECK THE FUNCTION OF THE CHARGING SYSTEM WARNING LIGHT
Is the charging system warning light illuminated?
Yes
Check for DTC P0623.
REFER to: Electronic Engine Controls (303-14B Electronic Engine Controls - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi
(110kW/150PS) - Puma, Diagnosis and Testing).
No
GO to B2.
B2: CHECK THE CHARGING SYSTEM OUTPUT UNDER LOAD (LOW VOLTAGE)
Turn the headlights and heated rear window to the ON position.
Raise the engine speed to between 2,800 rpm and 3,200 rpm and hold for ten seconds.
Whilst holding the engine rpm in the above range, measure the voltage between the battery positive terminal and
GROUND.
Allow the engine to idle.
Was the average battery voltage less than 12.85 volts?
Yes
GO to B4.
No
GO to B3.
B3: CHECK THE CHARGING SYSTEM OUTPUT UNDER LOAD (HIGH VOLTAGE)
Whilst holding the engine rpm in the above range, measure the voltage between the battery positive terminal and
GROUND.
Was the average battery voltage greater than 15.25 volts?
Yes
INSTALL a new generator.
No
Charging system output is within limits.
B4: CHECK THE CHARGING SYSTEM VOLTAGE AT THE GENERATOR CONNECTOR, PIN 01
WARNING: The following test may involve working in close proximity to hot components. Observe caution when working in this area.
Turn the headlights and heated rear window to the OFF position.
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7
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1
2
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5
1
2
1
1
2
3
4
5
1
2
1
Disconnect the generator three-way connector.
Connect a voltmeter between the generator, pin 01 and GROUND.
Start the engine.
Turn the headlights and heated rear window to the ON position.
Whilst holding the engine rpm in the above range, measure the voltage between the generator connector, pin 01
and GROUND.
Was the voltage between 11 and 16 volts?
Yes
Generator is within limits, suspect generator cables. GO to Pinpoint Test G.
No
PINPOINT TEST C : P0622: GENERATOR MONITOR CONTROL CIRCUIT FAULT
TEST
CONDITIONS
C1: CHECK THE GENERATOR MONITOR CIRCUIT FOR HIGH RESISTANCE
Disconnect the battery negative terminal.
Disconnect the ECM connector, DL01.
Measure the resistance between the three-way connector, pin 01 (W) and DL01, pin 47 (W).
Yes
No
GO to C2.
C2: CHECK THE GENERATOR MONITOR CIRCUIT FOR SHORT TO B+
Reconnect the battery negative terminal.
Measure the voltage between DL01, pin 47 (W) and GROUND.
Yes
REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC. TEST the system
No
GO to C3.
C3: CHECK THE GENERATOR MONITOR CIRCUIT FOR SHORT TO GROUND
Measure the resistance between DL01, pin 47 (W) and GROUND.
Yes
No
RECHECK DTCs.
PINPOINT TEST D : P1632: GENERATOR COMMUNICATIONS CIRCUIT FAULT
TEST
CONDITIONS
D1: CHECK THE GENERATOR COMMUNICATIONS CIRCUIT FOR HIGH RESISTANCE
Measure the resistance between the three-way connector, pin 02 (N) and DL01, pin 112 (N).
Yes
No
GO to D2.
D2: CHECK THE GENERATOR COMMUNICATIONS CIRCUIT FOR SHORT TO B+
Measure the voltage between DL01, pin 112 (N) and GROUND.
Yes
No
GO to D3.
D3: CHECK THE GENERATOR COMMUNICATIONS CIRCUIT FOR SHORT TO GROUND
Measure the resistance between DL01, pin 112 (N) and GROUND.
Yes
No
RECHECK DTCs.
PINPOINT TEST E : GENERATOR NOISY
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1
1
1
1
1
1
2
1
2
TEST
CONDITIONS
E1: CHECK THE GENERATOR FOR SECURITY
Inspect the generator fixings.
Is the generator secure?
Yes
GO to E2.
No
SECURE the generator.
E2: CHECK THE ACCESSORY DRIVE BELT
Remove and inspect the accessory drive belt. For additional information
REFER to: Accessory Drive Belt - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) - Puma (303-05 Accessory
Drive, Removal and Installation).
Is the accessory drive belt in good condition?
Yes
GO to E3.
No
INSTALL a new accessory drive belt.
E3: CHECK THE ACCESSORY DRIVE BELT TENSIONER
Remove and inspect the accessory drive belt tensioner.
Is the accessory drive belt tensioner in good condition?
Yes
GO to E4.
No
INSTALL a new accessory drive belt tensioner.
REFER to: Accessory Drive Belt Tensioner - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) - Puma (303-05
E4: CHECK THE GENERATOR FOR MECHANICAL NOISE
Rotate the generator pulley by hand.
Does the generator rotor shaft rotate smoothly and quietly?
Yes
GO to E5.
No
E5: CHECK THE ACCESSORY DRIVE BELT IDLER PULLEYS
Rotate the accessory drive belt idler pulleys by hand.
Do the accessory drive belt idler pulleys rotate smoothly and quietly?
Yes
GO to E6.
No
INSTALL new accessory drive belt pulleys as necessary.
REFER to: Accessory Drive Belt Tensioner - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) - Puma (303-05
E6: CHECK THE GENERATOR FOR ELECTRICAL NOISE
Install the accessory drive belt.
Start and run the engine at 1500 rpm. Apply a high electrical load to the battery.
Is the noise only heard with the high electrical load applied?
Yes
GO to E7.
No
CHECK the air conditioning compressor. For additional information
REFER to: Air Conditioning (A/C) Compressor - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27 (412-03 Air
CHECK the power steering pump. For additional information
E7: ELIMINATE THE GENERATOR AS THE CAUSE OF ELECTRICAL NOISE
Remove fuse 15 from the primary junction fuse box.
Start and run the engine at 1500 rpm.
Is the noise still present?
Yes
CHECK the air conditioning compressor. For additional information
REFER to: Air Conditioning (A/C) Compressor - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27 (412-03 Air
CHECK the power steering pump. For additional information
No
PINPOINT TEST F : RADIO INTERFERENCE
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1
2
1
2
3
1
2
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1
2
3
TEST
CONDITIONS
F1: CHECK IF THE GENERATOR IS THE CAUSE OF THE RADIO INTERFERENCE
Turn the radio to the ON position, and select the affected station.
Is the radio interference present?
Yes
GO to F3.
No
GO to F2.
F2: CHECK IF THE GENERATOR IS THE CAUSE OF THE RADIO INTERFERENCE WITH A HIGH ELECTRICAL LOAD APPLIED TO THE
BATTERY
Apply a high electrical load to the battery.
Yes
GO to F3.
No
DIAGNOSE the entertainment system. For additional information
REFER to: Audio System (415-00 Information and Entertainment System - General Information, Diagnosis and
Testing).
F3: ELIMINATE THE GENERATOR AS THE CAUSE OF RADIO INTERFERENCE
Remove fuse 33 from the primary junction fuse box.
Yes
DIAGNOSE the entertainment system. For additional information
REFER to: Audio System (415-00 Information and Entertainment System - General Information, Diagnosis and
Testing).
No
CLEAN and tighten all mounting points, positive and negative cable connections (including the bonnet, boot and
engine GROUND straps). INSTALL fuse 15 from the primary junction fuse box. TEST the system for normal operation. If
interference is still present, INSTALL a new generator.
PINPOINT TEST G : CHECK THE VOLT DROP ACROSS THE BATTERY CABLES
TEST
CONDITIONS
G1: CHECK THE VOLT DROP BETWEEN THE BATTERY AND THE GENERATOR
Measure the voltage between the battery terminals.
With the negative probe still on the battery negative terminal, connect the positive probe to the generator output
terminal.
Compare the voltages.
Is the voltage difference greater than 1 volt?
Yes
INSTALL a new battery cable.
REFER to: Battery Cables - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) - Puma (414-01 Battery, Mounting
No
CHECK for DTCs. Check the generator output.
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Battery and Charging System - General Information - Battery Charging
General Procedures
1. For additional information, refer to the battery care manual (BCM).
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Battery, Mounting and Cables -
Item Specification
Battery Capacity Vehicles With Petrol Engines 80 Ah
Battery Capacity Vehicles With Diesel Engines 80 Ah
Battery Cold Cranking Vehicles With Petrol Engines 680 Amps
Battery Cold Cranking Vehicles With Diesel Engines 640 Amps
Battery to starter motor solenoid cable retaining nut - vehicles with 2.0L, 2.5L or 3.0L engines 12 9 -
Battery ground cable to body retaining bolt 25 18 -
Battery ground cable to transmision retaining bolt 25 18 -
Battery ground cable to starter motor retaining bolt - vehicles with manual transmission and 2.0L, 2.5L or 3.0L engines 35 26 -
Generator positive cable retaining nut - vehicles with 2.0L diesel engine 8 - 71
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Battery, Mounting and Cables - Battery and Cables
Vehicles fitted with 2.0L, 2.5L and 3.0L engines
1 Battery clamp retaining nut
2 Battery clamp
3 Battery cover
4 Battery
5 Battery to starter motor solenoid cable
6 Battery tray
7 Battery ground cable
8 Battery clamp retaining bolt
Vehicles fitted with 2.0L diesel engines
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1 Battery to generator and starter motor positive cable
2 Battery cover
3 Battery
4 Battery tray
5 Battery ground cable
6 Battery clamp retaining bolt
7 Battery clamp
8 Battery clamp retaining nut
The battery fitted is a 12 volts (DC) 80 ampere hour.
The battery ground cable consists of two heavy duty cables which are connected between the battery ground distributor pole and both the
vehicle body and transmission.
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Battery, Mounting and Cables - Battery
For additional information, refer to the battery care manual.
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Battery, Mounting and Cables - Battery Connect
General Procedures
WARNINGS:
Batteries normally produce explosive gases which may cause personal injury, therefore do not allow lighted substances to come near
the battery. When charging or working near the battery always shield your face and protect your eyes. Always provide adequate ventilation.
Batteries contain sulphuric acid, avoid contact with skin, eyes or clothing. Shield your face and protect your eyes when working near
the battery to guard against possible splashing of the acid solution. In case of aci d contact with the skin or eyes, flush immediately for a
minimum of 15 minutes and seek prompt medical attention. If swallowed, call a physician immediately. Failure to follow these instructions
CAUTION: Make sure all electrical systems are OFF before connecting the battery ground cable. Failure to follow this instruction may
result in damage to the vehicles electrical system.
1. NOTE: Petrol engine shown, diesel engine similar.
Connect the battery ground cable.
Install the battery cover.
3. Enter the audio unit keycode and preset radio frequencies.
4. Reset the clock to the correct time.
5. NOTE: When the battery has been disconnected and connected the
settings for the windows one touch facility and the anti-trap facility will
have been erased.
Initialize the door window motors.
For additional information, refer to: Door Window Motor Initialization
(501-11 Glass, Frames and Mechanisms, General Procedures).
6. NOTE: When the battery has been disconnected and connected, the
stored idle and drive values contained within the engine control module
(ECM) will have been erased. The ECM must relearn the idle and drive
values.
Relearn the ECM fueling adaptations.
For additional information, refer to: Evaporative Emissions - 2.0L NA V6
- AJV6 (303-13 Evaporative Emissions, Diagnosis and Testing) /
Evaporative Emissions - 2.5L NA V6 - AJV6/3.0L NA V6 - AJ27 (303-13
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Battery, Mounting and Cables - Battery Disconnect and Connect
General Procedures
Disconnect
WARNINGS:
Batteries normally produce explosive gases which may cause personal injury, therefore do not allow lighted substances to come near
the battery. When charging or working near the battery always shield your face and protect your eyes. Always provide adequate ventilation.
Batteries contain sulphuric acid, avoid contact with skin, eyes or clothing. Shield your face and protect your eyes when working near
the battery to guard against possible splashing of the acid solution. In case of aci d contact with the skin or eyes, flush immediately for a
minimum of 15 minutes and seek prompt medical attention. If swallowed, call a physician immediately. Failure to follow these instructions
Audio unit key code saving devices must not be used when working on supplemental restraint or fuel systems. When using these
devices the vehicle electrical system is still live but with a reduced current flow. Failure to follow this instruction may result in personal
injury.
CAUTION: Make sure the engine is not running before disconnecting the battery ground cable. Failure to follow this instruction may
result in damage to the vehicles electrical system.
NOTE: Before disconnecting the battery make sure that no data is required from the engine control module (ECM), as battery cable
disconnection will erase any fault codes and idle/drive values held in the keep alive memory (KAM). It is not necessary to disconnect or
remove electronic control modules.
NOTE: This procedure should be used to disconnect the battery while carrying out repairs that refer to the battery being disconnected.
1. Obtain and record the audio unit keycode and preset radio frequencies.
Remove the battery cover.
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Battery, Mounting and Cables - Battery
Removal
Disconnect the battery positive cable.
Remove the battery clamp.
Disconnect the battery vent tube.
Remove the battery.
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Remove the battery heat shield.
Installation
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Battery, Mounting and Cables - Battery Cables2.0L NA V6 - AJV6/2.5L NA V6 -
Removal
2. Detach the battery junction box positive cable.
Remove the retaining nut.
3. Remove the battery.
6. Remove the battery ground cable.
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7. Detach the battery to starter motor solenoid cable cover.
8. Remove the battery to starter motor solenoid cable.
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13. Detach the generator battery positive cable protective cover.
14. Remove the battery positive cable.
Detach the generator battery positive cable electrical connector.
Installation
Tighten to 12 Nm.
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2. Tighten to 6 Nm.
6. Tighten to 4 Nm.
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Battery, Mounting and Cables - Battery Cables2.0L Duratorq-TDCi/2.2L Duratorq-TDCi
Removal
3. Detach the generator and starter motor positive cable away from the
battery positive terminal.
4. Detach the generator and starter motor positive cable from the battery
bracket and the wiring harness.
5. Detach the generator and starter motor positive cable from the starter
motor wiring harness support bracket.
6. Reposition the starter motor solenoid protective cover.
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7. Detach the generator and starter motor positive cable from the starter
motor.
8. Detach the generator and starter motor positive cable from the air
cleaner mounting bracket.
9. Detach the generator and starter motor positive cable from the power
steering pump belt cover mounting bracket.
10. Remove the retaining strap.
11. Detach the generator and starter motor positive cable from the engine
harness.
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13. Disconnect the generator wiring harness electrical connector.
generator cable mounting bracket.
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17. Detach the battery ground cable from the transmission retaining
bracket and battery bracket.
18. Detach the battery ground cable from the transmission.
19. Remove the battery ground cable.
Installation
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Tighten to 25 Nm.
3. Tighten to 8 Nm.
4. Tighten to 8 Nm.
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Battery, Mounting and Cables - Battery Tray
Removal
1. Remove the battery.
Remove the battery tray.
Installation
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Generator and Regulator -
Generator upper retaining bolt 47 35 -
Generator lower retaining bolts - vehicles with 2.0L, 2.5L or 3.0L engine 25 18 -
Generator lower mounting studs - vehicles with 2.0L diesel engine 15 11 -
Generator lower retaining nuts - vehicles with 2.0L diesel engine 47 35 -
Generator battery positive cable retaining nut 12 9 -
Generator cooling duct retaining nuts - vehicles with 2.0L diesel engine 4 - 35
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Generator and Regulator - Generator
Charging system components
Vehicles with 2.0L, 2.5L or 3.0L engine
2 Generator
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2 Generator
NOTE: Generators should be serviced as a unit and not dismantled for overhaul.
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Generator and Regulator - Generator
2.0L/2.5L/3.0L Vehicles
REFER to: Charging System - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27 (414-00 Battery and Charging System - General
Information, Diagnosis and Testing).
2.0L Diesel Vehicle
REFER to: Charging System - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) - Puma (414-00 Battery and Charging System - General
Information, Diagnosis and Testing).
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Generator and Regulator - Generator2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6
- AJ27
Removal
2. Remove air conditioning compressor. For additional information, refer to
Section 412-03 Air Conditioning.
3. Detach the generator battery positive cable protective cover.
4. Disconnect the generator battery positive cable electrical connector.
6. Remove the generator lower retaining bolt.
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Remove the generator upper retaining bolts.
Installation
Tighten to 47 Nm.
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Generator and Regulator - Generator2.0L Duratorq-TDCi/2.2L Duratorq-TDCi
Special Tool(s)
Separator, ball joint
204-192
303-676
Removal
3. Remove the front, right-hand wheel and tire.
4. Remove the right-hand wheel arch liner access cover.
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7. Detach the right-hand stabilizer bar link.
Reposition the anti-lock brake system (ABS) wiring harness
mounting bracket.
9. Remove the generator cooling duct from the generator.
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13. Remove the generator retaining nuts.
14. Remove the generator mounting studs.
Installation
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1. Install the generator.
2. Install the generator mounting studs.
Tighten to 15 Nm.
3. Loosely install the generator retaining nuts.
4. Install the generator upper retaining bolt.
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Tighten to 12 Nm.
8. Install the generator cooling duct to the generator.
Tighten to 4 Nm.
9. Using the special tool, attach the accessory drive belt.
10. Attach the right-hand stabilizer bar link.
Attach the ABS wiring harness mounting bracket.
Tighten to 48 Nm.
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11. Install the tie-rod end and the tie-rod end retaining nut.
Tighten to 35 Nm.
13. Install the front, right-hand wheel and tire.
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Information and Entertainment System - General Information - Audio System
For a detailed description of the Audio System and components, refer to the relevant Description and Operation section in the workshop
manual. REFER to:
Audio System (415-01 Audio Unit, Description and Operation),
Antenna (415-02 Antenna, Description and Operation),
Speakers (415-03 Speakers, Description and Operation).
NOTE: Before any testing of the 'audio sound quality' make sure that the cassette tape mechanism is cleaned using the Jaguar cleaning
tape. Any testing material (tape, CD, radio, mini disc) should be of known 'good quality'. Avoid using tapes that are old, home recordings, or
damaged. Avoid using compact discs that are scratched, dirty, CDR's or CDRW's. Avoid using radio stations that are in the AM band, weak
signal strength, inside buildings or poor reception areas. Use a good sound source for testing.
Cassette tape mechanism cleanliness
Compact disc cleanliness
Mini disc cleanliness
Fuse(s)
Wiring Harness For Damage And Corrosion
Electrical Connector(s) Loose, Damaged Or Corrosion
step.
3.
NOTE: If a new audio unit is being installed under warranty, please supply the digital data bus (D2B) ring configuration and the
diagnostic trouble code(s) with the returned unit to aid fault replication.
4. If the cause is not visually evident, verify the symptom and refer to the Jaguar approved diagnostic system.
4.
DTC Index
Gateway module
3548-1358-00
module/component.
NOTE: When performing voltage or resistance tests, always use a digital multi meter (DMM) accurate to three decimal places and with a
DTC Description Possible Causes Action
B11A4DAB L Band Antenna Gateway module (digital audio
broadcast band L band) antenna
circuit - short to power, ground
or open circuit
Carry out any pinpoint tests associated with this DTC using
the manufacturer approved diagnostic system. Refer to
electrical circuit diagrams, notes and check (digital audio
broadcast L band) antenna circuit for short to power, ground or
open circuit
B11A5DAB Band 3 Antenna Gateway module (digital audio
broadcast band 3) antenna
or open circuit
electrical circuit diagrams, notes and check (digital audio
broadcast band 3) antenna circuit for short to power, ground or
open circuit
B1238 High Temperature Gateway module - over
temperature
Check gateway module and location for causes of excessive
temperature, install a new gateway module as required, refer
to the new module installation note at the top of the DTC
Index
B1342 Internal failure in Gateway
module
Gateway module - internal
failure
Internal failure install a new gateway module as required,
refer to the new module installation note at the top of the
DTC Index
B1A89SDARS or Digital Tuner
Antenna
Gateway module satellite radio
module or digital tuner antenna
or open circuit
electrical circuit diagrams, notes and check satellite radio
module or digital tuner antenna circuit for short to power,
ground or open circuit
B2477 Module Configuration Failure Gateway module - configuration
failure
The module can be configured using the new module
procedure. Check and configure as required
U0193Lost Communication with
Digital Audio Control Module
A Satellite Radio Module
Gateway module - lost
communication with satellite
radio module
electrical circuit diagrams, notes and check satellite radio
module power and bus circuit to gateway module on MOST ring
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B Digital Audio Broadcast
Module
communication with digital
audio broadcast module
electrical circuit diagrams, notes and check digital audio
broadcast module power and bus circuit to gateway module on
MOST ring
C IBOC In Band On Channel /
HD Radio
communication with Digital
Audio Control Module C
electrical circuit diagrams, notes and check Digital Audio
Control Module C power and bus circuit to gateway module on
MOST ring
U1A15Incomplete MOST Ring
Reported By ICM
Gateway module - (MOST) ring
break
electrical circuit diagrams, notes and check (MOST) circuit for
ring break
U2601(D2B)Wake-up Line Short to
Ground
Gateway module - wake-up line
short to ground
electrical circuit diagrams, notes and check gateway module
(D2B) wake-up line for short to ground
U2609(D2B)Wake-up pulse width
out of spec
Gateway module - wake-up line
fault (pulse< 50mS, pulse >
110mS)
Refer to electrical circuit diagrams, notes and check gateway
module (D2B) wake-up line circuit for fault
U2610(D2B) Slave ECU fails to
receive a report position
Gateway module - during
initialization no position status
report is received from one or
more slave modules
Refer to electrical circuit diagrams, notes and check (D2B)
slave modules and circuit for fault, replace as required, refer to
the new module installation note at the top of the DTC Index
U2611(D2B) Slave ECU fails to
receive an alarm clear
command
Gateway module - on entering
alarm state, slave ECU has
failed to receive alarm clear
command
Refer to electrical circuit diagrams, notes and check (D2B)
slave modules and circuit for fault, replace as required, refer to
the new module installation note at the top of the DTC Index
U3004Digital Tuner (Most slave)
Internal fault
Gateway module - digital tuner
MOST slave module is
inoperative
Refer to electrical circuit diagrams, notes and check digital
tuner module replace as required, refer to the new
module/component installation note at the top of the DTC
Index
U3098Digital Tuner (Most slave)
Over temperature
Gateway module - digital tuner
(Most slave) is hot
Check digital tuner module and location for causes of
excessive temperature, install a new module as required, refer
to the new module installation note at the top of the DTC
Index
Radio Head Unit
3548-1358-00
module/component.
B1238Over Temperature
Fault
Radio head unit, CD
multichanger - overheated
(+80 degrees Celsius)
Check cd multichanger module and location for causes of excessive
temperature, install a new module as required, refer to the new module
B1342ECU Internal Failure Radio head unit - no radio
function
Refer to electrical circuit diagrams, notes and check Radio head unit radio
functions for fault, replace as required, refer to the new module
B2004Internal Media Over
Temperature Fault
Radio head unit - internal
cd/md has overheated
Check Radio head unit and location for causes of excessive temperature,
install a new module as required, refer to the new module installation
note at the top of the DTC Index
B2401Audio Tape Deck
Mechanism Fault
Radio head unit - tape
loading, tape eject, tape
stuck, tape cut and seek
stop error
Refer to electrical circuit diagrams, check radio head unit install a new
module as required, refer to the new module installation note at the top
of the DTC Index
B2403Audio CD/DJ Internal
Fault
Radio head unit, CD
multichanger module - cd
eject error, cd loading error
Refer to electrical circuit diagrams, notes and check cd multichanger
module install a new module as required, refer to the new module
B2477Module Configuration
Failure
Radio head unit -
configuration failure
The module can be configured using the new module procedure. Check
and configure as required
B2888Audio Headunit Media
Fault
Radio head unit - tape
loading, tape eject, tape
stuck, tape cut and seek
stop error
Check radio head unit install a new module as required, refer to the new
module installation note at the top of the DTC Index
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C1977Audio Steering Wheel
Switch Circuit Short To
Ground
Radio head unit, audio
steering wheel switch circuit
- short to ground
Refer to electrical circuit diagrams, notes suspect the audio steering
wheel switch check for circuit short to ground
U0147Lost Communication
With Gateway "B"
Radio head unit, gateway
module - no response
(D2B/MOST)
Refer to electrical circuit diagrams, notes and check radio head unit to
gateway module control and power circuit`s, install a new module as
required, refer to the new module installation note at the top of the DTC
Index
U1262SCP (J1850)
Communication Bus
Fault
Radio head unit, ECU not
responding - internal
standard corporate protocol
(SCP) chip failure
Refer to electrical circuit diagrams, notes and check radio head unit SCP
circuit for fault, suspect the radio head unit, install a new module as
required, refer to the new module installation note at the top of the DTC
Index
U2003Audio Compact Disk /
Disk Jockey Unit is Not
Responding
Radio head unit, CD
multichanger - no
response(D2B)
diagrams, notes and check cd multichanger module and D2B circuit for
fault, install a new module as required, refer to the new module
U2008Audio Phone Not
Responding
Radio head unit, telephone
control module - no
response(D2B)
diagrams, notes and check telephone control module and D2B circuit for
fault, install a new module as required, refer to the new module
U2019Audio Voice Module
Not Responding
Radio head unit, audio voice
module - no response(D2B)
diagrams, notes and check audio voice module and D2B circuit for fault,
install a new module as required, refer to the new module/component
U2601(D2B)Wake-up Line
Short To Ground
Radio head unit, gateway
module - wake-up line short
to ground
diagrams, notes and check gateway module (D2B) wake-up line for short
to ground
U2602Incomplete MOST Ring
(fault report received)
Radio head unit - (MOST)
ring circuit fault
manufacturer approved diagnostic system. Check radio head unit for most
ring circuit fault
(No Fault Report
Received)
ring circuit fault
manufacturer approved diagnostic system. Check (MOST) ring for circuit
fault
(Corrupted Fault
Report Received)
ring circuit fault
Refer to electrical circuit diagrams, notes and check (MOST) ring for circuit
fault
U2605Master ECU Unable To
Initialize It's Address
ring circuit fault (more than
one master on the MOST
ring)
Refer to electrical circuit diagrams, notes and check for configuration fault
on (MOST) ring modules. Install a new module as required, refer to the
new module installation note at the top of the DTC Index
U2606Slave ECU Unable To
Initialize It's Address
ring circuit fault slave ecu
configuration fault
Refer to electrical circuit diagrams, notes and check for configuration fault
on (MOST) ring modules. Install a new module as required, refer to the
new module installation note at the top of the DTC Index
U2607Slave ECU ( switched
into bypass mode)
ring circuit fault (slave ecu
configuration fault)
The module can be configured using the new module procedure. Check
and configure as required
U2609(D2B)Circuit Wake-up
Line (pulse width out
of spec)
Radio head unit - wake up
line circuit fault (pulse<
50mS, pulse > 110mS)
Refer to electrical circuit diagrams, notes and check radio head unit(D2B)
wake up line circuit for fault
U2613Navigation Module Not
Responding on D2B
Radio head unit - no
response from navigation
module
manufacturer approved diagnostic system. Check navigation module to
front audio control module circuit
U2614Amp Module Not
Responding on D2B
Radio head unit - no
response from audio
amplifier module
manufacturer approved diagnostic system. Check audio amplifier module
to front audio control module circuit
Digital Audio Broadcast Module
3548-1358-00
module/component.
B11A411 L-Band
antenna
DAB L-Band antenna Circuit -
short to ground
Refer to electrical circuit diagrams and check DAB L-band antenna circuit for
short to ground
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B11A413 L-Band
antenna
DAB L-Band antenna Circuit -
open circuit
Refer to electrical circuit diagrams and check DAB L-band antenna circuit for
open circuit
B11-A511Band 3
antenna
DAB band 3 antenna circuit -
short to ground
Refer to electrical circuit diagrams and check DAB band 3 antenna circuit for
short to ground
B11-A513Band 3
antenna
DAB band 3 antenna circuit -
open circuit
Refer to electrical circuit diagrams and check DAB band 3 antenna circuit for
open circuit
U300004 Control
module
System internal failure Install a new digital audio broadcast module
U30004A Control
module
Incorrect component installed Install a new digital audio broadcast module or reconfigure the digital audio
broadcast module using the manufacturer approved diagnositc system
U300055 Control
module
Incorrect car configuration file
data received
Check/update car configuration file using manufacturer approved diagnostic
system
U300087 Control
module
Missing message Check GEM for DTCs and refer to DTC index. Check information and
entertainment module for car configuration file and MOST network DTCs and
refer to relevant DTC index. Carry out MOST/CAN network tests using the
manufacturer approved equipment.
U300098 Control
module
Component or system over
temperature
Check for additional DTCs and refer to relevant DTC index, check/monitor
system for re-occurence
U300362 Battery
voltage
Mis-match in battery voltage of 2
volts or more between digital
broadcast module and GEM
Refer to electrical circuit diagrams and check power distribution to the DAB
module and GEM. Repair any wirirng faults using approved materials and
methods. Clear DTCs and tetest system to ensure correct operation.
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Audio Unit - Audio System
Base cassette
1 Dolby noise reduction button
2 Repeat CD button
3 Audio system display
4 - Seek a stored number from the phones memory
5 Radio station pre-set buttons
6 Seek a stored number from the phones memory
7 CD track mix button
8 Priority programme type button
9 Traffic announcement button
10 Auto memory button
11 Select CD changer
12 Cassette play and side change button
13 Audio Source - AM/FM radio
14 - Cassette eject button
15 CD seek forward, cassette fast forward, radio seek forward button
16 CD seek back, cassette fast rewind, radio seek back button
17 Mode button (volume/bass/treble/balance/fade)
18 ON/OFF push (rotary volume/bass/treble/balance/fade) knob
19 Phone mode - send/end button
20 Phone mode select button
21 Memory recall button
22 Cancel button
Base CD/MD
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1 - Mutes audio
2 - Repeat CD button
3 - Audio system display
5 - Radio station pre-set buttons
7 - Mix CDs or CD/MD tracks button
8 - Eject CD or MD
9 - Priority programme type button
10 - Traffic announcement button
11 - Auto memory button
12 - Select CD changer
13 - Select compact disc when in other audio mode, or CD pause
14 - Audio Source - AM/FM radio
15 - CD seek forward, cassette fast forward, radio seek forward button
16 - CD seek back, cassette fast rewind, radio seek back button
17 - Mode button (volume/bass/treble/balance/fade)
18 - ON/OFF push (rotary volume/bass/treble/balance/fade) knob
19 - Phone mode - send/end button
20 - Phone mode select button
21 - Memory recall button
22 - Cancel button
24 - Select mini disc play when in other audio mode or MD pause
Touch screen cassette
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1 - On/Off push for touch-screen controls
2 - Touch-screen display
3 - Press to access touch-screen options
4 - CD track mix button
9 - Cassette play and side change button
11 - Cassette eject button
Touch screen CD/MD
1 - On/Off push for touch-screen controls
2 - Touch-screen display
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3 - Press to access touch-screen options
4 - Eject CD or MD
5 - Mix CDs or CD/MD tracks button
10 - Select compact disc when in other audio mode, or CD pause
17 - Select mini disc play when in other audio mode or MD pause
The choice of two entertainment systems is available; base or premium. The radio or mini disc player and the aerial are common to both.
Both systems may be operated remotely by use of switches located on the steering wheel.
The premium system has the addition of different speakers, touch screen control and a CD autochanger. The CD autochanger is located in
the luggage compartment.
Refer to the Sound System Handbook for setting-up procedures and use, after diagnostic or repair operations.
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Audio Unit - Audio System
For additional information, refer toSection 415-00 Information and Entertainment System - General Information.
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Audio Unit - Audio Unit
Removal
1. Remove the climate control panel.
For additional information, refer to Section 412-04 Control Components.
2. Remove the navigation system screen (where fitted).
For additional information, refer to Section 419-07 Navigation System.
3. Remove the audio unit screws.
4. Remove the audio unit.
Installation
1. NOTE: A new audio unit must be configured using the Jaguar approved
diagnostic equipment.
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Audio Unit - Audio Unit Amplifier4-Door
Removal
1. Remove the luggage compartment front floor carpet.
2. Remove the luggage compartment rear floor carpet.
3. Remove the luggage compartment interior trim.
4. Disconnect the audio unit amplifier electrical connectors.
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5. Remove the audio unit amplifier.
Installation
Tighten to 9 Nm.
2. Using the Jaguar approved diagnostic system configure the audio unit
amplifier.
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Audio Unit - Audio Unit AmplifierWagon
Removal
1. NOTE: Make sure the audio unit pin code is available before
disconnecting the battery ground cable.
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6. Remove the left-hand loadspace side trim panel retaining screw.
7. Disconnect the parking aid speaker electrical connector.
8. Remove the parking aid speaker.
9. Remove the audio unit amplifier retaining bolt.
10. Remove the audio unit amplifier retaining bolts.
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Installation
Tighten to 9 Nm.
2. Tighten to 9 Nm.
4. Using the Jaguar approved diagnostic system configure the audio unit
amplifier.
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Audio Unit - Compact Disc (CD) Changer4-Door
Removal
1. NOTE: Make sure the ICE pin code is available before disconnecting the
battery ground cable.
5. Remove the audio unit amplifer.
For additional information, refer to: Audio Unit Amplifier - 4-Door
(415-01 Audio Unit, Removal and Installation).
6. Detach the module retaining bracket.
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8. Remove the compact disc (CD) player retaining bolts.
9. Remove the CD player.
Installation
Tighten to 1 Nm.
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2. Tighten to 1 Nm.
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Audio Unit - Compact Disc (CD) ChangerWagon
Removal
1. NOTE: Make sure the audio unit pin code is available before
disconnecting the battery ground cable.
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7. Remove the loadspace floor covering retaining screws.
8. Detach the loadspace floor covering upwards.
9. Remove the left-hand loadspace stowage compartment retaining screw.
10. Remove the left-hand loadspace stowage compartment.
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12. Disconnect the navigation system module electrical connectors.
13. Disconnect the compact disc (CD) changer electrical connectors.
14. Disconnect the multifunction voice activated module electrical
connectors.
15. Disconnect the cellular phone module electrical connectors.
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16. Remove the CD player retaining bolts.
17. Remove the CD player.
Installation
Tighten to 1 Nm.
2. Tighten to 1 Nm.
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3. Tighten the module retaining bracket upper and lower fixings.
Tighten the lower retaining nuts to 4 Nm.
Tighten the upper retaining bolt to 9 Nm.
4. Connect the battery ground cable
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Audio Unit - Steering Wheel Audio Controls
For additional information, refer to: Steering Wheel (211-04 Steering
2. Remove the steering wheel finisher trim panel.
4. Remove the steering wheel audio controls.
Installation
Tighten to 4 Nm.
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Antenna -
Module retaining bolt - 4 Door 9 80
Antenna retaining nut - Wagon 7 62
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Antenna - Antenna
ANTENNA - 4 DOOR
1 Roof pod antenna module (vehicles from 2009MY)
2 FM antenna
3 AM Antenna
4 - Digital Audio Broadcast (DAB)/Vehicle Information and Communication System (VICS - Japan only) antenna
5 - TV antenna
6 - DAB/VICS antenna amplifier
7 - AM/FM antenna amplifier
4-Door - Vehicles up to 2009MY
The audio unit to antenna module cable is located in the body wiring harness. The antenna module to antenna cable is located along the
C-pillar.
There are two antennas fitted to the vehicle, an AM antenna and an FM antenna, both located in the rear windshield glass.
4 Door - Vehicles from 2009MY
Vehicles from 2009MY are fitted with a roof pod antenna module. The module is secured to the vehicle roof panel with 2 lock nuts and
washers screwed onto captive studs in the module. The module can contain the following antennae dependant on the vehicle equipment
specification:
DAB antenna only
GPS (global positioning system) antenna only
DAB and GPS antennae.
NOTE: On vehicles not fitted with DAB or GPS an empty module is fitted.
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The DAB system uses the antenna in the roof pod antenna module and also the rear window heater elements for DAB reception. The
antenna module receives L band signals which are passed directly to the DAB module in the luggage compartment. The rear window
elements receive band 3 signals. The band 3 signals received by the rear window elements are passed through a DAB antenna amplifier
before being passed to the DAB module located in the luggage compartment. The DAB antenna amplifier is located on the RH (right-hand)
'C' pillar adjacent to the rear window. The amplifier is connected to the rear screen elements by a connector which attaches to the
uppermost press stud on the RH of the rear screen
The AM/FM signals are received by elements in the rear window. The AM signals are received by elements located mainly in the upper LH
(left-hand) side of the rear window. The FM signals are received by elements across the whole of the rear window. The received signals are
passed through an AM/FM antenna amplifier before being passed to the audio unit. The AM/FM antenna amplifier is located on the LH 'C'
pillar adjacent to the rear window. The amplifier is connected to the rear screen el ements by a connector which attaches to press studs on
the rear screen elements. The rear window elements also incorporate reception for TV signals where a TV system is fitted.
ANTENNA - WAGON
1 - Roof pod antenna module (vehicles from 2009MY)
2 - Antenna assembly (vehicles up to 2009MY)
3 - AM/FM antenna
4 - Television (TV) antenna
5 - AM/FM antenna amplifier
6 - DAB/VICS antenna amplifier
7 - DAB/VICS (Japan only) antenna
Wagon - Vehicles up to 2009MY
The antenna assembly is mounted at the rear of the roof panel, and incorporates the AM, FM and Cellular Phone functions.
The antenna is available in two versions:
AM, FM and Cellular Phone.
AM and FM only.
All vehicles with the pre-installed cellular phone wiring are fitted with the AM/FM and cellular phone antenna as standard.
Access to the antenna assembly fixing nut can only be gained by lowering the headliner.
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Wagon - Vehicles from 2009MY
Vehicles from 2009MY are fitted with a roof pod antenna module. The module is secured to the vehicle roof panel with 2 lock nuts and
washers screwed onto captive studs in the module. The module can contain the following antennae dependant on the vehicle equipment
specification:
DAB antenna only
GPS antenna only
DAB and GPS antennae.
NOTE: On vehicles not fitted with DAB or GPS an empty module is fitted.
The DAB system uses the antenna in the roof pod antenna module and also elements in the LH rear side window for DAB reception. The
antenna module receives L band signals which are passed directly to the DAB module in the luggage compartment. The side window
elements receive band 3 signals. The band 3 signals received by the side window elements are passed through a DAB antenna amplifier
before being passed to the DAB module located in the luggage compartment. The DAB antenna amplifier is located on the body above the
side window. The amplifier is connected to the elements by a connector which attaches to the center press stud on the LH side window
elements. The LH side window also incorporates elements for the TV system if fitted.
The AM/FM signals are received by elements in the RH rear side window. The AM/FM signals are received by the elements located centrally
in the side window. The received signals are passed through an AM/FM antenna amplifier before being passed to the audio unit. The AM/FM
antenna amplifier is located on the body above the side window. The amplifier is connected to the elements by a connector which attaches
to press studs on the side window elements. The RH side window also incorporates elements for the TV system if fitted.
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Antenna - Antenna
Electrical
Module
FM anntena
AM antenna
step.
3.
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Antenna - AntennaWagon
Removal
1. Remove the overhead console.
For additional information, refer to: Overhead Console (501-12
Instrument Panel and Console, Removal and Installation).
2. Remove the both sun visors.
For additional information, refer to: Sun Visor (501-05 Interior Trim and
Ornamentation, Removal and Installation).
3. Remove the sun visor retaining clips.
Detach the front door opening weatherstrip.
5. Remove both A-pillar trim panels.
For additional information, refer to: A-Pillar Trim Panel (501-05 Interior
Detach the B-pillar upper trim panel.
Detach the B-pillar lower trim panel.
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Detach the B-pillar upper trim panel from the B-pillar trim lower trim
panel.
9. Remove both C-pillar trim panel.
10. Detach the covers to expose the screws and remove the driver and
passenger assist handles.
Remove the luggage net retaining clip.
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15. CAUTION: The headliner must not be creased or folded during
removal or installation. Failure to follow this instruction may result in
Lower the headliner.
Remove the sunroof opening panel weatherstrip.
16. Disconnect the sunroof motor electrical connector.
17. Disconnect the rear washer hose connector.
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19. Detach the antenna harness.
21. Remove the antenna.
Installation
Tighten to 7 Nm.
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Antenna - Module
Removal
1. Remove the C-pillar trim. For additional information, refer toSection
501-05 Interior Trim and Ornamentation.
2. Disconnect the antenna cable electrical connector.
3. Detach the module.
1. Remove the module retaining bolt.
2. Detach the module.
Disconnect the module electrical connectors.
Installation
Tighten to 9 Nm.
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Speakers - Speakers
All Vehicles
Optimum acoustic detail is achieved through mounting the speakers high on each door panel.
The premium sound system speakers are powered by a separate, remote amplifier.
For additional information, refer to: Audio System (415-01 Audio Unit, Description and Operation).
The standard sound system speakers are powered by the audio unit.
4-Door
The standard sound system comprises six speakers, two mid/bass and two tweeters in the front doors, and two full range speakers in the
rear doors.
The premium sound system comprises ten speakers:
Four high power and high quality speakers mounted in each door.
Four door mounted tweeters.
Two sub-woofers mounted beneath the rear parcel shelf.
Wagon
The standard sound system on wagon comprises six speakers, two mid/bass and two tweeters in the front doors, and two full range
speakers in the rear doors.
The premium sound system comprises nine speakers:
Four high power and high quality speakers mounted in each door.
Four door mounted tweeters.
An enclosed sub-woofer mounted behind the right-hand loadspace trim.
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Speakers - Speakers
Electrical
Wiring for damage and corrosion
Speakers for damage or deterioration
Rear speaker amplifier
step.
3.
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Speakers - Front Door Speaker
Removal
1. Remove the door trim panel. For additional information, refer to Section
2. Remove the front speaker.
2. Remove the front speaker.
Installation
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Speakers - Front Door Tweeter Speaker
Removal
2. Remove the front tweeter speaker.
Installation
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Speakers - Parcel Shelf Speaker
1. Remove the parcel shelf.
For additional information, refer to: Parcel Shelf (501-05 Interior Trim
and Ornamentation, Removal and Installation).
3. Remove the parcel shelf speaker.
Installation
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Speakers - Rear Door Speaker
Removal
2. Remove the rear speaker.
Installation
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Speakers - Rear Door Tweeter Speaker
Removal
2. Remove the rear tweeter speaker.
2. Remove the rear tweeter speaker.
Installation
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Exterior Lighting -
Item Specification
Front turn signal lamp bulb PY21W
Front fog lamp bulb H1-55W
Parking/Side lamp bulb W5W
Low beam lamp bulb H1-55W
High beam lamp bulb H1-55W
High intensity discharge (HID) lamp bulb D2s-35W
Rear turn signal lamp bulb PY21W
Rear fog lamp bulb P21W
Stoplamp/rear lamp bulb P21/5W
Rear lamp bulb P21/5W
Reversing lamp bulb P21W
Side repeater lamp bulb W5W
Side marker lamp bulb W5W
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Exterior Lighting - Exterior Lighting
The headlamp switch is located on the driver side of the instrument panel. It also operates the sidelamps, fog lamps, "Auto Mode",
headlamp levelling and the trip switch.
Each headlamp assembly consists of two lamps. The side lamp and the high beam lamp are the inner and the low beam and turn signal
lamp are the outer. Access for bulb replacement is from the engine compartment.
High intensity discharge (HID) lighting is fitted as an option.
WARNING: Voltages of up to 25 KV are possible with HID lighting.
Burner wear for HID lamps is so low that the burner lasts the lifetime of the vehicle under normal use. The HID bulbs are dealer replaceable
only.
NOTE: After replacement of a sensor or module the HID lamps will need to be calibrated using a Jaguar Approved Diagnostic System.
The front fog lamps are located in recesses in the front bumper. The two retaining screws are located behind the splitter vane and are
accessible after removing the radiator splash shield.
The license plate lamp bulbs on all vehicles can be accessed by releasing the retaining tangs on the side of the lamps.
Each rear lamp assembly incorporates a stop/tail lamp, a fog lamp, a reversing lamp and a turn signal lamp. Access for bulb replacement is
from the luggage compartment.
The high mounted stop lamps for both 4-door vehicles and wagon are replaceable as units. On 4-door vehicles, the two retaining screws are
located behind the headliner and are accessible after the headliner has been removed. On wagon, the three retaining screws are located
below the tailgate spoiler, and are accessible after the tailgate spoiler has been removed.
On vehicles up to 2009MY, the side repeater lamps are located in the front fender. On vehicles from 2009MY, the side repeater lamps are
located in the door mirrors.
The side marker lamps on 4-door vehicles are located in the front bumper and rear bumper cover. These are located in each bumper cover by
tangs on one side of the unit and held in position by a spring clip on the other side. The rear side marker lamps on wagon are incorporated
in to each rear lamp assembly.
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Exterior Lighting - Headlamps
For a detailed description of the lighting system, refer to the relevant Description and Operation sections in the workshop manual. REFER
to: Exterior Lighting (417-01 Exterior Lighting, Description and Operation).
Switch
Headlamp levelling motor
Levelling sensors
Relay(s)
Bulb(s)
Fuse(s)
Control module
step.
3.
DTC Index
WARNING: Voltages of up to 25 KV are possible with HID lighting
CAUTIONS:
Observe all recommended safety precautions relating to the operation and repair of headlamp systems. Refer to health and safety
guidance in the owner guide and repair manual for further details.
When probing connectors to take measurements in the course of the pinpoint tests, use the adaptor kit, part number 3548-1358-00
module/component.
B1318Battery voltage low Charging system
fault
Wiring harness
concern
Battery voltage low, check charging system for faults. Charge level is
controlled by engine control module.
B1342ECU is faulted Auto levelling ECU
internal error
Detectable internal defect (RAM/EEPROM error), check module for external
connection problems, replace module as required.
B2477Module configuration
failure
Control module not
configured
Configure control module using manufacturer approved diagnostic system
B2608ECU output to left
headlamp stepper motor
short to ground
Wiring harness
concern
Refer to electrical circuit diagrams, check left headlamp stepper motor circuit
for short to ground. Repair wiring harness using approved methods and
materials. Clear DTC and retest system to ensure correct operation.
B2609ECU output to left
circuit failure
Wiring harness
concern
open circuit or short to power. Repair wiring harness using approved methods
and materials. Clear DTC and retest system to ensure correct operation.
B2610ECU output driver to left
overtemperature
Headlamp fault Check headlamp unit for blocking of stepper motor movement, or continuous
operation. Replace headlamp components as required. Clear DTC and retest
system to ensure correct operation
B2611ECU output to right
short to ground
Wiring harness
concern
Refer to electrical circuit diagrams, check right headlamp stepper motor circuit
B2612ECU output to right
circuit failure
Wiring harness
concern
open circuit or short to power. Repair wiring harness using approved methods
and materials. Clear DTC and retest system to ensure correct operation.
B2613ECU output driver to right
overtemperature
Headlamp fault Check headlamp unit for blocking of stepper motor movement, or continuous
operation. Replace headlamp components as required. Clear DTC and retest
system to ensure correct operation
B2614Front or rear axle vehicle
level sensor supply short
to ground
Wiring harness
concern
Refer to electrical circuit diagrams, check level sensor power supply circuit for
short to ground. Repair wiring harness using approved methods and materials.
Clear DTC and retest system to ensure correct operation.
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B2615Front or rear axle vehicle
level sensor supply circuit
failure
Wiring harness
concern
Refer to electrical circuit diagrams, check level sensor power supply circuit for
short to power. Repair wiring harness using approved methods and materials.
B2616Front axle vehicle level
sensor signal circuit failure
Wiring harness
concern
Refer to electrical circuit diagrams, check level sensor signal circuit for open
circuit, short to 5 volts, short to battery power. Repair wiring harness using
approved methods and materials. Clear DTC and retest system to ensure
correct operation.
sensor signal short to
ground
Wiring harness
concern
Refer to electrical circuit diagrams, check front level sensor signal circuit for
sensor signal not plausible
Sensor
fault/adjustment
wiring harness
concern
Front sensor signal out of range. Check lever position and adjustment of
sensor. Replace sensor if signal cannot be brought into range. Refer to
electrical circuit diagrams, check level sensor signal circuit for faults. Repair
wiring harness using approved methods and materials. Clear DTC and retest
system to ensure correct operation.
B2619Rear axle vehicle level
sensor signal circuit failure
Wiring harness
concern
Refer to electrical circuit diagrams, check level sensor signal circuit for open
circuit, short to 5 volts, short to battery power. Repair wiring harness using
approved methods and materials. Clear DTC and retest system to ensure
correct operation.
sensor signal short to
ground
Wiring harness
concern
Refer to electrical circuit diagrams, check rear level sensor signal circuit for
sensor signal not plausible
Sensor
fault/adjustment
wiring harness
concern
Rear sensor signal out of range. Check lever position and adjustment of
sensor. Replace sensor if signal cannot be brought into range. Refer to
electrical circuit diagrams, check level sensor signal circuit for faults. Repair
wiring harness using approved methods and materials. Clear DTC and retest
system to ensure correct operation.
B2622Auto levelling ECU speed
message invalid / not
available
CAN message invalid
or not available
wiring harness
concern
Refer to electrical circuit diagrams, check CAN circuits for faults. Repair wiring
harness using approved methods and materials. Clear DTC and retest system
to ensure correct operation.
B2623Auto levelling ECU low
beam message invalid /
not available
CAN message invalid
or not available
wiring harness
concern
B2624Auto levelling ECU speed
signal not available
speed signal circuit
malfunction
wiring harness
concern
B2625Auto levelling ECU low
beam signal input open
circuit
Wiring harness
concern
Refer to electrical circuit diagrams, check ECU low beam input circuits for open
circuits. Repair wiring harness using approved methods and materials. Clear
DTC and retest system to ensure correct operation.
B2626Auto levelling ECU not
calibrated
ECU not calibrated
or adjusted
Calibrate and adjust the headlamp levelling ECU using the manufacturer
approved diagnostic system. Clear DTC and retest system to confirm correct
operation
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Exterior Lighting - Headlamp Adjustment
General Procedures
1. NOTE: Headlamp adjustment should be made at room temperature.
Prepare the vehicle for headlamp adjustment.
1. Place the vehicle on a level surface.
2. Before adjusting the headlamps, check for faulty lenses,
reflectors and blackened bulbs. Install new components as
necessary.
3. Check the tire pressures and correct as necessary. For
additional information, refer to Section 204-04 Wheels and
Tires.
4. The vehicle must be at normal weight.
5. Normalize the suspension.
2. Rotate the headlamp adjustment switch to the 'O' position.
3. Adjust the headlamp using the adjustment bolts.
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Exterior Lighting - Ballast
Removal
1. Remove the headlamp assembly.
For additional information, refer to Headlamp Assembly - in this section.
2. Remove the bulb cover.
3. Disconnect the ballast module electrical connector.
4. Remove the ballast module.
Installation
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Exterior Lighting - Front Fog Lamp
Removal
1. Remove the radiator splash shield. For additional information, refer
toSection 501-02 Front End Body Panels.
2. Disconnect the fog lamp electrical connector.
3. Remove the fog lamp retaining screws.
4. Remove the fog lamp.
1. Release the fog lamp retaining tang.
2. Remove the fog lamp.
Installation
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Exterior Lighting - Headlamp Assembly
Removal
All vehicles
.
2. Remove the headlamp assembly retaining bolts.
3. Detach the headlamp assembly.
Vehicles with headlamp washers
4. Disconnect the headlamp washer hose.
1. Release the headlamp washer hose retaining clip.
2. Disconnect the headlamp washer hose.
All vehicles
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6. Remove the headlamp washer motor.
Installation
2. Check the headlamp adjustment, refer to
For additional information, refer to: Headlamp Adjustment (417-01
Exterior Lighting, General Procedures).
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Exterior Lighting - Headlamp BulbVehicles With: High Intensity Discharge Headlamps
Removal
For additional information, refer to Headlamp Assembly - in this section.
1. Detach the bulb cover retaining clips.
3. NOTE: The igniter assembly electrical connector will automatically
release as the igniter assembly is rotated.
Remove the igniter assembly.
1. Detach the igniter assembly.
2. Remove the igniter assembly.
4. Remove the headlamp bulb retaining ring.
5. Remove the headlamp bulb.
Installation
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Exterior Lighting - Headlamp Leveling Module
Removal
1. Remove the headlamp assembly. For additional information, refer to
Headlamp Assembly
2. Remove the headlamp bulb cover.
3. Disconnect the headlamp adjustment module electrical connector.
4. Remove the headlamp adjustment module.
Installation
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Exterior Lighting - Headlamp Leveling Sensor
Removal
For additional information, refer to Section 204-04 Wheels and Tires.
3. Disconnect the headlamp leveling sensor electrical connector.
5. Detach the fender splash shield.
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6. Remove the headlamp leveling sensor.
Installation
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Exterior Lighting - Headlamp Switch
Removal
1. Detach the headlamp switch.
2. Detach the headlamp switch.
2. Remove the headlamp switch.
1. Disconnect the headlamp switch electrical connectors.
Installation
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Exterior Lighting - High Mounted Stoplamp4-Door
Removal
1. Remove the headliner, for additional information, refer toSection 501-05
Interior Trim and Ornamentation.
2. Remove the high mounted stoplamp retaining screws.
3. Remove the high mounted stoplamp.
Installation
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Exterior Lighting - High Mounted StoplampWagon
Removal
1. Remove the rear spoiler
For additional information, refer to: Rear Spoiler - Wagon (501-08
Exterior Trim and Ornamentation, Removal and Installation).
2. Remove the high mounted stoplamp.
Installation
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Exterior Lighting - Rear Lamp Assembly4-Door
Removal
1. Detach and reposition the rear quarter trim panel.
2. Disconnect the rear lamp assembly electrical connector.
3. Remove the rear lamp assembly retaining nuts.
4. Remove the rear lamp assembly.
Installation
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Exterior Lighting - Rear Lamp AssemblyWagon
Removal
1. Remove the loadspace trim panel.
For additional information, refer to: Loadspace Trim Panel (501-05
2. Disconnect the rear lamp assembly electrical connector.
3. Remove the rear lamp assembly retaining nuts.
4. Detach the rear lamp assembly.
Press the tangs.
5. Remove the rear lamp assembly.
Installation
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Interior Lighting - Interior Lighting
The interior lighting system consists of the following components:
One front interior lamp.
Two map reading lamps.
Two front footwell lamps
One rear interior lamp.
Two front door/puddle lamps
One glove compartment lamp.
Two vanity mirror lamps.
One luggage compartment lamp on 4-door vehicles.
Two loadspace lamps on wagon.
The automatic operation of the interior lights is controlled by the general electronics module (GEM). Pressing the interior lamp switch in the
overhead console switches the interior lighting control from automatic to ON position. When the switch is in the ON position, if any of the
doors are open, only the rear interior lamp can be turned off.
If the rear interior lamp switch is in the AUTOMATIC position, the front interior lamp switch can operate the rear interior lamp.
In the AUTOMATIC position, when the interior lights have faded out, each lamp can be switched on or off by pressing the associated switch.
If the interior lamps are switched on and the ignition switch is turned to the OFF or ACCESSORY position, the lights will automatically turn
off after ten minutes.
With the switch in the AUTOMATIC position the following times apply to the interior lights fading out assuming lights on.
Condition Fade out time
Open any door with key not in ignition, close door Lamps will fade out after twenty seconds
Open any door with engine in RUN position, close door Lamps will fade out immediately
Open any door, switch ignition to the RUN position, close door Lamps will fade out immediately
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Interior Lighting - Interior Lighting
Door switch(s)
Interior lamp switch(s)
Bulb(s)
Fuse(s)
General electronics module(GEM)
step.
3.
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Interior Lighting - Front Interior Lamp
1. Remove the overhead console. For additional information, refer to
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Interior Lighting - Rear Interior Lamp
Removal
1. Detach the interior lamp.
2. Remove the interior lamp.
Installation
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Daytime Running Lamps (DRL) - Daytime Running Lamps (DRL)
DRL use the full intensity low beam headlamps which are permanently illuminated when the vehicle is being driven. DRL are used in a
number of markets and there are two systems to cover these markets.
DRL CANADIAN MARKET
DRL for this market use full intensity low beam headlamps. The side marker lamps and license plate lamps will be on, but instrument
cluster illumination will be off. DRL are active when the following parameters are met:
Parking brake is off on vehicles with manual transmission or PARK is not selected on vehicles with automatic transmission
Ignition switch is in the ignition position (II)
The central junction box receives an engine running signal
The lighting control switch is in the off or side lamps position. If the switch is i n the 'AUTO' position the DRL will be active when the
light sensor is not operating the headlamps using the auto lamps function.
If the above conditions are met, the low beam headlamps are illuminated by a Pulse Width Modulated signal (PWM) for the vehicles fitted
with halogen headlamps (when the average voltage exceeds 14V). Vehicles with High Intensity Discharge (HID) headlamps operate the dip
beam at normal supply voltage.
The front park lamps (including front side markers) and low beam lamps are illuminated from the Front Electronic Module (FEM), the rear
park lamps (including the rear side markers and the license plate lamps) are illuminated by the Rear Electronic Module (REM).
If the lighting control switch is moved to the side lamp or headlamp positions or the auto lamps feature has activated the headlamps, DRL
are deactivated and normal side lamp and headlamp functionality is operational.
NOTE: When DRL are active, the headlamp flash function using the left hand steering column multifunction switch will operate normally.
The high beam headlamp function using the left hand steering column stalk switch will be deactivated.
When the parking brake is applied on manual transmission vehicles or the selector lever is in the PARK position on automatic transmission
vehicles, DRL are turned off. This is to reduce battery discharge during long periods of engine idling in cold climate conditions. When the
parking brake is released or the selector lever is moved from the PARK position, normal DRL functionality is restored.
DRL DENMARK, HOLLAND, NORWAY, SWEDEN, FINLAND AND POLAND
NOTE: DRL for Poland is on vehicles from 2008MY.
DRL for these markets use full intensity low beam headlamps. Side lamps and license plate lamps will be on, but instrument cluster
illumination will be off. DRL are active when the following parameters are met:
Ignition switch is in the ignition position (II)
The central junction box receives an engine running signal
The lighting control switch is in the off position. If the switch is in the 'AUTO' position the DRL will be active when the light sensor is
not operating headlamps using the auto lamps function.
If the above conditions are met, the low beam headlamps are illuminated by a Pulse Width Modulated signal (PWM) for the vehicles fitted
with halogen headlamps (when the average voltage exceeds 14V). Vehicles with High Intensity Discharge (HID) headlamps operate the dip
beam at normal supply voltage.
The front park lamps (including front side markers) and low beam lamps are illuminated from the Front Electronic Module (FEM), the rear
park lamps (including the rear side markers and the license plate lamps) are illuminated by the Rear Electronic Module (REM).
If the lighting control switch is moved to the side lamp or headlamp positions or the auto lamps feature has activated the headlamps, DRL
are deactivated and normal side lamp and headlamp functionality is operational.
NOTE: When DRL are active, the headlamp flash function using the left hand steering column multifunction switch will operate normally.
The high beam headlamp function using the left hand steering column stalk switch will be deactivated.
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Daytime Running Lamps (DRL) - Daytime Running Lamps (DRL)
Master lighting switch
Relay(s)
Bulb(s)
Fuse(s)
Battery junction box (BJB)
Central electrical junction box (CEJB)
step.
3.
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Module Communications Network - Communications Network
1 Anti-lock brake control module
2 In car entertainment (ICE) module
3 Dual automatic temperature control (DATC)
4 J Gate module (JGM)
5 High intensity dipped (HID) headlight module
6 Instrument cluster (message center optional)
9 Voice activated control module (VACM)
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Module Communications Network - Communications NetworkVIN Range:
E96603->J28492
The vehicle has four module communication networks. Only three of which are connected to the diagnostic connector. The standard
corporate protocol (SCP) and controller area network (CAN), which are an unshielded twisted pair cable: data bus + and data bus - and
the International Standard Organization (ISO) 9141 communication network, which is a single wire network.
The domestic data bus (D2B), which is a fibre optic ring network, can be diagnosed through the SCP network, and with the optical bus
tester.
The SCP, CAN and ISO networks can be connected to the Jaguar approved diagnostic system by one diagnostic connector. This makes
troubleshooting these systems easier by allowing one smart tester to be able to diagnose any module on the three networks from one
connector. On-board diagnosis of the D2B network is through the in car entertainment (ICE) head.
The diagnostic connector is located under the instrument panel.
The ISO 9141 communications network does not permit inter-module communications. When the Jaguar approved diagnostic system
communicates with modules on the ISO 9141 communication network, the diagnostic system must ask for all information, the modules will
not initiate communications.
The SCP communication network remains operational even with severing of one of the bus wires. Communications will also continue if one
of the bus wires is shorted to ground or battery positive voltage (B+), or if some (but not all) termination resistors are lost.
Unlike the SCP communication network, the ISO 9141 communication network will not function if the wire is shorted to ground or battery
positive voltage (B+). Also, if one of the modules on the ISO 9141 network loses power or shorts internally, communication to that module
will fail.
The anti-lock brake control module is connected to the CAN communication network. The module comes in two forms. The first type is the
standard equipped anti-lock brake system (ABS) with traction control. It controls the brake pressure to the four wheels to keep the vehicle
under control while braking. The second type of ABS is optional and is called dynamic stability control (DSC). This module adds yaw and
steering wheel angle sensors to the package to help in sensing a loss of vehicle control. For additional information,
REFER to: Anti-Lock Control - Stability Assist (206-09 Anti-Lock Control - Stability Assist, Description and Operation).
The in car entertainment (ICE) head is connected to the SCP communication network and also to the D2B network. The D2B communicates
with the compact disc player, cellular phone transceiver, navigation system, amplifier, and the voice control module. For additional
information on the compact disc,
REFER to: Audio System (415-00 Information and Entertainment System - General Information, Diagnosis and Testing).
For additional information on the cellular phone,
REFER to: Cellular Phone (419-08 Cellular Phone, Diagnosis and Testing).
For additional information on the navigation system,
REFER to: Navigation System (419-07 Navigation System, Diagnosis and Testing).
For additional information on the amplifier,
REFER to: Audio System (415-01 Audio Unit, Description and Operation).
For additional information on the voice activated control system,
REFER to: Multifunction Electronic Module (419-10 Multifunction Electronic Modules, Diagnosis and Testing).
The electronic automatic temperature control (EATC) module is connected to the CAN communication network. The EATC module controls
automatic climate functions that maintain the vehicle at a constant temperature setting. For additional information,
The instrument cluster (also known as an instrument cluster module ICM) is connected to the CAN and SCP communication networks. The
instrument cluster displays information received on the SCP including speedometer, odometer, fuel, and message center warnings. The
instrument cluster displays information received on the CAN including ABS, air conditioning, transmission and engine condition. The
instrument cluster also controls the passive anti-theft system (PATS). For additional information;
REFER to: Instrument Cluster and Panel Illumination (413-00 Instrument Cluster and Panel Illumination, Diagnosis and Testing).
For instrument cluster operation and
REFER to: Anti-Theft - Passive (419-01B Anti-Theft - Passive, Diagnosis and Testing).
for PATS.
The general electronic module (GEM) is connected to the SCP communication network. The GEM controls both interior and exterior lighting,
active anti-theft functions and warning chimes. For additional information on interior lamps,
REFER to: Interior Lighting (417-02 Interior Lighting, Diagnosis and Testing).
For additional information on exterior lighting,
REFER to: Headlamps (417-01 Exterior Lighting, Diagnosis and Testing).
For additional information on active anti-theft,
REFER to: Anti-Theft - Active (419-01A Anti-Theft - Active, Diagnosis and Testing).
For additional information on warning chimes,
REFER to: Warning Devices (413-09 Warning Devices, Diagnosis and Testing).
The engine control module (ECM) is connected to both the CAN and ISO 9141 communication networks. The ECM controls the engine
performance, electronic ignition, emission controls, speed control, and on board diagnostics. For additional information;
REFER to: Electronic Engine Controls - 2.5L NA V6 - AJV6/3.0L NA V6 - AJ27, VIN Range: E96603->J28492 (303-14A Electronic Engine
Controls - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27, Diagnosis and Testing).
,
REFER to: Electronic Engine Controls - 2.0L NA V6 - AJV6 (303-14A Electronic Engine Controls - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA
or
The 'phone module is connected to the D2B communication network, and incorporates the VEMS, or Vehicle Emergency Messaging System.
The module allows a user to request emergency assistance (police, ambulance, fire, recovery) or directions to a desired location at the
touch of a button. Also, if any of the vehicle's airbags are deployed while the VEMS system is powered ON, the system automatically issues
a call for emergency assistance. For additional information,
REFER to: Compact Disc (CD) Changer - 4-Door (415-01 Audio Unit, Removal and Installation).
The airbag restraints module is connected to the ISO 9141 communication network. The airbag control module controls the deployment of
the air bags based on sensor input. For additional information;
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REFER to: Air Bag Supplemental Restraint System (SRS) (501-20B Supplemental Restraint System, Diagnosis and Testing).
The voice activated control module (VACM) is connected to the D2B communication network. This allows the user to select functions by
giving a voice command. The VACM sends the command information by D2B to the correct module or audio unit.
The navigation system (NAV) is connected to the D2B communication network, and performs it's diagnostics via the SCP network. The NAV
receives inputs from the GPS antenna and various other sensors. For additional information,
2. Visually inspect for obvious signs of mechanical, electrical or optical damage. 2.
Electrical
Fuses
Wiring harness
Loose or corroded connections
Correct engagement of electrical connectors
Controller area network (CAN)
Instrument cluster (IC)
Steering wheel rotation sensor (SWRS)
Gear selector module (GSI)
Headlight levelling module (HID)
Yaw rate sensor
Electronic air temperature control module (EATCM)
Memory seat control module
Transmission control module (TCM)
Anti-lock brake control module with or without dynamic stability control (ABS/DSC)
Standard corporate protocol (SCP)
Generic electronic module (GEM)
In-car entertainment (ICE)
Navigation system (NAV)
International standards organisation (ISO)
Fuel fired heater module
Reverse park aid module
Restraints control module (RCM)
Roof console scanner
Domestic data bus (D2B)
ICE head unit (HU)
Compact disc changer (CD)
Cellular phone module (CPM)
Voice module (VACM)
Navigation system module (NSM)
Amplifier (AMP)
Optical
Routing of fibre optic harnesses
Correct engagement of optical connectors
Correct placement of optical connectors (ring order)
Damage to fibre (chafing, abrasion, kinking, cuts, etc)
Correct assembly of optical connectors (backout, etc)
Default Modes
Possible TCM default
Fixed 4th gear
Erratic gear shifts
Possible ECM default
Throttle motor and relay disabled
Throttle valve opening set to default value
Idle speed controlled by fuel injection intervention
Idle speed adaptation inhibited
Throttle opening limited to 30%
Vehicle speed limited
Speed (cruise) control limited
Maximum throttle opening for N range inhibited
Maximum engine speed reduced
HO2 sensor control circuit inhibited
Maximum ignition retard
Symptom Chart
NOTE: Network DTCs may be set by an error or communications failure in the network. Individual DTCs are in the table, alongside their
respective modules, but may also be set by a combination of factors affecting the network, which would result in multiple DTCs being set
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for one error, or, as in the case of an open circuit, no DTC being set.
P1573 CAN throttle angle error TP sensor fault (additional
DTCs logged)
ECM CAN message error
For TP sensor circuit tests,
REFER to: Electronic Engine Controls - 2.0L NA V6 - AJV6 (303-14A
Electronic Engine Controls - 2.0L NA V6 - AJV6/2.5L NA V6 -
AJV6/3.0L NA V6 - AJ27, Diagnosis and Testing) /
Electronic Engine Controls - 2.5L NA V6 - AJV6/3.0L NA V6 - AJ27,
VIN Range: E96603->J28492 (303-14A Electronic Engine Controls -
2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27, Diagnosis
and Testing).
Error message sent on CAN, but not CAN related. Check for
additional DTCs indicating cause.
P1601 Incorrect ECM or TCM
fitted to vehicle
ECM configuration
TCM configuration
Configure the modules using the Jaguar approved diagnostic
system.
P1603 TCM EEPROM failure Battery disconnected while
the ignition switched ON
B+ power supply circuit;
open circuit
TCM failure
For TCM EEPROM tests, GO to Pinpoint Test B.
P1609 ECM microprocessor to
microprocessor
communication failure
ECM failure Please check part is not on any form of prior authorisation before
replacement.
P1611 ECM sub CPU failure ECM failure Please check part is not on any form of prior authorisation before
replacement.
P1633 ECM main CPU failure ECM failure Please check part is not on any form of prior authorisation before
replacement.
P1634 Throttle 'watch-dog'
circuit malfunction
replacement.
P1637 CAN ECM to ABS/TCCM or
DSC control module
network malfunction
Module power supply or
ground interruption
CAN open circuit fault;
ABS/TCCM or DSC to ECM
CAN short circuit fault
ABS/TCCM or DSC module
failure
ECM failure
Refer to power and ground test for suspect module. For ABS/TCCM
or DSC CAN circuit tests, GO to Pinpoint Test C. Please check part
is not on any form of prior authorisation before replacement.
P1638 CAN ECM / IC network
malfunction
ground interruption
CAN open circuit fault; IC
to ECM
IC failure
ECM failure
Refer to power and ground test for suspect module. For IC CAN
circuit tests, GO to Pinpoint Test D. Please check part is not on
any form of prior authorisation before replacement.
P1642 CAN circuit malfunction Module power supply or
ground interruption
Control module failure;
Check for additional logged
DTCs to locate module
source
Refer to power and ground test for suspect module. For network
short circuit tests, GO to Pinpoint Test E.
P1643 CAN ECM / TCM network
malfunction
ground interruption
CAN open circuit fault; TCM
to ECM
TCM failure
ECM failure
Refer to power and ground test for suspect module. For CAN open
circuit tests, GO to Pinpoint Test A. For network short circuit
tests, GO to Pinpoint Test E. Please check part is not on any form
P1646 ECM HO2 sensor control
malfunction, right-hand
bank
HO2 sensor heater failure
HO2 sensor sensing circuit;
short circuit to ground,
voltage, open circuit
ECM failure
For HO2 sensor circuit tests,
and Testing).
replacement.
malfunction, left-hand
bank
ECM failure
and Testing).
replacement.
P1648 ECM KS self-test failure ECM failure Please check part is not on any form of prior authorisation before
replacement.
P1656 TP sensor amplifier circuit
malfunction
replacement.
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P1699 CAN ECM to EATCM
network malfunction
ground interruption
EATCM to ECM
CAN short circuit fault;
EATCM to ECM
EATCM failure
ECM failure
Refer to power and ground test for suspect module. For EATCM
open circuit tests, GO to Pinpoint Test A. For network short circuit
tests, GO to Pinpoint Test F. Please check part is not on any form
P1777 CAN torque reduction
error
ECM CAN message error Error message sent on CAN, but not CAN related. Check for
P1796 CAN network malfunction Module power supply or
ground interruption
TCM failure
short circuit test, GO to Pinpoint Test A.
P1797 CAN TCM/ECM network
malfunction
ground interruption
to ECM
TCM failure
ECM failure
Refer to power and ground test for suspect module. For TCM
open/short circuit tests, GO to Pinpoint Test C.
P1799 CAN TCM to ABS/TCCM or
DSC module network
malfunction
ground interruption
failure
TCM failure
short circuit tests, GO to Pinpoint Test G.
U1041 GEM SCP network invalid
vehicle speed data
ABS/DSC wheel speed
message error
SCP network error
For GEM SCP network tests, GO to Pinpoint Test H.
ignition switch data
Instrument cluster ignition
switch message error
SCP network error
U1147 GEM anti-theft SCP
network invalid ignition
key-in data
GEM key-in message error
SCP network error
U1262 GEM SCP network ignition
switch state message
missing
SCP circuit(s); open circuit
SCP network error
U1262 ICE SCP network circuit
fault
SCP network circuit; open
circuit, short circuit to B+,
SCP network circuit fault
Audio unit fault
For ICE SCP network tests, GO to Pinpoint Test I.
U1900 CAN instrumentation
messages missing
Engine management, ABS,
or DSC fault
CAN network fault
For ABS/DSC CAN network tests, GO to Pinpoint Test G.
U1900 Automatic climate control
CAN fault
CAN circuit; open circuit,
short circuit to B+, short
circuit to ground
Automatic climate control
module internal CAN fault
CAN network fault
For EATC CAN network tests, GO to Pinpoint Test F.
U1900 ABS CAN fault CAN circuit: open circuit,
circuit to ground
ABS control module
internal CAN fault
CAN network fault
U1900 DSC CAN fault CAN circuit; open circuit,
circuit to ground
DSC control module
internal CAN fault
CAN network fault
U2003 CD autochanger not
responding on D2B
network
D2B network 'wake-up'
circuit; short circuit to B+,
D2B network fault
For D2B 'wake-up' circuit tests, GO to Pinpoint Test K. For CD
autochanger D2B network tests, GO to Pinpoint Test J. For D2B
permanent supply tests, GO to Pinpoint Test R.
U2008 Cellular telephone not
responding on D2B
network
D2B network fault
For D2B 'wake-up' circuit tests, GO to Pinpoint Test K. For cellular
telephone D2B network tests, GO to Pinpoint Test L. For D2B
permanent supply tests, GO to Pinpoint Test R. For D2B accessory
switched supply tests, GO to Pinpoint Test S. For D2B ignition
switched supply tests, GO to Pinpoint Test T.
U2019 VACM not responding on
D2B network
D2B network fault
For D2B 'wake-up' circuit tests, GO to Pinpoint Test K. For VACM
D2B network tests, GO to Pinpoint Test M. For D2B accessory
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U2196 Instrument cluster CAN
engine speed message
invalid
Verify integrity of engine
management system
CAN network fault
For instrument cluster CAN network tests, GO to Pinpoint Test D.
invalid
management system
CAN network fault
engine coolant
temperature message
invalid
management system
CAN network fault
odometer count message
invalid
Verify integrity of ABS or
DSC systems
CAN network fault
U2202 Invalid DSC control
module CAN configuration
data received from ECM
Reconfigure the ECM using
the Jaguar approved
diagnostic system
CAN network fault
For ECM CAN network tests, GO to Pinpoint Test E.
U2202 Invalid ABS control
the Jaguar approved
diagnostic system
CAN network fault
U2509 ECM unable to fulfill ABS
CAN torque reduction
request
management system
CAN network fault
U2509 ECM unable to fulfill DSC
request
management system
CAN network fault
U2510
(security
flash code
23)
Anti-theft ECM
identification mismatch
ECM configuration fault
Incorrect ECM installed
Reconfigure ECM using the Jaguar approved diagnostic system.
replacement.
U2511 Anti-theft ECM invalid
data
SCP network error
replacement.
U2514 GEM wash/wipe SCP
network vehicle speed
message missing
SCP network error
U2520 Memory seats CAN open circuit fault:
memory seat module to
diagnostic connector
Memory seat module
failure
For CAN open/short circuit tests, GO to Pinpoint Test A.
U2600 Audio D2B network
'wake-up' circuit fault
circuit; short circuit to B+
For D2B 'wake-up' circuit tests, GO to Pinpoint Test K.
U2601 Voice activation module
circuit fault
ground
U2602 Break in optical ring
FROM ICE head unit
(transmitter)
D2B network module
disconnected
D2B network optical ring
broken
For optical ring tests, GO to Pinpoint Test P.
U2603 Break in optical ring TO
ICE head unit (receiver)
D2B network module
disconnected
broken
For optical ring tests, GO to Pinpoint Test Q.
signal out of specification
circuit; high resistance
Voice activation module
failure
D2B network 'position
status report' not
received
D2B network fault For D2B 'wake-up' circuit tests, GO to Pinpoint Test K.
D2B network 'alarm clear
command' not received
U2613 Navigation control
module not responding
on D2B network
D2B network fault
Module permanent supply
fault
Module accessory switched
For D2B 'wake-up' circuit tests, GO to Pinpoint Test K. For
navigation module optical tests, GO to Pinpoint Test N. For D2B
switched supply tests, GO to Pinpoint Test S.
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supply fault
Module ignition switched
supply fault
U2614 Amplifier not responding
on D2B network
D2B network fault
amplifier optical tests, GO to Pinpoint Test O. For D2B permanent
supply tests, GO to Pinpoint Test R. For D2B accessory switched
supply tests, GO to Pinpoint Test S.
None ISO circuit malfunction,
RCM
RCM K-line circuit; open
circuit
RCM K-line circuit; short
circuit
For RCM ISO tests, GO to Pinpoint Test AP.
HID module
HID module K-line circuit;
open circuit
short circuit
For HID module ISO tests, GO to Pinpoint Test AQ.
roof console module
Roof console module K-line
circuit; short circuit
For roof console module ISO tests, GO to Pinpoint Test AR.
reverse park aid module
K-line circuit; open circuit
K-line circuit; short circuit
For reverse park aid module ISO tests, GO to Pinpoint Test AS.
ECM
ECM K-line circuit; open
circuit
ECM K-line circuit; short
circuit
For ECM ISO tests, GO to Pinpoint Test AT.
fuel fired heater (FFH)
module
FFH module K-line circuit;
open circuit
short circuit
For FFH module ISO tests, GO to Pinpoint Test AU.
Power and Ground circuit test index
Modules may log DTCs if the power supply or GROUND is interrupted. Supply and GROUND tests are covered below by module name.
Description Possible source Action
IC supply or ground fault B+ supply failure
Ign+ supply failure
Acc+ supply failure
GROUND failure
For IC circuit tests, GO to Pinpoint Test U.
SWRS supply or ground fault Module supply failure
GROUND failure
For SWRS circuit tests, GO to Pinpoint Test V.
Yaw rate sensor supply or ground fault Module supply failure
GROUND failure
For yaw rate sensor circuit tests, GO to Pinpoint Test W.
ABS/TCCM supply or ground fault Ign+ supply failure
Pump+ supply failure
Solenoid+ supply
failure
GROUND failure
Motor GROUND
failure
For ABS/TCCM circuit tests, GO to Pinpoint Test X.
DSC module supply or ground fault Ign+ supply failure
Solenoid+ supply
failure
GROUND failure
Motor GROUND
failure
For DSC module circuit tests, GO to Pinpoint Test Y.
GSI module supply or ground fault Ign+ supply failure
GROUND failure
For GSI module circuit tests, GO to Pinpoint Test Z.
HID module supply or ground fault Ign+ supply failure
GROUND failure
For HID module circuit tests, GO to Pinpoint Test AA.
EATC module supply or ground fault B+ supply failure
B+save supply failure
Ign+ supply failure
GROUND failure
For EATC module circuit tests, GO to Pinpoint Test AB.
Memory seat module supply or ground fault B+1 supply failure
B+2 supply failure
Ign+ supply failure
Electronic GROUND
failure
Power GROUND
failure
Signal GROUND
For memory seat module circuit tests, GO to Pinpoint Test
AC.
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failure
TCM supply or ground fault (16 bit) B+ supply failure
Ign+ supply failure
GROUND failure
For 16 bit TCM circuit tests, GO to Pinpoint Test AD.
Ign+ supply failure
GROUND failure
For 32 bit TCM circuit tests, GO to Pinpoint Test AE.
ECM supply or ground fault, vehicles with 2.0L
petrol engine
B+memory supply
failure
Control supply failure
GROUND failure
For ECM circuit tests, vehicles with 2.0L petrol engines, GO to
Pinpoint Test AF.
ECM supply or ground fault, vehicles with
2.5/3.0L petrol engine
B+memory supply
failure
GROUND failure
For ECM circuit tests, vehicles with 2.5/3.0L petrol engines,
GO to Pinpoint Test AG.
diesel engine
Vpwr supply failure
GROUND failure
For ECM circuit tests, vehicles with 2.0L diesel engines, GO to
Pinpoint Test AH.
ICE supply or ground fault B+memory supply
failure
Acc+ supply failure
GROUND failure
For ICE circuit tests, GO to Pinpoint Test AI.
CD supply or ground fault B+ supply failure
GROUND failure
For CD changer circuit tests, GO to Pinpoint Test AJ.
NAV module supply or ground fault B+ supply failure
Acc+ supply failure
GROUND failure
For NAV module circuit tests, GO to Pinpoint Test AK.
FFH module supply or ground fault B+ supply failure
Ign+ supply failure
GROUND failure
For FFH module circuit tests, GO to Pinpoint Test AL.
Park aid module supply or ground fault Ign+ supply failure
GROUND failure
For park aid module circuit tests, GO to Pinpoint Test AM.
RCM supply or ground fault Ign+ supply failure
GROUND failure
For RCM circuit tests, GO to Pinpoint Test AN.
GEM supply or ground fault B+ supply failure For GEM circuit tests, GO to Pinpoint Test AO.
Amplifier supply or ground fault B+ supply failure
GROUND failure
For amplifier circuit tests, GO to Pinpoint Test AV.
Pinpoint tests
CAUTIONS:
Diagnosis by substitution from a donor vehicle is NOT acceptable. Each vehicle is configured to it's own vehicle identification data
(VID) block, and substitution of control modules may not only not confirm a fault, but may cause faults in the vehicle being tested and/or
the donor vehicle. Failure to follow this instruction may result in damage to the vehicle.
Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. Failure to follow this
NOTE: Before beginning any diagnosis of the D2B system, codes B1342, U2602, or U2603 must be rectified. No D2B function is possible
with these failures present.
PINPOINT TEST A : CHECK THE CONTROLLER AREA NETWORK (CAN) CONTINUITY
NOTE: The following test is based on the maximum number of modules in the network. Refer to the wiring diagrams for information on
networks with fewer modules.
TEST
CONDITIONS
A1: CHECK THE RESISTANCE OF THE CAN NETWORK
Measure the resistance between pins 06 (Y) and 14 (G) of the diagnostic connector.
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Yes
GO to A3.
No
GO to A2.
A2: CHECK THE CAN NETWORK FOR SHORT CIRCUIT
Yes
CHECK the network for short circuit. For additional information, refer to the wiring diagrams. Clear any DTCs, test
No
GO to A3.
A3: CHECK THE CAN + CIRCUIT BETWEEN THE DIAGNOSTIC CONNECTOR AND THE STEERING WHEEL ROTATION SENSOR
Disconnect the steering wheel rotation sensor connector, IP19.
Measure the resistance between IP19, pin 03 (Y) and the diagnostic connector, pin 06 (Y).
Yes
REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. Clear any DTCs, test the
No
GO to A4.
A4: CHECK THE CAN - CIRCUIT BETWEEN THE DIAGNOSTIC CONNECTOR AND THE STEERING WHEEL ROTATION SENSOR
Measure the resistance between IP19, pin 04 (G) and the diagnostic connector, pin 14 (G).
Yes
No
GO to A5.
A5: CHECK THE CAN + CIRCUIT BETWEEN THE DIAGNOSTIC CONNECTOR AND THE YAW RATE SENSOR
Disconnect the yaw rate sensor connector, IP20.
Yes
No
GO to A6.
A6: CHECK THE CAN - CIRCUIT BETWEEN THE DIAGNOSTIC CONNECTOR AND THE YAW RATE SENSOR
Yes
No
GO to A7.
A7: CHECK THE CAN + CIRCUIT BETWEEN THE DIAGNOSTIC CONNECTOR AND THE MEMORY SEAT MODULE (WHERE FITTED)
Disconnect the memory seat module connector, DM01.
Measure the resistance between DM01, pin 12 (Y) and the diagnostic connector, pin 06 (Y).
Yes
No
GO to A8.
A8: CHECK THE CAN - CIRCUIT BETWEEN THE DIAGNOSTIC CONNECTOR AND THE MEMORY SEAT MODULE (WHERE FITTED)
Measure the resistance between DM01, pin 02 (G) and the diagnostic connector, pin 14 (G).
Yes
No
GO to A9.
A9: CHECK THE CAN + CIRCUIT BETWEEN THE DIAGNOSTIC CONNECTOR AND THE ABS/DSC MODULE
Disconnect the ABS/TCCM connector, JB45, or DSC module connector, JB185.
Measure the resistance between JB45/JB185, pin 24 (Y) and the diagnostic connector, pin 06 (Y).
Yes
No
GO to A10.
A10: CHECK THE CAN - CIRCUIT BETWEEN THE DIAGNOSTIC CONNECTOR AND THE ABS/DSC MODULE
Measure the resistance between JB45/JB185, pin 40 (G) and the diagnostic connector, pin 14 (G).
Yes
No
GO to A11.
A11: CHECK THE CAN + CIRCUIT BETWEEN THE DIAGNOSTIC CONNECTOR AND THE HID MODULE (WHERE FITTED)
Disconnect the HID module connector, IP130.
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Yes
No
GO to A12.
A12: CHECK THE CAN - CIRCUIT BETWEEN THE DIAGNOSTIC CONNECTOR AND THE HID MODULE (WHERE FITTED)
Yes
No
NO circuit fault found. Check DTCs for indications of a module fault.
PINPOINT TEST B : P1603. TCM EEPROM FAILURE
TEST
CONDITIONS
B1: DTC SET BY 3 POSSIBLE FACTORS
Check battery voltage.
Has the battery been discharged to a voltage where the engine would not crank?
Yes
CHARGE and test the battery. Install a new battery, if required.
REFER to: Battery (414-01 Battery, Mounting and Cables, Removal and Installation).
Carry out a drive-cycle.
(The vehicle may lose it's adaptive values and will need to re-learn them. These values will depend on the owner's driving style, and can only be learnt by
normal use.)
No
GO to B2.
Check the TCM for signs of water ingress.
Does the TCM show any indication of water ingress?
Yes
INSTALL a new TCM.
REFER to: Transmission Control Module (TCM) (307-01B Automatic Transmission/Transaxle - Vehicles With: 6-Speed
No
GO to B3.
Check if the battery has been disconnected with the ignition switched on.
Has the battery been disconnected with the ignition switched on?
Yes
CARRY out a drive-cycle. For additional information, refer to the DTC section of JTIS.
normal use.)
No
INSTALL a new TCM.
PINPOINT TEST C : P1637: CAN NETWORK MALFUNCTION, TRANSMISSION CONTROL MODULE (TCM)
TEST
CONDITIONS
C1: CHECK TCM FOR DAMAGE
Inspect the TCM
Does the TCM indicate any signs of damage?
Yes
INSTALL a new TCM.
No
GO to C2.
C2: CHECK CAN + FOR SHORT CIRCUIT TO GROUND
Measure the resistance between the diagnostic connector, pin 06, (Y) and GROUND.
Yes
normal operation.
No
GO to C3.
C3: CHECK CAN + FOR SHORT CIRCUIT TO BATTERY
Measure the resistance between the diagnostic connector, pins 06, (Y) and pin 16 (OY).
Yes
normal operation.
No
GO to C4.
C4: CHECK CAN - FOR SHORT CIRCUIT TO GROUND
Measure the resistance between the diagnostic connector, pin 14 (G) and GROUND.
Yes
normal operation.
No
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GO to C5.
C5: CHECK CAN - FOR SHORT CIRCUIT TO BATTERY
Measure the resistance between the diagnostic connector, pin 14 (G) and pin 16 (OY).
Yes
normal operation.
No
GO to C6.
C6: CHECK FOR SHORT CIRCUIT BETWEEN CAN + AND CAN -
Measure the resistance between the diagnostic connector, pins 6 (Y) and 14 (G).
Yes
normal operation.
No
GO to C7.
C7: CHECK FOR OPEN CIRCUIT ON CAN + BETWEEN DIAGNOSTIC CONNECTOR AND THE TCM
Vehicles with 16 bit modules -
Disconnect the TCM connector, JB131.
Measure the resistance between the diagnostic connector, pin 06 (Y) and JB131, pin 33 (Y).
Yes
No
GO to C8.
C8: CHECK FOR OPEN CIRCUIT ON CAN - BETWEEN THE DIAGNOSTIC CONNECTOR AND THE TCM
Measure the resistance between the diagnostic connector, pin 14 (G) and:
JB131, pin 12 (G).
JB230, pin 06 (G).
Yes
GO to C9.
No
REPAIR the CAN - circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC, test the system
C9: CHECK FOR CORRECT BUS TERMINATION
Reconnect the TCM connector, JB131 or JB230.
Yes
INSTALL a new TCM.
No
GO to C10.
C10: CHECK CONTINUITY OF THE CAN + CIRCUIT BETWEEN THE ECM AND THE IC
To test:
Vehicles with 2.5 and 3.0L engine -
Disconnect the ECM connector, EN16, and the IC connector, IP10.
Measure the resistance between EN16, pin 124 (Y) and IP10, pin 17 (Y).
Vehicles with 2.0L petrol engine -
Vehicles with 2.0L diesel engine -
Disconnect the ECM connector, DL01, and the IC connector, IP10.
Measure the resistance between DL01, pin 54 (Y) and IP10, pin 17 (Y).
Yes
REPAIR the CAN + circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC, test the system
No
GO to C11.
C11: CHECK CONTINUITY OF THE CAN - CIRCUIT BETWEEN THE ECM AND THE IC
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EN16, pin 123 (G) and IP10, pin 18 (G).
DL01, pin 73 (G) and IP10, pin 18 (G).
Yes
No
GO to C12.
C12: CHECK FOR LOSS OF TERMINATION WITHIN THE ECM
To test:
Measure the resistance between pins 123 and 124 of the ECM.
Yes
GO to C13.
No
C13: CHECK FOR LOSS OF TERMINATION WITHIN THE IC
Measure the resistance between pins 17 and 18 of the IC.
Yes
POSSIBLE intermittent fault. Recheck DTCs.
No
PINPOINT TEST D : P1638: CAN NETWORK MALFUNCTION, INSTRUMENT CLUSTER (IC)
TEST
CONDITIONS
D1: CHECK THE IC FOR DAMAGE
Inspect the IC for damage.
Does the IC indicate any signs of damage?
Yes
No
GO to D2.
D2: CHECK CAN + FOR SHORT CIRCUIT TO GROUND
Measure the resistance between the diagnostic connector, pin 06 (Y) and GROUND.
Yes
No
GO to D3.
D3: CHECK CAN + FOR SHORT CIRCUIT TO BATTERY
Measure the resistance between the diagnostic connector, pin 06 (Y) and pin 16 (OY).
Yes
No
GO to D4.
D4: CHECK CAN - FOR SHORT CIRCUIT TO GROUND
Yes
No
GO to D5.
D5: CHECK CAN - FOR SHORT CIRCUIT TO BATTERY
Measure the resistance between the diagnostic connector, pins 14 (G) and 16 (OY).
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Yes
No
GO to D6.
D6: CHECK FOR SHORT CIRCUIT BETWEEN CAN + AND CAN -
Yes
No
GO to D7.
D7: CHECK FOR OPEN CIRCUIT ON CAN + BETWEEN THE DIAGNOSTIC CONNECTOR AND THE IC
Disconnect the IC connector, IP10.
Measure the resistance between the diagnostic connector, pin 06 (Y) and IP10, pin 17 (Y).
Yes
No
GO to D8.
D8: CHECK FOR OPEN CIRCUIT ON CAN - BETWEEN THE DIAGNOSTIC CONNECTOR AND THE IC
Measure the resistance between the diagnostic connector, pin 14 (G) and IP10, pin 18 (G).
Yes
No
GO to D9.
D9: CHECK FOR CORRECT BUS TERMINATION
Reconnect the IC connector, IP10.
Yes
No
GO to D10.
D10: CHECK CONTINUITY OF THE CAN + CIRCUIT BETWEEN THE ECM AND THE IC
To test:
Yes
No
GO to D11.
D11: CHECK CONTINUITY OF THE CAN - CIRCUIT BETWEEN THE ECM AND THE IC
Yes
No
GO to D12.
D12: CHECK FOR LOSS OF TERMINATION WITHIN THE ECM
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pins 123 and 124 of the ECM.
Yes
GO to D13.
No
D13: CHECK FOR LOSS OF TERMINATION WITHIN THE IC
Yes
No
PINPOINT TEST E : P1642; P1643; P1797: CAN NETWORK MALFUNCTION, ECM
TEST
CONDITIONS
E1: CHECK THE ECM FOR DAMAGE
Inspect the ECM.
Does the ECM indicate any signs of damage?
Yes
No
GO to E2.
E2: CHECK CAN + FOR SHORT CIRCUIT TO GROUND
Yes
No
GO to E3.
E3: CHECK CAN + FOR SHORT CIRCUIT TO BATTERY
Measure the resistance between the diagnostic connector, pin 06, (Y) and pin 16 (OY).
Yes
No
GO to E4.
E4: CHECK CAN - FOR SHORT CIRCUIT TO GROUND
Yes
No
GO to E5.
E5: CHECK CAN - FOR SHORT CIRCUIT TO BATTERY
Yes
No
GO to E6.
E6: CHECK FOR SHORT CIRCUIT BETWEEN CAN + AND CAN -
Yes
No
GO to E7.
E7: CHECK FOR OPEN CIRCUIT ON CAN + BETWEEN THE DIAGNOSTIC CONNECTOR AND THE ECM
Disconnect the ECM connector, EN16.
Measure the resistance between IP22 pin 06 (Y) and EN16, pin 124 (Y).
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Measure the resistance between the diagnostic connector, pin 06 (Y) and DL01, pin 54 (Y).
Yes
No
GO to E8.
E8: CHECK FOR OPEN CIRCUIT ON CAN - BETWEEN THE DIAGNOSTIC CONNECTOR AND THE ECM
To test:
Measure the resistance between the diagnostic connector, pin 14 (G) and EN16, pin 123 (G).
Measure the resistance between the diagnostic connector, pin 14 (G) and DL01, pin 73 (G).
Yes
No
GO to E9.
E9: CHECK FOR CORRECT BUS TERMINATION
Reconnect the ECM connector.
Yes
No
GO to E10.
E10: CHECK CONTINUITY OF THE CAN + CIRCUIT
To test:
Yes
No
GO to E11.
E11: CHECK CONTINUITY OF THE CAN - CIRCUIT
Yes
No
GO to E12.
E12: CHECK FOR LOSS OF TERMINATION WITHIN THE ECM
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Yes
GO to E13.
No
E13: CHECK FOR LOSS OF TERMINATION WITHIN THE IC
Yes
No
PINPOINT TEST F : P1699: CAN NETWORK MALFUNCTION, ELECTRONIC AUTOMATIC TEMPERATURE CONTROL
(EATC) MODULE
TEST
CONDITIONS
F1: CHECK THE EATC MODULE FOR DAMAGE
Inspect the EATC module for damage.
Does the EATC module indicate any signs of damage?
Yes
INSTALL a new EATC module.
REFER to: Climate Control System (412-00 Climate Control System - General Information, Description and
Operation).
No
GO to F2.
F2: CHECK CAN + FOR SHORT CIRCUIT TO GROUND
Yes
No
GO to F3.
F3: CHECK CAN + FOR SHORT CIRCUIT TO BATTERY
Yes
No
GO to F4.
F4: CHECK CAN - FOR SHORT CIRCUIT TO GROUND
Yes
No
GO to F5.
F5: CHECK CAN - FOR SHORT CIRCUIT TO BATTERY
Yes
No
GO to F6.
F6: CHECK FOR SHORT CIRCUIT BETWEEN CAN + AND CAN -
Yes
No
GO to F7.
F7: CHECK FOR OPEN CIRCUIT ON CAN + BETWEEN THE DIAGNOSTIC CONNECTOR AND THE EATC MODULE
Disconnect the EATC module connector, IP101.
Yes
No
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GO to F8.
F8: CHECK FOR OPEN CIRCUIT ON CAN - BETWEEN THE DIAGNOSTIC CONNECTOR AND THE EATC MODULE
Yes
No
GO to F9.
F9: CHECK FOR CORRECT BUS TERMINATION
Reconnect the EATC module connector, IP101.
Yes
Operation).
No
GO to F10.
F10: CHECK CONTINUITY OF THE CAN + CIRCUIT BETWEEN THE ECM AND THE IC
To test:
Yes
No
GO to F11.
F11: CHECK CONTINUITY OF THE CAN - CIRCUIT BETWEEN THE ECM AND THE IC
Yes
No
GO to F12.
F12: CHECK FOR LOSS OF TERMINATION WITHIN THE ECM
Yes
GO to F13.
No
F13: CHECK FOR LOSS OF TERMINATION WITHIN THE IC
Yes
No
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PINPOINT TEST G : P1799: CAN NETWORK MALFUNCTION, ANTI-LOCK BRAKE (ABS)/DYNAMIC STABILITY
CONTROL (DSC) CONTROL MODULE
TEST
CONDITIONS
G1: CHECK THE ABS OR DSC MODULE FOR DAMAGE
Inspect the ABS/TCCM or DSC module.
Does the ABS/TCCM or DSC module indicate any signs of damage?
Yes
INSTALL a new ABS/TCCM or DSC module.
REFER to: Hydraulic Control Unit (HCU) - VIN Range: C00001->J12991 (206-09 Anti-Lock Control - Stability Assist,
No
GO to G2.
G2: CHECK CAN + FOR SHORT CIRCUIT TO GROUND
Yes
No
GO to G3.
G3: CHECK CAN + FOR SHORT CIRCUIT TO BATTERY
Yes
No
GO to G4.
G4: CHECK CAN - FOR SHORT CIRCUIT TO GROUND
Yes
No
GO to G5.
G5: CHECK CAN - FOR SHORT CIRCUIT TO BATTERY
Measure the resistance between the diagnostic connector, pins 14 (G) and pin 16 (OY).
Yes
No
GO to G6.
G6: CHECK FOR SHORT CIRCUIT BETWEEN CAN + AND CAN -
Yes
No
GO to G7.
G7: CHECK FOR OPEN CIRCUIT ON CAN + BETWEEN THE DIAGNOSTIC CONNECTOR AND THE ABS OR DSC MODULE
Measure the resistance between the diagnostic connector, pin 06 (Y) and JB45/JB185, pin 24 (Y).
Yes
No
GO to G9.
G8: CHECK FOR OPEN CIRCUIT ON CAN - BETWEEN THE DIAGNOSTIC CONNECTOR AND THE ABS OR DSC MODULE
Measure the resistance between the diagnostic connector, pin 14 (G) and JB45/JB185, pin 40 (G).
Yes
No
GO to G9.
G9: CHECK FOR CORRECT BUS TERMINATION
Reconnect the ABS/TCCM module connector, JB45, or DSC module connector, JB185.
Yes
INSTALL a new ABS/TCCM module, or DSC module.
REFER to: Hydraulic Control Unit (HCU) - VIN Range: C00001->J12991 (206-09 Anti-Lock Control - Stability Assist,
No
GO to G10.
G10: CHECK CONTINUITY OF THE CAN + CIRCUIT BETWEEN THE ECM AND THE IC
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To test:
Yes
No
GO to G11.
G11: CHECK CONTINUITY OF THE CAN - CIRCUIT
Yes
No
GO to G12.
G12: CHECK FOR LOSS OF TERMINATION WITHIN THE ECM
Yes
GO to G13.
No
G13: CHECK FOR LOSS OF TERMINATION WITHIN THE IC
Measure the resistance between pins 17 and 18 of the instrument cluster.
Yes
Possible intermittent fault. Recheck DTCs. Repeat tests from A1.
No
PINPOINT TEST H : SCP NETWORK MALFUNCTION, GENERIC ELECTRONIC MODULE (GEM)
TEST
CONDITIONS
H1: CHECK GEM FOR DAMAGE
Inspect the GEM for damage.
Does the GEM indicate any signs of damage?
Yes
INSTALL a new GEM.
REFER to: Generic Electronic Module (GEM) (419-10 Multifunction Electronic Modules, Removal and Installation).
No
GO to H2.
H2: CHECK THE SCP + FOR SHORT CIRCUIT TO GROUND
Yes
No
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GO to H3.
H3: CHECK THE SCP + FOR SHORT CIRCUIT TO BATTERY
Measure the resistance between the diagnostic connector, pins 02 (Y) and 16 (OY).
Yes
No
GO to H4.
H4: CHECK THE SCP - FOR SHORT CIRCUIT TO GROUND
Measure the resistance between the diagnostic connector, pin 10 (U) and GROUND.
Yes
No
GO to H5.
H5: CHECK THE SCP - FOR SHORT CIRCUIT TO BATTERY
Measure the resistance between the diagnostic connector, pins 10 (U) and 16 (OY).
Yes
No
GO to H6.
H6: CHECK FOR SHORT CIRCUIT BETWEEN SCP + AND SCP -
Measure the resistance between the diagnostic connector, pins 10 (U) and 02, (Y).
Yes
No
GO to H7.
H7: CHECK FOR OPEN CIRCUIT ON SCP + BETWEEN THE DIAGNOSTIC CONNECTOR AND THE GEM
Disconnect the GEM connector, IP05.
Yes
No
GO to H8.
H8: CHECK FOR OPEN CIRCUIT ON SCP - BETWEEN THE DIAGNOSTIC CONNECTOR AND THE GEM
Measure the resistance between the diagnostic connector, pin 10 (U) and IP05, pin 18 (U).
Yes
No
GO to H9.
H9: CHECK FOR CORRECT BUS TERMINATION ON SCP +
Reconnect the GEM connector, IP05.
Is the resistance 150 to 210 ohms?
Yes
INSTALL a new GEM.
No
GO to H10.
H10: CHECK THE CONTINUITY OF THE GENERIC ELECTRONIC MODULE (GEM) SCP + CIRCUIT
Yes
No
GO to H11.
H11: CHECK FOR LOSS OF SCP + TERMINATION WITHIN THE GEM
Measure the resistance between IP05, pin 19, and IP06, pin 01 of the GEM.
Yes
GO to H12.
No
INSTALL a new GEM.
H12: CHECK CONTINUITY OF THE INSTRUMENT CLUSTER (IC) SCP + CIRCUIT
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Yes
No
GO to H13.
H13: CHECK FOR LOSS OF SCP + TERMINATION WITHIN THE INSTRUMENT CLUSTER
Yes
No
INSTALL a new IC.
PINPOINT TEST I : SCP NETWORK MALFUNCTION, IN CAR ENTERTAINMENT (ICE) HEAD
TEST
CONDITIONS
I1: CHECK ICE FOR DAMAGE
Inspect the ICE head for damage.
Does the ICE head indicate any signs of damage?
Yes
INSTALL a new ICE head.
REFER to: Audio Unit (415-01 Audio Unit, Removal and Installation).
No
GO to I2.
I2: CHECK THE SCP + FOR SHORT CIRCUIT TO GROUND
Yes
No
GO to I3.
I3: CHECK THE SCP + FOR SHORT CIRCUIT TO BATTERY
Yes
No
GO to I4.
I4: CHECK THE SCP - FOR SHORT CIRCUIT TO GROUND
Yes
No
GO to I5.
I5: CHECK THE SCP - FOR SHORT CIRCUIT TO BATTERY
Yes
No
GO to I6.
I6: CHECK FOR SHORT CIRCUIT BETWEEN SCP + AND SCP -
Measure the resistance between the diagnostic connector, pins 10 (U) and 02 (Y).
Yes
No
GO to I7.
I7: CHECK FOR OPEN CIRCUIT ON SCP + BETWEEN THE DIAGNOSTIC CONNECTOR AND THE ICE HEAD UNIT
Disconnect the ICE connector, IP65.
Yes
No
GO to I8.
I8: CHECK FOR OPEN CIRCUIT ON SCP - BETWEEN THE DIAGNOSTIC CONNECTOR AND THE ICE HEAD UNIT
Yes
No
GO to I9.
I9: CHECK FOR CORRECT BUS TERMINATION ON SCP +
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Reconnect the ICE connector, IP65.
Yes
INSTALL a new ICE head unit.
No
GO to I10.
I10: CHECK THE CONTINUITY OF THE GENERIC ELECTRONIC MODULE (GEM) SCP + CIRCUIT
Measure the resistance between IP22, pin 02 (Y) and IP05, pin 19 (Y).
Yes
No
GO to I11.
I11: CHECK FOR LOSS OF SCP + TERMINATION WITHIN THE GEM
Yes
GO to I12.
No
INSTALL a new GEM.
I12: CHECK CONTINUITY OF THE IC SCP + CIRCUIT
Yes
No
GO to I13.
I13: CHECK FOR LOSS OF SCP + TERMINATION WITHIN THE IC
Measure the resistance between IP10, pin 22 (Y) and IP11, pin 08 of the IC.
Yes
No
INSTALL a new IC.
PINPOINT TEST J : U2003: COMPACT DISC CHANGER NOT RESPONDING
CAUTION: The following tests involve disconnection of the fibre optic harnesses. The harness connectors must be protected by
suitable dust caps as soon as they are disconnected, or damage may result. The use of tools to unlatch connectors must be avoided, or the
connector locking function may be lost. Failure to follow this instruction may result in damage to the vehicle.
NOTE: The following test sequence is based on a five node network. Refer to the wiring diagrams for network configuration for networks
with a diferent number of nodes (all possible network combinations are shown in the wiring diagrams).
NOTE: Should a break occur in the D2B ring, then codes, U2602, or U2603 will be set, depending on the location of the break. U2602 will
set if the break is in the optical harness FROM the ICE head unit (the transmitter signal). U2603 will set if the break is in the optical
harness TO the ICE head unit (the receiver signal). GO to Pinpoint Test P. GO to Pinpoint Test Q.
J1: CHECK CD CHANGER MODULE, USING OPTICAL BUS TESTER
Connect the Optical Bus Tester to the fibre optic lead connector, CD02.
Set the Optical Bus Tester to BY-PASS.
Clear the DTC.
Turn the ignition switch to the ACC position.
Wait for 10 seconds.
Check for 'not responding' DTCs.
Is U2003 set?
Yes
CHECK the 'wake-up' signal to the module.
No
GO to J2.
J2: CHECK FOR DTC U2602 OR U2603
Check DTCs.
Are codes U2602 or U2603 logged?
Yes
CHECK for break in optical harness.
No
Recheck DTCs. No break in optical harness.
PINPOINT TEST K : ONE OR MORE D2B MODULES NOT RESPONDING. 'WAKE-UP' SIGNAL FAULT
NOTE: The D2B 'wake-up' signal is not a constant, but will generate a pulse at each cycle of the ignition key. The ignition key must be
turned to the OFF position following each step of the tests, and turned to the position indicated by the test step for each module. To avoid
missing the signal, use an assistant to operate the key while reading the oscilloscope. The 'wake-up' line is battery voltage, switching to 0
volts for between 50 milliseconds and 110 milliseconds as the ICE head unit sends it's signal.
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K1: CHECK THE 'WAKE-UP' SIGNAL TO THE CD CHANGER
Disconnect the CD changer connector, CA301.
Measure the voltage between CA301, pin 03 (O) and GROUND, using an oscilloscope (see note above).
Does the oscilloscope show a 'wake-up' signal as described?
Yes
GO to K2.
No
REPAIR the circuit between CA301, pin 03 and the ICE head unit connector, IP65, pin 19. For additional
K2: CHECK THE 'WAKE-UP' SIGNAL TO THE VOICE ACTIVATED CONTROL MODULE
Disconnect the voice activated control module connector, PH02.
Measure the voltage between PH02, pin 14 (O) and GROUND, using an oscilloscope (see note above).
Yes
GO to K3.
No
REPAIR the circuit between PH02, pin 14 and the ICE head unit connector, IP65, pin 19. For additional
K3: CHECK THE 'WAKE-UP' SIGNAL TO THE 'PHONE MODULE
Disconnect the 'phone module connector, PH01.
Yes
GO to K4.
No
information, refer to the wiring diagrams. CLEAR the DTC, test the system for normal operation.
K4: CHECK THE 'WAKE-UP' SIGNAL TO THE NAVIGATION COMPUTER
Disconnect the navigation system connector, NA07.
Measure the voltage between NA07, pin 03 (O) and GROUND, using an oscilloscope (see note above).
Yes
GO to K5.
No
REPAIR the circuit between NA07, pin 03 and the ICE head unit connector, IP65, pin 19. For additional
K5: CHECK THE 'WAKE-UP' SIGNAL TO THE AMPLIFIER
Disconnect the amplifier connector, CA425.
Yes
CHECK for DTCs indicating a module failure.
No
PINPOINT TEST L : U2008: 'PHONE MODULE NOT RESPONDING
L1: CHECK 'PHONE MODULE, USING OPTICAL BUS TESTER
Clear the DTC.
Is U2008 set?
Yes
No
GO to L2.
L2: CHECK FOR DTC U2602 OR U2603
Check DTCs.
Yes
No
RECHECK DTCs. No break in optical harness.
PINPOINT TEST M : U2019: VOICE CONTROL MODULE NOT RESPONDING
M1: CHECK VOICE CONTROL MODULE, USING OPTICAL BUS TESTER
Clear the DTC.
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Is U2019 set?
Yes
No
GO to M2.
M2: CHECK FOR DTC U2602 OR U2603
Check DTCs.
Yes
No
PINPOINT TEST N : U2613: NAVIGATION CONTROL MODULE NOT RESPONDING
N1: CHECK NAVIGATION CONTROL MODULE, USING OPTICAL BUS TESTER
Connect the Optical Bus Tester to the fibre optic connector, CD05.
Clear the DTC.
Check for DTCs.
Is U2613 set?
Yes
No
GO to N2.
N2: CHECK FOR DTC U2602 OR U2603
Check DTCs.
Yes
No
PINPOINT TEST O : U2614: AMPLIFIER NOT RESPONDING
O1: CHECK AMPLIFIER, USING OPTICAL BUS TESTER
Clear the DTC.
Check for DTCs.
Is U2614 set?
Yes
No
GO to O2.
O2: CHECK FOR DTC U2602 OR U2603
Check DTCs.
Yes
No
PINPOINT TEST P : U2602: BREAK IN OPTICAL HARNESS FROM ICE HEAD UNIT (TRANSMITTER)
TEST
CONDITIONS
P1: CHECK FIBRE OPTIC LEAD BETWEEN LUGGAGE COMPARTMENT JOINT AND CD CHANGER
Disconnect the fibre optic connector, CD02.
Set the Optical Bus Tester to TX.
Set the Optical Bus Tester to ON.
Check for light pulses at the receiver pin of disconnected D2B connector, CD02.
Are light pulses visible?
Yes
GO to P2.
No
INSTALL a new telematic harness between CD06 and CD02. For additional information, refer to the wiring diagrams.
P2: CHECK CABIN FIBRE OPTIC HARNESS
Connect the Optical Bus Tester to CD01 using adaptor lead.
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Yes
GO to P3.
No
INSTALL a new cabin optical harness between CD06 and CD01. For additional information, refer to the wiring
P3: CHECK FIBRE OPTIC LEAD BETWEEN 'A' POST AND ICE HEAD UNIT
Disconnect the fibre optic connector, ID01.
Connect the Optical Bus Tester to ID01 using the adaptor lead.
Yes
GO to P4.
No
INSTALL a new instrument optical harness between CD01 and ID01. For additional information, refer to the wiring
P4: CHECK THE ICE HEAD UNIT
Check for light pulses at the transmitter pin of disconnected D2B connector, ID01 (rear of ICE head unit).
Yes
GO to P5.
No
INSTALL a new ICE head unit,
P5: CHECK THE FIBRE OPTIC LEAD FROM THE CD CHANGER TO THE 'PHONE MODULE
Disconnect the fibre optic connector CD02.
Connect the Optical Bus Tester to CD02.
Check for light pulses at the transmitter pin of disconnected D2B connector, CD03.
Yes
GO to P6.
No
P6: CHECK THE FIBRE OPTIC LEAD FROM THE 'PHONE MODULE TO THE VOICE MODULE
Yes
GO to P7.
No
P7: CHECK THE FIBRE OPTIC LEAD FROM THE VOICE MODULE TO THE NAVIGATION COMPUTER
Yes
GO to P8.
No
P8: CHECK THE FIBRE OPTIC LEAD FROM THE NAVIGATION COMPUTER TO THE AMPLIFIER
Yes
CHECK for DTC U2603.
No
PINPOINT TEST Q : U2603: BREAK IN OPTICAL HARNESS TO ICE HEAD UNIT (RECEIVER)
TEST
CONDITIONS
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Q1: CHECK FIBRE OPTIC LEAD BETWEEN LUGGAGE COMPARTMENT JOINT AND AMPLIFIER
Yes
GO to Q2.
No
INSTALL a new telematic harness between CD06 and C07. For additional information, refer to the wiring diagrams.
CLEAR the DTC,test the system for normal operation.
Q2: CHECK CABIN FIBRE OPTIC HARNESS
Yes
GO to Q3.
No
Q3: CHECK FIBRE OPTIC LEAD BETWEEN 'A' POST AND ICE HEAD UNIT
Connect the Optical Bus Tester to ID01.
Check for light pulses at the receiver pin of disconnected D2B connector, ID01.
Yes
GO to Q4.
No
Q4: CHECK THE ICE HEAD UNIT
Connect the optical short link between the receiver and transmitter of the ICE head unit.
Check for DTC.
Is U2603 logged?
Yes
No
RECHECK DTCs. No fault found in D2B system.
PINPOINT TEST R : ONE OR MORE D2B MODULES NOT RESPONDING. PERMANENT SUPPLY FAULT
TEST
CONDITIONS
R1: CHECK THE PERMANENT SUPPLY TO THE CD CHANGER
Measure the voltage between CA301, pin 02 (OY) and GROUND.
Yes
REPAIR the circuit between the CD changer connector, CA301, pin 02, and fuse 72 of the central junction fuse box. For
additional information, refer to the wiring diagrams. CLEAR the DTC, test the system for normal operation.
No
CHECK the module for GROUND. INSTALL a new CD Changer.
CLEAR the DTC, test the system for normal operation.GO to R2.
R2: CHECK THE PERMANENT SUPPLY TO THE VOICE ACTIVATED CONTROL MODULE
Measure the voltage between PH02, pin 22 (NR) and GROUND.
Yes
REPAIR the circuit between the voice activated control module connector, PH02, pin 22, and fuse 71 of the central
junction fuse box. For additional information, refer to the wiring diagrams. CLEAR the DTC, test the system for normal
operation.
No
CHECK the module for GROUND. INSTALL a new VACM.
REFER to: Multifunction Voice Activated Module - 4-Door (419-10 Multifunction Electronic Modules, Removal and
Installation).
R3: CHECK THE PERMANENT SUPPLY TO THE 'PHONE MODULE
Measure the voltage between PH01, pins 12 and 13 (NR) and GROUND.
Yes
REPAIR the circuit between the 'phone module connector, PH01, pins 12 and 13 and fuse 71 of the central junction
fuse box. For additional information, refer to the wiring diagrams. CLEAR the DTC, test the system for normal
operation.
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No
CHECK the module for GROUND. INSTALL a new 'phone module.
REFER to: Module - 4-Door (419-08 Cellular Phone, Removal and Installation).
R4: CHECK THE PERMANENT SUPPLY TO THE NAVIGATION MODULE
Disconnect the navigation module connector, NA07.
Measure the voltage between NA07, pin 01 (OY) and GROUND.
Yes
Repair the circuit between the navigation module connector, NA07, pin 01 and fuse 72 of the central junction fuse
box. For additional information, refer to the wiring diagrams. CLEAR the DTC, test the system for normal operation.
No
CHECK the module for GROUND. INSTALL a new navigation module.
REFER to: Navigation System Module - 4-Door (419-07 Navigation System, Removal and Installation).
R5: CHECK THE PERMANENT SUPPLY TO THE AMPLIFIER
Measure the voltage between CA425, pin 09 (NR) and GROUND.
Yes
Repair the circuit between the amplifier connector, CA425 and fuse 20 of the primary junction box. For additional
No
CHECK the module for GROUND. INSTALL a new amplifier. CLEAR the DTC, test the system for normal operation.
PINPOINT TEST S : ONE OR MORE D2B MODULES NOT RESPONDING. ACCESSORY SWITCHED SUPPLY FAULT
TEST
CONDITIONS
S1: CHECK THE ACCESSORY SWITCHED SUPPLY TO THE VOICE ACTIVATED CONTROL MODULE
Measure the voltage between PH02, pin 08 (YG) and GROUND.
Yes
REPAIR the circuit between the voice activated control module connector, PH02, pin 08 and the ignition switch. For
(This circuit includes the central junction fuse box, fuse 69)
.
No
GO to S2.
S2: CHECK THE ACCESSORY SWITCHED SUPPLY TO THE 'PHONE MODULE
Yes
REPAIR the circuit between the 'phone module connector, PH01, pin 14 and the ignition switch. This circuit includes
the central junction fuse box, fuse 69. For additional information, refer to the wiring diagrams. CLEAR the DTC, test
No
GO to S3.
S3: CHECK THE ACCESSORY SWITCHED SUPPLY TO THE NAVIGATION MODULE
Disconnect the navigation module electrical connector, NA07.
Measure the voltage between NA07, pin 11 (YG) and GROUND.
Yes
REPAIR the circuit between the navigation module connector, NA07, pin 11 and the ignition switch. This circuit
includes the central junction fuse box, fuse 69. For additional information, refer to the wiring diagrams. CLEAR the
No
PINPOINT TEST T : ONE OR MORE D2B MODULES NOT RESPONDING. IGNITION SWITCHED SUPPLY FAULT
TEST
CONDITIONS
T1: CHECK THE IGNITION SWITCHED SUPPLY TO THE VOICE ACTIVATED CONTROL MODULE
Measure the voltage between PH02, pin 06 (WR) and GROUND.
Yes
REPAIR the circuit between the voice activated control module connector, PH02, pin 06 and the central junction fuse
box, fuse 67. For additional information, refer to the wiring diagrams. CLEAR the DTC, test the system for normal
operation.
No
GO to T2.
T2: CHECK THE IGNITION SWITCHED SUPPLY TO THE 'PHONE MODULE
Measure the voltage between PH01, pin 29 (Y) and GROUND.
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REPAIR the circuit between the 'phone module connector, PH01, pin 29 and the central junction fuse box, fuse 78. For
No
Check the module for GROUND. INSTALL a new 'phone module.
PINPOINT TEST U : IC SUPPLY OR GROUND FAULT
TEST
CONDITIONS
U1: CHECK THE B+ SUPPLY TO THE IC
Measure the voltage between IP11, pin 07 (OG) and GROUND.
Yes
REPAIR the circuit between IP11, pin 07 and battery. This circuit includes the primary junction box, fuse 45. For
additional information, refer to the wiring diagrams.
No
GO to U2.
U2: CHECK THE ACC SUPPLY TO THE IC
Measure the voltage between IP11, pin 13 (YU) and GROUND.
Yes
No
GO to U3.
U3: CHECK THE IGNITION SUPPLY TO THE IC
Turn the ignition switch to the IGN position.
Measure the voltage between IP11, pin 11 (GR) and GROUND.
Yes
No
GO to U4.
U4: CHECK THE GROUND TO THE IC
Yes
No
No fault found with power or ground supplies. Check for DTCs indicating a module fault.
PINPOINT TEST V : SWRS SUPPLY OR GROUND FAULT
V1: CHECK THE MODULE SUPPLY TO THE SWRS
Disconnect the SWRS connector, IP19.
Yes
GO to V2.
No
GO to V3.
V2: CHECK THE MODULE SUPPLY CIRCUIT TO THE SWRS FOR HIGH RESISTANCE
Disconnect the DSC module connector, JB185.
Yes
No
GO to V3.
V3: CHECK THE GROUND TO THE SWRS
Reconnect the DSC module connector, JB185.
Measure the resistance between IP19, pin 08 (U) and GROUND.
Yes
No
PINPOINT TEST W : YAW RATE SENSOR SUPPLY OR GROUND FAULT
W1: CHECK THE MODULE SUPPLY TO THE YAW RATE SENSOR
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GO to W2.
No
GO to W3.
W2: CHECK THE MODULE SUPPLY CIRCUIT TO THE YAW RATE SENSOR FOR HIGH RESISTANCE
Yes
No
GO to W3.
W3: CHECK THE GROUND TO THE YAW RATE SENSOR
Yes
No
PINPOINT TEST X : ABS/TCCM SUPPLY OR GROUND FAULT
TEST
CONDITIONS
X1: CHECK THE IGNITION SUPPLY TO THE ABS/TC MODULE
Disconnect the ABS/TCCM connector, JB45.
Measure the voltage between JB45, pin 23 (GW) and GROUND.
Yes
REPAIR the circuit between JB45, pin 23 and battery. This circuit includes the front power distribution box, fuse 13
and the ignition relay. For additional information, refer to the wiring diagrams.
No
GO to X2.
X2: CHECK THE PUMP+ SUPPLY TO THE ABS/TCCM
Measure the voltage between JB45, pin 02 (R) and GROUND.
Yes
REPAIR the circuit between JB45, pin 02 and battery. This circuit includes the front power distribution box, fuse 41.
For additional information, refer to the wiring diagrams.
No
GO to X3.
X3: CHECK THE SOLENOID+ SUPPLY TO THE ABS/TCCM
Yes
No
GO to X4.
X4: CHECK THE GROUND TO THE ABS/TCCM
Yes
No
GO to X5.
X5: CHECK THE MOTOR GROUND TO THE ABS/TCCM
Yes
No
PINPOINT TEST Y : DSC MODULE SUPPLY OR GROUND FAULT
TEST
CONDITIONS
Y1: CHECK THE IGNITION SUPPLY TO THE DSC MODULE
Yes
No
GO to Y2.
Y2: CHECK THE PUMP+ SUPPLY TO THE DSC MODULE
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No
GO to Y3.
Y3: CHECK THE SOLENOID+ SUPPLY TO THE DSC MODULE
Yes
No
GO to Y4.
Y4: CHECK THE GROUND TO THE DSC MODULE
Yes
No
GO to Y5.
Y5: CHECK THE MOTOR GROUND TO THE DSC MODULE
Yes
No
PINPOINT TEST Z : GSI MODULE SUPPLY OR GROUND FAULT
TEST
CONDITIONS
Z1: CHECK THE IGNITION SUPPLY TO THE GSI MODULE
Disconnect the GSI module connector, IP14.
Yes
No
GO to Z2.
Z2: CHECK THE GROUND TO THE GSI MODULE
Yes
No
PINPOINT TEST AA : HID MODULE SUPPLY OR GROUND FAULT
TEST
CONDITIONS
AA1: CHECK THE IGNITION SUPPLY TO THE HID MODULE
Yes
No
GO to AA2.
AA2: CHECK THE GROUND TO THE HID MODULE
Yes
No
PINPOINT TEST AB : EATC MODULE SUPPLY OR GROUND FAULT
TEST
CONDITIONS
AB1: CHECK THE B+ SUPPLY TO THE EATC MODULE
Yes
No
GO to AB2.
AB2: CHECK THE IGNITION SUPPLY TO THE EATC MODULE
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Yes
REPAIR the circuit between IP101, pin 02 and battery. This circuit includes the primary junction box, fuse 39, and the
ignition relay. For additional information, refer to the wiring diagrams.
No
GO to AB3.
AB3: CHECK THE B+ SAVE SUPPLY TO THE EATC MODULE
Measure the voltage between IP101, pin 01 (OY) and GROUND.
Yes
battery save relay. For additional information, refer to the wiring diagrams.
No
GO to AB4.
AB4: CHECK THE GROUND TO THE EATC MODULE
Yes
No
PINPOINT TEST AC : MEMORY SEAT MODULE SUPPLY OR GROUND FAULT
TEST
CONDITIONS
AC1: CHECK THE B+1 SUPPLY TO THE MEMORY SEAT MODULE
Measure the voltage between DM02, pin 01 (OG) and GROUND.
Yes
REPAIR the circuit between DM02, pin 01 and battery. This circuit includes the primary junction box, fuse 16. For
No
GO to AC2.
Measure the voltage between DM02, pin 06 (GB) and GROUND.
Yes
No
GO to AC3.
AC3: CHECK THE IGNITION SUPPLY TO THE MEMORY SEAT MODULE
Yes
No
GO to AC4.
AC4: CHECK THE ELECTRONIC GROUND TO THE MEMORY SEAT MODULE
Measure the resistance between DM02, pin 10 (B) and GROUND.
Yes
No
GO to AC5.
AC5: CHECK THE POWER GROUND TO THE MEMORY SEAT MODULE
Yes
No
GO to AC6.
AC6: CHECK THE SIGNAL GROUND TO THE MEMORY SEAT MODULE
Yes
No
PINPOINT TEST AD : TCM (16 BIT) SUPPLY OR GROUND FAULT
TEST
CONDITIONS
AD1: CHECK THE B+ SUPPLY TO THE TCM
Measure the voltage between JB131, pin 06 (UY) and GROUND.
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Yes
No
GO to AD2.
AD2: CHECK THE IGNITION 1 SUPPLY TO THE TCM
Yes
REPAIR the circuit between JB131, pin 36 and battery. This circuit includes the front power distribution box, fuse 11,
No
GO to AD3.
Yes
No
GO to AD4.
AD4: CHECK THE GROUND 1 TO THE TCM
Yes
No
GO to AD5.
Yes
No
PINPOINT TEST AE : TCM (32 BIT) SUPPLY OR GROUND FAULT
TEST
CONDITIONS
AE1: CHECK THE B+ SUPPLY TO THE TCM
Yes
No
GO to AE2.
AE2: CHECK THE IGNITION 1 SUPPLY TO THE TCM
Yes
No
GO to AE3.
Yes
No
GO to AE4.
AE4: CHECK THE GROUND 1 TO THE TCM
Yes
No
GO to AE5.
Yes
No
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PINPOINT TEST AF : ECM SUPPLY OR GROUND FAULT (VEHICLES WITH 2.0L PETROL ENGINE)
TEST
CONDITIONS
AF1: CHECK THE B+ SUPPLY TO THE ECM
Measure the voltage between EN65, pin 21 (NR) and GROUND.
Yes
REPAIR the circuit between EN65, pin 21 and battery. This circuit includes the front power distribution box, fuse 36.
No
GO to AF2.
AF2: CHECK THE CONTROL SUPPLY TO THE ECM
Measure the voltage between EN65, pin 69 (B) and GROUND.
Yes
REPAIR the circuit between EN65, pin 69 and battery. This circuit includes the EMS control relay, pin 2. For additional
No
GO to AF3.
AF3: CHECK THE POWER GROUND (1) TO THE ECM
Measure the resistance between EN65, pin 19 (B) and GROUND.
Yes
No
GO to AF4.
Yes
No
PINPOINT TEST AG : ECM SUPPLY OR GROUND FAULT (VEHICLES WITH 2.5/3.0L PETROL ENGINE)
TEST
CONDITIONS
AG1: CHECK THE B+ SUPPLY TO THE ECM
Yes
No
GO to AG2.
AG2: CHECK THE CONTROL SUPPLY TO THE ECM
Yes
REPAIR the circuit between EN16, pin 40 and battery. This circuit includes the EMS control relay, pin 02. For
No
GO to AG3.
AG3: CHECK THE POWER GROUND (1) TO THE ECM
Yes
No
GO to AG4.
Yes
No
PINPOINT TEST AH : ECM SUPPLY OR GROUND FAULT (VEHICLES WITH 2.0L DIESEL ENGINE)
TEST
CONDITIONS
AH1: CHECK THE B+ SUPPLY TO THE ECM
Measure the voltage between DL01, pin 03 (WG) and GROUND.
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Yes
REPAIR the circuit between DL01, pin 03 and battery. This circuit includes the front power distribution box, fuse 21,
and the EMS control relay. For additional information, refer to the wiring diagrams.
No
GO to AH2.
AH2: CHECK THE CONTROL SUPPLY TO THE ECM
Measure the voltage between DL01, pin 09 (B) and GROUND.
Yes
REPAIR the circuit between DL01, pin 09 and battery. This circuit includes the EMS control relay, pin 02. For
No
GO to AH3.
AH3: CHECK THE POWER GROUND (1) TO THE ECM
Measure the resistance between DL01, pin 01 (B) and GROUND.
Yes
No
GO to AH4.
Yes
No
GO to AH5.
Yes
No
GO to AH6.
Yes
No
GO to AH7.
Yes
No
PINPOINT TEST AI : ICE SUPPLY OR GROUND FAULT
TEST
CONDITIONS
AI1: CHECK THE B+ SUPPLY TO THE ICE
Measure the voltage between IP65, pin 11 (NW) and GROUND.
Yes
No
GO to AI2.
AI2: CHECK THE ACC SUPPLY TO THE ICE
Measure the voltage between IP65, pin 02 (YG) and GROUND.
Yes
No
GO to AI3.
AI3: CHECK THE GROUND TO THE ICE
Yes
No
PINPOINT TEST AJ : CD CHANGER SUPPLY OR GROUND FAULT
TEST
CONDITIONS
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AJ1: CHECK THE B+ SUPPLY TO THE CD CHANGER
Yes
REPAIR the circuit between CA301, pin 02 and battery. This circuit includes the primary junction box, fuse 44. For
No
GO to AJ2.
AJ2: CHECK THE GROUND TO THE CD CHANGER
Yes
No
PINPOINT TEST AK : NAV MODULE SUPPLY OR GROUND FAULT
TEST
CONDITIONS
AK1: CHECK THE B+ SUPPLY TO THE NAV MODULE
Disconnect the NAV module connector, NA07.
Yes
REPAIR the circuit between NA07, pin 01 and battery. This circuit includes the primary junction box, fuse 44. For
No
GO to AK2.
AK2: CHECK THE ACC SUPPLY TO THE NAV MODULE
Yes
No
GO to AK3.
AK3: CHECK THE GROUND TO THE NAV MODULE
Measure the resistance between NA07, pin 02 (B) and GROUND.
Yes
No
PINPOINT TEST AL : FFH MODULE SUPPLY OR GROUND FAULT
TEST
CONDITIONS
AL1: CHECK THE B+ SUPPLY TO THE FFH MODULE
Disconnect the FFH module connector, JB232.
Measure the voltage between JB232, pin 01 (GR) and GROUND.
Yes
No
GO to AL2.
AL2: CHECK THE IGNITION SUPPLY TO THE FFH MODULE
Measure the voltage between JB232, pin 04 (RW) and GROUND.
Yes
No
GO to AL3.
AL3: CHECK THE GROUND TO THE FFH MODULE
Yes
No
PINPOINT TEST AM : PARK AID MODULE SUPPLY OR GROUND FAULT
TEST
CONDITIONS
AM1: CHECK THE IGNITION SUPPLY TO THE PARK AID MODULE
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Disconnect the park aid module connector, CA418.
Measure the voltage between CA418, pin 01 (N) and GROUND.
Yes
REPAIR the circuit between CA418, pin 01 and battery. This circuit includes the primary junction box, fuse 33 and the
No
GO to AM2.
AM2: CHECK THE GROUND TO THE PARK AID MODULE
Yes
No
PINPOINT TEST AN : RCM SUPPLY OR GROUND FAULT
TEST
CONDITIONS
AN1: CHECK THE IGNITION SUPPLY TO THE RCM
Disconnect the RCM connector, IP74.
Measure the voltage between IP74, pin 12 (G) and GROUND.
Yes
REPAIR the circuit between IP74, pin 12 and battery. This circuit includes the primary junction box, fuse 53 and the
No
GO to AN2.
AN2: CHECK THE GROUND TO THE RCM
Yes
No
PINPOINT TEST AO : GEM SUPPLY FAULT
TEST
CONDITIONS
AO1: CHECK THE B+ SUPPLY TO THE GEM
Disconnect the GEM connector, JB172.
Measure the voltage between JB172, pin 01 (OY) and GROUND.
Yes
REPAIR the circuit between JB172, pin 01 and battery. This circuit includes the primary junction box, fuse 22. For
No
No fault found with power supplies. Check for DTCs indicating a module fault.
PINPOINT TEST AP : RESTRAINTS CONTROL MODULE (RCM) ISO CIRCUIT MALFUNCTION
WARNING: To avoid accidental deployment and possible injury, the backup power supply must be depleted before repairing or
replacing any airbag supplemental restraint system (SRS) components. To deplete the backup power supply energy, disconnect the battery
ground cable and wait one minute. Failure to follow this instruction may result in personal injury.
AP1: CHECK THE RCM FOR DAMAGE
Inspect the RCM for damage.
Does the RCM indicate signs of damage?
Yes
INSTALL a new RCM.
REFER to: Restraints Control Module (RCM) (501-20B Supplemental Restraint System, Removal and
Installation).
No
GO to AP2.
AP2: CHECK K-LINE FOR SHORT CIRCUIT TO GROUND
Measure the resistance between diagnostic connector, pin 07 (W) and GROUND.
Yes
REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC, test the
No
GO to AP3.
AP3: CHECK K-LINE FOR SHORT CIRCUIT TO BATTERY
Measure the resistance between diagnostic connector, pins 07 (W) and pin 16 (OY).
Yes
No
GO to AP4.
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AP4: CHECK FOR OPEN CIRCUIT ON K-LINE BETWEEN DIAGNOSTIC CONNECTOR AND RCM
Measure the resistance between diagnostic connector, pin 07 (W) (K-line) and IP74, pin 11 (W).
Yes
REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC,
test the system for normal operation.
No
INSTALL a new RCM.
Installation).
PINPOINT TEST AQ : HEADLAMP LEVELLING MODULE (HID) ISO CIRCUIT MALFUNCTION
TEST
CONDITIONS
AQ1: CHECK HEADLAMP LEVELLING MODULE FOR DAMAGE
Inspect the HID module for damage.
Does the HID module indicate signs of damage?
Yes
INSTALL a new HID module.
REFER to: Headlamp Leveling Module (417-01 Exterior Lighting, Removal and Installation).
No
GO to AQ2.
AQ2: CHECK K-LINE FOR SHORT CIRCUIT TO GROUND
Yes
No
GO to AQ3.
AQ3: CHECK K-LINE FOR SHORT CIRCUIT TO BATTERY
Yes
No
GO to AQ4.
AQ4: CHECK FOR OPEN CIRCUIT ON K-LINE BETWEEN DIAGNOSTIC CONNECTOR AND HID MODULE
Measure the resistance between diagnostic connector, pin 07 (W) and IP130, pin 05 (W).
Yes
No
PINPOINT TEST AR : ROOF CONSOLE ISO CIRCUIT MALFUNCTION
NOTE: There are two levels of Roof Console. High-line, with moon roof, and/or reading lamps, plus VEMS and/or garage door opener
(electrical connector, RC22). Low-line, with moon roof and/or reading lamps only (electrical connector, RC33).
AR1: CHECK ROOF CONSOLE MODULE FOR DAMAGE
Inspect the roof console module for damage.
Does the roof console module indicate signs of damage?
Yes
INSTALL a new roof console module. CLEAR the DTC, test the system for normal operation.
No
GO to AR2.
AR2: CHECK K-LINE FOR SHORT CIRCUIT TO GROUND
Yes
No
GO to AR3.
AR3: CHECK K-LINE FOR SHORT CIRCUIT TO BATTERY
Measure the resistance between diagnostic connector, pin 07 (W) and pin 16 (OY).
Yes
No
GO to AR4.
AR4: CHECK FOR OPEN CIRCUIT ON K-LINE BETWEEN THE DIAGNOSTIC CONNECTOR AND THE ROOF CONSOLE MODULE
Disconnect the roof console module connector (RC23, high-line, RC33, low-line).
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Measure the resistance between the diagnostic connector, pin 07 (W) and:
Vehicles with low-line console -
RC23, pin 08 (W).
Vehicles with high-line console -
RC33, pin 03 (W).
Yes
No
PINPOINT TEST AS : REVERSE PARK AID ISO CIRCUIT MALFUNCTION
TEST
CONDITIONS
AS1: CHECK THE REVERSE PARK AID MODULE FOR DAMAGE
Inspect the reverse park aid module for damage.
Does the reverse park aid module indicate signs of damage?
Yes
INSTALL a new reverse park aid module.
REFER to: Parking Aid Module - 4-Door (413-13 Parking Aid, Removal and Installation).
No
GO to AS2.
AS2: CHECK K-LINE FOR SHORT CIRCUIT TO GROUND
Yes
No
GO to AS3.
AS3: CHECK K-LINE FOR SHORT CIRCUIT TO BATTERY
Yes
No
GO to AS4.
AS4: CHECK FOR OPEN CIRCUIT ON K-LINE BETWEEN THE DIAGNOSTIC CONNECTOR AND THE REVERSE PARK AID MODULE
Disconnect the reverse park aid module connector, RB07.
Measure the resistance between diagnostic connector, pin 07 (W) and RB07, pin 05 (W).
Yes
No
PINPOINT TEST AT : ECM ISO CIRCUIT MALFUNCTION
NOTE: These pinpoint tests apply only to OBD2 diagnostics. The ECM does most of it's diagnostics via CAN.
TEST
CONDITIONS
AT1: CHECK ECM FOR DAMAGE
Inspect the ECM for damage.
Does the ECM indicate signs of damage?
Yes
No
GO to AT2.
AT2: CHECK K-LINE FOR SHORT CIRCUIT TO GROUND
Measure the resistance between the diagnostic connector, pin 07 (W) and GROUND.
Yes
No
GO to AT3.
AT3: CHECK K-LINE FOR SHORT CIRCUIT TO BATTERY
Measure the resistance between the diagnostic connector, pins 07 (W) and 16 (OY).
Yes
No
GO to AT4.
AT4: CHECK FOR OPEN CIRCUIT ON K-LINE BETWEEN THE DIAGNOSTIC CONNECTOR AND THE ECM
NOTE: The diesel ECM is not part of the ISO network.
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Measure the resistance between the diagnostic connector, pin 07 (W) and EN16, pin 105 (W).
Yes
No
PINPOINT TEST AU : FUEL FIRED HEATER (FFH) MODULE ISO CIRCUIT MALFUNCTION
TEST
CONDITIONS
AU1: CHECK THE FFH MODULE FOR DAMAGE
Inspect the FFH module for damage.
Does the FFH module indicate signs of damage?
Yes
No
GO to AU2.
AU2: CHECK K-LINE FOR SHORT CIRCUIT TO GROUND
Yes
No
GO to AU3.
AU3: CHECK K-LINE FOR SHORT CIRCUIT TO BATTERY
Yes
No
GO to AU4.
AU4: CHECK FOR OPEN CIRCUIT ON K-LINE BETWEEN THE DIAGNOSTIC CONNECTOR AND THE FFH MODULE
Measure the resistance between the diagnostic connector, pin 07 (W) and JB232, pin 03 (W).
Yes
No
PINPOINT TEST AV : AMPLIFIER SUPPLY OR GROUND FAULT
TEST
CONDITIONS
AV1: CHECK THE B+ SUPPLY TO THE AMPLIFIER
Yes
REPAIR the circuit between CA425, pins 03/09 and battery. This circuit includes the primary junction box, fuse 20.
No
GO to AV2.
AV2: CHECK THE GROUND TO THE AMPLIFIER
Yes
No
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Module Communications Network - Communications NetworkVIN Range:
J28493->V99999
The vehicle has four module communication networks. Only three of which are connected to the diagnostic connector. The standard
corporate protocol (SCP) and controller area network (CAN), which are an unshielded twisted pair cable: data bus + and data bus - and
the International Standard Organization (ISO) 9141 communication network, which is a single wire network.
The domestic data bus (D2B), which is a fibre optic ring network, can be diagnosed through the SCP network, and with the optical bus
tester.
The SCP, CAN and ISO networks can be connected to the Jaguar approved diagnostic system by one diagnostic connector. This makes
troubleshooting these systems easier by allowing one smart tester to be able to diagnose any module on the three networks from one
connector. On-board diagnosis of the D2B network is through the in car entertainment (ICE) head.
The diagnostic connector is located under the instrument panel.
The ISO 9141 communications network does not permit inter-module communications. When the Jaguar approved diagnostic system
communicates with modules on the ISO 9141 communication network, the diagnostic system must ask for all information, the modules will
not initiate communications.
The SCP communication network remains operational even with severing of one of the bus wires. Communications will also continue if one
of the bus wires is shorted to ground or battery positive voltage (B+), or if some (but not all) termination resistors are lost.
Unlike the SCP communication network, the ISO 9141 communication network will not function if the wire is shorted to ground or battery
positive voltage (B+). Also, if one of the modules on the ISO 9141 network loses power or shorts internally, communication to that module
will fail.
The anti-lock brake control module is connected to the CAN communication network. The module comes in two forms. The first type is the
standard equipped anti-lock brake system (ABS) with traction control. It controls the brake pressure to the four wheels to keep the vehicle
under control while braking. The second type of ABS is optional and is called dynamic stability control (DSC). This module adds yaw and
steering wheel angle sensors to the package to help in sensing a loss of vehicle control. For additional information,
REFER to: Anti-Lock Control - Stability Assist (206-09 Anti-Lock Control - Stability Assist, Description and Operation).
The in car entertainment (ICE) head is connected to the SCP communication network and also to the D2B network. The D2B communicates
with the compact disc player, cellular phone transceiver, navigation system, amplifier, and the voice control module. For additional
information on the compact disc,
REFER to: Audio System (415-00 Information and Entertainment System - General Information, Diagnosis and Testing).
For additional information on the cellular phone,
REFER to: Cellular Phone (419-08 Cellular Phone, Diagnosis and Testing).
For additional information on the navigation system,
For additional information on the amplifier,
REFER to: Audio System (415-01 Audio Unit, Description and Operation).
For additional information on the voice activated control system,
REFER to: Multifunction Electronic Module (419-10 Multifunction Electronic Modules, Diagnosis and Testing).
The electronic automatic temperature control (EATC) module is connected to the CAN communication network. The EATC module controls
automatic climate functions that maintain the vehicle at a constant temperature setting. For additional information,
The instrument cluster (also known as an instrument cluster module ICM) is connected to the CAN and SCP communication networks. The
instrument cluster displays information received on the SCP including speedometer, odometer, fuel, and message center warnings. The
instrument cluster displays information received on the CAN including ABS, air conditioning, transmission and engine condition. The
instrument cluster also controls the passive anti-theft system (PATS). For additional information;
REFER to: Instrument Cluster and Panel Illumination (413-00 Instrument Cluster and Panel Illumination, Diagnosis and Testing).
For instrument cluster operation and
REFER to: Anti-Theft - Passive (419-01B Anti-Theft - Passive, Diagnosis and Testing).
for PATS.
The general electronic module (GEM) is connected to the SCP communication network. The GEM controls both interior and exterior lighting,
active anti-theft functions and warning chimes. For additional information on interior lamps,
REFER to: Interior Lighting (417-02 Interior Lighting, Diagnosis and Testing).
For additional information on exterior lighting,
REFER to: Headlamps (417-01 Exterior Lighting, Diagnosis and Testing).
For additional information on active anti-theft,
REFER to: Anti-Theft - Active (419-01A Anti-Theft - Active, Diagnosis and Testing).
For additional information on warning chimes,
REFER to: Warning Devices (413-09 Warning Devices, Diagnosis and Testing).
The engine control module (ECM) is connected to both the CAN and ISO 9141 communication networks. The ECM controls the engine
performance, electronic ignition, emission controls, speed control, and on board diagnostics. For additional information;
REFER to: Electronic Engine Controls - 2.5L NA V6 - AJV6/3.0L NA V6 - AJ27, VIN Range: E96603->J28492 (303-14A Electronic Engine
Controls - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27, Diagnosis and Testing).
,
REFER to: Electronic Engine Controls - 2.0L NA V6 - AJV6 (303-14A Electronic Engine Controls - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA
or
The 'phone module is connected to the D2B communication network, and incorporates the VEMS, or Vehicle Emergency Messaging System.
The module allows a user to request emergency assistance (police, ambulance, fire, recovery) or directions to a desired location at the
touch of a button. Also, if any of the vehicle's airbags are deployed while the VEMS system is powered ON, the system automatically issues
a call for emergency assistance. For additional information,
The airbag restraints module is connected to the ISO 9141 communication network. The airbag control module controls the deployment of
the air bags based on sensor input. For additional information;
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REFER to: Air Bag Supplemental Restraint System (SRS) (501-20B Supplemental Restraint System, Diagnosis and Testing).
The voice activated control module (VACM) is connected to the D2B communication network. This allows the user to select functions by
giving a voice command. The VACM sends the command information by D2B to the correct module or audio unit.
The navigation system (NAV) is connected to the D2B communication network, and performs it's diagnostics via the SCP network. The NAV
receives inputs from the GPS antenna and various other sensors. For additional information,
2. Visually inspect for obvious signs of mechanical, electrical or optical damage. 2.
Electrical
Fuses
Wiring harness
Loose or corroded connections
Correct engagement of electrical connectors
Controller area network (CAN)
Steering wheel rotation sensor (SWRS)
Gear selector module (GSI)
Yaw rate sensor
Electronic air temperature control module (EATCM)
Memory seat control module
Transmission control module (TCM)
Anti-lock brake control module with or without dynamic stability control (ABS/DSC)
Standard corporate protocol (SCP)
Generic electronic module (GEM)
In-car entertainment (ICE)
Navigation system (NAV)
International standards organization (ISO)
Fuel fired heater module
Restraints control module (RCM)
Roof console scanner
Domestic data bus (D2B)
ICE head unit (HU)
Compact disc changer (CD)
Cellular phone module (CPM)
Voice module (VACM)
Navigation system module (NSM)
Amplifier (AMP)
Optical
Routing of fibre optic harnesses
Correct engagement of optical connectors
Correct placement of optical connectors (ring order)
Damage to fibre (chafing, abrasion, kinking, cuts, etc)
Correct assembly of optical connectors (backout, etc)
Default Modes
Possible TCM default
Fixed 4th gear
Erratic gear shifts
Possible ECM default
Throttle motor and relay disabled
Throttle valve opening set to default value
Idle speed controlled by fuel injection intervention
Idle speed adaptation inhibited
Throttle opening limited to 30%
Vehicle speed limited
Speed (cruise) control limited
Maximum throttle opening for N range inhibited
Maximum engine speed reduced
HO2 sensor control circuit inhibited
Maximum ignition retard
Symptom Chart
NOTE: Network DTCs may be set by an error or communications failure in the network. Individual DTCs are in the table, alongside their
respective modules, but may also be set by a combination of factors affecting the network, which would result in multiple DTCs being set
for one error, or, as in the case of an open circuit, no DTC being set.
P0860 CAN ECM / JGM network
malfunction
ground interruption
CAN open circuit fault; JGM
to ECM
Refer to power and ground test for suspect module. For JGM CAN
circuit tests, GO to Pinpoint Test AW. Please check part is not on
any form of prior authorization before replacement.
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JGM failure
ECM failure
P1573 CAN throttle angle error TP sensor fault (additional
DTCs logged)
ECM CAN message error
For TP sensor circuit tests,
REFER to: Electronic Engine Controls - 2.5L NA V6 - AJV6/3.0L NA
V6 - AJ27, VIN Range: E96603->J28492 (303-14A Electronic
Engine Controls - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6
- AJ27, Diagnosis and Testing) /
and Testing).
Error message sent on CAN, but not CAN related. Check for
P1601 Incorrect ECM or TCM
fitted to vehicle
ECM configuration
TCM configuration
Configure the modules using the Jaguar approved diagnostic
system.
P1603 TCM EEPROM failure Battery disconnected while
the ignition switched ON
B+ power supply circuit;
open circuit
TCM failure
For TCM EEPROM tests, GO to Pinpoint Test B.
P1609 ECM microprocessor to
microprocessor
ECM failure Please check part is not on any form of prior authorization before
replacement.
P1611 ECM sub CPU failure ECM failure Please check part is not on any form of prior authorization before
replacement.
P1633 ECM main CPU failure ECM failure Please check part is not on any form of prior authorization before
replacement.
P1634 Throttle 'watch-dog'
circuit malfunction
replacement.
P1637 CAN ECM to ABS/TCCM or
DSC control module
network malfunction
ground interruption
ABS/TCCM or DSC to ECM
failure
ECM failure
or DSC CAN circuit tests, GO to Pinpoint Test C. Please check part
is not on any form of prior authorization before replacement.
P1638 CAN ECM / IC network
malfunction
ground interruption
CAN open circuit fault; IC
to ECM
IC failure
ECM failure
Refer to power and ground test for suspect module. For IC CAN
circuit tests, GO to Pinpoint Test D. Please check part is not on
any form of prior authorization before replacement.
P1642 CAN circuit malfunction Module power supply or
ground interruption
Control module failure;
Check for additional logged
DTCs to locate module
source
short circuit tests, GO to Pinpoint Test E.
P1643 CAN ECM / TCM network
malfunction
ground interruption
to ECM
TCM failure
ECM failure
Refer to power and ground test for suspect module. For CAN open
circuit tests, GO to Pinpoint Test A. For network short circuit
tests, GO to Pinpoint Test E. Please check part is not on any form
of prior authorization before replacement.
malfunction, right-hand
bank
ECM failure
and Testing).
Please check part is not on any form of prior authorization before
replacement.
malfunction, left-hand
bank
ECM failure
and Testing).
replacement.
P1648 ECM KS self-test failure ECM failure Please check part is not on any form of prior authorization before
replacement.
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P1656 TP sensor amplifier circuit
malfunction
replacement.
P1699 CAN ECM to EATCM
network malfunction
ground interruption
EATCM to ECM
CAN short circuit fault;
EATCM to ECM
EATCM failure
ECM failure
Refer to power and ground test for suspect module. For EATCM
open circuit tests, GO to Pinpoint Test A. For network short circuit
tests, GO to Pinpoint Test F. Please check part is not on any form
of prior authorization before replacement.
P1777 CAN torque reduction
error
ECM CAN message error Error message sent on CAN, but not CAN related. Check for
P1796 CAN network malfunction Module power supply or
ground interruption
TCM failure
short circuit test, GO to Pinpoint Test A.
P1797 CAN TCM/ECM network
malfunction
ground interruption
to ECM
TCM failure
ECM failure
Refer to power and ground test for suspect module. For TCM
open/short circuit tests, GO to Pinpoint Test C.
P1799 CAN TCM to ABS/TCCM or
DSC module network
malfunction
ground interruption
failure
TCM failure
short circuit tests, GO to Pinpoint Test G.
vehicle speed data
ABS/DSC wheel speed
message error
SCP network error
ignition switch data
Instrument cluster ignition
switch message error
SCP network error
U1147 GEM anti-theft SCP
network invalid ignition
key-in data
GEM key-in message error
SCP network error
U1262 GEM SCP network ignition
switch state message
missing
SCP network error
U1262 ICE SCP network circuit
fault
SCP network circuit; open
circuit, short circuit to B+,
SCP network circuit fault
Audio unit fault
For ICE SCP network tests, GO to Pinpoint Test I.
U1900 CAN instrumentation
messages missing
Engine management, ABS,
or DSC fault
CAN network fault
U1900 Automatic climate control
CAN fault
CAN circuit; open circuit,
circuit to ground
Automatic climate control
module internal CAN fault
CAN network fault
For EATC CAN network tests, GO to Pinpoint Test F.
U1900 ABS CAN fault CAN circuit: open circuit,
circuit to ground
ABS control module
internal CAN fault
CAN network fault
U1900 DSC CAN fault CAN circuit; open circuit,
circuit to ground
DSC control module
internal CAN fault
CAN network fault
U2003 CD autochanger not
responding on D2B
network
D2B network fault
For D2B 'wake-up' circuit tests, GO to Pinpoint Test K. For CD
autochanger D2B network tests, GO to Pinpoint Test J. For D2B
permanent supply tests, GO to Pinpoint Test R.
U2008 Cellular telephone not
responding on D2B
network
D2B network fault
For D2B 'wake-up' circuit tests, GO to Pinpoint Test K. For cellular
telephone D2B network tests, GO to Pinpoint Test L. For D2B
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U2019 VACM not responding on
D2B network
D2B network fault
For D2B 'wake-up' circuit tests, GO to Pinpoint Test K. For VACM
D2B network tests, GO to Pinpoint Test M. For D2B accessory
invalid
management system
CAN network fault
invalid
management system
CAN network fault
engine coolant
temperature message
invalid
management system
CAN network fault
odometer count message
invalid
Verify integrity of ABS or
DSC systems
CAN network fault
U2202 Invalid DSC control
the Jaguar approved
diagnostic system
CAN network fault
U2202 Invalid ABS control
the Jaguar approved
diagnostic system
CAN network fault
U2509 ECM unable to fulfill ABS
request
management system
CAN network fault
U2509 ECM unable to fulfill DSC
request
management system
CAN network fault
U2510
(security
flash code
23)
Anti-theft ECM
identification mismatch
replacement.
U2511 Anti-theft ECM invalid
data
SCP network error
replacement.
U2514 GEM wash/wipe SCP
network vehicle speed
message missing
SCP network error
U2520 Memory seats CAN open circuit fault:
memory seat module to
diagnostic connector
Memory seat module
failure
For CAN open/short circuit tests, GO to Pinpoint Test A.
circuit fault
ground
U2602 Break in optical ring
FROM ICE head unit
(transmitter)
D2B network module
disconnected
broken
For optical ring tests, GO to Pinpoint Test P.
U2603 Break in optical ring TO
ICE head unit (receiver)
D2B network module
disconnected
broken
For optical ring tests, GO to Pinpoint Test Q.
signal out of specification
circuit; high resistance
Voice activation module
failure
D2B network 'position
status report' not
received
D2B network 'alarm clear
command' not received
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U2613 Navigation control
module not responding
on D2B network
D2B network fault
Module permanent supply
fault
Module accessory switched
supply fault
Module ignition switched
supply fault
navigation module optical tests, GO to Pinpoint Test N. For D2B
switched supply tests, GO to Pinpoint Test S.
U2614 Amplifier not responding
on D2B network
D2B network fault
amplifier optical tests, GO to Pinpoint Test O. For D2B permanent
supply tests, GO to Pinpoint Test R. For D2B accessory switched
supply tests, GO to Pinpoint Test S.
RCM
RCM K-line circuit; open
circuit
RCM K-line circuit; short
circuit
For RCM ISO tests, GO to Pinpoint Test AP.
HID module
open circuit
short circuit
For HID module ISO tests, GO to Pinpoint Test AQ.
roof console module
For roof console module ISO tests, GO to Pinpoint Test AR.
reverse park aid module
K-line circuit; open circuit
K-line circuit; short circuit
For reverse park aid module ISO tests, GO to Pinpoint Test AS.
ECM
ECM K-line circuit; open
circuit
ECM K-line circuit; short
circuit
For ECM ISO tests, GO to Pinpoint Test AT.
fuel fired heater (FFH)
module
open circuit
short circuit
For FFH module ISO tests, GO to Pinpoint Test AU.
Power and Ground circuit test index
Modules may log DTCs if the power supply or GROUND is interrupted. Supply and GROUND tests are covered below by module name.
IC supply or ground fault B+ supply failure
Ign+ supply failure
Acc+ supply failure
GROUND failure
For IC circuit tests, GO to Pinpoint Test U.
SWRS supply or ground fault Module supply failure
GROUND failure
For SWRS circuit tests, GO to Pinpoint Test V.
Yaw rate sensor supply or ground fault Module supply failure
GROUND failure
For yaw rate sensor circuit tests, GO to Pinpoint Test W.
ABS/TCCM supply or ground fault Ign+ supply failure
Solenoid+ supply
failure
GROUND failure
Motor GROUND
failure
For ABS/TCCM circuit tests, GO to Pinpoint Test X.
DSC module supply or ground fault Ign+ supply failure
Solenoid+ supply
failure
GROUND failure
Motor GROUND
failure
For DSC module circuit tests, GO to Pinpoint Test Y.
GSI module supply or ground fault Ign+ supply failure
GROUND failure
For GSI module circuit tests, GO to Pinpoint Test Z.
HID module supply or ground fault Ign+ supply failure
GROUND failure
For HID module circuit tests, GO to Pinpoint Test AA.
EATC module supply or ground fault B+ supply failure
B+save supply failure
Ign+ supply failure
GROUND failure
For EATC module circuit tests, GO to Pinpoint Test AB.
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Memory seat module supply or ground fault B+1 supply failure
B+2 supply failure
Ign+ supply failure
Electronic GROUND
failure
Power GROUND
failure
Signal GROUND
failure
For memory seat module circuit tests, GO to Pinpoint Test
AC.
Ign+ supply failure
GROUND failure
For 16 bit TCM circuit tests, GO to Pinpoint Test AD.
Ign+ supply failure
GROUND failure
For 32 bit TCM circuit tests, GO to Pinpoint Test AE.
petrol engine
B+memory supply
failure
GROUND failure
For ECM circuit tests, vehicles with 2.0L petrol engines, GO to
Pinpoint Test AF.
ECM supply or ground fault, vehicles with
2.5/3.0L petrol engine
B+memory supply
failure
GROUND failure
For ECM circuit tests, vehicles with 2.5/3.0L petrol engines,
GO to Pinpoint Test AG.
diesel engine
Vpwr supply failure
GROUND failure
For ECM circuit tests, vehicles with 2.0L diesel engines, GO to
Pinpoint Test AH.
ICE supply or ground fault B+memory supply
failure
Acc+ supply failure
GROUND failure
For ICE circuit tests, GO to Pinpoint Test AI.
CD supply or ground fault B+ supply failure
GROUND failure
For CD changer circuit tests, GO to Pinpoint Test AJ.
NAV module supply or ground fault B+ supply failure
Acc+ supply failure
GROUND failure
For NAV module circuit tests, GO to Pinpoint Test AK.
FFH module supply or ground fault B+ supply failure
Ign+ supply failure
GROUND failure
For FFH module circuit tests, GO to Pinpoint Test AL.
Park aid module supply or ground fault Ign+ supply failure
GROUND failure
For park aid module circuit tests, GO to Pinpoint Test AM.
RCM supply or ground fault Ign+ supply failure
GROUND failure
For RCM circuit tests, GO to Pinpoint Test AN.
GEM supply or ground fault B+ supply failure For GEM circuit tests, GO to Pinpoint Test AO.
Amplifier supply or ground fault B+ supply failure
GROUND failure
For amplifier circuit tests, GO to Pinpoint Test AV.
JGM supply or ground fault Ign+ supply failure
GROUND failure
For JGM circuit tests, GO to Pinpoint Test AX.
Pinpoint tests
CAUTIONS:
Diagnosis by substitution from a donor vehicle is NOT acceptable. Each vehicle is configured to it's own vehicle identification data
(VID) block, and substitution of control modules may not only not confirm a fault, but may cause faults in the vehicle being tested and/or
the donor vehicle. Failure to follow this instruction may result in damage to the vehicle.
Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. Failure to follow this
NOTE: Before beginning any diagnosis of the D2B system, codes B1342, U2602, or U2603 must be rectified. No D2B function is possible
with these failures present.
PINPOINT TEST A : CHECK THE CONTROLLER AREA NETWORK (CAN) CONTINUITY
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NOTE: The following test is based on the maximum number of modules in the network. Refer to the wiring diagrams for information on
networks with fewer modules.
TEST
CONDITIONS
A1: CHECK THE RESISTANCE OF THE CAN NETWORK
Yes
GO to A3.
No
GO to A2.
A2: CHECK THE CAN NETWORK FOR SHORT CIRCUIT
Yes
CHECK the network for short circuit. For additional information, refer to the wiring diagrams. Clear any DTCs, test
No
GO to A3.
A3: CHECK THE CAN + CIRCUIT BETWEEN THE DIAGNOSTIC CONNECTOR AND THE STEERING WHEEL ROTATION SENSOR
Disconnect the steering wheel rotation sensor connector, IP19.
Yes
No
GO to A4.
A4: CHECK THE CAN - CIRCUIT BETWEEN THE DIAGNOSTIC CONNECTOR AND THE STEERING WHEEL ROTATION SENSOR
Yes
No
GO to A5.
A5: CHECK THE CAN + CIRCUIT BETWEEN THE DIAGNOSTIC CONNECTOR AND THE YAW RATE SENSOR
Yes
No
GO to A6.
A6: CHECK THE CAN - CIRCUIT BETWEEN THE DIAGNOSTIC CONNECTOR AND THE YAW RATE SENSOR
Yes
No
GO to A7.
A7: CHECK THE CAN + CIRCUIT BETWEEN THE DIAGNOSTIC CONNECTOR AND THE MEMORY SEAT MODULE (WHERE FITTED)
Measure the resistance between DM01, pin 12 (Y) and the diagnostic connector, pin 06 (Y).
Yes
No
GO to A8.
A8: CHECK THE CAN - CIRCUIT BETWEEN THE DIAGNOSTIC CONNECTOR AND THE MEMORY SEAT MODULE (WHERE FITTED)
Measure the resistance between DM01, pin 02 (G) and the diagnostic connector, pin 14 (G).
Yes
No
GO to A9.
A9: CHECK THE CAN + CIRCUIT BETWEEN THE DIAGNOSTIC CONNECTOR AND THE ABS/DSC MODULE
Measure the resistance between JB45/JB185, pin 24 (Y) and the diagnostic connector, pin 06 (Y).
Yes
No
GO to A10.
A10: CHECK THE CAN - CIRCUIT BETWEEN THE DIAGNOSTIC CONNECTOR AND THE ABS/DSC MODULE
Measure the resistance between JB45/JB185, pin 40 (G) and the diagnostic connector, pin 14 (G).
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Yes
No
GO to A11.
A11: CHECK THE CAN + CIRCUIT BETWEEN THE DIAGNOSTIC CONNECTOR AND THE HID MODULE (WHERE FITTED)
Yes
No
GO to A12.
A12: CHECK THE CAN - CIRCUIT BETWEEN THE DIAGNOSTIC CONNECTOR AND THE HID MODULE (WHERE FITTED)
Yes
No
NO circuit fault found. Check DTCs for indications of a module fault.
PINPOINT TEST B : P1603. TCM EEPROM FAILURE
TEST
CONDITIONS
Check battery voltage.
Has the battery been discharged to a voltage where the engine would not crank?
Yes
CHARGE and test the battery. Install a new battery, if required.
REFER to: Battery (414-01 Battery, Mounting and Cables, Removal and Installation).
Carry out a drive-cycle.
normal use.)
No
GO to B2.
Check the TCM for signs of water ingress.
Does the TCM show any indication of water ingress?
Yes
INSTALL a new TCM.
No
GO to B3.
Check if the battery has been disconnected with the ignition switched on.
Has the battery been disconnected with the ignition switched on?
Yes
CARRY out a drive-cycle. For additional information, refer to the DTC section of GTR.
normal use.)
No
INSTALL a new TCM.
PINPOINT TEST C : P1637: CAN NETWORK MALFUNCTION, TRANSMISSION CONTROL MODULE (TCM)
TEST
CONDITIONS
C1: CHECK TCM FOR DAMAGE
Inspect the TCM
Does the TCM indicate any signs of damage?
Yes
INSTALL a new TCM.
No
GO to C2.
C2: CHECK CAN + FOR SHORT CIRCUIT TO GROUND
Yes
normal operation.
No
GO to C3.
C3: CHECK CAN + FOR SHORT CIRCUIT TO BATTERY
Measure the resistance between the diagnostic connector, pins 06, (Y) and pin 16 (OY).
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Yes
normal operation.
No
GO to C4.
C4: CHECK CAN - FOR SHORT CIRCUIT TO GROUND
Yes
normal operation.
No
GO to C5.
C5: CHECK CAN - FOR SHORT CIRCUIT TO BATTERY
Yes
normal operation.
No
GO to C6.
C6: CHECK FOR SHORT CIRCUIT BETWEEN CAN + AND CAN -
Yes
normal operation.
No
GO to C7.
C7: CHECK FOR OPEN CIRCUIT ON CAN + BETWEEN DIAGNOSTIC CONNECTOR AND THE TCM
Yes
No
GO to C8.
C8: CHECK FOR OPEN CIRCUIT ON CAN - BETWEEN THE DIAGNOSTIC CONNECTOR AND THE TCM
Measure the resistance between the diagnostic connector, pin 14 (G) and:
JB131, pin 12 (G).
JB230, pin 06 (G).
Yes
GO to C9.
No
C9: CHECK FOR CORRECT BUS TERMINATION
Reconnect the TCM connector, JB131 or JB230.
Yes
INSTALL a new TCM.
No
GO to C10.
C10: CHECK CONTINUITY OF THE CAN + CIRCUIT BETWEEN THE ECM AND THE IC
To test:
Vehicles with 2.0L and 2.2L diesel engine -
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Yes
REPAIR the CAN + circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC, test the system
No
GO to C11.
C11: CHECK CONTINUITY OF THE CAN - CIRCUIT BETWEEN THE ECM AND THE IC
Yes
No
GO to C12.
C12: CHECK FOR LOSS OF TERMINATION WITHIN THE ECM
To test:
Yes
GO to C13.
No
Please check part is not on any form of prior authorization before replacement.
C13: CHECK FOR LOSS OF TERMINATION WITHIN THE IC
Yes
No
PINPOINT TEST D : P1638: CAN NETWORK MALFUNCTION, INSTRUMENT CLUSTER (IC)
TEST
CONDITIONS
D1: CHECK THE IC FOR DAMAGE
Inspect the IC for damage.
Does the IC indicate any signs of damage?
Yes
No
GO to D2.
D2: CHECK CAN + FOR SHORT CIRCUIT TO GROUND
Yes
No
GO to D3.
D3: CHECK CAN + FOR SHORT CIRCUIT TO BATTERY
Yes
No
GO to D4.
D4: CHECK CAN - FOR SHORT CIRCUIT TO GROUND
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Yes
No
GO to D5.
D5: CHECK CAN - FOR SHORT CIRCUIT TO BATTERY
Yes
No
GO to D6.
D6: CHECK FOR SHORT CIRCUIT BETWEEN CAN + AND CAN -
Yes
No
GO to D7.
D7: CHECK FOR OPEN CIRCUIT ON CAN + BETWEEN THE DIAGNOSTIC CONNECTOR AND THE IC
Yes
No
GO to D8.
D8: CHECK FOR OPEN CIRCUIT ON CAN - BETWEEN THE DIAGNOSTIC CONNECTOR AND THE IC
Yes
No
GO to D9.
D9: CHECK FOR CORRECT BUS TERMINATION
Reconnect the IC connector, IP10.
Yes
No
GO to D10.
D10: CHECK CONTINUITY OF THE CAN + CIRCUIT BETWEEN THE ECM AND THE IC
To test:
Yes
No
GO to D11.
D11: CHECK CONTINUITY OF THE CAN - CIRCUIT BETWEEN THE ECM AND THE IC
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Yes
No
GO to D12.
D12: CHECK FOR LOSS OF TERMINATION WITHIN THE ECM
Yes
GO to D13.
No
D13: CHECK FOR LOSS OF TERMINATION WITHIN THE IC
Yes
No
PINPOINT TEST E : P1642; P1643; P1797: CAN NETWORK MALFUNCTION, ECM
TEST
CONDITIONS
E1: CHECK THE ECM FOR DAMAGE
Inspect the ECM.
Does the ECM indicate any signs of damage?
Yes
No
GO to E2.
E2: CHECK CAN + FOR SHORT CIRCUIT TO GROUND
Yes
No
GO to E3.
E3: CHECK CAN + FOR SHORT CIRCUIT TO BATTERY
Yes
No
GO to E4.
E4: CHECK CAN - FOR SHORT CIRCUIT TO GROUND
Yes
No
GO to E5.
E5: CHECK CAN - FOR SHORT CIRCUIT TO BATTERY
Yes
No
GO to E6.
E6: CHECK FOR SHORT CIRCUIT BETWEEN CAN + AND CAN -
Yes
No
GO to E7.
E7: CHECK FOR OPEN CIRCUIT ON CAN + BETWEEN THE DIAGNOSTIC CONNECTOR AND THE ECM
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Measure the resistance between the diagnostic connector, pin 06 (Y) and DL01, pin 54 (Y).
Yes
No
GO to E8.
E8: CHECK FOR OPEN CIRCUIT ON CAN - BETWEEN THE DIAGNOSTIC CONNECTOR AND THE ECM
To test:
Measure the resistance between the diagnostic connector, pin 14 (G) and DL01, pin 73 (G).
Yes
No
GO to E9.
E9: CHECK FOR CORRECT BUS TERMINATION
Yes
No
GO to E10.
E10: CHECK CONTINUITY OF THE CAN + CIRCUIT
To test:
Yes
No
GO to E11.
E11: CHECK CONTINUITY OF THE CAN - CIRCUIT
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Yes
No
GO to E12.
E12: CHECK FOR LOSS OF TERMINATION WITHIN THE ECM
Yes
GO to E13.
No
E13: CHECK FOR LOSS OF TERMINATION WITHIN THE IC
Yes
No
PINPOINT TEST F : P1699: CAN NETWORK MALFUNCTION, ELECTRONIC AUTOMATIC TEMPERATURE CONTROL
(EATC) MODULE
TEST
CONDITIONS
F1: CHECK THE EATC MODULE FOR DAMAGE
Inspect the EATC module for damage.
Does the EATC module indicate any signs of damage?
Yes
Operation).
No
GO to F2.
F2: CHECK CAN + FOR SHORT CIRCUIT TO GROUND
Yes
No
GO to F3.
F3: CHECK CAN + FOR SHORT CIRCUIT TO BATTERY
Yes
No
GO to F4.
F4: CHECK CAN - FOR SHORT CIRCUIT TO GROUND
Yes
No
GO to F5.
F5: CHECK CAN - FOR SHORT CIRCUIT TO BATTERY
Yes
No
GO to F6.
F6: CHECK FOR SHORT CIRCUIT BETWEEN CAN + AND CAN -
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Yes
No
GO to F7.
F7: CHECK FOR OPEN CIRCUIT ON CAN + BETWEEN THE DIAGNOSTIC CONNECTOR AND THE EATC MODULE
Yes
No
GO to F8.
F8: CHECK FOR OPEN CIRCUIT ON CAN - BETWEEN THE DIAGNOSTIC CONNECTOR AND THE EATC MODULE
Yes
No
GO to F9.
F9: CHECK FOR CORRECT BUS TERMINATION
Reconnect the EATC module connector, IP101.
Yes
Operation).
No
GO to F10.
F10: CHECK CONTINUITY OF THE CAN + CIRCUIT BETWEEN THE ECM AND THE IC
To test:
Yes
No
GO to F11.
F11: CHECK CONTINUITY OF THE CAN - CIRCUIT BETWEEN THE ECM AND THE IC
Yes
No
GO to F12.
F12: CHECK FOR LOSS OF TERMINATION WITHIN THE ECM
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Yes
GO to F13.
No
F13: CHECK FOR LOSS OF TERMINATION WITHIN THE IC
Yes
No
PINPOINT TEST G : P1799: CAN NETWORK MALFUNCTION, ANTI-LOCK BRAKE (ABS)/DYNAMIC STABILITY
CONTROL (DSC) CONTROL MODULE
TEST
CONDITIONS
G1: CHECK THE ABS OR DSC MODULE FOR DAMAGE
Inspect the ABS/TCCM or DSC module.
Does the ABS/TCCM or DSC module indicate any signs of damage?
Yes
INSTALL a new ABS/TCCM or DSC module.
REFER to: Hydraulic Control Unit (HCU) - VIN Range: J12992->V99999 (206-09 Anti-Lock Control - Stability Assist,
No
GO to G2.
G2: CHECK CAN + FOR SHORT CIRCUIT TO GROUND
Yes
No
GO to G3.
G3: CHECK CAN + FOR SHORT CIRCUIT TO BATTERY
Yes
No
GO to G4.
G4: CHECK CAN - FOR SHORT CIRCUIT TO GROUND
Yes
No
GO to G5.
G5: CHECK CAN - FOR SHORT CIRCUIT TO BATTERY
Measure the resistance between the diagnostic connector, pins 14 (G) and pin 16 (OY).
Yes
No
GO to G6.
G6: CHECK FOR SHORT CIRCUIT BETWEEN CAN + AND CAN -
Yes
No
GO to G7.
G7: CHECK FOR OPEN CIRCUIT ON CAN + BETWEEN THE DIAGNOSTIC CONNECTOR AND THE ABS OR DSC MODULE
Measure the resistance between the diagnostic connector, pin 06 (Y) and JB45/JB185, pin 24 (Y).
Yes
No
GO to G9.
G8: CHECK FOR OPEN CIRCUIT ON CAN - BETWEEN THE DIAGNOSTIC CONNECTOR AND THE ABS OR DSC MODULE
Measure the resistance between the diagnostic connector, pin 14 (G) and JB45/JB185, pin 40 (G).
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Yes
No
GO to G9.
G9: CHECK FOR CORRECT BUS TERMINATION
Reconnect the ABS/TCCM module connector, JB45, or DSC module connector, JB185.
Yes
INSTALL a new ABS/TCCM module, or DSC module.
REFER to: Hydraulic Control Unit (HCU) - VIN Range: J12992->V99999 (206-09 Anti-Lock Control - Stability Assist,
No
GO to G10.
G10: CHECK CONTINUITY OF THE CAN + CIRCUIT BETWEEN THE ECM AND THE IC
To test:
Yes
No
GO to G11.
G11: CHECK CONTINUITY OF THE CAN - CIRCUIT
Yes
No
GO to G12.
G12: CHECK FOR LOSS OF TERMINATION WITHIN THE ECM
Yes
GO to G13.
No
G13: CHECK FOR LOSS OF TERMINATION WITHIN THE IC
Measure the resistance between pins 17 and 18 of the instrument cluster.
Yes
Possible intermittent fault. Recheck DTCs. Repeat tests from A1.
No
PINPOINT TEST H : SCP NETWORK MALFUNCTION, GENERIC ELECTRONIC MODULE (GEM)
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TEST
CONDITIONS
H1: CHECK GEM FOR DAMAGE
Inspect the GEM for damage.
Does the GEM indicate any signs of damage?
Yes
INSTALL a new GEM.
No
GO to H2.
H2: CHECK THE SCP + FOR SHORT CIRCUIT TO GROUND
Yes
No
GO to H3.
H3: CHECK THE SCP + FOR SHORT CIRCUIT TO BATTERY
Yes
No
GO to H4.
H4: CHECK THE SCP - FOR SHORT CIRCUIT TO GROUND
Yes
No
GO to H5.
H5: CHECK THE SCP - FOR SHORT CIRCUIT TO BATTERY
Yes
No
GO to H6.
H6: CHECK FOR SHORT CIRCUIT BETWEEN SCP + AND SCP -
Measure the resistance between the diagnostic connector, pins 10 (U) and 02, (Y).
Yes
No
GO to H7.
H7: CHECK FOR OPEN CIRCUIT ON SCP + BETWEEN THE DIAGNOSTIC CONNECTOR AND THE GEM
Yes
No
GO to H8.
H8: CHECK FOR OPEN CIRCUIT ON SCP - BETWEEN THE DIAGNOSTIC CONNECTOR AND THE GEM
Yes
No
GO to H9.
H9: CHECK FOR CORRECT BUS TERMINATION ON SCP +
Reconnect the GEM connector, IP05.
Yes
INSTALL a new GEM.
No
GO to H10.
H10: CHECK THE CONTINUITY OF THE GENERIC ELECTRONIC MODULE (GEM) SCP + CIRCUIT
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Yes
No
GO to H11.
H11: CHECK FOR LOSS OF SCP + TERMINATION WITHIN THE GEM
Yes
GO to H12.
No
INSTALL a new GEM.
H12: CHECK CONTINUITY OF THE INSTRUMENT CLUSTER (IC) SCP + CIRCUIT
Yes
No
GO to H13.
H13: CHECK FOR LOSS OF SCP + TERMINATION WITHIN THE INSTRUMENT CLUSTER
Yes
No
INSTALL a new IC.
PINPOINT TEST I : SCP NETWORK MALFUNCTION, IN CAR ENTERTAINMENT (ICE) HEAD
TEST
CONDITIONS
I1: CHECK ICE FOR DAMAGE
Inspect the ICE head for damage.
Does the ICE head indicate any signs of damage?
Yes
INSTALL a new ICE head.
No
GO to I2.
I2: CHECK THE SCP + FOR SHORT CIRCUIT TO GROUND
Yes
No
GO to I3.
I3: CHECK THE SCP + FOR SHORT CIRCUIT TO BATTERY
Yes
No
GO to I4.
I4: CHECK THE SCP - FOR SHORT CIRCUIT TO GROUND
Yes
No
GO to I5.
I5: CHECK THE SCP - FOR SHORT CIRCUIT TO BATTERY
Yes
No
GO to I6.
I6: CHECK FOR SHORT CIRCUIT BETWEEN SCP + AND SCP -
Measure the resistance between the diagnostic connector, pins 10 (U) and 02 (Y).
Yes
No
GO to I7.
I7: CHECK FOR OPEN CIRCUIT ON SCP + BETWEEN THE DIAGNOSTIC CONNECTOR AND THE ICE HEAD UNIT
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No
GO to I8.
I8: CHECK FOR OPEN CIRCUIT ON SCP - BETWEEN THE DIAGNOSTIC CONNECTOR AND THE ICE HEAD UNIT
Yes
No
GO to I9.
I9: CHECK FOR CORRECT BUS TERMINATION ON SCP +
Reconnect the ICE connector, IP65.
Yes
INSTALL a new ICE head unit.
No
GO to I10.
I10: CHECK THE CONTINUITY OF THE GENERIC ELECTRONIC MODULE (GEM) SCP + CIRCUIT
Measure the resistance between IP22, pin 02 (Y) and IP05, pin 19 (Y).
Yes
No
GO to I11.
I11: CHECK FOR LOSS OF SCP + TERMINATION WITHIN THE GEM
Yes
GO to I12.
No
INSTALL a new GEM.
I12: CHECK CONTINUITY OF THE IC SCP + CIRCUIT
Yes
No
GO to I13.
I13: CHECK FOR LOSS OF SCP + TERMINATION WITHIN THE IC
Measure the resistance between IP10, pin 22 (Y) and IP11, pin 08 of the IC.
Yes
No
INSTALL a new IC.
PINPOINT TEST J : U2003: COMPACT DISC CHANGER NOT RESPONDING
CAUTION: The following tests involve disconnection of the fibre optic harnesses. The harness connectors must be protected by
suitable dust caps as soon as they are disconnected, or damage may result. The use of tools to unlatch connectors must be avoided, or the
connector locking function may be lost. Failure to follow this instruction may result in damage to the vehicle.
NOTE: The following test sequence is based on a five node network. Refer to the wiring diagrams for network configuration for networks
with a different number of nodes (all possible network combinations are shown in the wiring diagrams).
NOTE: Should a break occur in the D2B ring, then codes, U2602, or U2603 will be set, depending on the location of the break. U2602 will
set if the break is in the optical harness FROM the ICE head unit (the transmitter signal). U2603 will set if the break is in the optical
harness TO the ICE head unit (the receiver signal). GO to Pinpoint Test P. GO to Pinpoint Test Q.
J1: CHECK CD CHANGER MODULE, USING OPTICAL BUS TESTER
Clear the DTC.
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Is U2003 set?
Yes
No
GO to J2.
J2: CHECK FOR DTC U2602 OR U2603
Check DTCs.
Yes
No
Recheck DTCs. No break in optical harness.
PINPOINT TEST K : ONE OR MORE D2B MODULES NOT RESPONDING. 'WAKE-UP' SIGNAL FAULT
NOTE: The D2B 'wake-up' signal is not a constant, but will generate a pulse at each cycle of the ignition key. The ignition key must be
turned to the OFF position following each step of the tests, and turned to the position indicated by the test step for each module. To avoid
missing the signal, use an assistant to operate the key while reading the oscilloscope. The 'wake-up' line is battery voltage, switching to 0
volts for between 50 milliseconds and 110 milliseconds as the ICE head unit sends it's signal.
K1: CHECK THE 'WAKE-UP' SIGNAL TO THE CD CHANGER
Yes
GO to K2.
No
K2: CHECK THE 'WAKE-UP' SIGNAL TO THE VOICE ACTIVATED CONTROL MODULE
Yes
GO to K3.
No
K3: CHECK THE 'WAKE-UP' SIGNAL TO THE 'PHONE MODULE
Yes
GO to K4.
No
K4: CHECK THE 'WAKE-UP' SIGNAL TO THE NAVIGATION COMPUTER
Disconnect the navigation system connector, NA07.
Measure the voltage between NA07, pin 03 (O) and GROUND, using an oscilloscope (see note above).
Yes
GO to K5.
No
REPAIR the circuit between NA07, pin 03 and the ICE head unit connector, IP65, pin 19. For additional
K5: CHECK THE 'WAKE-UP' SIGNAL TO THE AMPLIFIER
Yes
CHECK for DTCs indicating a module failure.
No
PINPOINT TEST L : U2008: 'PHONE MODULE NOT RESPONDING
L1: CHECK 'PHONE MODULE, USING OPTICAL BUS TESTER
Clear the DTC.
Is U2008 set?
Yes
No
GO to L2.
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L2: CHECK FOR DTC U2602 OR U2603
Check DTCs.
Yes
No
PINPOINT TEST M : U2019: VOICE CONTROL MODULE NOT RESPONDING
M1: CHECK VOICE CONTROL MODULE, USING OPTICAL BUS TESTER
Clear the DTC.
Is U2019 set?
Yes
No
GO to M2.
M2: CHECK FOR DTC U2602 OR U2603
Check DTCs.
Yes
No
PINPOINT TEST N : U2613: NAVIGATION CONTROL MODULE NOT RESPONDING
N1: CHECK NAVIGATION CONTROL MODULE, USING OPTICAL BUS TESTER
Clear the DTC.
Check for DTCs.
Is U2613 set?
Yes
No
GO to N2.
N2: CHECK FOR DTC U2602 OR U2603
Check DTCs.
Yes
No
PINPOINT TEST O : U2614: AMPLIFIER NOT RESPONDING
O1: CHECK AMPLIFIER, USING OPTICAL BUS TESTER
Clear the DTC.
Check for DTCs.
Is U2614 set?
Yes
No
GO to O2.
O2: CHECK FOR DTC U2602 OR U2603
Check DTCs.
Yes
No
PINPOINT TEST P : U2602: BREAK IN OPTICAL HARNESS FROM ICE HEAD UNIT (TRANSMITTER)
TEST
CONDITIONS
P1: CHECK FIBRE OPTIC LEAD BETWEEN LUGGAGE COMPARTMENT JOINT AND CD CHANGER
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Yes
GO to P2.
No
P2: CHECK CABIN FIBRE OPTIC HARNESS
Yes
GO to P3.
No
P3: CHECK FIBRE OPTIC LEAD BETWEEN 'A' POST AND ICE HEAD UNIT
Disconnect the fibre optic connector, ID01.
Connect the Optical Bus Tester to ID01 using the adaptor lead.
Yes
GO to P4.
No
P4: CHECK THE ICE HEAD UNIT
Check for light pulses at the transmitter pin of disconnected D2B connector, ID01 (rear of ICE head unit).
Yes
GO to P5.
No
P5: CHECK THE FIBRE OPTIC LEAD FROM THE CD CHANGER TO THE 'PHONE MODULE
Yes
GO to P6.
No
P6: CHECK THE FIBRE OPTIC LEAD FROM THE 'PHONE MODULE TO THE VOICE MODULE
Yes
GO to P7.
No
P7: CHECK THE FIBRE OPTIC LEAD FROM THE VOICE MODULE TO THE NAVIGATION COMPUTER
Yes
GO to P8.
No
P8: CHECK THE FIBRE OPTIC LEAD FROM THE NAVIGATION COMPUTER TO THE AMPLIFIER
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CHECK for DTC U2603.
No
PINPOINT TEST Q : U2603: BREAK IN OPTICAL HARNESS TO ICE HEAD UNIT (RECEIVER)
TEST
CONDITIONS
Q1: CHECK FIBRE OPTIC LEAD BETWEEN LUGGAGE COMPARTMENT JOINT AND AMPLIFIER
Yes
GO to Q2.
No
INSTALL a new telematic harness between CD06 and C07. For additional information, refer to the wiring diagrams.
Q2: CHECK CABIN FIBRE OPTIC HARNESS
Yes
GO to Q3.
No
Q3: CHECK FIBRE OPTIC LEAD BETWEEN 'A' POST AND ICE HEAD UNIT
Connect the Optical Bus Tester to ID01.
Check for light pulses at the receiver pin of disconnected D2B connector, ID01.
Yes
GO to Q4.
No
Q4: CHECK THE ICE HEAD UNIT
Connect the optical short link between the receiver and transmitter of the ICE head unit.
Check for DTC.
Is U2603 logged?
Yes
No
RECHECK DTCs. No fault found in D2B system.
PINPOINT TEST R : ONE OR MORE D2B MODULES NOT RESPONDING. PERMANENT SUPPLY FAULT
TEST
CONDITIONS
R1: CHECK THE PERMANENT SUPPLY TO THE CD CHANGER
Yes
REPAIR the circuit between the CD changer connector, CA301, pin 02, and fuse 72 of the central junction fuse box. For
No
CHECK the module for GROUND. INSTALL a new CD Changer.
R2: CHECK THE PERMANENT SUPPLY TO THE VOICE ACTIVATED CONTROL MODULE
Measure the voltage between PH02, pin 22 (NR) and GROUND.
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Yes
REPAIR the circuit between the voice activated control module connector, PH02, pin 22, and fuse 71 of the central
junction fuse box. For additional information, refer to the wiring diagrams. CLEAR the DTC, test the system for normal
operation.
No
CHECK the module for GROUND. INSTALL a new VACM.
REFER to: Multifunction Voice Activated Module - 4-Door (419-10 Multifunction Electronic Modules, Removal and
Installation).
R3: CHECK THE PERMANENT SUPPLY TO THE 'PHONE MODULE
Measure the voltage between PH01, pins 12 and 13 (NR) and GROUND.
Yes
REPAIR the circuit between the 'phone module connector, PH01, pins 12 and 13 and fuse 71 of the central junction
fuse box. For additional information, refer to the wiring diagrams. CLEAR the DTC, test the system for normal
operation.
No
CHECK the module for GROUND. INSTALL a new 'phone module.
R4: CHECK THE PERMANENT SUPPLY TO THE NAVIGATION MODULE
Disconnect the navigation module connector, NA07.
Yes
Repair the circuit between the navigation module connector, NA07, pin 01 and fuse 72 of the central junction fuse
box. For additional information, refer to the wiring diagrams. CLEAR the DTC, test the system for normal operation.
No
R5: CHECK THE PERMANENT SUPPLY TO THE AMPLIFIER
Yes
Repair the circuit between the amplifier connector, CA425 and fuse 20 of the primary junction box. For additional
No
CHECK the module for GROUND. INSTALL a new amplifier. CLEAR the DTC, test the system for normal operation.
PINPOINT TEST S : ONE OR MORE D2B MODULES NOT RESPONDING. ACCESSORY SWITCHED SUPPLY FAULT
TEST
CONDITIONS
S1: CHECK THE ACCESSORY SWITCHED SUPPLY TO THE VOICE ACTIVATED CONTROL MODULE
Yes
REPAIR the circuit between the voice activated control module connector, PH02, pin 08 and the ignition switch. For
(This circuit includes the central junction fuse box, fuse 69)
.
No
GO to S2.
S2: CHECK THE ACCESSORY SWITCHED SUPPLY TO THE 'PHONE MODULE
Yes
REPAIR the circuit between the 'phone module connector, PH01, pin 14 and the ignition switch. This circuit includes
the central junction fuse box, fuse 69. For additional information, refer to the wiring diagrams. CLEAR the DTC, test
No
GO to S3.
S3: CHECK THE ACCESSORY SWITCHED SUPPLY TO THE NAVIGATION MODULE
Disconnect the navigation module electrical connector, NA07.
Yes
REPAIR the circuit between the navigation module connector, NA07, pin 11 and the ignition switch. This circuit
includes the central junction fuse box, fuse 69. For additional information, refer to the wiring diagrams. CLEAR the
No
PINPOINT TEST T : ONE OR MORE D2B MODULES NOT RESPONDING. IGNITION SWITCHED SUPPLY FAULT
TEST
CONDITIONS
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T1: CHECK THE IGNITION SWITCHED SUPPLY TO THE VOICE ACTIVATED CONTROL MODULE
Measure the voltage between PH02, pin 06 (WR) and GROUND.
Yes
REPAIR the circuit between the voice activated control module connector, PH02, pin 06 and the central junction fuse
box, fuse 67. For additional information, refer to the wiring diagrams. CLEAR the DTC, test the system for normal
operation.
No
GO to T2.
T2: CHECK THE IGNITION SWITCHED SUPPLY TO THE 'PHONE MODULE
Measure the voltage between PH01, pin 29 (Y) and GROUND.
Yes
REPAIR the circuit between the 'phone module connector, PH01, pin 29 and the central junction fuse box, fuse 78. For
No
Check the module for GROUND. INSTALL a new 'phone module.
PINPOINT TEST U : IC SUPPLY OR GROUND FAULT
TEST
CONDITIONS
U1: CHECK THE B+ SUPPLY TO THE IC
Yes
No
GO to U2.
U2: CHECK THE ACC SUPPLY TO THE IC
Measure the voltage between IP11, pin 13 (YU) and GROUND.
Yes
No
GO to U3.
U3: CHECK THE IGNITION SUPPLY TO THE IC
Turn the ignition switch to the IGN position.
Yes
No
GO to U4.
U4: CHECK THE GROUND TO THE IC
Yes
No
PINPOINT TEST V : SWRS SUPPLY OR GROUND FAULT
V1: CHECK THE MODULE SUPPLY TO THE SWRS
Disconnect the SWRS connector, IP19.
Yes
GO to V2.
No
GO to V3.
V2: CHECK THE MODULE SUPPLY CIRCUIT TO THE SWRS FOR HIGH RESISTANCE
Yes
No
GO to V3.
V3: CHECK THE GROUND TO THE SWRS
Reconnect the DSC module connector, JB185.
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No
PINPOINT TEST W : YAW RATE SENSOR SUPPLY OR GROUND FAULT
W1: CHECK THE MODULE SUPPLY TO THE YAW RATE SENSOR
Yes
GO to W2.
No
GO to W3.
W2: CHECK THE MODULE SUPPLY CIRCUIT TO THE YAW RATE SENSOR FOR HIGH RESISTANCE
Yes
No
GO to W3.
W3: CHECK THE GROUND TO THE YAW RATE SENSOR
Yes
No
PINPOINT TEST X : ABS/TCCM SUPPLY OR GROUND FAULT
TEST
CONDITIONS
X1: CHECK THE IGNITION SUPPLY TO THE ABS/TC MODULE
Disconnect the ABS/TCCM connector, JB45.
Yes
No
GO to X2.
X2: CHECK THE PUMP+ SUPPLY TO THE ABS/TCCM
Yes
No
GO to X3.
X3: CHECK THE SOLENOID+ SUPPLY TO THE ABS/TCCM
Yes
No
GO to X4.
X4: CHECK THE GROUND TO THE ABS/TCCM
Yes
No
GO to X5.
X5: CHECK THE MOTOR GROUND TO THE ABS/TCCM
Yes
No
PINPOINT TEST Y : DSC MODULE SUPPLY OR GROUND FAULT
TEST
CONDITIONS
Y1: CHECK THE IGNITION SUPPLY TO THE DSC MODULE
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Yes
No
GO to Y2.
Y2: CHECK THE PUMP+ SUPPLY TO THE DSC MODULE
Yes
No
GO to Y3.
Y3: CHECK THE SOLENOID+ SUPPLY TO THE DSC MODULE
Yes
No
GO to Y4.
Y4: CHECK THE GROUND TO THE DSC MODULE
Yes
No
GO to Y5.
Y5: CHECK THE MOTOR GROUND TO THE DSC MODULE
Yes
No
PINPOINT TEST Z : GSI MODULE SUPPLY OR GROUND FAULT
TEST
CONDITIONS
Z1: CHECK THE IGNITION SUPPLY TO THE GSI MODULE
Disconnect the GSI module connector, IP14.
Yes
No
GO to Z2.
Z2: CHECK THE GROUND TO THE GSI MODULE
Yes
No
PINPOINT TEST AA : HID MODULE SUPPLY OR GROUND FAULT
TEST
CONDITIONS
AA1: CHECK THE IGNITION SUPPLY TO THE HID MODULE
Yes
No
GO to AA2.
AA2: CHECK THE GROUND TO THE HID MODULE
Yes
No
PINPOINT TEST AB : EATC MODULE SUPPLY OR GROUND FAULT
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TEST
CONDITIONS
AB1: CHECK THE B+ SUPPLY TO THE EATC MODULE
Yes
No
GO to AB2.
AB2: CHECK THE IGNITION SUPPLY TO THE EATC MODULE
Yes
No
GO to AB3.
AB3: CHECK THE B+ SAVE SUPPLY TO THE EATC MODULE
Measure the voltage between IP101, pin 01 (OY) and GROUND.
Yes
battery save relay. For additional information, refer to the wiring diagrams.
No
GO to AB4.
AB4: CHECK THE GROUND TO THE EATC MODULE
Yes
No
PINPOINT TEST AC : MEMORY SEAT MODULE SUPPLY OR GROUND FAULT
TEST
CONDITIONS
Measure the voltage between DM02, pin 01 (OG) and GROUND.
Yes
No
GO to AC2.
Yes
No
GO to AC3.
AC3: CHECK THE IGNITION SUPPLY TO THE MEMORY SEAT MODULE
Yes
No
GO to AC4.
AC4: CHECK THE ELECTRONIC GROUND TO THE MEMORY SEAT MODULE
Yes
No
GO to AC5.
AC5: CHECK THE POWER GROUND TO THE MEMORY SEAT MODULE
Yes
No
GO to AC6.
AC6: CHECK THE SIGNAL GROUND TO THE MEMORY SEAT MODULE
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PINPOINT TEST AD : TCM (16 BIT) SUPPLY OR GROUND FAULT
TEST
CONDITIONS
AD1: CHECK THE B+ SUPPLY TO THE TCM
Yes
No
GO to AD2.
Yes
No
GO to AD3.
Yes
No
GO to AD4.
Yes
No
GO to AD5.
Yes
No
PINPOINT TEST AE : TCM (32 BIT) SUPPLY OR GROUND FAULT
TEST
CONDITIONS
AE1: CHECK THE B+ SUPPLY TO THE TCM
Yes
No
GO to AE2.
Yes
No
GO to AE3.
Yes
No
GO to AE4.
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Yes
No
GO to AE5.
Yes
No
PINPOINT TEST AF : ECM SUPPLY OR GROUND FAULT (VEHICLES WITH 2.0L PETROL ENGINE)
TEST
CONDITIONS
AF1: CHECK THE B+ SUPPLY TO THE ECM
Yes
No
GO to AF2.
AF2: CHECK THE CONTROL SUPPLY TO THE ECM
Yes
REPAIR the circuit between EN65, pin 69 and battery. This circuit includes the EMS control relay, pin 2. For additional
No
GO to AF3.
Yes
No
GO to AF4.
Yes
No
PINPOINT TEST AG : ECM SUPPLY OR GROUND FAULT (VEHICLES WITH 2.5/3.0L PETROL ENGINE)
TEST
CONDITIONS
AG1: CHECK THE B+ SUPPLY TO THE ECM
Yes
No
GO to AG2.
AG2: CHECK THE CONTROL SUPPLY TO THE ECM
Yes
REPAIR the circuit between EN16, pin 40 and battery. This circuit includes the EMS control relay, pin 02. For
No
GO to AG3.
Yes
No
GO to AG4.
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No
PINPOINT TEST AH : ECM SUPPLY OR GROUND FAULT (VEHICLES WITH 2.0L DIESEL ENGINE)
TEST
CONDITIONS
AH1: CHECK THE B+ SUPPLY TO THE ECM
Measure the voltage between DL01, pin 03 (WG) and GROUND.
Yes
REPAIR the circuit between DL01, pin 03 and battery. This circuit includes the front power distribution box, fuse 21,
and the EMS control relay. For additional information, refer to the wiring diagrams.
No
GO to AH2.
AH2: CHECK THE CONTROL SUPPLY TO THE ECM
Measure the voltage between DL01, pin 09 (B) and GROUND.
Yes
REPAIR the circuit between DL01, pin 09 and battery. This circuit includes the EMS control relay, pin 02. For
No
GO to AH3.
Yes
No
GO to AH4.
Yes
No
GO to AH5.
Yes
No
GO to AH6.
Yes
No
GO to AH7.
Yes
No
PINPOINT TEST AI : ICE SUPPLY OR GROUND FAULT
TEST
CONDITIONS
AI1: CHECK THE B+ SUPPLY TO THE ICE
Measure the voltage between IP65, pin 11 (NW) and GROUND.
Yes
No
GO to AI2.
AI2: CHECK THE ACC SUPPLY TO THE ICE
Measure the voltage between IP65, pin 02 (YG) and GROUND.
Yes
No
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GO to AI3.
AI3: CHECK THE GROUND TO THE ICE
Yes
No
PINPOINT TEST AJ : CD CHANGER SUPPLY OR GROUND FAULT
TEST
CONDITIONS
AJ1: CHECK THE B+ SUPPLY TO THE CD CHANGER
Yes
REPAIR the circuit between CA301, pin 02 and battery. This circuit includes the primary junction box, fuse 44. For
No
GO to AJ2.
AJ2: CHECK THE GROUND TO THE CD CHANGER
Yes
No
PINPOINT TEST AK : NAV MODULE SUPPLY OR GROUND FAULT
TEST
CONDITIONS
AK1: CHECK THE B+ SUPPLY TO THE NAV MODULE
Disconnect the NAV module connector, NA07.
Yes
No
GO to AK2.
AK2: CHECK THE ACC SUPPLY TO THE NAV MODULE
Yes
No
GO to AK3.
AK3: CHECK THE GROUND TO THE NAV MODULE
Measure the resistance between NA07, pin 02 (B) and GROUND.
Yes
No
PINPOINT TEST AL : FFH MODULE SUPPLY OR GROUND FAULT
TEST
CONDITIONS
AL1: CHECK THE B+ SUPPLY TO THE FFH MODULE
Measure the voltage between JB232, pin 01 (GR) and GROUND.
Yes
No
GO to AL2.
AL2: CHECK THE IGNITION SUPPLY TO THE FFH MODULE
Measure the voltage between JB232, pin 04 (RW) and GROUND.
Yes
No
GO to AL3.
AL3: CHECK THE GROUND TO THE FFH MODULE
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Yes
No
PINPOINT TEST AM : PARK AID MODULE SUPPLY OR GROUND FAULT
TEST
CONDITIONS
AM1: CHECK THE IGNITION SUPPLY TO THE PARK AID MODULE
Disconnect the park aid module connector, CA418.
Measure the voltage between CA418, pin 01 (N) and GROUND.
Yes
REPAIR the circuit between CA418, pin 01 and battery. This circuit includes the primary junction box, fuse 33 and the
No
GO to AM2.
AM2: CHECK THE GROUND TO THE PARK AID MODULE
Yes
No
PINPOINT TEST AN : RCM SUPPLY OR GROUND FAULT
TEST
CONDITIONS
AN1: CHECK THE IGNITION SUPPLY TO THE RCM
Measure the voltage between IP74, pin 12 (G) and GROUND.
Yes
No
GO to AN2.
AN2: CHECK THE GROUND TO THE RCM
Yes
No
PINPOINT TEST AO : GEM SUPPLY FAULT
TEST
CONDITIONS
AO1: CHECK THE B+ SUPPLY TO THE GEM
Disconnect the GEM connector, JB172.
Measure the voltage between JB172, pin 01 (OY) and GROUND.
Yes
REPAIR the circuit between JB172, pin 01 and battery. This circuit includes the primary junction box, fuse 22. For
No
No fault found with power supplies. Check for DTCs indicating a module fault.
PINPOINT TEST AP : RESTRAINTS CONTROL MODULE (RCM) ISO CIRCUIT MALFUNCTION
WARNING: To avoid accidental deployment and possible injury, the backup power supply must be depleted before repairing or
replacing any airbag supplemental restraint system (SRS) components. To deplete the backup power supply energy, disconnect the battery
ground cable and wait one minute. Failure to follow this instruction may result in personal injury.
AP1: CHECK THE RCM FOR DAMAGE
Inspect the RCM for damage.
Does the RCM indicate signs of damage?
Yes
INSTALL a new RCM.
Installation).
No
GO to AP2.
AP2: CHECK K-LINE FOR SHORT CIRCUIT TO GROUND
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Yes
No
GO to AP3.
AP3: CHECK K-LINE FOR SHORT CIRCUIT TO BATTERY
Yes
No
GO to AP4.
AP4: CHECK FOR OPEN CIRCUIT ON K-LINE BETWEEN DIAGNOSTIC CONNECTOR AND RCM
Measure the resistance between diagnostic connector, pin 07 (W) (K-line) and IP74, pin 11 (W).
Yes
REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC,
test the system for normal operation.
No
INSTALL a new RCM.
Installation).
PINPOINT TEST AQ : HEADLAMP LEVELLING MODULE (HID) ISO CIRCUIT MALFUNCTION
TEST
CONDITIONS
AQ1: CHECK HEADLAMP LEVELLING MODULE FOR DAMAGE
Inspect the HID module for damage.
Does the HID module indicate signs of damage?
Yes
No
GO to AQ2.
AQ2: CHECK K-LINE FOR SHORT CIRCUIT TO GROUND
Yes
No
GO to AQ3.
AQ3: CHECK K-LINE FOR SHORT CIRCUIT TO BATTERY
Yes
No
GO to AQ4.
AQ4: CHECK FOR OPEN CIRCUIT ON K-LINE BETWEEN DIAGNOSTIC CONNECTOR AND HID MODULE
Measure the resistance between diagnostic connector, pin 07 (W) and IP130, pin 05 (W).
Yes
No
PINPOINT TEST AR : ROOF CONSOLE ISO CIRCUIT MALFUNCTION
NOTE: There are two levels of Roof Console. High-line, with moon roof, and/or reading lamps, plus VEMS and/or garage door opener
(electrical connector, RC22). Low-line, with moon roof and/or reading lamps only (electrical connector, RC33).
AR1: CHECK ROOF CONSOLE MODULE FOR DAMAGE
Inspect the roof console module for damage.
Does the roof console module indicate signs of damage?
Yes
No
GO to AR2.
AR2: CHECK K-LINE FOR SHORT CIRCUIT TO GROUND
Yes
No
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GO to AR3.
AR3: CHECK K-LINE FOR SHORT CIRCUIT TO BATTERY
Yes
No
GO to AR4.
AR4: CHECK FOR OPEN CIRCUIT ON K-LINE BETWEEN THE DIAGNOSTIC CONNECTOR AND THE ROOF CONSOLE MODULE
Disconnect the roof console module connector (RC23, high-line, RC33, low-line).
Measure the resistance between the diagnostic connector, pin 07 (W) and:
Vehicles with low-line console -
RC23, pin 08 (W).
Vehicles with high-line console -
RC33, pin 03 (W).
Yes
No
PINPOINT TEST AS : REVERSE PARK AID ISO CIRCUIT MALFUNCTION
TEST
CONDITIONS
AS1: CHECK THE REVERSE PARK AID MODULE FOR DAMAGE
Inspect the reverse park aid module for damage.
Does the reverse park aid module indicate signs of damage?
Yes
No
GO to AS2.
AS2: CHECK K-LINE FOR SHORT CIRCUIT TO GROUND
Yes
No
GO to AS3.
AS3: CHECK K-LINE FOR SHORT CIRCUIT TO BATTERY
Yes
No
GO to AS4.
AS4: CHECK FOR OPEN CIRCUIT ON K-LINE BETWEEN THE DIAGNOSTIC CONNECTOR AND THE REVERSE PARK AID MODULE
Disconnect the reverse park aid module connector, RB07.
Measure the resistance between diagnostic connector, pin 07 (W) and RB07, pin 05 (W).
Yes
No
PINPOINT TEST AT : ECM ISO CIRCUIT MALFUNCTION
NOTE: These pinpoint tests apply only to OBD2 diagnostics. The ECM does most of it's diagnostics via CAN.
TEST
CONDITIONS
AT1: CHECK ECM FOR DAMAGE
Inspect the ECM for damage.
Does the ECM indicate signs of damage?
Yes
No
GO to AT2.
AT2: CHECK K-LINE FOR SHORT CIRCUIT TO GROUND
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Yes
No
GO to AT3.
AT3: CHECK K-LINE FOR SHORT CIRCUIT TO BATTERY
Yes
No
GO to AT4.
AT4: CHECK FOR OPEN CIRCUIT ON K-LINE BETWEEN THE DIAGNOSTIC CONNECTOR AND THE ECM
NOTE: The diesel ECM is not part of the ISO network.
Yes
No
PINPOINT TEST AU : FUEL FIRED HEATER (FFH) MODULE ISO CIRCUIT MALFUNCTION
TEST
CONDITIONS
AU1: CHECK THE FFH MODULE FOR DAMAGE
Inspect the FFH module for damage.
Does the FFH module indicate signs of damage?
Yes
No
GO to AU2.
AU2: CHECK K-LINE FOR SHORT CIRCUIT TO GROUND
Yes
No
GO to AU3.
AU3: CHECK K-LINE FOR SHORT CIRCUIT TO BATTERY
Yes
No
GO to AU4.
AU4: CHECK FOR OPEN CIRCUIT ON K-LINE BETWEEN THE DIAGNOSTIC CONNECTOR AND THE FFH MODULE
Measure the resistance between the diagnostic connector, pin 07 (W) and JB232, pin 03 (W).
Yes
No
PINPOINT TEST AV : AMPLIFIER SUPPLY OR GROUND FAULT
TEST
CONDITIONS
AV1: CHECK THE B+ SUPPLY TO THE AMPLIFIER
Yes
REPAIR the circuit between CA425, pins 03/09 and battery. This circuit includes the primary junction box, fuse 20.
No
GO to AV2.
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AV2: CHECK THE GROUND TO THE AMPLIFIER
Yes
No
PINPOINT TEST AW : P0860: CAN ECM / JGM NETWORK MALFUNCTION
TEST
CONDITIONS
AW1: CHECK THE JGM FOR DAMAGE
Inspect the JGM.
Does the JGM indicate any signs of damage?
Yes
No
GO to AW2.
AW2: CHECK CAN + FOR SHORT CIRCUIT TO GROUND
Yes
No
GO to AW3.
AW3: CHECK CAN + FOR SHORT CIRCUIT TO BATTERY
Yes
No
GO to AW4.
AW4: CHECK CAN - FOR SHORT CIRCUIT TO GROUND
Yes
No
GO to AW5.
AW5: CHECK CAN - FOR SHORT CIRCUIT TO BATTERY
Yes
No
GO to AW6.
AW6: CHECK FOR SHORT CIRCUIT BETWEEN CAN + AND CAN -
Yes
No
GO to AW7.
AW7: CHECK FOR OPEN CIRCUIT ON CAN + BETWEEN THE DIAGNOSTIC CONNECTOR AND THE JGM
Disconnect the JGM connector, IP14.
Measure the resistance between IP22 pin 06 (Y) and IP14, pin 11 (Y).
Yes
No
GO to AW8.
AW8: CHECK FOR OPEN CIRCUIT ON CAN - BETWEEN THE DIAGNOSTIC CONNECTOR AND THE JGM
To test:
Yes
No
GO to AW9.
AW9: CHECK FOR CORRECT BUS TERMINATION
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Yes
No
GO to AW10.
AW10: CHECK CONTINUITY OF THE CAN + CIRCUIT
To test:
Yes
No
GO to AW11.
AW11: CHECK CONTINUITY OF THE CAN - CIRCUIT
Yes
No
GO to AW12.
AW12: CHECK FOR LOSS OF TERMINATION WITHIN THE ECM
Yes
GO to AW13.
No
AW13: CHECK FOR LOSS OF TERMINATION WITHIN THE IC
Yes
No
PINPOINT TEST AX : JGM SUPPLY OR GROUND FAULT
TEST
CONDITIONS
AX1: CHECK THE IGNITION SUPPLY TO THE JGM
Disconnect the JGM connector, IP14.
Yes
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No
GO to AX2.
AX2: CHECK THE GROUND TO THE JGM
Yes
No
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Module Configuration - Module Configuration
NOTE: Newly released modules will require configuration after being installed on the vehicle. All configurable modules will be packaged in
a kit which contains a warning label and a multi-language sheet re-emphasizing the requirements to configure replacement modules.
NOTE: Newly released modules must be configured using the Jaguar approved diagnostic system.
There are two types of configuration data. The first type is 'market configuration' data, this data is required so that the module can interact
with the vehicle correctly. By using the Jaguar approved diagnostic system this data will be retrieved in the following ways:
indirectly from a mirrored image of the old module's data stored in the engine control module's (ECM) vehicle identification data
(VID) block
indirectly from information stored in the Jaguar approved diagnostic system vehicle configuration and test system (VCATS)
Modules on the vehicle that require configuration when installing a replacement module are:
instrument cluster (IC)
high intensity discharge (HID) headlights
intrusion sensor module (ISM)
phone module
transmission control module (TCM)
voice module (VACM)
generic electronic module (GEM)
electronic automatic temperature control (EATC) module
airbag control module
audio unit
Inhale/exhale procedure
For all modules, except diesel engine control module:
Install the new module
Upload the information from the VID block using the Jaguar approved diagnostic system
Download the information to the VID block using the Jaguar approved diagnostic system
For diesel engine control module:
Upload the information from the VID block using the Jaguar approved diagnostic system
Install the new module
Download the information to the VID block using the Jaguar approved diagnostic system
CAUTION: If the diesel engine control module is removed before 'inhaling' it's information, adaptations may be lost.
NOTE: The Jaguar approved diagnostic system will not retain the stored configuration information for longer than 24 hours.
For additional information on the IC,
REFER to: Instrument Cluster (413-01 Instrument Cluster, Description and Operation).
For additional information on the ECM,
REFER to: Electronic Engine Controls (303-14A Electronic Engine Controls - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27,
For additional information on the HID,
REFER to: Exterior Lighting (417-01 Exterior Lighting, Description and Operation).
For additional information on the ISM,
REFER to: Anti-Theft - Active (419-01A Anti-Theft - Active, Description and Operation).
For additional information on the phone module,
REFER to: Cellular Phone (419-08 Cellular Phone, Description and Operation).
For additional information on the TCM,
REFER to: Transmission Description (307-01 Automatic Transmission/Transaxle, Description and Operation).
For additional information on the voice module,
REFER to: Cellular Phone (419-08 Cellular Phone, Description and Operation).
For additional information on the GEM,
REFER to: Module Controlled Functions (419-10 Multifunction Electronic Modules, Description and Operation).
For additional information on the EATC,
REFER to: Climate Control System (412-00 Climate Control System - General Information, Description and Operation).
For additional information on the airbag control module,
REFER to: Air Bag Supplemental Restraint System (SRS) (501-20B Supplemental Restraint System, Description and Operation).
Customer Driven Preferences
The second type of configuration data is customer preference driven. These are items that the customer may or may not want to have
enabled. Typically, customer preference items can be toggled on or off by the use of the Jaguar approved diagnostic system.
To carry out the customer configuration process, select the option the customer wants enabled or disabled from the configuration menu.
The current status of each option will be displayed, and the options can be enabled or disabled from this menu by following the instructions
on-screen.
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Module Configuration - Module Configuration
General Procedures
1. The complexity of the electronics involved with module configuration, of
which the GEM and instrument cluster are a part, and the multiplexed
communication network which are connected to them preclude the use
of workshop general electrical test equipment. Therefore, reference
should be made to the Jaguar Approved Diagnostic System User Guide
for detailed instructions on module configuration.
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Wiring Harnesses - Wiring Harness
Introduction
CAUTION: Do not use any other heat shrink sleeve other than the approved glue lined heat shrink sleeve mentioned in the repair
procedure.
The purpose of this document is to promote quick and efficient minor repair to harness connectors or cables using approved methods and
the wiring harness repair kit. Repairs may only be made to cables and connectors which have been mechanically, not electrically damaged.
It also applies where the whole extent of the damage can be clearly identified and rectified.
Care and neatness are essential requirements in making a perfect repair.
Caution:
At the time of this first issue of the Harness Repair Guide, do not approve repairs to any of the following circuits:
Any media orientated system transport network harnesses.
Supplement restraint system (SRS) firing circuits (Air bags).
Link lead assembles, which are unique to safety critical circuits such as anti-lock brake system (ABS) and thermocouple circuits. An
example of this is the ABS wheel speed sensors with moulded connectors.
4. Screened cables, leads and wiring harness(s).
If any harness(s) with defective electrical connector terminals or wires from the above circuits are a concern, new components must
be installed.
Repair Kit
CAUTION: Where the repair procedure indicates that a glue lined heat shrink sleeve should be applied, apply sufficient heat to the
glue lined heat shrink to melt the glue in order to provide a water tight seal. Do not over heat the glue lined heat shrink sleeve so that the
wiring harness insulation becomes damaged.
The wiring harness repair kit has been produced which comprises:
Pre-terminated wiring harness(s) of different sizes and types
Three sizes of butt splice connectors
A selection of colored cable identification sleeves
Two sizes of glue lined heat shrink sleeves
Crimping pliers
A wire cutter and insulation stripper
An electrical connector terminal extraction handle and tips
A suitable heat source, for shrinking heat shrink sleeves will be required.
The pre-insulated diamond grip range of electrical connector terminals and in-line, butt splice connectors contained within the wiring
harness repair kit are the only acceptable product for the repairs of wiring harnesses. The butt connectors not only grip the wire but also the
insulation, making a very secure joint.
If an electrical connector terminal is not included in the wiring harness repair kit then approval for the repair is NOT given and in these
circumstances a new wiring harness must be installed.
Pre-Terminated Wiring Harness(s) and Butt Splice Connectors
All pre-terminated wiring harness(s) and butt splice connectors in the wiring harness repair kit are contained in bags which can be resealed
after use. Each bag is marked with the part number of the items stored within the bag. Each storage compartment in the wiring harness
repair kit is identified with the corresponding part number. Make sure that pre-terminated wiring harness(s) and connectors are not mixed up
it is advisable to only open one bag at a time and to reseal the bag securely before opening another bag. Also, replace the bag in its
mating part number compartment within the case.
The pre-terminated wiring harness(s) are supplied with the insulation in one of three colors, red, blue or yellow. The colors do not apply to
any particular circuit but to the harness wire size. See the Relationship Table in the Repair Method section.
Butt splice connectors are also supplied with red, blue or yellow coverings, which must be matched to the pre-terminated wiring harness
insulation color.
Pre-Terminated Wiring Harness(s)
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The illustration shows:
The pre-terminated wiring harness(s) which are included in the wiring harness repair kit
The part number of the pre-terminated wiring harness
The letter showing the extractor tip which must be used to remove this type of electrical connector terminal
Those electrical connector terminals which are gold
Some of the pre-terminated wiring harness(s) have seals installed to the insulation for sealed connector applications. It is essential for
prevention of moisture ingress that a sealed pre-terminated wiring harness must be used where a sealed terminal was removed.
CAUTION: Where the repair procedure indicates that a glue lined heat shrink sleeve should be applied, apply sufficient heat to the
glue lined heat shrink to melt the glue in order to provide a water tight seal. Do not over heat the glue lined heat shrink sleeve so that the
wiring harness insulation becomes damaged.
Two sizes of heat shrink sleeving are supplied in the wiring harness repair kit. Each heat shrink sleeve contains a sealant glue. These must
be used when connecting wiring harness(s) or electrical connector terminal(s) at all times. The smaller diameter heat shrink sleeve is to be
used with the red and blue butt splice connectors and the larger diameter sleeve with the yellow butt splice connectors.
For ease and speed, some of the pre-terminated wiring harness(s) may already have the insulation partly stripped at the splice end. If the
repair requires insulation to be stripped from the cable, refer to the Relationship Table for the correct length of insulation to be stripped.
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The Pre-Terminated Wiring Harness(s) illustration shows the electrical connector terminal type, the part number of the pre-terminated wiring
harness and the letter of the extractor tip which must be used to extract the electrical connector terminal from the connector housing.
Additionally, those electrical connector terminal(s) which are gold are identified, all others are therefore, tinned and not gold.
Wiring Harness Cable Identification Sleeves
A selection of colored sleeves are contained in the wiring harness repair kit for maintaining the wiring harness cable identification on the
pre-terminated wiring harness. Place the correct colored sleeve(s) over the pre-terminated wiring harness insulation as near to the electrical
connector as possible with the main wiring harness cable color nearest to the electrical connector.
For example, if the original wiring harness cable color is pink with a black trace put the pink wiring harness cable identification sleeve on the
pre-terminated wiring harness first followed by a black sleeve, and slide both along the wiring harness cable to the electrical connector
terminal.
Extraction Handle and Tips
The extraction handle, in conjunction with the correct tip, is used to remove a terminal from an electrical connector. Each tip contained in
the wiring harness repair kit is marked with an identification letter, A to K inclusive. Each tip has been specially designed to extract a
particular type of electrical connector terminal. The use of any other tool is not recommended and is liable to cause damage to the electrical
connector. The tip is fastened to the handle by a screw which holds the tip firmly yet allows it to be easily replaced.
Extraction Handle and Tips
Insulation Stripper
The moving jaw has an adjuster wheel which has a series of holes in it. Turning the wheel and placing the cable in the matching size hole
will automatically adjust the jaw to the correct pressure. Note that some wiring harness(s) may have a harder insulation and slight
adjustment of the wheel may be needed to make a clean strip but exercise care not to damage the wire.
Insulation Stripper
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By pressing the outer edges of the wiring harness cable length stop together the adjuster can be slid up or down the jaw. This decreases or
increases the length by which the wiring harness cable insulation will be stripped from the pre-terminated wiring harness or wiring harness
wire. The adjuster has a position indicator to align with a graduated scale and this sets the correct length in millimetres, of insulation to be
stripped. The amount of insulation to be stripped is shown in the Relationship Table.
The illustration shows the insulation stripper tool and a wiring harness correctly gripped in the jaws. A wire cutter is provided on the outer
side of the fixed jaw.
Cable Correctly Gripped in Stripper Blades
Crimping Pliers
Crimping Pliers
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The crimping pliers have a moving jaw and a stationary jaw, with three different sized crimping enclosures. Each of the enclosures is
identified by a red, blue or yellow coloured dot which corresponds to the three colours of the pre-terminated wiring harness(s) and butt
splice connector colors.
List of Parts
Description Part Number Quantity
Wiring Harness Repair Kit 418-S065 1
Pre-Terminated Wiring Harness(s) 418-066 to 418-103 inclusive 10 each
Glue Lined Heat Shrink Pack small diameter 418-104 25 per pack
Glue Lined Heat Shrink Pack larger diameter 418-105 10 per pack
Case Assembly Comprising carry case, lid, inner lid, base, insert, trays foam spacers 418-106 1
Butt Splice Connector Red 418-107 50 per pack
Butt Splice Connector Blue 418-108 50 per pack
Butt Splice Connector Yellow 418-109 20 per pack
Extraction Tool Handle 418-110 1
Extraction Tip Pack consists of 2 spare screws plus 418-S111 1
Tip A 418-118 1
Tip B 418-119 1
Tip C 418-120 1
Tip D 418-121 1
Tip E 418-122 1
Tip F 418-123 1
Tip G 418-124 1
Tip H 418-125 1
Tip I 418-126 1
Tip J 418-127 1
Tip K 418-128 1
Sleeve Identification Pack for Red insulation 418-112 500
Sleeve Identification Pack for Blue insulation 418-113 500
Sleeve Identification Pack for Yellow insulation 418-114 500
Instruction Manual JTP 593 1
Crimping Pliers YRW500010 1
Wire Stripping Tool 418-117 1
Items can be ordered from:
SPX United Kingdom Limited
Ironstone Way
Brixworth
Northants
NN6 9UD
United Kingdom
Telephone: +44 (0) 1327 704461
Fax: +44 (0) 1327 706632
Repair Methods
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CAUTION: Several different types and sizes of terminal may be found in a single electrical connector housing.
It is necessary to identify:
The conductor (wire) size of the affected wiring harness
The electrical connector range from which the damaged wiring harness is to be removed
The terminal type
Use of the approved diagnostic tool will greatly assist in the quick identification of electrical connectors and faulty pin terminal(s).
Reference can also be made to the vehicle Electrical Guides, held by Dealers, to identify wiring harness(s) and electrical connector(s).
By using the Relationship Table, the wiring harness conductor (wire) size can be rel ated to a suitable pre-terminated wiring harness by the
color of the insulation. Also, the correct length of insulation to be stripped from the wiring harness lead is identified.
Relationship Table
CABLE RANGE SPLICE STRIP LENGTH
0.35 mm to 1.50 mm RED 6.00 to 7.00 mm
1.00 mm to 2.50 mm BLUE 6.00 to 7.00 mm
4.00 mm to 6.00 mm YELLOW 9.00 to 9.50 mm
Electrical Connector Terminal Extraction
It must be noted that some electrical connector(s) have anti-backout devices which prevent the terminals from being removed from the
electrical connector. Some examples of these are shown in following illustrations. The anti-backout device must be released before
attempting to remove the terminal from the electrical connector. Some anti-backout devices require a special tip to release the device and
these have been included in the kit. Most can be released by carefully using a suitable small screwdriver.
Various types of electrical connector have seals installed internally or externally to prevent moisture ingress. These normally do not have to
be removed but make sure that they are installed when the electrical connectors are connected.
The illustrations show examples of each tip used on different types of electrical connector(s). There are a large number of different types of
electrical connector used on vehicles therefore only one example using each tip is shown. Technicians experience and judgement will dictate
which type of tip should be used for those electrical connector(s) which are not shown. Care should be exercised to avoid further damage
when removing the terminals from the electrical connector.
NOTE: Examples of the extraction tips and anti-backout tips.
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NOTE: The chart shows the electrical connector types, terminal pins/sockets, extractor tip and anti-backout tip.
Electrical connector terminal type Pin or socket Extractor tip Anti-backout tip
Mulitlock 040 series D A
Mulitlock 040 series B A
Mulitlock 070 series B B
Mulitlock 040 series D B
Econoseal III 070 series D B
Econoseal III 070 series B B
Econoseal III 070 series B B
Econoseal III J2 D B
Econoseal III 250 series B F
Micro-timer II 1.5mm D C
Micro-timer II 1.5mm B C
Std power timer 4.8 flat D G
Std power timer 5.8 flat B D
Std power timer 2.8 flat D D
Std power timer 4.8 flat D G
Ford 2.8 flat D E H
Mulitlock 070 series D B
Mulitlock 070 series B B
Junior power timer 2.8 flat D D
Sumitomo TS90 connector B B H
Modu IV gold plated D B
Mulitlock 040 series gold plated D A
Micro qualock D I
EECV D B
EECV D B
Kostal dia 1.50 series D J
AMP 6.3 flat D B
Junior power timer 2.8 flat D D
2.8 series D B I
Sumitomo TS90 connector D B H
Ducon 0.60 gold plated D K
AMP 6.3 flat D D
Repair Procedure
CAUTIONS:
Do not use crimping pliers, insulation strippers, butt splice connectors, heat shrink sleeves or pre-terminated wiring harness(s) that
are not supplied with the Jaguar wiring harness repair kit. Each part has been designed to be used only with the other parts in this wiring
harness repair kit.
Where the repair procedure indicates that a glue lined heat shrink sleeve should be applied, apply sufficient heat to the glue lined
heat shrink to melt the glue in order to provide a water tight seal. Do not over heat the glue lined heat shrink sleeve so that the wiring
harness insulation becomes damaged.
It is not correct to make more than five repair joints on the wiring harness to any electrical connector and if more damage is found at the
same electrical connector then a new wiring harness must be installed.
Remove the faulty terminal from the electrical connector using the extractor tool and correct tip. Make sure that any anti-backout
device is released before trying to remove the terminal.
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CAUTION: : A number of electrical connector terminals are gold plated or gold flashed. When defective, they must be installed
with a gold pre-terminated wiring harness(s) from the wiring harness repair kit. It is not always easy to identify the female as gold
but the male pins are visually easier, therefore always check both male and female terminals to identify those which are gold. Under
no circumstances are gold and tin terminals to be mixed as this will lead to early failure of the electrical contact.
NOTE: Never use a harness lead with a smaller diameter than the original harness lead.
Select the correct size and type of pre-terminated wiring harness and butt splice connector from the wiring harness repair kit.
Using the wire cutter on the stripping tool, cut the pre-terminated wiring harness and the harness cable to the required length.
NOTE: See illustration: Stripping Insulation
From the Relationship Table, find the correct length of insulation to be stripped from the pre-terminated wiring harness and set the
adjustable cable length stop to the correct length. Place the pre-terminated wiring harness in the wire stripper and remove the
insulation.
Put the cable identification sleeve(s) on to the wiring harness with the main cable colour nearest to the terminal.
During this next step do not overtighten. Place the selected butt splice connector in the crimping tool, matching the aperture and the
butt connector colours. Make sure that the window indentation in the butt connector is resting over the guide bar on the lower jaw.
Partially close the grip until the butt connector is securely held in the aperture. This will give support to the butt connector while the
pre-terminated wiring harness is inserted into it.
NOTE: See illustration: Spice Correctly Located
Insert the pre-terminated wiring harness into the butt connector and make sure that the wire is against the wire stop. Close the grip
firmly, crimping the lead to the butt connector. When the handles have been completely closed the butt connector will be freed from
the tool as the handles are released. If the handles have not been completely closed then the jaws will hold the butt connector and
it cannot be removed from the tool until the crimp is fully made by closing the handles completely.
Make sure that the harness cable has been squarely cut and the correct length of insulation removed. If more than one splice is
needed the butt connectors must be not be crimped to the wiring harness at the same distance from the connector. The splices must
be staggered to prevent a bulk of splices in the same area of the wiring harness.
It is preferable to cover the butt splice joint with heat shrink sleeve. This is desirable not essential, except where the electrical
connector is a sealed electrical connector. Use the smaller diameter sleeve for red and blue pre-terminated wiring harness(s) and the
large diameter sleeve for the yellow pre-terminated wiring harness(s). It is advisable to place the heat shrink over the completed
joint but in some instances the sleeve will not pass over the terminal. Check, and if required, place the correct size sleeve onto the
harness cable or pre-terminated wiring harness before crimping the butt splice to the wiring harness.
Place the harness cable into the butt splice with the splice window over the guide bar. Make sure that the cable harness wire is
against the stop in the butt splice, crimp the butt splice connector to the wiring harness.
Gently pull the harness cables each side of the butt splice to make sure that a secure joint has been made.
WARNING: Do not use a naked flame in areas where fuel or oil have been spilt. Clean the area of residual oil and fuel and wait
until the fuel spill has fully evaporated.
CAUTIONS:
When using a heat source make sure that it is localised and causes no damage to surrounding materials.
Where the repair procedure indicates that a glue lined heat shrink sleeve should be applied, apply sufficient heat to the glue
lined heat shrink to melt the glue in order to provide a water tight seal. Do not over heat the glue lined heat shrink sleeve so that
the wiring harness insulation becomes damaged.
Using a suitable heat source, shrink the sleeve over the butt splice.
If further pre-terminated wiring harness(s) are to be installed to the same electrical connector, make sure that the lead is cut at a
different length to the previous joint. This makes sure that the splices will, where possible, be staggered on the wiring harness and
prevent a bulk of splices in one area.
When all of the splices have been made, fit the terminal(s) to the electrical connector, taking care that the terminals are correctly
orientated.
Install the wiring harness cover and secure with adhesive electrical tape. Do not cover the wiring harness right to the electrical
connector as the terminals must have a little movement and not be firmly bound to the electrical connector or wiring harness. Make
sure that the cable identification sleeve(s) are showing at the wiring harness electrical connector.
Stripping Insulation
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Spice Correctly Located
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Wiring Harnesses - Wiring Harness Repair
General Procedures
1. For additional information, refer to: Wiring Harness (418-02 Wiring
Harnesses, Description and Operation).
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Anti-Theft - Active - Anti-Theft - Active
1 General electronic module
2 Audio unit
3 Intrusion sensor (if equipped)
4 Door actuator
5 Inclination sensor (if equipped)
6 Door latch and ajar switch
8 Hood switch
9 Vehicle horn
10 Battery back up sounder (if equipped)
11 Security LED
The anti theft system provides protection from unauthorized entry into the vehicle. The system is incorporated and controlled by the generic
electronic module (GEM). When the alarm is triggered the system flashes the turn signal lamps and sounds the alarm system horns.
The security LED (light) provides the driver with the status of the security system when the ignition is switched in the off position and the
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PATS system when the ignition is switched to position II. When the ignition is switched in the off position, the LED will flash every four
seconds when the security system is in the pre-arm or armed state. The security LED will illuminate for three seconds when the ignition is
turned to position II, while the key is read. If there is a fault in the system, a fault code will be flashed out on the LED 60 seconds after the
key entered position II.
Security System Arming
The system will be activated by the keyless entry remote transmitter when the following input sequence is followed:
1. Make sure the ignition is off and the key is not in the ignition barrel. 1.
2. Close all the doors (unlocked), trunk and hood. 2.
3. Operate the lock button on the transmitter to lock the doors. The turn signal lamps will flash once. 3.
4. Operate the lock button a second time within three seconds to double lock the doors. The turn signal lamps will provide a long
flash.
4.
5. If any door, trunk or hood is ajar when the lock button is operated on the transmitter, there will be two short horn chirps and five
flashes of the turn signal lamps to alert the driver that the car is not secure and has not been locked.
5.
The system will also be activated when the following input sequence is followed:
6. Make sure the ignition is off and the key is not in the ignition barrel. 6.
7. Close all the doors (unlocked), trunk and hood. 7.
8. Lock all the doors, with the ignition key in the drivers door key barrel. The turn signal lamps will flash once. 8.
9. The vehicle will lock even if there is a door open when using the key, however there will be two short horn chirps and five flashes
of the turn signal lamps to alert the driver that the car is not secure.
9.
10. To double lock the car through the drivers key barrel follow steps six and seven and then cycle the key to the unlocked position
and then to the locked position within three seconds. The turn signal lamps will provide a long flash. If a door is open when an
attempt is made to double lock, the car WILL NOT double lock, but follow the actions in step nine.
10.
Opening any of the doors or the hood, after the system has been armed for 20 seconds (pre arm phase) will trigger the alarm. The alarm
will sound for up to 28 seconds and will be accompanied by the turn signal warning lamps flashing (60 seconds in NA).
Disarming The Alarm System
The system can be disarmed by carrying out one of the following procedures, which would also stop the alarm from sounding.
Driver door is unlocked with the ignition key (non EURO markets)
If unlocked from the drivers door (EURO markets) the ignition is switched to position II (with a valid ignition key).
Turn the ignition switch to position II with a valid ignition key at any time.
Or
Operate the UNLOCK button on the keyless entry remote transmitter.
Panic Alarm Activation (All Markets)
Operating the headlamp convenience button on the remote keyless entry transmitter three times within three seconds will activate the
panic alarm. The alarm will be sounded for up to 28 seconds and be accompanied by the turn signals flashing.
The panic alarm can be stopped by again by pressing the headlamp convenience button three times within three seconds, or operating the
unlock button on the transmitter, or switching the ignition to position II (with a valid key). It is also possible to stop the panic alarm
through the drivers door key barrel (non EURO markets) if the vehicle is in the locked and armed state.
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Anti-Theft - Active - Anti-Theft - Active
Door cylinder(s)
Door lock linkage(s)
Door lock cable(s)
Switch(s)
Fuse(s)
Switch(s)
Module (GEM)
Sensor(s)
Siren
step.
3.
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Anti-Theft - Active - Anti-Theft Alarm Horn
Removal
1. Remove the left-hand front fender splash shield.
2. Detach the anti-theft alarm horn electrical connector.
3. Disconnect the anti-theft alarm horn electrical connector.
4. Detach the front bumper electrical connector.
5. Remove the anti-theft alarm horn.
Installation
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Anti-Theft - Passive - Anti-Theft - Passive
1 PATS transceiver module
The passive anti theft system (PATS) is a feature to prevent the vehicle from being driven away by an unauthorized person. The PATS
system consists of electronically coded keys, a transceiver device and a control module. When the ignition is switched to position II, the
transceiver energizes the ignition key to read it's electronic code that is transmitted back. If the code read equals a code stored in the
control module, the engine control module (ECM) will let the engine start. Otherwise, starting of the engine is disabled (through the starter
disable relay and the ECM). Note a different code is used by the PATS system everyti me.
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Anti-Theft - Passive - Anti-Theft - Passive
Ignition lock cylinder
PATS key
Two PATS keys on the same keyring
Uncoded PATS key
Relay(s)
Ignition switch
Range sensor (Auto transmission)
Tansceiver
fuse(s)
step.
3.
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Anti-Theft - Passive - Anti-Theft Security Access
General Procedures
1. The complexity of the electronics involved with the anti theft, of which
the security access is a part, and the multiplexed communication
network which are connected to it preclude the use of workshop general
electrical test equipment. Therefore, reference should be made to the
WDS User Guide for detailed instructions on security access . The WDS
systematically tests and analyses all functions and the various systems
affected by it. Where a fault is indicated, some basic diagnostic
methods may be necessary to confirm that connections are good and
that wiring is not damaged before installing a new component.
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Anti-Theft - Passive - Key Programming Using Diagnostic Equipment
General Procedures
1. The complexity of the electronics involved with the anti theft, of which
the key programming is a part, and the multiplexed communication
network which are connected to it preclude the use of workshop general
WDS User Guide for detailed instructions on key programming . The
WDS systematically tests and analyses all functions and the various
systems affected by it. Where a fault is indicated, some basic
diagnostic methods may be necessary to confirm that connections are
good and that wiring is not damaged before installing a new component.
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Anti-Theft - Passive - Passive Anti-Theft System (PATS) Transceiver
Removal
1. Remove the instrument panel lower trim panel.
2. Remove the driver lower airbag module.
All vehicles
4. Disconnect the passive anti-theft system (PATS) transceiver electrical
connector.
5. Remove the PATS transceiver module.
Installation
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Remote Convenience - Universal Transmitter
The HomeLink universal transmitter provides a convenient way to replace up to three hand-held transmitters with a single built-in device.
The universal transmitter:
will operate garage doors, gates and home/office lighting and security systems.
will actually learn and transmit the radio frequency of up to three hand-held transmitters from any of the systems mentioned above.
is an integral part of the roof console assembly and is powered by the vehicle battery and charging system.
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1
1
Remote Convenience - Universal Transmitter
Visual Inspection
Mechanical
Damaged universal transmitter
Damaged receiver
step.
3.
4. If the concern is not visually evident, verify the concern and refer to the Symptom Chart. Refer to the electrical circuit diagrams for
schematic and connector information.
4.
Symptom Chart
Symptom Possible Cause Action
The universal transmitter is inoperative Universal transmitter
Receiver unit
Pinpoint Tests
PINPOINT TEST A : THE UNIVERSAL TRANSMITTER IS INOPERATIVE
TEST
CONDITIONS
A1: CHECK THE ROOF CONSOLE ASSEMBLY OPERATION
Check the illumination of the interior lamp.
Does the interior lamp illuminate?
Yes
GO to A2. .
No
Check and rectify fault with interior lamp circuit. TEST the system for normal operation.
A2: PROGRAM HAND-HELD TRANSMITTER INTO UNIVERSAL TRANSMITTER
NOTE: If the garage door is equipped with rolling codes, refer to Training a Garage Door Opener Equipped With
"Rolling Codes."
Program the universal transmitter.
REFER to: Universal Transmitter Programming (419-02 Remote Convenience, General Procedures).
Did the universal transmitter program successfully?
Yes
The universal transmitter is OK. VERIFY receiver operation.
No
REPLACE the roof console assembly. TEST the system for normal operation.
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Remote Convenience - Universal Transmitter Programming
General Procedures
WARNING: A garage door opening system that cannot stop or reverse itself after detecting an object in its path does not meet current
federal safety standards. To decrease the risk of serious injury or death, do not use this HomeLink transmitter with a door opening system
that lacks stop and reverse features as required by federal standards. This includes any garage door opening system manufactured before
April 1, 1982. For more information, call HomeLink customer assistance at 1-800-355-3515.
1. CAUTION: During this procedure, the system that you are
programming will be made to operate. Make sure that people or objects
are clear of the garage door or gate being programmed.
Verify the hand-held transmitter is operative.
2. Prepare for programming the universal transmitter by erasing all three
channels by holding down the two outside buttons until the red light
begins to flash (20-30 seconds). Release both buttons.
3. Select one of the three universal transmitter channels to be
programmed by pressing the desired button.
4. Hold the end of the hand-held transmitter 50-150mm (2-6 in) from the
front surface of the universal transmitter so that the red light can still
be seen.
5. NOTE: During programming, the hand-held transmitter may
automatically stop transmitting after two seconds, which may not be long
enough to program the universal transmitter. If programming this type of
hand-held transmitter, continue to hold the button on the universal
transmitter while re-pressing the hand-held transmitter button every two
seconds (Canada only).
Use both hands to press the hand-held transmitter button and the
desired button on the universal transmitter. Do not release either
button.
6. Hold down both buttons until the red light on the universal transmitter
flashes, first slowly and then rapidly. Release both buttons when the
rapid flashing begins. The universal transmitter has successfully learned
the new frequency signal and can be used in place of the hand-held
transmitter(s).
7. NOTE: If the hand-held transmitter appears to program the universal
transmitter but does not open the garage door, the garage door opener
may have a "code protected" or "rolling code" feature.
To operate, simply press the appropriate button on the universal
transmitter. The red light is on while the signal is being transmitted.
Training a Garage Door Opener Equipped With "Rolling Codes"
1. Program the hand-held transmitter to the universal transmitter.
For additional information, refer to Universal Transmitter Programming
in this section.
2. Train the garage door opener receiver to recognize the universal
transmitter.
1. Remove the cover panel from the garage door opener receiver.
2. Locate the training button on the garage door opener receiver.
Location and color of the button may vary by garage door
opener manufacturer. Refer to the garage door opener
instruction manual or call HomeLink customer assistance at
1-800-355-3515.
3. Press the training button on the garage door opener receiver
for 1-2 seconds.
4. Press the programmed universal transmitter button for as long
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as the universal transmitter red light flashes (1-2 seconds).
Release the button and re-press the button to confirm that the
universal transmitter is trained to the receiver.
5. The garage door opener should recognize the universal
transmitter.
Erasing Channels
1. NOTE: Individual channels cannot be erased, but can be reprogrammed
using the procedures for programming.
For additional information, refer to Universal Transmitter Programming in
this section.
To erase all three programmed channels, hold down the two outside
buttons until the red light begins to flash (20-30 seconds). Release both
buttons.
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Navigation System - Navigation System
4-Door
1 Roof pod antenna module (from 2009MY)
2 Navigation GPS antenna (up to 2009MY)
3 Navigation computer
4 - Navigation system display
Wagon
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1 - Roof pod antenna module (from 2009MY)
2 - Navigation GPS antenna (up to 2009MY)
3 - Navigation computer
4 - Navigation system display
The navigation system utilizes the following functions.
Voice guidance volume controlled via audio head unit
Screen brightness controlled via on screen menus
Any key turns system "ON"
Language choice controlled via on screen menus
The navigation head unit comprises of a 7" full color screen which also provides control of the phone, audio system, climate control, vehicle
emergency messaging system (VEMS), voice control, and TV. The navigation computer is situated in the luggage compartment on the LH
(left-hand) side and is covered by a protective trim panel.
On vehicles up to 2009MY, the GPS (global positioning system) antenna is located beneath the parcel shelf trim on a 4-door vehicle and
beneath the rear spoiler on wagon.
On vehicles from 2009MY, the GPS antenna is located in the roof pod antenna module on both the 4-door and the wagon.
The system utilizes signals from the GPS antenna, speed messages from the instrument cluster, ABS (anti-lock brake system) unit and the
GYRO sensor's signals to enable the navigation computer to calculate, with the aid of DVD (digital versatile disc) map data, the position of
the vehicle. After entering the required destination, the driver is guided along by both visual guidance and voice instructions. Even if the
driver strays off the route, the system calculates a new route showing the easiest way back to the original destination. On route, it can also
point out useful landmarks such as, petrol stations, restaurants, hotels, Jaguar dealers, and car parks.
Japanese market vehicles have a navigation computer with integrated voice recognition for control of the navigation system. The Japanese
system also has the addition of Vehicle Information and Communication System (VICS) which provides real time traffic information.
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Navigation System - Navigation System
For a detailed description of the navigation system, refer to the relevant Description and Operation sections in the workshop manual. REFER
to: Navigation System (419-07 Navigation System, Description and Operation).
Navigation system DVD player Mechanism Navigation system display
Navigation system module
GPS antenna
Wiring harness for damage and corrosion
ABS Module
Audio unit
step.
3.
4. If the cause is not visually evident, check for Diagnostic Trouble Codes (DTCs) and refer to the DTC Index. 4.
DTC Index
CAUTION: When probing connectors to take measurements in the course of pin point tests, use the adapter kit, part number
3548-1358-00
NOTE: If the control module/component is suspect and the vehicle remains under manufacturer warranty, refer to the warranty policy and
procedures manual (section B1.2), or determine if any prior approval program is in operation, prior to the installation of a new component.
B1342ECU is defective Satellite navigation system module -
internal ECU failure
manufacturer approved diagnostic system. check navigation
system module for internal failure. Install a new module as
required, refer to the new module installation not at the top of
the DTC index.
B2197TV module error Satellite navigation system display -
module or switch fault
manufacturers approved diagnostic equipment. Check the
satellite navigation system module for failure. Install a new
module as required, refer to the new module installation note
at the top of the DTC index.
B2198Traffic Master module
error
Satellite navigation system module -
traffic master module fault
Refer to electrical circuit diagrams, notes and check navigation
system module communication circuit to traffic master module
for failure. install a new module as required, refer to the new
module installation note at the top of the DTC index.
B2199VICS Module Error Satellite navigation system module -
VICS (vehicle information control
system) module fault
system module communication circuit to vehicle information
control system module for faults. install a new module as
required, refer to the new module installation note at the top
of the DTC index.
B2201No communication
with traffic master
module
traffic master communication fault. This
DTC is logged if the module is not
fitted. It must be masked out by the
tester when the module is not fitted to
a particular vehicle
system module communication circuit to traffic master module
for a fault. Install a new module as required, refer to the new
module installation note at the top of the DTC index.
B2202No communication to
VICS module
Satellite navigation system module to
vehicle information control module -
communication fault. This DTC is logged
if the module is not fitted. It must be
masked out when it is not fitted to a
particular vehicle.
Refer to electrical diagrams, nots and check navigation system
module communications circuit to vehicle information control
module for faults.
B2204GPS Antenna
connection open or
short
Satellite navigation module (GPS)
Antenna - open circuit or short circuit
manufacturer approved diagnostic system. refer to electrical
circuit diagrams, notes and check navigation system module
(GPS) antenna for open or short circuit.
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B2205GPS receiver fault Satellite navigation system module -
global positioning satellite receiver fault
manufacturer approved diagnostic system. Refer to the
electrical circuit diagrams, notes and check navigation system
module global positioning satellite (GPS) antenna circuit.
Check the antenna is not obstructed (vehicle must be outside
when being tested). Replace module is fault persists.
B2206Gyroscope fault Satellite navigation system module -
gyroscope fault
manufacturer approved diagnostic system. Refer to electrical
circuit diagrams, nots and check navigation system module for
faults. Install a new module as required, refer to the new
index.
B2207Internal ECU ROM
checksum fault
Satellite navigation system - module
internal failure
Refer to electrical circuit diagrams, notes and check the
navigation system module for faults. Install a new module as
required, refer to the new module/component installation note
at them top of the DTC index.
B2208Navigation module to
display and switch
module
communication error
communication to display and switch
module fault.
system display and switch module communication circuit for
fault
B2646Antenna circuit open
circuit #1
Satellite navigation system module
navigation system antenna - open
circuit
refer to electrical diagrams, notes and check navigation
systems antenna circuit for open circuit. To restore power the
fault must be removed and the user must key off and on.
circuit #2
circuit
Refer to electrical diagrams, notes and check navigation
circuit #3
circuit
circuit #4
circuit
B2650Antenna circuit short
circuit #1
navigation system antenna - short to
power or ground
systems antenna circuit for short to power or ground. To
restore power the fault must be removed and the user must
key off and on.
circuit #2
power or ground
key off and on.
circuit #3
power or ground
key off and on.
circuit #4
power or ground
key off and on.
B2655Switch and display
module is defective
display faulty
system display and switch module for failure. Install a new
display module as required. Refer to the new
index
B2656DVD (Digital Versatile
Disk) error
-DVD error (DVD is integral to the
navigation system module ECU)
system module for faults. Install a new module as required.
Refer to the new module/component installation note at the
top of the DTC index
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Navigation System - Navigation System Antenna4-Door, VIN Range: E96603->J39905
Removal
1. Detach the rear door opening weather-strips.
2. Remove the rear seat side bolsters. For additional information, refer to
Section 501-10 Seating.
3. Remove the C-pillar trim panels. For additional information, refer to
4. Detach the seat belt reel trim panels.
5. Remove the rear seat backrest latch covers.
6. Detach the parcel shelf trim panel.
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7. Remove the GPS antenna.
1. Disconnect the GPS antenna electrical connector.
2. Remove the GPS antenna.
1. Remove the pop rivet.
Installation
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Navigation System - Navigation System Antenna4-Door, VIN Range: J39906->V99999
Removal
1. Fold down the rear seat backrests.
2. Detach the rear seat backrest bolsters.
Press the tangs.
3. Remove the rear seat backrest bolsters.
Detach the rear door opening weather-strips.
5. NOTE: The C-pillar trim panel is secured to the top of the C-pillar by a
retaining strap. The retaining strap must be detached from the C-pillar
before the C-pillar trim panel is removed.
Detach the C-pillar trim panels.
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6. Remove the C-pillar trim panels.
7. Detach the covers to expose the screws and remove the rear passenger
assist handles.
Detach the rear of the headliner.
9. CAUTION: Make sure that the latch is pressed before
disconnecting the electrical connector.
Release the global positioning sensor (GPS) antenna.
Remove the 2 nuts.
Remove the GPS antenna.
Tighten to 6 Nm.
Installation
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Navigation System - Navigation System AntennaWagon
Removal
1. Remove the rear spoiler
4. Remove the navigation system antenna.
Installation
www.JagDocs.com
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Navigation System - Navigation System Display Module
Removal
1. NOTE: To aid removal of the navigation module and audio unit place the
J-gate in the 'D' position.
Remove the J-gate surround.
All vehicles
5. Remove the ashtray
Remove the ashtray.
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6. Remove the switch pack trim cover.
7. Remove the retaining screw cover plate.
8. Remove the display mounting bracket upper retaining screws.
9. Remove the display mounting bracket lower retaining screws.
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1. Disconnect the electrical connectors and the fibre optic
connector.
12. Remove the navigation system display module.
1. Remove the navigation system display retaining screws.
2. Remove the navigation system display module.
Installation
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Navigation System - Navigation System Module4-Door
Removal
1. NOTE: Make sure the navigation DVD has been removed and the ICE pin
code is available before disconnecting the battery ground cable.
5. Disconnect the audio unit amplifier electrical connectors.
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9. Remove the navigation module retaining bolts.
10. Remove the navigation module.
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Installation
Tighten to 3 Nm.
2. Tighten to 3 Nm.
3. Tighten to 9 Nm.
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Navigation System - Navigation System ModuleWagon
Removal
1. NOTE: Make sure the navigation DVD disc has been removed and the
audio unit pin code is available before disconnecting the battery ground
cable.
Disconnect the battery ground cable
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8. Detach the loadspace floor covering upwards.
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12. Disconnect the navigation system module electrical connectors.
13. Disconnect the compact disc (CD) changer electrical connectors.
14. Disconnect the voice activated control module (VACM) electrical
connectors.
15. Disconnect the cellular phone module electrical connectors.
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16. Remove the navigation system module retaining bolts.
17. Remove the system navigation module.
Installation
Tighten to 3 Nm.
2. Tighten to 3 Nm.
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3. Tighten the module retaining bracket upper and lower fixings.
Tighten the lower retaining nuts to 4 Nm.
Tighten the upper retaining bolt to 9 Nm.
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Cellular Phone -
Cellular phone module 5 - 44
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Cellular Phone - Cellular Phone
CELLULAR PHONE - UP TO 2006MY
The portable cellular phone system consists of:
Cellular phone handset (GSM).
Cradle (GSM).
Cellular portable (US Only).
Handset battery (US Only).
Hang up cup (US Only).
Roof console mounted microphone.
Steering wheel switch controls.
Portable support electronics (PSE) module (US Only).
Transceiver (GSM).
In-bumper cellular phone antenna.
Antenna cable.
Audio unit controls.
The cellular phone handset is located within the floor console armrest. The audio control unit and the steering wheel controls are utilized to
operate the system.
The vehicle utilizes two unique cellular phones systems:
GSM
US CDMA/TDMA digital and AMPS analogue systems
The voice activation control module provides the handsfree operation for cellular phone.
To activate the handsfree function:
1. Switch the ignition to the RUN position. After 4-6 seconds the system will be initialized and "VOICE READY" will be displayed in
the message center.
1.
2. Operate the VOICE/PHONE switch on the steering wheel. 2.
3. Clearly state the command when "LISTENING" is displayed in the message center. 3.
4. Operate the VOICE/PHONE switch on the steering wheel or remain silent for 1 second. If speech is detected "PROCESSING" will be
displayed in the message center. Operating the VOICE/PHONE switch again will cancel the voice session.
4.
Refer to the Cellular Phone user guide for complete operating instructions.
For additional information on the voice activation control module, refer to
For additional information, refer to: Module Controlled Functions (419-10 Multifunction Electronic Modules, Description and Operation).
.
CELLULAR PHONE - FROM 2006MY - UP TO 2009MY
The system allows the driver to use a Bluetooth equipped cellular phone handset through the vehicle's Information and Entertainment
system. Bluetooth is an international standard that allows electronic components to communicate with each other, using a short-range
radio link. Bluetooth eliminates the need for wires or cables: typically, devices can communicate at a range of up to 10 metres (33 feet).
Bluetooth is a registered trademark of Bluetooth SIG, Inc.
The Bluetooth system is as described in the following section for vehicles from 2009MY with the exception that only 1 telephone can be
paired with the system and the Bluetooth antenna is located in the floor console.
Telephone Voice Control
The vehicle system is able to use any voice tags which are stored in the mobile telephone. There is no voice dialling feature of the cellular
telephone system. Voice dialling is accessed via a long press of the voice button on the LH (left-hand) side of the steering wheel. The audio
unit displays that Voice Tag dialling is in progress and an audible prompt is generated from the Bluetooth phone module. After the prompt
the handset waits several seconds for the voice command. Refer to the Owners Handbook for further details on voice operation.
CELLULAR PHONE - FROM 2009MY
The system allows the driver to use a Bluetooth equipped cellular phone handset through the vehicles Information and Entertainment
system. Bluetooth is an international standard that allows electronic components to communicate with each other, using a short-range
radio link. Bluetooth eliminates the need for wires or cables: typically, devices can communicate at a range of up to 10 metres (33 feet).
Bluetooth is a registered trademark of Bluetooth SIG, Inc.
The Bluetooth in-car telephone system allows certain mobile phones to be used hands-free in your vehicle: there is no need to connect the
mobile phone to a cradle or cable. The vehicles Bluetooth telephone system can be used with an appropriate, Bluetooth equipped mobile
phone. The mobile phone must be paired with the vehicle system before use - Refer to the Owners Handbook for details.
NOTE: There is no physical connection (cradle) between the phone handset and the telephone control module. Communications between
the 2 components are purely Bluetooth. This can limit the available functions dependant on the handset used.
Once paired, the mobile phone can be operated via the steering wheel switches or the keypad and phone buttons on the audio panel or
touch-screen. The mobile phone doesnt need to be physically connected to the vehicle: it can be left in a jacket pocket, for instance. Calls
are routed through the vehicles audio speakers, and a dedicated microphone is fitted in the overhead console, near the drivers head.
The system can be used to answer or reject incoming calls, make outgoing calls or alter the call volume. The system does not support Short
Message Service (SMS) text messages. The vehicle starter switch must be set to position I or II in order to use the phone.
The volume of telephone calls can be adjusted for hands-free phone operation. To adjust the volume, operate the audio systems ON/OFF
volume control on the steering wheel or audio unit during a phone call. If the audio system is in use when the phone becomes active, the
audio system source is suppressed for the duration of the call. The Jaguar telephone system is designed to function with a wide variety of
Bluetooth equipped mobile phones. The audio and echo characteristics vary between models of mobile phones: as a result, it may take a
few seconds for the vehicle system to adapt to provide optimal audio performance. In order to achieve the best possible audio performance,
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it may be necessary to reduce the system volume slightly when using certain mobile phones.
Phone related messages are shown on the audio unit panel display or touch-screen when the phone system is active. The Bluetooth
telephone system can be used in conjunction with the Voice Activation system to provide the driver with completely hands-free
communication. Voice commands are picked up by the system microphone.
The cellular phone system comprises the following components:
Bluetooth phone module
Microphone
Bluetooth antenna.
Phone dialling is achieved using one of the following methods:
Dialling a number using the audio unit or touch screen
Selecting a number from the handsets phonebook via the audio unit and the Bluetooth phone module
Selecting from the handsets call register via the Bluetooth phone module.
The Bluetooth phone module is connected to the Information and Entertainment system on the D2B bus. This allows audio and control
signals to be routed to and from the Bluetooth phone module. The Bluetooth phone module has a separate integral Bluetooth antenna
located on the LH side of the luggage compartment on wagon vehicles and on the rear parcel shelf on 4 door vehicles.
Telephone handsets must be paired with the Bluetooth phone module before they can be used with the vehicle system. Up to 5 telephone
handsets can be paired with the vehicle, but only 1 telephone can used at a time. If more than one phone is present in the vehicle, the last
connected phone will be given priority on connection. Phone connection is active at ignition on. The phone will be disconnected 6 minutes
after the ignition is switched off.
Phonebook and last number redial list are stored & synchronized for each of the 5 phones and are resynchronized when each phone
reconnects.
Bluetooth Phone Module
The Bluetooth phone module is located in the rear LH side of the luggage compartment. The Bluetooth phone module is connected on
the D2B ring to the voice control module. The D2B ring allows control instructions and audio to be transferred to the relevant modules.
Microphone
The microphone is located adjacent to the overhead console which surrounds the front interior lamp. The microphone is hardwired to the
voice module and the Bluetooth phone module.
Telephone Control Switches
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1 - Rotary Volume control
2 - Rotary control Telephone mode - scroll through stored numbers
3 - Phone mode select button
4 - Start voice mode button, answer telephone or send/end in phone mode
The telephone switches are located on the LH side of the steering wheel. Two rotary thumbwheels operate the volume of the selected audio
function including the telephone and also allow the driver to scroll through stored telephone numbers when in phone mode or select radio
stations or CD's when in audio modes. The 'source' switch allows the driver to select phone mode by pressing the switch for 2 seconds. The
switch can also be used to cycle through the AM, FM radio stations and CD's in the auto changer. The voice button will allow the start of the
voice function or mute when voice system is not fitted and also answer a call when phone ringing and also send/end when in a phone call.
Bluetooth Antenna
The Bluetooth antenna is located on the LH side of the luggage compartment on wagon vehicles and on the rear parcel shelf on 4 door
vehicles. The antenna is used to connect the Bluetooth phone module to a Bluetooth compatible phone.
Telephone Voice Control
The vehicle system is able to use any voice tags which are stored in the Jaguar Voice system. There is no voice dialling feature of the
cellular telephone system. Voice dialling is accessed via a short press of the voice button on the LH side of the steering wheel. Refer to the
Owners Handbook for further details on voice operation.
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Cellular Phone - Cellular Phone
For a detailed description of the phone system, refer to the relevant Description and Operation sections in the workshop manual. REFER to:
Cellular Phone (419-08 Cellular Phone, Description and Operation).
Where a fault involving the cellular phone is indicated by the Jaguar Approved Diagnostic System, some basic diagnostic methods may be
necessary to confirm that connections are good and that the wiring is not damaged, before installing new components.
1. Verify the customer concern by operating the portable cellular phone both in portable mode and while connected to the vehicle. 1.
2. Make sure the portable convertible phone (US Only) is switched ON. With the power button ON, the system should be on while the
ignition switch is in ACC or RUN.
2.
3. Make sure the customer is calling within the coverage area. No Svc will appear in the display if the customer is calling from
outside the coverage area.
3.
4. Check to see if the Roam indicator is on. If so, follow the roaming instructions in the Cellular Phone User Guide. 4.
5. Check to see if the display reads Locked CDMA/TDMA or pin for GSM. If so, press Clr and enter the customer three-digit unlock
code for CDMA/TDMA or the customer pin number on the phone handset for GSM.
5.
6. Make sure the portable cellular phone (US Only) is securely seated in the holder. 6.
7. Make sure the GSM handset coil cord connector is correctly fitted to the armrest connector. 7.
8. Check the portable cellular phone (US Only) antenna connections. 8.
9. Check the portable cellular phone system registration (US Only). Also, check to make sure that the portable cellular phone is
correctly programmed. Incorrect programming can result in single system scanning, loss of speed dialing, loss of hands-free audio,
loss of auto redial, loss of dial tone multi-frequency tones, and the loss of other keypad/portable cellular phone functions.
9.
10. Make sure that a valid SIM card is inserted in the handset SIM card reader (GSM Only) 10.
11. Check the customer account status with the cellular carrier. 11.
If the customer concern is still present, follow these steps to diagnose the concern:
12. Visually inspect for obvious signs of mechanical or electrical damage: 12.
Portable cellular phone (US only)
Microphone
Portable cellular phone holder (US only)
Coil cord
Fuses
System/Carrier Concerns - All Systems
Dropped calls, bad connections, noisy audio and other intermittent symptoms usually indicate a system or cellular carrier concern, and are
not the fault of the phone itself. Such symptoms may occur in situations such as the following:
In certain geographic areas (for example: areas of excessive foliage or hills) or at the edge of coverage areas.
At the same place each day.
At the same time each day.
Under bridges, tunnels, in lower freeways, or in congested downtown areas.
If the customer phone exhibits any of the above symptoms or symptoms occur under the above conditions, the customer or the dealer
should contact customer assistance at their particular cellular provider/carrier or call the assistance number provided in the Jaguar Cellular
System Dealer kit.
Other Possible Concerns - All Systems
1. If, for some reason, the customer's electronic serial number was incorrectly recorded in the carrier switch, the phone will not work.
Call the assistance number provided in the Jaguar Cellular System Dealer kit to check the electronic serial number CDMA/TDMA
only.
1.
2. A customer initial call must be made in his/her home coverage area for correct activation of the Jaguar Cellular System. 2.
3. A customer may have to wait until after 24 hours of the coverage activation before making a call from outside of his/her home
coverage area or the phone might be reported stolen and coverage stopped.
3.
4. There may be a slight delay in activation after leaving the dealership from initial delivery. 4.
If, after checking these possibilities, the phone still does not function, do not attempt to repair the phone. Call the cellular phone
distributor.
DTC Index
CAUTION: When probing connectors to take measurements in the course of the pinpoint tests, use the adapter kit, part number
3548-1358-00
NOTE: If the control module/component is suspect and the vehicle remains under manufacturer warranty, refer to the Warranty policy and
procedures manual (section B1.2), or determine if any prior approval program is in operation, prior to the installation of a new module or
component
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NOTE: Check and rectify basic faults before beginning diagnostic routines that involve pinpoint tests
NOTE: Inspect connectors for signs of water ingress, and pins for damage and/or corrosion
B1038Microphone input circuit -
short to ground
Microphone fault
Wiring harness
fault
Refer to appropriate circuit diagram, check microphone input circuits for short to
ground. Repair circuit faults using appropriate materials and methods. Clear DTC,
retest system to verify correct operation.
B1039Microphone input circuit -
short to battery
Microphone fault
Wiring harness
fault
Refer to appropriate circuit diagram, check microphone input circuits for short to
battery. Repair circuit faults using appropriate materials and methods. Clear DTC,
B1342ECU is defective Internal ECU
fault
This DTC also includes memory failure. Replace telephone ECU and clear DTC.
B1893GPS antenna open circuit GPS Antenna
Wiring harness
fault
Check Antenna circuit for open circuits, repair wiring faults using approved
methods and materials, clear DTC and retest to confirm correct operation.
B2102Antenna circuit short to
ground
GPS Antenna
Wiring harness
fault
Check Antenna circuit for short circuits, repair wiring faults using approved
methods and materials, clear DTC and retest to confirm correct operation.
B2103Antenna not connected GSM or
Bluetooth
Antenna
Wiring harness
fault
Check GSM and Bluetooth antenna circuits for open circuits, repair wiring faults
using approved methods and materials, clear DTC and retest to confirm correct
operation.
B2141NVM configuration failure No phone
number
invalid phone
number
Software error or SIM card error, confirm SIM is valid and download new software
to phone module. Clear DTC and retest system to confirm operation.
failure
Configuration
fault
No vehicle identification number present, configure vehicle. Clear DTC and recheck
system to confirm correct operation.
B2633Microphone not
connected
Microphone
Wiring harness
fault
Check microphone is connected correctly, Check microphone lines for open circuits.
install connectors correctly or repair wiring harness using appropriate methods and
materials.
B2636SOS switch input short
circuit to ground
SOS switch
Wiring harness
fault
Check SOS switch is not stuck. Check SOS switch input line for short circuit to
ground. Repair wiring harness faults using appropriate methods and materials.
Replace SOS switch as required. Clear DTC and retest system for correct operation.
B2637Information switch input
short to ground
Information
switch
Wiring harness
fault
Check information switch for faults, check wiring harness for information switch
circuits shorted to ground. Repair wiring harness faults using approved methods
and materials. Clear DTC and retest system for correct operation.
B2638Phone rechargeable
battery fault
Phone battery
faulty
Wiring harness
fault
Check if the phone battery is correct for the phone in use. Confirm battery
charging connections are in good condition and are connected to the power supply.
B2640Deployment indication
input short to ground
Wiring harness Check wiring harness for airbag deployment indication circuit short to ground.
Repair wiring fault using approved methods and materials. Clear DTC and retest
B2641Deployment indication
input short to battery
Wiring harness Check wiring harness for airbag deployment indication circuit short to power.
Repair wiring fault using approved methods and materials. Clear DTC and retest
B2904Partial mute circuit
failure
Wiring harness Check mute circuits from phone ECU to radio head unit and nav system ECUs are
not short to ground. Repair wiring harness using approved methods and materials
U2601D2B wake up short to
ground
Wiring harness Check D2B wake up circuit for short to ground. Repair Wiring harness using
approved materials and methods. Clear DTC and retest to confirm correct
operation.
U2609D2B wake up pulse width
out of specification
Module software
issue
D2B pulse width specification is <50mS - >110mS, if the pulse width is outside
this range check the module configuration and programming. Reconfigure and
reprogramme module, clear DTC and retest system to confirm correct operation.
U2610D2B Slave ECU fails to
receive a report position
D2B network
concern
During initialisation no position status report is received, check D2B network for
open circuits, shorts. Repair wiring harness using approved methods and
U2611D2B Slave ECU fails to
receive an alarm clear
command
D2B network
concern
On entering alarm state, slave ECU has fail to receive alarm clear command, check
D2B network for open circuits, shorts. Repair wiring harness using approved
methods and materials. Clear DTC and retest system to ensure correct operation.
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Cellular Phone - Cellular PhoneVehicles With: Bluetooth
Overview
This section covers the components of the Bluetooth cellular phone system.
For information on the description and operation of the Bluetooth cellular phone system :
REFER to: Cellular Phone - VIN Range: N52048->N99999 (419-08 Cellular Phone, Description and Operation).
For additional information on the Bluetooth cellular phone system : REFER to owner information - Bluetooth telephone system handbook.
NOTE: Only cellular phones and software versions featured in the Jaguar Bluetooth approved phones and software list can be
guaranteed to operate correctly.
Check the D2B ring order and circuit integrity.
Before pairing a handset to the Bluetooth phone system make sure that the handbook for the specific handset is available.
1. Verify the customer concern by operating the system using the customers cellular phone. 1.
Electrical
Fuse(s)
Wiring harness
Bluetooth cellular phone
Microphone
Steering wheel control
Bluetooth upgrade module
Portable support electronics (PSE) module
Voice module
step.
3.
4. Use the approved diagnostic system or a scan tool to retrieve any DTCs before moving onto the symptom chart.
4.
Symptom Chart
Symptom Action
"NO PHONE FITTED" (touch-screen) message displayed continuously or "NO PHONE" message displayed every time the
phone mode button is pressed
GO to Pinpoint
Test A.
"HANDSET IN USE" (touch-screen) message displayed for more than 2 minutes, or "HANDSET" message displayed every
time the phone mode button is pressed and never changes to "SIG*"
GO to Pinpoint
Test B.
Unable to pair the handset to telephone system GO to Pinpoint
Test C.
"PHONE OFF" message displayed (touch-screen only) GO to Pinpoint
Test D.
Cannot answer/reject/end call from the audio head unit/touch screen/steering wheel control GO to Pinpoint
Test E.
Unable to connect the handset to telephone system GO to Pinpoint
Test F.
Bluetooth connection is dropped GO to Pinpoint
Test G.
Incorrect or no phonebook entries GO to Pinpoint
Test H.
No third party audio GO to Pinpoint
Test I.
No in-vehicle audio GO to Pinpoint
Test J.
No ringing heard through the vehicle speakers GO to Pinpoint
Test K.
Low audio volume GO to Pinpoint
Test L.
Cannot dial out from audio head unit/touch-screen/steering wheel control GO to Pinpoint
Test M.
Voice activated phone functions inoperative GO to Pinpoint
Test N.
Call is dropped GO to Pinpoint
Test O.
Interference and distortion GO to Pinpoint
Test P.
Unable to transfer call between hands free and handset GO to Pinpoint
Test Q.
Pinpoint Tests
NOTE: When performing voltage or resistance tests, always use a digital multimeter (DMM) accurate to three decimal places, and with an
up-to-date calibration certificate. When testing resistance always take the resistance of the DMM leads into account.
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NOTE: If a control module or component is suspect and the vehicle remains under manufacturer warranty, refer to the Warranty Policy and
Procedures manual (section B1.2), or determine if any prior approval program is in operation, before the replacement of a component.
PINPOINT TEST A : "NO PHONE FITTED" (TOUCH-SCREEN) MESSAGE DISPLAYED CONTINUOUSLY OR "NO PHONE"
MESSAGE DISPLAYED EVERY TIME THE PHONE MODE BUTTON IS PRESSED
TEST
CONDITIONS
A1:
Is the car a USA/Mexico/Canada car?
Yes
GO to A3.
No
GO to A2.
A2:
Is the VIN of the car post VIN break for Bluetooth? (Refer to Technical Helpline for VIN break information).
Yes
GO to A3.
No
The Bluetooth system cannot be retrofitted to rest of world cars pre-VIN break or to those cars not fitted with the
Bluetooth pre-wire due to a harness architecture change.
A3:
Has the correct harness been fitted to the car?
Yes
GO to A4.
No
The Bluetooth system cannot be retrofitted to rest of world cars pre-VIN break or to those cars not fitted with the
Bluetooth pre-wire due to a harness architecture change. (Refer to Technical Helpline for VIN break and pre-wire
information).
A4:
Does the display ever return to the main phone screen or ever display "PHONE"?
Yes
GO to A6.
No
GO to A5.
A5:
Check the part number of the portable support electronics (PSE) module. Has the correct part been fitted?
Yes
Check power, ignition and ground circuits/connections at the PSE module.GO to A7.
No
Refer to the warranty policy and procedures manual if the PSE module is suspect.
A6:
Are any of the D2B connections loose or damaged?
Yes
Reconnect/change/repair the D2B leads and check for normal operation.
No
GO to A7.
A7:
Are power, ignition and ground being supplied to the portable support electronics (PSE) module?
Yes
No
Rectify as necessary. Refer to the electrical guides.
PINPOINT TEST B : "HANDSET IN USE" (TOUCH-SCREEN) MESSAGE DISPLAYED FOR MORE THAN 2 MINUTES OR
"HANDSET" MESSAGE DISPLAYED EVERY TIME THE PHONE MODE BUTTON IS PRESSED AND NEVER CHANGES TO
"SIG*"
TEST
CONDITIONS
B1:
Has the system been paired to a handset?
Yes
Key off ignition and wait 6 minutes for the portable support electronics (PSE) module to shut down. The Bluetooth
upgrade module remains active for 6 minutes after the ignition has been switched off. It is important to wait this 6
minutes so that a clean boot-up of the Bluetooth upgrade module is achieved and the correct information is stored.
Switch off the paired handset; remove the battery from the back of the handset. Replace the battery into the handset
and switch on, make sure the Bluetooth function is on and the handset is within range. Key on ignition. GO to B2.
No
GO to B3.
B2:
Does the system still display "HANDSET IN USE" (touch-screen) message displayed for more than 2 minutes, or "HANDSET"
message displayed every time the phone mode button is pressed and then drops out of phone mode?
Yes
GO to B3.
No
Problem may have been due to the Bluetooth link being disconnected.
B3:
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Is the connection between the Bluetooth upgrade module and the phone harness loose?
Yes
Reconnect the Bluetooth upgrade module and check for normal operation.
No
GO to B5.
B4:
Are any of the Bluetooth upgrade module pins damaged?
Yes
Refer to the warranty policy and procedures manual if the Bluetooth upgrade module is suspect.
No
Check harness to/from the Bluetooth upgrade module and the portable support electronics (PSE) module.GO to B5.
B5:
Is power being supplied to the Bluetooth upgrade module?
Yes
No
GO to B6.
B6:
Are power, ignition, and ground being supplied to the portable support electronics (PSE) module?
Yes
No
PINPOINT TEST C : - UNABLE TO PAIR THE HANDSET TO TELEPHONE SYSTEM
TEST
CONDITIONS
C1:
Has another handset previously been paired to the system?
Yes
GO to C2.
No
GO to C3.
C2:
Is the "HANDSET IN USE" (touch-screen) or "HANDSET" message displayed, or does the system drop out of phone mode?
Yes
Go to'"HANDSET IN USE" or "HANDSET"' message displayed - GO to Pinpoint Test B.
No
GO to C3.
C3:
Does the touch-screen display "Discover Me" with 4 or 5 bars (The 5th bar will flash slowly) or does the audio head unit
display "SIG****" or "SIG*****" (The 5th '*' will flash slowly)?
Yes
Retry the pairing process following the 'quick guide information' for the specific handset.GO to C4.
No
Enter the ##3#*# pairing key sequence.GO to C5.
C4:
Has the handset paired with the system successfully? ("Phone connected" displayed (touch screen) or "SIG*" displayed
(audio head unit display))?
Yes
Problem may have been due to a faulty Bluetooth connection.
No
Key off ignition and wait 6 minutes for the portable support electronics (PSE) module to shut down. The Bluetooth
upgrade module remains active for 6 minutes after the ignition has been switched off. It is important to wait this 6
minutes so that a clean boot-up of the Bluetooth upgrade module is achieved and the correct information is stored.
Switch off the paired handset; remove the battery from the back of the handset. Replace the battery into the handset
and switch on, make sure the Bluetooth function is on and the handset is within range. Key on ignition. GO to C7.
C5:
Yes
Retry the pairing process following the 'quick guide information' for the specific handset.
No
Key off ignition and wait 6 minutes for the portable support electronics (PSE) module to shut down. Key on ignition. GO
to C6.
C6:
Yes
Retry the pairing process following the 'quick guide information' for the specific handset.
No
GO to C9.
C7:
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Has the handset paired with the system successfully ("Phone connected" displayed (touch screen) or "SIG*" displayed
Yes
Problem may have been due to a faulty Bluetooth connection.
No
Pair and connect a different known 'good' handset to the vehicle phone system. GO to C8.
C8:
Has the handset paired with the system successfully ("Phone connected" displayed (touch screen) or "SIG*" displayed
Yes
Problem may be an issue with the user's handset, consult the handset supplier.
No
GO to C9.
C9:
Is the connection between the Bluetooth upgrade module and the phone harness loose?
Yes
Reconnect the Bluetooth upgrade module and check for normal operation.
No
GO to C10.
C10:
Is power being supplied to the Bluetooth upgrade module?
Yes
No
GO to C11.
C11:
Are power, ignition, and ground being supplied to the portable support electronics (PSE) module?
Yes
No
PINPOINT TEST D : "PHONE OFF" MESSAGE DISPLAYED (TOUCH-SCREEN ONLY)
TEST
CONDITIONS
D1:
Is the Bluetooth system paired to a mobile phone handset?
Yes
GO to D2.
No
Key off ignition and wait 6 minutes for the portable support electronics (PSE) module to shut down. Key on
ignition.GO to D5.
D2:
Is the paired phone handset within range and switched on?
Yes
GO to D3.
No
GO to D4.
D3:
Is the paired phone handset 'connected' to the vehicle phone system?
Yes
GO to D4.
No
Follow instructions to 'connect' specific handset with the vehicle phone system.GO to D4.
D4:
Has the user switched out of phone mode e.g. audio, and then back to phone mode?
Yes
This is a system issue carried over from the previous phone system. Make sure that the last paired phone is on and
within range, and test for normal operation.
No
Call Technical Helpline.
D5:
Does the display still show the "PHONE OFF" message?
Yes
GO to D6.
No
Check for normal operation.
D6:
Are the D2B connections loose or damaged?
Yes
No
GO to D7.
D7:
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Check all connections/connectivity to and from the portable support electronics (PSE) module and the Bluetooth upgrade
module. Are any of the harness connections loose or damaged?
Yes
No
Refer to the warranty policy and procedures manual if a module is suspect.
PINPOINT TEST E : CANNOT ANSWER/REJECT/END CALL FROM THE AUDIO HEAD UNIT/TOUCH SCREEN/STEERING
WHEEL CONTROL
TEST
CONDITIONS
E1:
Cannot answer call?
Yes
Read DTCs from the portable support electronics (PSE) module using the approved diagnostic system and rectify as
necessary.GO to E3.
No
GO to E2.
E2:
Cannot reject/end call?
Yes
This is a network dependant feature, consult the relevant mobile phone network before continuing. Read DTCs from
the portable support electronics (PSE) module using the approved diagnostic system and rectify as necessary.GO to
E3.
No
GO to E3.
E3:
Can call be answered/rejected/ended from the handset (with Bluetooth link still connected)?
Yes
GO to E4.
No
Disconnect the Bluetooth link between the handset and vehicle phone system and re-try the call.GO to E5.
E4:
Is audio heard during call/call set up?
Yes
Refer to audio head unit diagnostics using the approved diagnostic system.
No
Check D2B ring is complete. Rectify as necessary.
E5:
Can call be answered/rejected/ended from the handset with Bluetooth link disconnected?
Yes
Key off ignition and wait 6 minutes for the portable support electronics (PSE) module to shut down. Switch off the
handset; remove the battery from the back of the handset. Replace the battery into the handset and switch on. Key
on ignition. Make sure the Bluetooth link is reconnected and re-try the call.GO to E6.
No
This may be a handset issue, consult the handset supplier.
E6:
Can the call be answered/rejected/ended from the handset (with Bluetooth link connected)?
Yes
Problem may have been due to the Bluetooth link being inoperative.
No
Pair and connect a different known 'good' handset to the vehicle phone system and make an incoming call.GO to E7.
E7:
Can the call be answered/rejected/ended from the handset (with Bluetooth link connected)?
Yes
No
GO to E8.
E8:
Yes
No
PINPOINT TEST F : UNABLE TO CONNECT THE HANDSET TO TELEPHONE SYSTEM
TEST
CONDITIONS
F1:
Was the handset the last device to be connected to the vehicle?
Yes
GO to F2.
No
In the handset Bluetooth menu, delete any existing "Jaguar" devices from the list. Enter the ##3#*# key sequence to
initiate the pairing process. Follow pairing process for the specific handset. GO to F6.
F2:
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In the handset Bluetooth menu, is "Jaguar" listed as a paired device?
Yes
GO to F3.
No
Follow pairing process for the specific handset. GO to F6.
F3:
Is the handset 'connected' to another Bluetooth device (i.e. not "Jaguar")?
Yes
Check "Active Devices" in the handset's Bluetooth menu and disconnect the handset from the other Bluetooth device.
Follow the instructions for the specific handset to allow the handset to 'connect' to the vehicle.GO to F8.
No
GO to F4.
F4:
What message does the vehicle display show, "Connected" or "No BT Phone"?
Yes
Follow the vehicle un-pairing process, delete "Jaguar" from the handset device list and key off ignition for 6 minutes.
Key on ignition. Follow the pairing process for the specific handset.GO to F6.
No
GO to F5.
F5:
Is the vehicle in "Discover Me" mode?
Yes
Follow pairing process for the specific handset. GO to F6.
No
Go to'"HANDSET IN USE" or "HANDSET"' message displayed - GO to Pinpoint Test B.
F6:
Has the handset paired successfully with the vehicle?
Yes
GO to F7.
No
Go to 'Unable to pair' - GO to Pinpoint Test C.
F7:
Has the handset automatically connected to the vehicle phone system?
Yes
Following the instructions for the specific handset to make sure that the Bluetooth settings are set for automatic
connection, connection should now be complete.
No
Follow the instructions for the specific handset to allow the handset to 'connect' to the vehicle.GO to F8.
F8:
Has the handset connected to the vehicle phone system?
Yes
No
on ignition. Re-try pairing and connecting. GO to F9.
F9:
Has the handset connected to the vehicle phone system?
Yes
No
Pair and connect a different known 'good' handset to the vehicle phone system. GO to F10.
F10:
Does the handset 'connect' OK?
Yes
This is a handset issue, consult the handset supplier.
No
PINPOINT TEST G : BLUETOOTH CONNECTION IS DROPPED
TEST
CONDITIONS
G1:
Does the handset battery have a good level of charge?
Yes
GO to G2.
No
Recharge the handset battery. Bluetooth performance cannot be guaranteed with low battery power.
G2:
Does the handset show good signal strength?
Yes
GO to G3.
No
Without good signal strength, the vehicle display will show "SIG______" or "No BT Phone" or "No Service". Move into
an area with good signal strength and check for normal operation.
G3:
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Check the handset menu. Has auto connect been turned on?
Yes
GO to G4.
No
Switch auto connect on and check for normal operation.
G4:
Has the user tried to transfer a call from hands free to handset?
Yes
Check the handset guide info, some handsets will not auto reconnect Bluetooth after a handset call.
No
GO to G5.
G5:
Does the handset display show that it is connected to the vehicle?
Yes
GO to G7.
No
GO to G6.
G6:
Does the vehicle display "SIG______" or "No BT Phone"?
Yes
Follow instructions for the specific handset to 'connect' the handset to vehicle.GO to G10.
No
GO to G7.
G7:
Does the vehicle display "SIG*" or "Phone Connected"?
Yes
Bluetooth connection has not been dropped, check for normal operation.
No
on ignition. GO to G8.
G8:
Does the vehicle display "SIG*" or "Phone Connected"?
Yes
No
Follow the vehicle un-pairing process, delete "Jaguar" from the handset device list and key off ignition for 6 minutes.
Key on ignition. Follow pairing process for the specific handset. GO to G9.
G9:
Has the handset paired successfully with the vehicle?
Yes
Follow instructions for the specific handset to 'connect' the handset to vehicle.GO to G10.
No
Go to 'Unable to pair' - GO to Pinpoint Test C.
G10:
Does the handset 'connect'?
Yes
GO to G11.
No
Go to 'Unable to connect' - GO to Pinpoint Test F.
G11:
Does the vehicle display show that it is 'connected'?
Yes
No
PINPOINT TEST H : INCORRECT OR NO PHONEBOOK ENTRIES
TEST
CONDITIONS
H1:
Check the Jaguar Bluetooth approved phone list guide: Does the handset support phonebook download?
Yes
GO to H2.
No
Advise user that the handset does not support phonebook download.
H2:
Is the Bluetooth system paired and connected to a phone handset?
Yes
GO to H3.
No
Pair and connect an approved handset to the vehicle phone system.GO to H2.
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Has the user followed vehicle and handset instructions for downloading phonebook?
Yes
GO to H4.
No
Refer to the vehicle handbooks/handset 'quick guide information' regarding phonebook download. Check for normal
operation.
H4:
After "Downloading the phonebook" has the ignition been switched off for 6 minutes?
Yes
GO to H7.
No
Make sure that the ignition has been switched off for 6 minutes after following process for downloading phonebook. The
Bluetooth upgrade module remains active for 6 minutes after the ignition has been switched off. It is important to wait
this 6 minutes so that a clean boot-up of the Bluetooth upgrade module is achieved and the correct information is
stored. Switch ignition on to prompt the portable support electronics (PSE) module to pull phonebook entries from the
Bluetooth upgrade module. GO to H5.
H5:
Can the user view the phonebook entries on the vehicle display?
Yes
End.
No
GO to H6.
H6:
Have two or more handsets been tried?
Yes
GO to H9.
No
Pair and connect a different known 'good' handset which will automatically download the phonebook to the vehicle
phone system. GO to H9.
H7:
After switching the ignition back on, does the handset connect to the vehicle phone system?
Yes
GO to H8.
No
Reconnect the handset and make sure auto-reconnect is set to on.GO to H7.
H8:
Is the phonebook available on the vehicle display?
Yes
End
No
Pair and connect a different known 'good' handset which will automatically download the phonebook to the vehicle
phone system.GO to H9.
H9:
Is the phonebook available on the vehicle display?
Yes
This is an issue with the user's handset, consult the handset supplier.
No
PINPOINT TEST I : NO THIRD PARTY AUDIO
TEST
CONDITIONS
I1:
Check the handset manual and the handset settings to make sure user's speech is routed through the vehicle
microphone and not the handset microphone.
Does 3rd party call audio work with the call in 'handset' mode?
Yes
Check for telephone related DTCs using the approved diagnostic system. Rectify as necessary.GO to I5.
No
GO to I2.
I2:
Is there any 3rd party call audio with the handset disconnected from the Bluetooth system?
Yes
Pair and connect a different known 'good' handset to the vehicle phone system and make a call to the 3rd party. GO
to I4.
No
Try calling another 3rd party from the handset.GO to I3.
I3:
Is there any 3rd party audio?
Yes
Initial audio problem may be due to a fault at 3rd party end. Check by calling them on another number.
No
I4:
Does the 3rd party call audio work with the Bluetooth system?
Yes
No
Check for telephone related DTCs using the approved diagnostic system. Rectify as necessary.GO to I5.
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I5:
Is there any 3rd party audio?
Yes
End.
No
Disconnect the Bluetooth link between the handset and vehicle phone system and re-try the call.GO to I6.
I6:
Does the 3rd party call audio work with the mobile phone disconnected from the vehicle?
Yes
Re-connect the Bluetooth link between the handset and the vehicle phone system and re-try the call.GO to I8.
No
Switch off the handset, remove the battery from the back of the handset. Replace the battery into the handset and
switch on. Make sure the Bluetooth link is disconnected and re-try the call.GO to I7.
I7:
Does the 3rd party call audio work with the mobile phone disconnected from the vehicle?
Yes
Problem may be due to a faulty Bluetooth connection.
No
I8:
Yes
No
GO to I9.
I9:
Does the 3rd party call audio work with the mobile phone in 'handset' mode?
Yes
GO to I10.
No
Key off ignition and wait 6 minutes for the portable support electronics (PSE) module to shut down. Key on ignition.
Make sure the Bluetooth link is re-connected and re-try the call pairing and connecting.GO to I14.
I10:
Does the vehicle have voice control fitted?
Yes
GO to I11.
No
GO to I12.
I11:
Does the voice control pick up commands from the user?
Yes
Check harness connections between the microphone and the portable support electronics (PSE) module are not loose
or damaged.GO to I16.
No
Refer to the warranty policy and procedures manual if the voice control module is suspect.
I12:
Is the vehicle a USA/Canada/Mexico vehicle?
Yes
GO to I13.
No
I13:
Does the vehicle have the voice control shorting loop fitted?
Yes
No
Fit the voice control shorting loop and check for normal operation.
I14:
Yes
No
Pair and connect a different known 'good' handset to the vehicle phone system and make an incoming call.GO to I15.
I15:
Yes
No
I16:
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Are the microphone harness connections damaged?
Yes
No
Replace the microphone and re-try the call. GO to I17.
I17:
Yes
Problem may have been due to a faulty microphone.
No
PINPOINT TEST J : NO IN-VEHICLE AUDIO
TEST
CONDITIONS
J1:
Can the audio sources be heard through the vehicle speakers e.g. radio?
Yes
GO to J2.
No
Check D2B connections are not loose or damaged. Reconnect/change/repair the D2B leads and check for normal
operation.
J2:
Can the call be heard when transferred to the handset?
Yes
Make sure the Bluetooth link is reconnected and re-try the call. GO to J3.
No
Disconnect the Bluetooth link between the handset and vehicle phone system and re-try the call. GO to J4.
J3:
Can the audio be heard through the vehicle speakers?
Yes
The audio problem may have been due to the Bluetooth link being disconnected.
No
Pair and connect a different known 'good' handset to the vehicle phone system and make a call to the 3rd party.GO to
J7.
J4:
Does the handset audio work with mobile phone disconnected from the vehicle?
Yes
Switch off the handset; remove the battery from the back of the handset. Replace the battery into the handset and
switch on. Key on ignition. Make sure the Bluetooth link is reconnected and re-try the call. GO to J6.
No
Try calling another 3rd party from the handset. GO to J5.
J5:
Is there any call audio on the handset?
Yes
Initial audio problem may be due to a fault at the 3rd party end, check by calling them on another number.
No
J6:
Yes
No
Pair and connect a different known 'good' handset to the vehicle phone system and make a call to the 3rd party.GO to
J7.
J7:
Yes
No
Check harness connections between the Bluetooth upgrade module and the portable support electronics (PSE) module.
GO to J8.
J8:
Are any of the harness connections damaged?
Yes
No
PINPOINT TEST K : NO RINGING HEARD THROUGH THE VEHICLE SPEAKERS
TEST
CONDITIONS
K1:
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When there is no call in progress, and the audio source is changed, is any audio heard e.g. from radio?
Yes
GO to K3.
No
Check D2B connections are not loose and that all nodes are connected on the D2B ring. Rectify as necessary.GO to
K2.
K2:
Are any of the D2B connections damaged?
Yes
Change/repair the D2B leads and check for normal operation.
No
K3:
Is the vehicle phone system volume set to more than 15?
Yes
GO to K4.
No
Make sure that the vehicle phone system is set to more than 15 and retry the call.
K4:
Is the message "incoming call" displayed?
Yes
GO to K5.
No
GO to K6.
K5:
On answering the incoming call using the vehicle controls, can the 3rd party be heard through the vehicle speakers?
Yes
GO to K6.
No
Go to 'No in-vehicle audio' - GO to Pinpoint Test J.
K6:
Is there any ringing heard on the handset with the Bluetooth link connected?
Yes
GO to K7.
No
GO to K10.
K7:
Does the handset support in-band ringing or send its ringing status to the Bluetooth upgrade module?
Yes
Make sure the Bluetooth link is re-connected and re-try the call. GO to K8.
No
This is a handset issue, contact the handset supplier or replace with another handset from the approved list.
K8:
Can any ringing be heard through the vehicle speakers?
Yes
No
Un-pair the current handset and pair/connect a known good handset with the vehicle. Make an incoming call. GO to
K9.
K9:
Yes
Contact the handset supplier, the handset may be faulty.
No
GO to K10.
K10:
Is the message "incoming call" displayed?
Yes
Check the handset instructions to find "profile" settings.GO to K14.
No
GO to K11.
K11:
Does the handset have good signal strength?
Yes
Disconnect the Bluetooth connection. Make sure the handset is not set to silent. Then make an incoming call. GO to
K12.
No
Move into area where the handset receives good signal strength. Make an incoming call and check for normal
operation.
K12:
Is there any ringing heard on the handset with the Bluetooth link disconnected?
Yes
Reconnect the Bluetooth connection, and then make an incoming call. GO to K13.
No
Contact the handset supplier, the handset may be faulty.
K13:
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Yes
Problem due to a faulty Bluetooth link.
No
GO to K4.
K14:
Has the handset "profile" been set to "silent"?
Yes
Change settings within profile, make an incoming call and check for normal operation.
No
GO to K15.
K15:
Has the handset volume been set to minimum?
Yes
Increase volume setting, make an incoming call and check for normal operation.
No
Check Bluetooth connection between the handset and vehicle is OK. GO to K16.
K16:
Is the Bluetooth connection OK?
Yes
Disconnect the Bluetooth connection. Make sure that the handset is NOT set to silent, then make an incoming
call.GO to K17.
No
Follow the handset instructions for 'connecting' the Bluetooth link, then make an incoming call and check for normal
operation.
K17:
Is there any ringing heard on the handset?
Yes
Reconnect Bluetooth link between the handset and vehicle.GO to K18.
No
Un-pair the current handset and pair/connect a known good handset with the vehicle. Make an incoming call. GO to
K9.
K18:
Yes
Change settings within profile, make an incoming call and check for normal operation.
No
Check harness connections between the Bluetooth upgrade module and the portable support electronics (PSE)
module.GO to K19.
K19:
Are any of the harness connections damaged?
Yes
No
PINPOINT TEST L : LOW AUDIO VOLUME
TEST
CONDITIONS
L1:
Low volume in vehicle (rather than at 3rd party)?
Yes
GO to L2.
No
If volume is low at 3rd party.GO to L9.
L2:
Is the vehicle phone volume set at 12 or above?
Yes
Check fade & balance are both set at '0' or mid point on slider controls. GO to L3.
No
Increase phone volume to above 12. GO to L1.
L3:
Is radio volume OK?
Yes
GO to L4.
No
L4:
Is Bluetooth link between the handset and vehicle still connected?
Yes
GO to L5.
No
Re-connect the Bluetooth link and re-try the call.GO to L1.
L5:
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Is call volume still low when call transferred to 'handset' mode?
Yes
GO to L6.
No
Key off ignition and wait 6 minutes for the portable support electronics (PSE) module to shut down. Key on ignition
and re-try the call. GO to L16.
L6:
Is the call volume still low with the handset disconnected from the Bluetooth system?
Yes
GO to L7.
No
Try calling another 3rd party from the handset.GO to L8.
L7:
Is the handset volume setting low?
Yes
Increase the handset volume setting and re-try the call.GO to L6.
No
Low audio issue due to the handset, consult the handset supplier.
L8:
Is the call volume still low with the handset disconnected from the Bluetooth system?
Yes
Low audio issue due to the handset, consult the handset supplier.
No
Initial audio problem may be due to a fault at the 3rd party end. Check by calling them on another number.
L9:
Check that handset volume setting and signal strength are not low. Is call volume still low when call transferred to
'handset' mode?
Yes
GO to L14.
No
GO to L10.
L10:
Is the microphone fitted OK? Check DTCs using the approved diagnostic system.
Yes
GO to L12.
No
Rectify as necessary.GO to L11.
L11:
Is volume still low?
Yes
GO to L12.
No
Issue caused by faulty microphone or microphone circuit.
L12:
Is voice control fitted to vehicle?
Yes
Disconnect the voice control module and fit the voice control shorting loop to the wiring harness.GO to L13.
No
GO to L14.
L13:
Yes
GO to L14.
No
Refer to voice control diagnostics.
L14:
Is the 3rd party call audio still low with the handset disconnected from the Bluetooth system?
Yes
Pair and connect a different known 'good' handset to the vehicle phone system and make a call to a 3rd party.GO to
L17.
No
Re-connect Bluetooth link and re-try the call.GO to L15.
L15:
Yes
Key off ignition and wait 6 minutes for the portable support electronics (PSE) module to shut down. Key on ignition
and re-try the call.GO to L16.
No
Issue caused by a faulty Bluetooth connection.
L16:
Yes
No
Issue caused by a faulty Bluetooth connection.
L17:
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Yes
No
Low audio issue caused by the handset, consult the handset supplier.
PINPOINT TEST M : CANNOT DIAL OUT FROM AUDIO HEAD UNIT/TOUCH-SCREEN/STEERING WHEEL CONTROL
TEST
CONDITIONS
M1:
Is D2B ring complete?
Yes
GO to M2.
No
M2:
Does display show "NO SERVICE" or drop out of phone mode?
Yes
GO to M3.
No
GO to M4.
M3:
Signal strength on the handset greater than 1?
Yes
GO to M4.
No
Re-try call in a stronger signal strength area, low signal strength can cause interference and distortion in car and at
3rd party.
M4:
Can user dial out from the handset?
Yes
Make sure the Bluetooth link is reconnected and re-try the call.GO to M5.
No
switch on. Make sure the Bluetooth link is reconnected and re-try the call.GO to M5.
M5:
Can user dial out from audio head unit or steering wheel control?
Yes
Problem may have been caused by the Bluetooth link being disconnected.
No
Pair and connect a different known 'good' handset to the vehicle phone system and make an incoming call.GO to M6.
M6:
Can user dial out from audio head unit or steering wheel control?
Yes
No
PINPOINT TEST N : VOICE ACTIVATED PHONE FUNCTIONS INOPERATIVE
TEST
CONDITIONS
N1:
Make sure that the customer has completed voice recognition training.
Check audio head unit DTCs using the approved diagnostic system, are there any audio head unit DTCs stored?
Yes
Carry out the pinpoint tests associated with the relevant DTCs using the manufacturer approved diagnostic system.
No
GO to N2.
N2:
Is there a dial problem?
Yes
GO to N3.
No
GO to N5.
N3:
Dials wrong number?
Yes
GO to N7.
No
GO to N4.
N4:
Will not dial?
Yes
GO to N9.
No
GO to N5.
N5:
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Cannot dial using voice control?
Yes
GO to N8.
No
GO to N6.
N6:
Cannot turn phone on/off?
Yes
GO to N8.
No
GO to N10.
N7:
Is the handset on the approved phone list?
Yes
No
Only handsets specified in the approved list with the correct level of software can be guaranteed to work.
N8:
Is voice control on the D2B ring?
Yes
GO to N9.
No
Not a phone issue.
N9:
Does verbal communication confirm correct number?
Yes
GO to N10.
No
Not a phone issue.
N10:
Does the audio head unit/touch-screen show "NO PHONE" or "PHONE NOT FITTED" (i.e. is phone off the D2B ring)?
Yes
GO to N11.
No
GO to N12.
N11:
Are any of the D2B connections loose or damaged?
Yes
No
N12:
Yes
No
PINPOINT TEST O : CALL IS DROPPED
TEST
CONDITIONS
O1:
Is the 3rd party call to another cellular phone?
Yes
GO to O3.
No
GO to O2.
O2:
Is the 3rd party call to a landline?
Yes
Disconnect the Bluetooth link between the handset and vehicle phone system. Re-try the call in the vehicle,
preferably with the handset in the same position as when connected via the Bluetooth link. GO to O4.
No
GO to O5.
O3:
Is the signal strength on the 3rd party handset greater than 1?
Yes
Disconnect the Bluetooth link between the handset and vehicle phone system. Re-try the call in the vehicle,
preferably with the handset in the same position as when connected via the Bluetooth link. GO to O4.
No
Re-try call in stronger signal strength area. Low signal strength can lead to calls being dropped.
O4:
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Is the call dropped again?
Yes
Pair and connect a different known 'good' handset to the vehicle phone system and make an incoming call. GO to O7.
No
switch on. Make sure the Bluetooth link is reconnected and re-try the call.GO to O5.
O5:
Yes
Make sure the Bluetooth link is reconnected and re-try the call.GO to O6.
No
O6:
Yes
Pair and connect a different known 'good' handset to the vehicle phone system and make an incoming call.GO to O7.
No
O7:
Yes
No
PINPOINT TEST P : INTERFERENCE AND DISTORTION
TEST
CONDITIONS
P1:
Is interference present with Bluetooth link disconnected?
Yes
GO to P2.
No
Check for external sources of interference. Drive to where the customer has problems to identify if location
dependant. Test in an area of known high signal strength.GO to P4.
P2:
Is it present with a different known 'good' handset paired/connected?
Yes
GO to P3.
No
P3:
Is it present with other network carriers?
Yes
Check for external sources of interference. Drive to where the customer has problems to identify if location
dependant. Test in an area of known high signal strength.GO to P4.
No
This may be a network or handset issue, consult the handset supplier/network provider.
P4:
Are there any powered items/aftermarket accessories in the car?
Yes
Switch off any powered items/aftermarket accessories in the car.GO to P5.
No
P5:
Is interference still present?
Yes
No
User to be advised of interference from aftermarket accessories.
PINPOINT TEST Q : UNABLE TO TRANSFER CALL BETWEEN HANDS FREE AND HANDSET
TEST
CONDITIONS
Q1:
Does the specific handset guide state that the handset does not support call transfer?
Yes
Advise user that some software levels are not guaranteed to function correctly. Software to be changed to approved
level or the handset to be changed.
No
switch on. Make sure the Bluetooth link is reconnected and re-try the call.GO to Q2.
Q2:
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Can the call be transferred between hands free and handset?
Yes
No
Key off ignition for 6 minutes for the portable support electronics (PSE) module to shut down. Key on ignition and
re-try the call.GO to Q3.
Q3:
Yes
No
Pair and connect a different known 'good' handset to the vehicle phone system and make an incoming call. GO to Q4.
Q4:
Yes
This is a handset issue, consult the handset supplier.
No
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Cellular Phone - Bluetooth Module
Removal
2. Remove the Bluetooth module.
Installation
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Cellular Phone - Handset Holder
Removal
All vehicles
1. Remove the floor console
2. NOTE: US models only have an additional antenna connector.
Disconnect the cellular phone electrical connector.
Vehicles with cordless cellular phone
3. Remove the cellular phone.
4. Remove the handset holder.
1. Detach the handset holder.
2. Remove the handset holder.
5. Remove the armrest.
Vehicles with corded cellular phone
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6. Remove the armrest.
7. Remove the non slip mat.
8. Remove the handset hang up cup.
Installation
Vehicles with corded cellular phone
1. Install the handset hang up cup.
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2. Install the non slip mat.
3. Install the armrest.
4. Install the armrest.
5. Attach the handset holder.
1. Install the handset holder.
2. Attach the handset holder.
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6. Install the cellular phone.
All vehicles
7. NOTE: US models only have an additional antenna connector.
Connect the cellular phone electrical connector.
8. Install the floor console
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Cellular Phone - Module4-Door
Removal
1. Remove the compact disc (CD) changer
For additional information, refer to: Compact Disc (CD) Changer - 4-Door
Installation
Tighten to 5 Nm.
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Cellular Phone - ModuleWagon
Removal
1. Disconnect the battery ground cable
2. Remove the compact disc changer
For additional information, refer to: Compact Disc (CD) Changer - Wagon
3. Remove the multifunction voice activated module
For additional information, refer to: Multifunction Voice Activated Module
- Wagon (419-10 Multifunction Electronic Modules, Removal and
Installation).
Installation
Tighten to 5 Nm.
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Multifunction Electronic Modules -
Voice activated control module 5 - 44
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Multifunction Electronic Modules - Module Controlled Functions
1 Voice activated control module (VACM)
Voice Activated Control Component Location
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1 Microphone
2 Visual feedback message center display
3 Audible feedback (incorporated in audio system)
4 Steering wheel controls
Generic Electronic Module (GEM)
The GEM module is located on the right hand side, below the instrument panel. The GEM module controls the wiper and security systems.
Voice Activated Control Module (VACM)
The VACM is located in the left hand side luggage compartment behind the trim panel. The VACM module controls and processes all the
voice commands given by the driver, then delivers this information to the audio unit, navigation system module, television module,
intergrated cellular phones and the climate control modules which then carry out these commands.
Microphone
The microphone is used for the cellular phone and to receive voice commands. The microphone supplies the information to the VACM which
processes the commands and supplies the necessary information to the correct modules.
Visual Feedback Message Center Display
This display keeps the driver informed of the function which is being selected or processed.
Audible Feedback (Speakers)
This audible tone informs the driver when the system is able to receive commands for processing.
The verbal feedback speakers are incorporated in the audio speakers. These speakers are utilized to confirm to the driver that there verbal
command has been accepted and is being proceeded.
Steering Wheel Controls VOICE/PHONE Button
This button is automatically configured by the audio unit depending on which systems are installed on the vehicle. For additional
information, refer to the Owner Guide.
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Multifunction Electronic Modules - Multifunction Electronic Module
For a detailed description of the multifunction electronic modules, refer to the relevant Description and Operation sections in the workshop
manual. REFER to: Module Controlled Functions (419-10 Multifunction Electronic Modules, Description and Operation).
Electrical
VACM module
GEM module
Microphone
Instrument cluster
Switch(s)
Speakers
step.
3.
DTC Index
Voice Activated Control Module
CAUTION: when probing connectors to take measurements in the course of pinpoint tests, use the adapter kit, part number
3548-1358-00
NOTE: if the control module/component is suspect and the vehicle remains under manufacturer warranty, refer to the Warranty Policy and
Procedures manual (section B1.2), or determine if any prior approval program is in operation, prior to the installation of a new module or
component.
NOTE: When performing voltage or resistance tests always use a digital multimeter (DMM) accurate to three decimal places and with a
NOTE: Check and rectify basic faults first before beginning diagnostic routines that involve pinpoint tests.
NOTE: If DTCs are recorded and, after performing pinpoint tests, a fault is not present, an intermittent concern may be the cause. Always
check for loose connectors and corroded terminals.
U2601D2B wake up - short
to ground
Voice activated control
module
Wake up line short to ground
Refer to electrical circuit diagrams, check D2B wake up circuit for shorts to
ground. Repair wiring harness using approved methods and materials.
Clear DTC and retest system to confirm correct operation.
U2609D2B wake up -
pulse width out of
spec
module wake up line - circuit
fault (pulse <50mS - pulse
>110mS)
Refer to electrical circuit diagrams and notes, check voice activated control
module D2B wake up line circuit for faults. Repair any defects, clear DTC
and retest to confirm correct operation.
U2610D2B slave ECU fails
to receive a report
position
During initialization no
position status report is
received from one or more
slave modules
Carry out any pin point tests associated with this DTC using the
diagrams, notes and check D2B slave modules and circuit for faults.
Replace as required, refer to the new module installation note at the top
of the DTC index. Repair any defects, clear DTC and retest to confirm
correct operation.
U2611D2B slave ECU fails
to receive an alarm
clear command
module - on entering alarm
state, slave ECU has failed to
receive alarm clear command
Refer to electrical circuit diagrams, notes and check D2B slave modules
and circuit for faults. Replace as required, refer to the new module
installation note at the top of the DTC index. Repair any defects, clear
DTC and retest to confirm correct operation.
B2477Module
module - module
The module can be configured using the new module procedure. Check and
configure as required.
Generic Electronic Module
CAUTION: when probing connectors to take measurements in the course of pinpoint tests, use the adapter kit, part number
3548-1358-00
NOTE: if the control module/component is suspect and the vehicle remains under manufacturer warranty, refer to the Warranty Policy and
Procedures manual (section B1.2), or determine if any prior approval program is in operation, prior to the installation of a new module or
component.
NOTE: When performing voltage or resistance tests always use a digital multimeter (DMM) accurate to three decimal places and with a
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NOTE: Check and rectify basic faults first before beginning diagnostic routines that involve pinpoint tests.
NOTE: If DTCs are recorded and, after performing pinpoint tests, a fault is not present, an intermittent concern may be the cause. Always
check for loose connectors and corroded terminals.
C1445Vehicle speed failure Vehicle speed signal circuit
failure
Refer to electrical diagrams, check vehicle speed signal circuit for faults
such as open circuits, short to ground or power. Repair faults using
approved methods and materials. Clear DTC and retest system to
ensure correct operation.
B1298Power supply sensor
circuit short to battery
Intrusion and inclination
sensor power supply short to
Battery.
Refer to electrical diagrams, check intrusion and inclination sensor
circuits for short to power. Repair faults using approved methods and
B1299Power supply sensor
Intrusion and inclination
sensor power supply short to
ground.
Refer to electrical diagrams, check intrusion and inclination sensor
circuits for short to ground. Repair faults using approved methods and
B1315Battery saver relay coil
Battery saver relay fault
Refer to electrical diagrams, battery saver relay coil circuits for short to
power. Repair faults using approved methods and materials. Clear DTC
and retest system to ensure correct operation. Replace relay as
required, clear DTC and retest system to ensure correct operation.
B1549Power window master
Global closing output circuit
shorted to battery
Refer to electrical diagrams, power window master circuit for short to
and retest system to ensure correct operation.
B1550Power window master
Global closing output circuit
shorted to ground
Wiring harness concern
Refer to electrical diagrams, power window master circuit for short to
ground. Repair faults using approved methods and materials. Clear DTC
B1570Lamp headlamp
high-beam circuit short
to ground
Headlamp high beam circuit
shorted to ground
wiring harness concern
Refer to electrical diagrams, headlamp high beam circuit for short to
B1438Wiper mode select
switch circuit failure
Wiper switch stuck or in
wrong position during wiper
test routine
Inspect switch for signs of damage or incorrect operation or sticking,
replace switch as required. Check wiper control switch circuits for open
circuits, shorts to power or ground. Repair faults using approved
methods and materials. Clear DTC and retest system to ensure correct
operation.
B1446Wiper park sense
circuit failure
Wiper park to park time
incorrect (12 second limit
exceeded)
Inspect wiper motor harness for damage, Refer to electrical circuit
diagrams and check wiper motor circuits for open circuits, shorts to
ground or power. Repair faults using approved methods and materials.
B1450Wiper wash/delay
switch circuit failure
Wrong position or short circuit
to battery detected during
wiper test diagnostic routine
Check wiper wash/delay switch for correct operation. Refer to electrical
diagrams, check wiper control circuits for short to battery. Repair faults
using approved methods and materials. Clear DTC and retest system to
B1499Lamp turn signal left
circuit failure
Left turn signal lamp circuit
open circuit or short to ground
Refer to electrical diagrams, check left turn signal circuit for open
circuits or short to ground. Repair faults using approved methods and
B1503Lamp turn signal right
circuit failure
Right turn signal lamp circuit
open circuit or short to ground
Refer to electrical diagrams, check right turn signal circuit for open
circuits or short to ground. Repair faults using approved methods and
B1553Deck lid release circuit
short to battery
Deck lid release circuit
shorted to battery
Refer to electrical diagrams, check deck lid release circuit for short to
B1554Deck lid release circuit
short to ground
Deck lid release circuit
shorted to ground
Refer to electrical diagrams, check deck lid release circuit for short to
B2108Front wiper short to
battery
Wiper motor relay
Inspect from wiper motor relay, replace as required. Refer to electrical
wiring circuit diagrams, check wiper relay circuit for short to power.
Repair faults using approved methods and materials. Clear DTC and
retest system to ensure correct operation.
B2111Front wiper short to
ground
Wiper motor relay
Inspect from wiper motor relay, replace as required. Refer to electrical
wiring circuit diagrams, check wiper relay circuit for short to ground.
Repair faults using approved methods and materials. Clear DTC and
retest system to ensure correct operation.
B2114Front washer input
short to ground
Switch stuck or short circuited
to ground
wiring harness concern
Check front washer switch operation for sticking. Replace switch as
required. Refer to electrical circuit wiring diagrams. Check washer input
circuit for short to ground. Repair wiring harness using approved
methods and materials. Clear DTC and retest system to confirm correct
operation.
B2177Interior scanning
sensor circuit failure
Interior sensor missing or
failed
Check sensor is present and appears undamaged. Refer to electrical
circuit wiring diagrams. Check sensor circuit for open circuits, short to
power or ground. Replace sensor as required, repair wiring harness
B2258Headlamp washer relay
Headlamp wash relay fault
Refer to electrical circuit diagrams, check headlamp washer relay circuits
for open circuits, short to power or ground. Repair any faults found
using approved methods and materials. Replace relay as required. Clear
DTC and retest system to confirm correct operation.
B2281Right turn switch short
to ground
Turn switch faulty
Check right turn switch operation for sticking. Replace switch as
required. Refer to electrical circuit wiring diagrams. Check right turn
switch input circuit for short to ground. Repair wiring harness using
approved methods and materials. Clear DTC and retest system to
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B2282Left turn switch short
to ground
Turn switch faulty
Check left turn switch operation for sticking. Replace switch as required.
Refer to electrical circuit wiring diagrams. Check left turn switch input
operation.
B2283Turn signal chime short
to battery
Wiring harness concern, ECU
output to loud speaker in
steering column switchgear is
Refer to electrical circuit wiring diagrams. Check ECU output circuit to
the steering column speaker for short to power. Repair wiring harness
B2284Turn signal chime short
to ground
wiring harness concern, ECU
output to loud speaker in
steering column switchgear is
Refer to electrical circuit wiring diagrams. Check ECU output circuit to
the steering column speaker for short to ground. Repair wiring harness
B2287Inclination sensor
circuit failure
Sensor missing or failed
Inspect vehicle for presence of and condition of inclination sensor.
Replace sensor if required. Refer to electrical circuit wiring diagrams.
Check inclination sensor circuits for open circuits or short to power or
ground. Repair wiring harness using approved methods and materials.
Clear DTC and retest system to confirm correct operation.
B2414Headlamp washer relay
circuit short circuit to
ground
Headlamp wash relay internal
fault
Check headlamp wash relay for condition, replace as required. Refer to
electrical circuit wiring diagrams. Check headlamp washer relay circuits
materials. Clear DTC and retest system to confirm correct operation.
failure
ECU configuration issue The ECU has not been configured or has been configured incorrectly.
Use the manufacturer approved diagnostic equipment to configure the
ECU correctly then retest to ensure correct operation.
B2494Anti theft horn output
Wiring harness concern Refer to electrical circuit wiring diagrams. Check anti theft horn output
circuit for short to battery. Repair wiring harness using approved
operation.
B2496Anti theft horn output
Wiring harness concern Refer to electrical circuit wiring diagrams. Check anti theft horn output
operation.
B2511Horn output relay
Wiring harness concern Refer to electrical circuit wiring diagrams. Check vehicle horn output
relay circuit for short to battery. Repair wiring harness using approved
operation.
B2555Dome lamp output
courtesy lamp fault
Inspect Dome lamp for defects which may cause a short circuit to
power. Replace or repair as required. If no faults are found in the dome
lamp itself, check ECU output circuit to dome lamp for shorts to battery.
Repair wiring harness using approved methods and materials. Clear DTC
and retest system to confirm correct operation.
U1041SCP (J1850) invalid or
missing data for
vehicle speed
Data in the speed signal
message is missing or
outside of normal limits
Refer to electrical circuit diagrams, check for SCP network wire broken,
or short circuit to power or ground. Repair wiring harness using
approved materials and methods. Clear DTC and retest system to
missing data for
ignition switch/starter
Data in the ignition signal
missing data for
vehicle security
Data in the security key
U1262SCP (J1850)
communication bus
fault
Missing message
Refer to electrical circuit diagrams, check for SCP network wire broken.
Repair wiring harness using approved materials and methods. Clear DTC
B1823Wiper rear park sense
input circuit open
Rear wiper park sense switch
Rear wiper park sense switch not detected for 4 seconds. Refer to
electrical circuit diagrams and check rear wiper circuits for open circuits,
short to power or short to ground. Repair wiring harness using approved
materials and methods. Clear DTC and retest system to ensure correct
operation.
U2514Missing message for
vehicle speed
Wiring harness concern Refer to electrical wiring diagrams, Check SCP network for open circuit.
Repair wiring harness using approved methods and materials. Clear DTC
and retest to ensure correct operation.
B1041Direction indicator
power feed fuse blown
Power distribution box
Check power distribution box fuses, if blown refer to electrical circuit
diagrams and check for short circuits to ground on indicator circuits.
Repair wiring harness and fit replacement fuses as required. Clear DTC
B2090Remote key entry data
line failure
Wiring harness concern Refer to electrical circuit diagrams, check RKE data line for short to
ground. Repair wiring harness, clear DTC and retest system to ensure
correct operation.
B2091Remote key
Wiring harness concern Refer to electrical circuit diagrams, check RKE data line for short to
battery. Repair wiring harness, clear DTC and retest system to ensure
correct operation.
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Multifunction Electronic Modules - Generic Electronic Module (GEM)
Removal
1. CAUTION: Electronic modules are sensitive to static electrical
charges. If exposed to these charges, damage may result.
2. Disconnect the generic electronic module (GEM) electrical connectors.
3. Remove the GEM.
1. Press the tang.
2. Remove the GEM
Installation
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Multifunction Electronic Modules - Multifunction Voice Activated Module4-Door
Removal
1. CAUTION: Electronic modules are sensitive to static electrical
5. Disconnect the voice activated control module (VACM) electrical
connector and fibre optic connector.
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6. Remove the VACM.
Installation
Tighten to 6 Nm.
3. Configure the voice activated control module using the Jaguar approved
diagnostic system.
4. Test the operation to confirm that the correct language is installed, if
the language is wrong then replace the voice module for the correct
language.
5. Switch the ignition on and wait for the system to initialize. Press the
voice button and say the command "Voice Help" list the options given in
the feedback.
6. Compare the options given with the vehicle specification if there is an
error reconfigure the voice module and repeat steps 4 and 5.
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Multifunction Electronic Modules - Multifunction Voice Activated ModuleWagon
Removal
1. Disconnect the battery ground cable
2. Remove the Compact Disc changer
For additional information, refer to: Compact Disc (CD) Changer - Wagon
3. Remove the voice activated control module.
Installation
Tighten to 5 Nm.
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Front End Body Panels - Front End Body Panels
Front Bumper Assembly and Undertray
The front body structure is designed to satisfy bumper impact requirements and primarily comprises the front bumper assembly which is
fully described inSection 501-19 Bumpers.
An undertray is fitted to assist air flow through the cooling pack. It is secured to the bottom of the bumper casing and the body front cross-
member.
Hood
The hood assembly consists of a one piece inner and outer panel, clinched and bonded together with a bead sealant applied to each clinch
joint. The hood opens from the front and is secured by means of a double catch in the hood latch.
Plenum Cover and Front Seals
Protective GMT liners fitted in the wheel arches each incorporate a readily detachable panel for access to the spot lamp assembly. An
injection molded plenum cover is secured to the bodywork by securing clips. The plenum cover gives easy access to the windscreen wiper
components and the ventilation system pollen filter.
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Front End Body Panels - Air Deflector2.0L Duratorq-TDCi/2.2L Duratorq-TDCi
Removal
All vehicles
Installation
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Front End Body Panels - Cowl Vent Screen
Removal
All vehicles
1. Remove the wiper arms and blades.
For additional information, refer to: Wiper Pivot Arm (501-16 Wipers and
Washers, Removal and Installation).
3. Remove the cowl vent screen heatshield.
Installation
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Front End Body Panels - Fender Splash Shield
Removal
3. Remove wheel arch liner.
Installation
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Front End Body Panels - Radiator Splash Shield
Removal
2. Remove undertray assembly.
Installation
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Body Closures -
Door hinge bolt - hinge to body 35 26
Door hinge bolt - hinge to door 47 35
Door hinge grub screw 18 13
Door checkstrap to body 35 26
Door checkstrap to door 6 53
Door striker plate screw 25 18
Luggage compartment lid hinge - hinge to lid nuts 25 18
Luggage compartment lid hinge - hinge to body bolts 25 18
Luggage compartment lid striker plate 10 7
Hood hinge screw 20 15
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Body Closures - Body Closures
Doors
The passenger compartment doors each comprise of an inner and outer panel, clinched and bonded together to form a door assembly. Both
panels incorporate extensions spot welded together to form a cheater assembly and a sealant is applied in cosmetic bead form to all clinch
joints.
The doors are of a conventional latch to striker plate design with the strikers located on the body pillars.
A joint-less single profile bulb seal is installed on each door together with a water shedder and separate vacuum formed speaker cup. Upper
and lower door hinges and multi-stage checkstraps require no lubrication throughout vehicle life.
Luggage Compartment Lid
The luggage compartment lid comprises of an inner and outer panel clinched and bonded together to form a complete assembly. A cosmetic
bead sealant is applied to all clinch joints.
Hinge reinforcements and a latch striker mounting reinforcement are attached to the lid inner panel and a combined hinge and gas strut
mounting assemblies are secured by bolts and nuts to the inner panel and the luggage compartment flange at each side.
The luggage compartment lid utilizes a conventional lock to striker plate design, with the striker located centrally on the edge of the load
space floor.
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Body Closures - Door Alignment
General Procedures
1. NOTE: Rear door shown, front door similar.
Remove the rear door aperture seal.
2. Remove the striker plate.
3. Loosen the door hinge bolts.
4. NOTE: Initial door fitting, set the front door 4 mm or the rear door 3
mm higher than nominal.
Set the door to the correct alignment.
5. Tighten the door hinge bolts.
Tighten to 47 Nm.
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6. Install the striker plate.
Tighten to 25 Nm.
7. Install the rear door aperture seal.
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Body Closures - Hood Alignment
General Procedures
1. Remove the hood latch. For additional information, refer toSection
501-14 Handles, Locks, Latches and Entry Systems.
2. NOTE: Right hand shown, left hand similar.
Remove the A-pillar exterior trim.
Remove the lower A-pillar drainage channel.
4. Loosen the hood hinge screws to 3-5 Nm.
5. Pull up/push down on hood.
6. Set hood to the correct alignment.
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7. Tighten the hood hinge screws to 20 Nm.
Install the lower A-pillar drainage channel.
Install the A-pillar exterior trim.
10. Install the hood latch. For additional information, refer toSection
501-14 Handles, Locks, Latches and Entry Systems.
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Body Closures - Liftgate Alignment
General Procedures
1. Open the liftgate.
Adjust both liftgate bump stops counter-clockwise to their fully seated
position.
3. Remove the loadspace scuff plate trim panel.
For additional information, refer to: Loadspace Scuff Plate Trim Panel
(501-05 Interior Trim and Ornamentation, Removal and Installation).
Remove both the liftgate gas struts.
5. Close the liftgate.
6. Open the liftgate window glass.
7. Loosen the liftgate striker retaining bolts.
8. NOTE: Make sure the liftgate aligns flush to the rear quarter panels and
rear bumper.
Set the alignment of the liftgate to the rear quarter panels and rear
bumper cover.
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9. Tighten the liftgate striker retaining bolts.
Tighten to 25 Nm.
10. Loosen the upper liftgate hinge retaining bolts.
11. NOTE: Make sure the gap between the liftgate and the rear quarter
panels, rear lamp assemblies and rear bumper cover are equal.
Set the liftgate gaps to the rear quarter panels, rear lamp assemblies
and the rear bumper cover.
12. Tighten the liftgate hinge retaining bolts.
Tighten to 25 Nm.
Loosen both the lower liftgate hinge retaining bolts.
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15. NOTE: Make sure the gaps between the liftgate and rear lamp
assemblies are equal on both sides.
Set the liftgate gaps to the rear lamp assemblies.
16. Tighten the lower liftgate hinge retaining bolts.
Tighten to 14 Nm.
Install both liftgate gas struts.
18. Install the loadspace scuff plate trim panel.
19. CAUTION: Do not over adjust the liftgate bump stops. Failure to
follow this instruction may result in damage to the component.
Using a suitable piece of paper check the clearance between the liftgate
bump stops and the liftgate, if the paper can be removed with ease
adjust the liftgate bump stops counter-clockwise equally until the paper
is lightly clamped between the bump stops and liftgate.
21. NOTE: Check the liftgate window glass adjustment. If the liftgate
window glass adjustment is correct, no further adjustment is required.
Close the liftgate window glass.
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22. Make sure the rear wiper pivot arm is in the parked position.
25. Remove the liftgate trim panel.
For additional information, refer to: Liftgate Trim Panel (501-05 Interior
26. Loosen the rear wiper motor retaining nuts.
28. Make sure the liftgate glass latch and rear wiper mounting arm locate
correctly into the liftgate latch actuator and rear wiper motor.
29. Close the liftgate glass.
30. CAUTIONS:
With the aid of an assistant in the loadspace, fully tighten the rear
wiper motor retaining nuts. Failure to follow this instruction may result in
Make sure the rear wiper motor does not move whilst tightening the
retaining nuts. Failure to follow this instruction may result in damage to
the vehicle.
Tighten the rear wiper motor retaining nuts in the sequence shown.
Tighten to 8 Nm.
31. Visually check the liftgate for correct alignment.
32. Install the liftgate trim panel.
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Body Closures - Luggage Compartment Lid Alignment
General Procedures
1. Remove the luggage compartment lid aperture seal.
2. Remove the striker plate.
Remove the gas strut.
Loosen the luggage compartment lid hinge bolts.
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5. Pull up/push down on luggage compartment lid.
6. NOTE: Set the alignment to 2 mm lower than nominal.
Set the luggage compartment lid alignment.
7. Tighten the luggage compartment lid hinge bolts.
Tighten to 25 Nm.
8. Adjust the luggage compartment lid stop screw.
9. Install the gas struts.
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10. Install the striker plate.
Tighten to 10 Nm.
11. Install the luggage compartment lid aperture seal.
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Body Closures - Weatherstrip
Removal
1. NOTE: Front door shown, rear door similar.
Detach the door checkstrap.
2. Remove the window aperture trim.
3. Remove the frame seal.
4. NOTE: A start point locator can be found on each weatherstrip in the
form of a dot. The start point is on the 'B' Post corner of the door. Using
an indelible marker record the start point.
Using an indelible marker, trace around the door weatherstrip.
5. Remove the door weatherstrip.
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6. Using a suitable tool remove any residual adhesive from the door.
Installation
1. NOTE: Door weatherstrips are identified by a color coded dot which is
also the start point. The right hand front door is red, the left hand front
door is yellow, the right hand rear door is green and the left hand rear
door is blue.
NOTE: Make sure the indelible mark is not removed.
Make sure the weatherstrip mounting surface is clean using a suitable
solvent and dry with a lint free cloth.
2. NOTE: Align the start point locator to the previously recorded start
point.
Install the door weatherstrip.
3. Using a suitable solvent, remove the indelible marks.
4. Install the frame seal.
5. Install the window aperture trim.
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6. Install the door check strap.
Tighten to 35 Nm.
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Interior Trim and Ornamentation -
Seat belt anchoring bolt 55 41
Loadspace retaining hook - Wagon 8 71
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Interior Trim and Ornamentation - Interior Trim
This section covers removal and installation of the interior moldings and trim panels. In many instances, one component overlaps another
component. If this condition is found, it will be necessary to loosen or remove the overlapping component before removal, to prevent
damage to either component.
The headliner is a one-piece design covering the entire interior of the roof and is made of a molded composite with cloth covering. Finger
depressions give pull-down access for the sun visors and passenger assist handles are provided.
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Interior Trim and Ornamentation - A-Pillar Trim Panel
Removal
1. Detach the front door opening weather-strip.
2. NOTE: The A-pillar trim panel is secured to the top of the A-pillar by a
retaining strap. The retaining strap must be detached from the A-pillar
before the A-pillar trim panel is removed.
Detach the A-pillar trim panel.
3. Remove the A-pillar trim panel.
Installation
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Interior Trim and Ornamentation - B-Pillar Lower Trim Panel
Removal
1. Remove the front scuff plate trim panel. For additional information,
refer to Scuff Plate Trim PanelFront.
2. Remove the rear scuff plate trim panel. For additional information, refer
to Scuff Plate Trim PanelRear.
3. Remove the B-pillar upper trim panel. For additional information, refer
to B-Pillar Trim PanelUpper.
4. Remove the B-pillar lower trim panel.
Installation
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Interior Trim and Ornamentation - B-Pillar Upper Trim Panel
Removal
1. Detach the rear door opening weather-strip.
3. Detach the B-Pillar upper trim panel.
4. Detach the B-pillar lower trim panel.
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5. Detach the safety belt lower anchor from the underside of the seat.
6. Remove the B-pillar upper trim panel.
Installation
Tighten to 55 Nm.
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Interior Trim and Ornamentation - Cowl Side Trim Panel
Removal
2. Remove the front scuff plate trim panel. For additional information,
refer to Scuff Plate Trim PanelFront.
3. Remove the cowl side trim panel.
Installation
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Interior Trim and Ornamentation - C-Pillar Trim Panel4-Door
Removal
1. Remove the rear seat side bolster. For additional information, refer to
2. NOTE: The C-pillar trim panel is secured to the top of the C-pillar by a
Detach the C-pillar trim panel.
3. Remove the C-pillar trim panel.
Installation
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Interior Trim and Ornamentation - C-Pillar Trim PanelWagon
Removal
1. Remove the loadspace cover.
2. Fold down the rear seat backrest.
3. Detach the loadspace cover retaining bracket finisher trim.
4. Reposition the rear seat bolster.
1. Press the tang.
2. Reposition the rear seat bolster.
5. Remove the seat bolster upper retaining latch.
6. Remove the C-pillar trim panel lower retaining screw.
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7. Detach the rear door opening weatherstrip.
Installation
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Interior Trim and Ornamentation - D-Pillar Trim Panel
Removal
1. Detach the liftgate opening weatherstrip.
2. Detach the D-Pillar trim panel.
3. Remove the D-Pillar trim panel.
Installation
1. Attach the D-Pillar trim panel to the rear quarter window glass edge
clips.
2. NOTE: Make sure the D-pillar trim panel is correctly located to the
loadspace trim panel.
Locate the D-Pillar trim panel fir tree clips to the D-Pillar.
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3. Install the D-Pillar trim panel.
4. Attach the liftgate opening weatherstrip.
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Interior Trim and Ornamentation - Front Door Trim Panel
Removal
1. Remove the retaining screw cover.
2. Remove the retaining screw.
4. Detach the front door trim panel.
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5. Detach the door handle cable.
6. Remove the door handle cable.
7. Remove the front door trim panel.
Disconnect the electrical connectors and detach the wiring harness.
Installation
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Interior Trim and Ornamentation - Front Scuff Plate Trim Panel
Removal
1. Remove the scuff plate trim panel.
Installation
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Interior Trim and Ornamentation - Headliner4-Door
Removal
2. Remove both sun visors.
3. Remove both sun visor retaining clips.
Detach the front door opening weather-strip.
6. Disconnect the left-hand electrical connector and detach the wiring
harness.
7. Disconnect the right-hand electrical connector and detach the wiring
harness.
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Detach the rear door opening weather-strip.
Detach the B-pillar upper trim panels from the B-pillar trim lower trim
panel.
NOTE: The C-pillar trim panel is secured to the top of the C-pillar by a
Detach the C-pillar trim panel.
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16. Recline both the front seat backrests to allow removal of the headliner
through the rear door opening.
With the aid of an assistant, remove the headliner.
Installation
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Interior Trim and Ornamentation - HeadlinerWagon
Removal
2. Remove both sun visors.
3. Remove both sun visor retaining clips.
Detach the front door opening weatherstrip.
6. Disconnect the left-hand electrical connector and detach the wiring
harness.
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8. Disconnect the right-hand electrical connector and detach the wiring
harness.
Detach the B-pillar upper trim panel from the B-pillar trim lower trim
panel.
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16. Remove both luggage net retaining clips.
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19. Disconnect the roof opening panel motor electrical connector.
21. NOTE: Headliner shown removed for clarity.
Using a suitable adhesive tape, protect both front corners of the
headliner.
22. NOTE: Headliner shown removed for clarity.
Using a suitable adhesive tape, protect both rear corners of the
headliner.
23. CAUTIONS:
Make sure the headliner is not creased or folded where it is not
protected by adhesive tape. Failure to follow this instruction may result in
Make sure the headliner is fully supported during removal. Failure to
follow this instruction may result in damage to the component.
With the aid of an assistant, remove the headliner.
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Installation
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Interior Trim and Ornamentation - Liftgate Trim Panel
Removal
1. Detach the liftgate window glass weatherstrip.
2. Remove the liftgate window glass latch actuator finisher trim panel.
3. Remove the liftgate trim panel upper retaining screws.
4. Remove the liftgate latch actuator finisher trim panel.
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5. Remove the liftgate finisher trim panel.
6. Deatch the liftgate trim panel.
Installation
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Interior Trim and Ornamentation - Loadspace Scuff Plate Trim Panel
Removal
4. Detach the loadspace opening weatherstrip.
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5. Detach the loadspace scuff plate trim panel.
Installation
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Interior Trim and Ornamentation - Loadspace Trim Panel
Removal
2. Remove the loadspace stowage compartment lid.
4. Detach the loadspace courtesy lamp.
5. Remove the loadspace courtesy lamp.
6. Remove the D-pillar trim panel.
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8. Remove the retaining hook.
9. Remove the loadspace trim panel retaining screws.
10. Detach the loadspace trim panel rear retaining clips.
11. Detach the loadspace trim panel front retaining clips.
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Installation
Tighten to 8 Nm.
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Interior Trim and Ornamentation - Parcel Shelf
Removal
Vehicles with split rear seat backrest
2. Remove the rear center safety belt and buckle.
All vehicles
For additional information, refer to: C-Pillar Trim Panel - 4-Door (501-05
Detach the rear safety belt retractor trim panel.
Vehicles with split rear seat backrest
Remove the rear seat backrest latch cover.
All vehicles
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6. Remove the parcel shelf.
Pass the rear centre safety belt through the parcel shelf.
Installation
Tighten to 55 Nm.
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Interior Trim and Ornamentation - Rear Door Trim Panel
Removal
1. Remove the retaining screw cover.
4. Detach the rear door trim panel.
5. Detach the door handle cable.
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6. Remove the door handle cable.
7. Remove the rear door trim panel.
Disconnect the electrical connectors and detach the wiring harness.
Installation
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Interior Trim and Ornamentation - Rear Scuff Plate Trim Panel
Removal
1. Detach the scuff plate trim panel.
2. Remove the scuff plate trim panel.
Installation
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Interior Trim and Ornamentation - Rear Window Blind
Removal
1. Detach the rear door opening weather-strips.
2. Remove the rear seat side bolster. For additional information, refer to
3. Remove the C-pillar trim panels. For additional information, refer to
C-Pillar Trim Panel.
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7. Remove the rear window blind retaining clips.
8. Remove the rear window blind.
Press the sides of the rear window blind inwards.
9. Remove the rear window blind roof fixing.
Installation
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Interior Trim and Ornamentation - Sun Visor
Removal
1. Remove the sun visor retaining screw cover.
2. Detach the sun visor.
3. Remove the sun visor.
Installation
1. NOTE: Using a suitable adhesive tape, secure the electrical connector to
the headliner.
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Exterior Trim and Ornamentation -
Radiator grill retaining bolts 7 - 62
Rear spoiler retaining nuts 5 - 44
Roof rail retaining bolts 14 10 -
Liftgate moulding retaining nuts 3 - 27
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Exterior Trim and Ornamentation - Exterior Trim
4-Door
1 Radiator grille
2 Front bumper insert moulding
3 Front door lower moulding
4 Front door glass moulding
5 Rear door lower moulding
6 Rear door glass moulding
7 Rear bumper insert moulding
Wagon
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1 - Roof rail
2 - Rear spoiler
3 - Liftgate moulding
4 - Rocker panel moulding
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Exterior Trim and Ornamentation - Door Moulding
Removal
1. Apply suitable protective tape to adjacent areas of paintworks.
2. Using a hand-held heat gun, apply heat uniformly along the moulding
length.
3. Applying local heat at one end and using a suitable thin lever to avoid
damaging paintwork, progessively ease the moulding away from the
door panel.
4. Discard the moulding and remove protective tape.
5. Remove any residual adhesive and thoroughly clean area using isopropyl
alcohol.
Installation
1. NOTE: Optimum adhesion is achieved by warming body panel and
moulding to 30C (86F)
Using isopropyl alcohol, make sure that mounting area is clean, dry and
de-greased.
2. Remove protective backing tape from the moulding.
3. NOTE: Do not allow the moulding to contact the body panel until it is
correctly aligned.
Aligning with adjacent mouldings or to match opposite side of vehicle,
press the new moulding firmly onto the body panel.
4. Apply hand pressure along the moulding length to make sure
satisfactory adhesion.
5. Allow the moulding and door panel to cool, then thoroughly clean both
using isopropyl alcohol.
6. Apply a coat of suitable polish to the moulding and body panel.
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Exterior Trim and Ornamentation - Liftgate Moulding
Removal
Remove the liftgate moulding retaining nuts.
4. Remove the liftgate moulding retaining screw covers.
5. Remove the licence plate lamp covers.
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6. Remove the liftgate moulding retaining screws.
8. Remove the liftgate moulding.
Installation
Tighten to 3 Nm.
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Exterior Trim and Ornamentation - Radiator Grille
Removal
1. Remove the radiator grille.
Remove the radiator grille retaining bolts.
Installation
Tighten to 7 Nm.
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Exterior Trim and Ornamentation - Rear SpoilerWagon
Removal
1. Remove and discard the tailgate opening window finisher trim panel.
2. Remove the rear spoiler retaining nuts.
3. Detach the rear spoiler.
4. Remove the rear spoiler.
Disconnect the high mounted stoplamp electrical connector.
Disconnect the rear washer jet hose.
Installation
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1. NOTE: A new tailgate opening window finisher trim panel must be
installed.
Tighten to 5 Nm.
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Exterior Trim and Ornamentation - Rocker Panel Moulding
Removal
1. Remove the rocker panel moulding retaining screws.
2. NOTE: Both doors will need to be open to remove the rocker panel
moulding.
Remove the rocker panel moulding.
Installation
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Exterior Trim and Ornamentation - Roof Rail
Removal
1. NOTE: Using a suitable tie strap remove the roof rail front trim.
Remove the roof rail front trim.
2. Remove the roof rail front retaining bolts.
3. NOTE: Using a suitable tie strap remove the roof rail rear trim.
Remove the roof rail rear trim.
4. NOTE: Remove and discard the seals.
Remove the roof rail.
Installation
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1. NOTE: Install new seals.
Tighten to 14 Nm.
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Exterior Trim and Ornamentation - Window Moulding
Removal
1. Detach the door window glass aperture seal.
2. Remove the window moulding.
Installation
1. NOTE: Install new rivets.
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Rear View Mirrors -
Exterior mirror retaining nut 12 9 -
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Rear View Mirrors - Rear View Mirrors
The manual dipping interior mirror is a prismatic unit with mirror dipping achieved by pulling the lever forward.
Where fitted an electrochromic interior mirror will automatically darken to prevent glare from following vehicle headlamps. An ambient light
sensor is fitted to the reflecting surface of the mirror to achieve automatic darkening.
During daytime driving, the ambient light sensor will detect high light levels and control the electrochromic interior mirror to provide a full,
clear reflection. During night driving, the ambient light sensor will detect low light levels and automatic glare reduction will occur.
A day/night mirror sensitivity switch on the interior electrochromic mirror will allow the driver to select the sensitivity range from "MIN"
(minimum) to "MAX" (maximum) sensitivity. The switch can also be set to an "OFF" position to disable all automatic glare functions.
The exterior mirrors are colour-coded, electrically adjustable and heated. Adjustment of both exterior mirrors is carried out from the driver
door switch pack. A slider switch selects the mirror to be adjusted and a toggle switch adjusts the selected mirror to the required position.
Where fitted, power fold back mirrors can be operated by the mirror fold button incorporated in the driver door switch pack on the driver door
trim panel. The power fold back mirrors only operate when the mirror select switch is in the middle position, and the vehicle speed is below
19 km/h (12 mph).
Vehicles from 2009MY
Vehicles built from 2009MY feature direction indicator repeaters located in the exterior rear view mirrors. The functionality and operation of
the direction indicator repeaters remains the same as the previous fender mounted items.
The direction indicator repeater bulb is accessed by removal of the mirror glass and backplate.
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Rear View Mirrors - Rear View Mirrors
Electrical
Switch(s)
Motor assembly
Electrochromic interior mirror
step.
3.
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Rear View Mirrors - Auto-Dimming Interior Mirror
Removal
1. Detach the interior mirror trim panel.
2. Detach the interior mirror.
3. Remove the interior mirror.
Disconnect the interior mirror electrical connector.
Installation
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Rear View Mirrors - Exterior Mirror
Removal
1. Remove the front door trim panel. For additional information, refer to
2. Remove the window surround trim panel.
3. Disconnect the exterior mirror electrical connector.
4. NOTE: Support the exterior mirror while removing the exterior mirror
retaining nut.
Detach the exterior mirror.
5. Remove the exterior mirror.
Detach the grommet.
Installation
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Tighten to 12 Nm.
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Rear View Mirrors - Exterior Mirror Control Switch
Removal
2. Remove the exterior mirror control switch.
Installation
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Rear View Mirrors - Exterior Mirror Cover
Removal
1. Remove the exterior mirror glass. For additional information, refer to
Exterior Mirror Glass.
2. Apply light pressure to the inner edge of the exterior mirror cover.
3. Detach the outer edge of the exterior mirror cover.
4. Remove the exterior mirror cover.
Installation
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Rear View Mirrors - Exterior Mirror Glass
Removal
1. Apply light pressure to the mirror glass.
2. Detach the mirror glass.
1. Apply light pressure to the inner edge of the mirror glass.
2. Pull the outer edge of the mirror glass to detach the mirror
glass.
3. Detach the exterior mirror glass.
1. Reposition the mirror glass motor.
2. Detach the exterior mirror glass.
4. Remove the exterior mirror glass.
Disconnect the mirror glass heater electrical connectors.
Installation
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Rear View Mirrors - Exterior Mirror Motor
Removal
1. Remove the exterior mirror glass. For additional information, refer to
Exterior Mirror Glass.
2. Detach the exterior mirror motor.
1. Remove the exterior mirror motor retaining screws.
2. Detach the exterior mirror motor.
3. Remove the exterior mirror motor.
Disconnect the exterior mirror motor electrical connector.
Installation
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Rear View Mirrors - Interior Mirror
Removal
Installation
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Seating -
Front seat retaining bolts 20 15 -
Front seat backrest retaining bolts 25 18 -
Front seat cushion retaining nuts 15 11 -
Front seat track motor retaining bolt 10 7 -
Front seat cushion front height adjustment motor retaining bolt 10 7 -
Front seat cushion rear height adjustment motor retaining bolts 10 7 -
Front safety belt lower anchor retaining bolt 55 41 -
Front seat safety belt pretensioner retaining bolt 50 37 -
Fixed rear seat backrest retaining bolts 55 41 -
Fixed rear seat retainer block bolt 20 15 -
Folding rear seat backrest hinge retaining bolts - All vehicles 55 41 -
Folding rear seat backrest centre hinge plate retaining bolts - Wagon 23 17 -
Folding rear seat latch retaining bolts - 4-door vehicles 22 16 -
Folding rear seat latch retaining bolts - Wagon 32 24 -
Rear center safety belt retractor retaining bolt - 4-door vehicles 55 41 -
Rear center safety belt retractor retaining bolt - Wagon 38 28 -
Rear center safety belt buckle retaining bolt - All vehicles 55 41 -
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Seating - Seats
Front Seat - High Specification, Vehicles without Seat Position Memory
1 Front seat
2 Front seat track and cushion front/rear height adjustment switch
3 Front seat backrest recliner switch
4 Front seat lumbar support switch
Front Seat - High Specification, Vehicles with Seat Position Memory
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1 Front seat memory store switch
2 Front seat memory switch
3 Front seat backrest recliner switch
4 Front seat lumbar support switch
5 Front seat track and cushion front/rear height adjustment switch
Front Seat - Low Specification
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1 Front seat track adjustment locking bar
2 Front seat backrest recliner hand wheel
3 Front seat cushion height adjustment switch (Driver side only)
4-Door, Vehicles with 70/30 Split Seat
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1 Rear seat backrest bolster - RH
2 Rear seat backrest
3 Rear seat head restraints (Center rear seat head restraint is optional)
5 Rear seat backrest bolster - LH
6 Rear seat cushion
7 Rear seat center arm rest
4-Door, Vehicles without 70/30 Split Seat
3 Rear seat cushion
Wagon
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1 Rear seat backrest bolster - RH
5 Rear seat backrest bolster - LH
6 Rear seat cushion
7 Rear seat center arm rest
Driver Front Seat - High Specification
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1 Front seat backrest recliner motor
2 Front seat cushion front height adjustment motor
3 Front seat track motor
4 Front seat cushion rear height adjustment motor
Passenger Front Seat - High Specification
1 Front seat cushion rear height adjustment motor
2 Front seat cushion front height adjustment motor
3 Front seat track motor
Front Seat Lumbar Support
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1 Front seat lumbar support bag
2 Front seat lumbar motor
Passenger Front Seat Weight Sensing system
1 Front seat weight sensor
2 Front seat weight sensor module
Heated Seat Module - High Specification, Vehicles without Seat Position Memory
1 Seat Control Switch
2 Heated Seat Module
Front Seats
All front seats are fitted with the following features as standard:
integral side air bags
head restraints
safety belt buckle/pretensioner
The driver and passenger seats, although almost identical, have some unique components fitted. The driver seat has a seat track position
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sensor and the passenger seat has a weight sensing system. In both instances the components form an integral part of the occupant
restraint system.
For additional information, refer to: Seat Position Sensor (501-20B Supplemental Restraint System, Removal and Installation) /
Occupant Classification Sensor (501-20B Supplemental Restraint System, Removal and Installation).
The high option front seat has the following features:
electrically adjustable seat positioning
electrically adjustable lumbar support (optional)
heated seat (optional)
The basic option front seat has the following standard features:
electrically adjustable seat height positioning (driver seat only)
Seat Position Memory (Optional)
The seat position memory can be programmed for up to three different driver seat configurations and the seat memory switch, located in
the seat control switch pack, can be used to store and retrieve the programmed configurations.
The seat position memory front seat has the following features:
electrically adjustable seat positioning with three position memory
electrically adjustable lumbar support
Heated Seats (Optional)
The heated seat system comprises:
heated seat module (incorporated in the seat control switch pack on vehicles with seat position memory)
heated seat switches
backrest heater element
cushion heater element and thermostat
The heated seat function permits the electrical heating of the seat back and cushion on the driver and front passenger seats. The heating
system of each seat is selected by separate switches located at the top of the center console.
Pressing the appropriate switch activates the first stage of a three stage operation of the heated seat function:
one press of the switch activates the high setting (providing a seat surface temperature of approximately 42C).
a second press of the switch activates the low setting (providing a seat surface temperature of approximately 37C).
a third press of the switch deactivates the heating function.
Once the heated seat function has been activated, it will persist until one of the following conditions have been satisfied:
A fixed period of time has expired (10 minutes).
The engine is not running.
The function is deactivated by pressing the switch for a third time.
A malfunction is detected by the heated seat module.
Confirmation that the heated seat function is active is indicated by the illumination of the relevant switch, a yellow light indicates the low
temperature setting and a red light indicates the high temperature setting.
Heated Seat Module
The heated seat module is located behind the outer side trim panel of the front seat on vehicles without seat position memory, and is
incorporated in to the seat control switch pack on vehicles with seat position memory. The module controls the seat heating function by
providing the appropriate response depending on the status of the heated seat switches.
Power Lumbar Support
The power lumbar is a self-contained unit controlled directly by the seat mounted power lumbar switch. On vehicles with seat position
memory, the power lumbar switch is incorporated in to the recliner switch in the seat control switch pack.
Rear Seats - 4-Door
Depending on the market specification the rear seats will be one of the following:
fixed bench style seat
folding 70/30 split seat
Folding Seatbacks (if equipped)
The rear seatbacks can be folded forward to provide additional luggage space if required. Release handles for each seat back are located in
the luggage compartment under the parcel shelf on 4-door vehicles, and on the top of the each seatback on wagon.
Rear Seats - Wagon
The rear seats on wagon are of the folding type with a 70/30 split, fitted with a folding armrest in the left-hand seat backrest. The
left-hand seat also incorporates the rear centre safety belt retractor, which has a release cable connected to the rear seat backrest latch to
prevent the safety belt from operating if the rear seat backrest is not in the fully latched position.
Head Restraints
The front seat head restraints are adjustable for height and forward and rearward ti lt.
The rear seat head restraints can be set to one of two height positions. The optional centre rear seat head restraint (excluding Federal
specification vehicles) can also be set to one of two height positions.
Ski Hatch - 4-Door Vehicles only (if equipped)
Skis or similar objects can be stowed in the vehicle by utilizing the two door hatch fitted to the rear seat. The inner door is accessible after
folding down the armrest, the second door is accessible from inside the luggage compartment. A sack complete with strap is provided for
holding the stored items, the strap connects to the center rear seat belt buckle to secure the sack and contents.
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Seating - Seats
Seat base
Seat backrest
Seat track(s)
Lumbar assembly bag
Fuse(s)
Wiring harness
Motor(s)
Switch(es)
Heated seat module
Lumbar assembly pump
step.
3.
4. If the concern is not visually evident, verify the symptom and refer to the symptom chart. 4.
Symptom Chart
Symptom Chart
The power seat is inoperative - high
specification seat only
Seat control
switch.
CARRY OUT the Seat Control Switch Component Test. REFER to the Wiring
Diagrams.
Circuit(s).
Motor(s).
The power seat is inoperative - low
Seat control
switch.
Diagrams.
Circuit(s).
Motor(s).
The power seat does not move
horizontally - high specification seat only
Seat control
switch.
Diagrams.
Circuit(s).
Motor(s).
The power seat does not move vertically -
high specification seat only
Seat control
switch.
Diagrams.
Circuit(s).
Motor(s).
The power seat does not recline - high
Seat control
switch.
Diagrams.
Circuit(s).
Motor(s).
The power lumbar is inoperative - high
Seat control
switch.
Diagrams.
Lumbar
assembly bag
INSPECT the seat lumbar assembly bag. INSTALL a new lumbar assembly as
necessary. For additional information, refer to Lumbar Assembly.
Circuit(s).
Motor(s).
Pinpoint Tests
NOTE: Use a digital multimeter for all electrical measurements.
PINPOINT TEST A : THE POWER SEAT IS INOPERATIVE - HIGH SPECIFICATION SEAT
A1: CHECK THE FRONT SEAT OPERATION
Operate the LH seat control switch
Is the LH seat inoperative?
Yes
GO to A2. .
No
GO to A4. .
A2: CHECK THE VOLTAGE TO THE SEAT CONTROL SWITCH
Disconnect the seat control switch electrical connector LS1.
Switch the ignition switch to the ON position.
Measure the voltage between the seat control switch electrical connector LS1 pin 6, (OG), and ground.
Yes
GO to A3. .
No
REPAIR the circuit. TEST the system for normal operation.
A3: CHECK THE SEAT CONTROL SWITCH GROUND CIRCUIT
Measure the resistance between the seat control switch electrical connector LS1 pin 1, (B), and ground.
Yes
INSTALL a new seat control switch. For additional information, refer to Seat Control Switch.
No
A4: CHECK THE VOLTAGE TO THE SEAT CONTROL SWITCH
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Disconnect the seat control switch electrical connector RS1.
Switch the ignition switch to the ON position.
Measure the voltage between the seat control switch electrical connector RS1 pin 6, (OY), and ground.
Yes
GO to A5. .
No
A5: CHECK THE SEAT CONTROL SWITCH GROUND CIRCUIT
Measure the resistance between the seat control switch electrical connector RS1 pin 1, (B), and ground.
Yes
No
PINPOINT TEST B : THE POWER SEAT IS INOPERATIVE - LOW SPECIFICATION SEAT ONLY
TEST
CONDITIONS
B1: CHECK THE LH FRONT SEAT HEIGHT ADJUSTMENT MOTOR OPERATION
Operate the LH seat control switch to the UP position.
Is the LH seat height adjustment inoperative?
Yes
GO to B2. .
No
GO to B8. .
B2: CHECK THE LH SEAT CONTROL SWITCH POWER SUPPLY
Yes
GO to B3. .
No
B3: CHECK THE LH SEAT CONTROL SWITCH GROUND CIRCUIT
Measure the resistance between the seat control switch electrical connector LS16 pin 3, (B), and ground and
between LS16 pin 6, (B), and ground.
Are the resistances less than 5 ohms?
Yes
GO to B4. .
No
B4: CHECK THE LH SEAT HEIGHT ADJUSTMENT MOTOR CIRCUITS
Disconnect the seat height motor electrical connector LS10.
Operate the seat control switch to the UP position.
Measure the voltage between the seat height motor electrical connector LS10 pin 1, (YG), and LS10 pin 2, (WG).
Yes
INSTALL a new front seat height motor. TEST the system for normal operation.
No
GO to B5. .
B5: CHECK THE LH SEAT HEIGHT ADJUSTMENT MOTOR CIRCUIT
Measure the voltage between the seat height motor electrical connector LS10 pin 1, (YG), and ground.
Yes
GO to B6. .
No
GO to B7. .
B6: CHECK THE LH SEAT HEIGHT ADJUSTMENT MOTOR CIRCUIT FOR OPEN
Measure the resistance between the seat height motor electrical connector LS10 pin 2, (WG), and the seat control
switch electrical connector LS16 pin 7, (WG).
Yes
INSTALL a new seat control switch. TEST the system for normal operation.
No
B7: CHECK THE LH SEAT HEIGHT ADJUSTMENT MOTOR CIRCUIT FOR OPEN
Measure the resistance between the seat height motor electrical connector LS10 pin 1, (YG), and the seat control
switch electrical connector LS16 pin 1, (YG).
Yes
No
B8: CHECK THE RH SEAT CONTROL SWITCH POWER SUPPLY
Yes
GO to B9. .
No
B9: CHECK THE RH SEAT CONTROL SWITCH GROUND CIRCUIT
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Measure the resistance between the seat control switch electrical connector RS16 pin 3, (B), and ground and
between RS16 pin 6, (B), and ground.
Yes
GO to B10. .
No
B10: CHECK THE RH SEAT HEIGHT ADJUSTMENT MOTOR CIRCUITS
Disconnect the seat height motor electrical connector RS10.
Measure the voltage between the seat height motor electrical connector RS10 pin 1, (WG), and RS10 pin 2, (YG).
Yes
INSTALL a new front seat height motor. TEST the system for normal operation.
No
GO to B11. .
B11: CHECK THE RH SEAT HEIGHT ADJUSTMENT MOTOR CIRCUIT
Measure the voltage between the seat height motor electrical connector RS10 pin 1, (WG), and ground.
Yes
GO to B12. .
No
GO to B13. .
B12: CHECK THE RH SEAT HEIGHT ADJUSTMENT MOTOR CIRCUIT FOR OPEN
Measure the resistance between the seat height motor electrical connector RS10 pin 2, (YG), and the seat control
switch electrical connector RS16 pin 7, (YG).
Yes
No
B13: CHECK THE RH SEAT HEIGHT ADJUSTMENT MOTOR CIRCUIT FOR OPEN
Measure the resistance between the seat height motor electrical connector RS10 pin 1, (WG), and the seat control
switch electrical connector RS16 pin 1, (WG).
Yes
No
PINPOINT TEST C : THE POWER SEAT DOES NOT MOVE HORIZONTALLY
TEST
CONDITIONS
C1: CHECK THE LH FRONT SEAT TRACK MOTOR OPERATION
Operate the LH seat control switch to the REARWARD track position.
Is the LH seat track inoperative?
Yes
GO to C2. .
No
GO to C6. .
C2: CHECK THE LH FRONT SEAT TRACK MOTOR CIRCUIT
Disconnect the seat track motor electrical connector LS4.
Operate the seat control switch to the REARWARD track position.
Measure the voltage between the seat track motor electrical connector LS4 pin 2, (WG), and LS4 pin 1, (YG).
Yes
INSTALL a new front seat track motor. For additional information, refer to MotorFront Seat Track.
No
GO to C3. .
C3: CHECK THE LH FRONT SEAT TRACK MOTOR CIRCUIT
Measure the voltage between the seat track motor electrical connector LS4 pin 2, (WG), and ground.
Yes
GO to C4. .
No
GO to C5. .
C4: CHECK THE LH FRONT SEAT TRACK MOTOR CIRCUIT FOR OPEN
Measure the resistance between the seat track motor electrical connector LS4 pin 1, (YG), and the seat control
switch electrical connector LS1 pin 3, (YG).
Yes
No
C5: CHECK THE LH FRONT SEAT TRACK MOTOR CIRCUIT FOR OPEN
Measure the resistance between the seat track motor electrical connector LS4 pin 2, (WG), and the seat control
switch electrical connector LS1 pin 11, (WG).
Yes
No
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C6: CHECK THE RH FRONT SEAT TRACK MOTOR CIRCUIT
Disconnect the seat track motor electrical connector RS4.
Measure the voltage between the seat track motor electrical connector RS4 pin 2, (YG), and RS4 pin 1, (WG).
Yes
INSTALL a new front seat track motor. For additional information, refer to MotorFront Seat Track.
No
GO to C7. .
C7: CHECK THE RH FRONT SEAT TRACK MOTOR CIRCUIT
Measure the voltage between the seat track motor electrical connector RS4 pin 2, (YG), and ground.
Yes
GO to C8. .
No
GO to C9. .
C8: CHECK THE RH FRONT SEAT TRACK MOTOR CIRCUIT FOR OPEN
Measure the resistance between the seat track motor electrical connector RS4 pin 1, (WG), and the seat control
electrical connector switch RS1 pin 3, (WG).
Yes
No
C9: CHECK THE RH FRONT SEAT TRACK MOTOR CIRCUIT FOR OPEN
Measure the resistance between the seat track motor electrical connector RS4 pin 2, (YG), and the seat control
switch electrical connector RS1 pin 11, (YG).
Yes
No
PINPOINT TEST D : THE POWER SEAT DOES NOT MOVE VERTICALLY - HIGH SPECIFICATION SEAT
TEST
CONDITIONS
D1: CHECK THE LH FRONT SEAT CUSHION HEIGHT ADJUSTMENT MOTORS FOR CORRECT OPERATION
Operate the LH seat control switch to the seat cushion front/rear height adjustment position.
Is the LH seat cushion height adjustment inoperative?
Yes
GO to D2. .
No
GO to D11. .
D2: CHECK THE LH FRONT SEAT CUSHION FRONT HEIGHT ADJUSTMENT MOTOR OPERATION
Operate the LH seat control switch to the seat cushion front height adjustment position.
Is the LH seat cushion front height adjustment inoperative?
Yes
GO to D3. .
No
GO to D7. .
D3: CHECK THE LH FRONT SEAT CUSHION FRONT HEIGHT ADJUSTMENT MOTOR CIRCUITS
Disconnect the seat cushion front height adjustment motor electrical connector LS5.
Operate the seat control switch to the FRONT HEIGHT adjustment UP position.
Measure the voltage between the seat cushion front height adjustment motor electrical connector LS5 pin 1, (YB),
and LS5 pin 2, (WB).
Yes
INSTALL a new seat cushion front height adjustment motor. For additional information, refer to MotorFront Seat
Cushion Front Height Adjustment.
No
GO to D4. .
D4: CHECK THE LH FRONT SEAT CUSHION FRONT HEIGHT ADJUSTMENT MOTOR CIRCUIT
Measure the voltage between the seat cushion front height adjustment motor electrical connector LS5 pin 1, (YB),
and ground.
Yes
GO to D5. .
No
GO to D6. .
D5: CHECK THE LH FRONT SEAT CUSHION FRONT HEIGHT ADJUSTMENT MOTOR CIRCUIT FOR OPEN
Measure the resistance between the seat cushion front height adjustment motor electrical connector LS5 pin 2,
(WB), and the seat control switch electrical connector LS1 pin 5, (WB).
Yes
No
D6: CHECK THE LH FRONT SEAT CUSHION FRONT HEIGHT ADJUSTMENT MOTOR CIRCUIT FOR OPEN
Measure the resistance between the seat cushion front height adjustment motor electrical connector LS5 pin 1, (YB),
and the seat control switch electrical connector LS1 pin 4, (YB).
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No
D7: CHECK THE LH FRONT SEAT CUSHION REAR HEIGHT ADJUSTMENT MOTOR CIRCUITS
Disconnect the seat cushion rear height adjustment motor electrical connector LS2.
Operate the seat control switch to the REAR HEIGHT adjustment UP position.
Measure the voltage between the seat cushion rear height adjustment motor electrical connector LS2 pin 1, (YU),
and LS2 pin 2, (WR).
Yes
INSTALL a new seat cushion rear height adjustment motor. For additional information, refer to MotorFront Seat
Cushion Rear Height Adjustment.
No
GO to D8. .
D8: CHECK THE LH FRONT SEAT CUSHION REAR HEIGHT ADJUSTMENT MOTOR CIRCUIT
Measure the voltage between the seat cushion rear height adjustment motor electrical connector LS2 pin 1, (YU),
and ground.
Yes
GO to D9. .
No
GO to D10. .
D9: CHECK THE LH FRONT SEAT CUSHION REAR HEIGHT ADJUSTMENT MOTOR CIRCUIT FOR OPEN
Measure the resistance between the seat cushion rear height adjustment motor electrical connector LS5 pin 2, (WR),
and the seat control switch electrical connector LS1 pin 8, (WR).
Yes
No
D10: CHECK THE LH FRONT SEAT CUSHION REAR HEIGHT ADJUSTMENT MOTOR CIRCUIT FOR OPEN
Measure the resistance between the seat cushion rear height adjustment motor electrical connector LS2 pin 1, (YU),
and the seat control switch electrical connector LS1 pin 9, (YU).
Yes
No
D11: CHECK THE RH FRONT SEAT CUSHION FRONT HEIGHT ADJUSTMENT MOTOR OPERATION
Operate the RH seat control switch to the seat cushion front height adjustment position.
Is the RH seat cushion front height adjustment inoperative?
Yes
GO to D12. .
No
GO to D16. .
D12: CHECK THE RH FRONT SEAT CUSHION FRONT HEIGHT ADJUSTMENT MOTOR CIRCUITS
Disconnect the seat cushion front height adjustment motor electrical connector RS5.
Measure the voltage between the seat cushion front height adjustment motor electrical connector RS5 pin 1, (WB),
and RS5 pin 2, (YB).
Yes
INSTALL a new seat cushion front height adjustment motor. For additional information, refer to MotorFront Seat
Cushion Front Height Adjustment.
No
GO to D13. .
D13: CHECK THE RH FRONT SEAT CUSHION FRONT HEIGHT ADJUSTMENT MOTOR CIRCUIT
Measure the voltage between the seat cushion front height adjustment motor electrical connector RS5 pin 1, (WB),
and ground.
Yes
GO to D14. .
No
GO to D15. .
D14: CHECK THE RH FRONT SEAT CUSHION FRONT HEIGHT ADJUSTMENT MOTOR CIRCUIT FOR OPEN
Measure the resistance between the seat cushion front height adjustment motor electrical connector RS5 pin 2, (YB),
and the seat control switch electrical connector RS1 pin 5, (YB).
Yes
No
D15: CHECK THE RH FRONT SEAT CUSHION FRONT HEIGHT ADJUSTMENT MOTOR CIRCUIT FOR OPEN
Measure the resistance between the seat cushion front height adjustment motor electrical connector RS5 pin 1,
(WB), and the seat control switch electrical connector RS1 pin 4, (WB).
Yes
No
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D16: CHECK THE RH FRONT SEAT CUSHION REAR HEIGHT ADJUSTMENT MOTOR CIRCUITS
Disconnect the seat cushion rear height adjustment motor electrical connector RS2.
Measure the voltage between the seat cushion rear height adjustment motor electrical connector RS2 pin 1, (WR),
and RS2 pin 2, (YU).
Yes
INSTALL a new seat cushion rear height adjustment motor. For additional information, refer to MotorFront Seat
Cushion Rear Height Adjustment.
No
GO to D17. .
D17: CHECK THE RH FRONT SEAT CUSHION REAR HEIGHT ADJUSTMENT MOTOR CIRCUIT
Measure the voltage between the seat cushion rear height adjustment motor electrical connector RS2 pin 1, (WR),
and ground.
Yes
GO to D18. .
No
GO to D19. .
D18: CHECK THE RH FRONT SEAT CUSHION REAR HEIGHT ADJUSTMENT MOTOR CIRCUIT FOR OPEN
Measure the resistance between the seat cushion rear height adjustment motor electrical connector RS2 pin 2, (YU),
and the seat control switch electrical connector RS1 pin 8, (YU).
Yes
No
D19: CHECK THE RH FRONT SEAT CUSHION REAR HEIGHT ADJUSTMENT MOTOR CIRCUIT FOR OPEN
Measure the resistance between the seat cushion rear height adjustment motor electrical connector RS2 pin 1, (WR),
and the seat control switch electrical connector RS1 pin 9, (WR).
Yes
No
PINPOINT TEST E : THE POWER SEAT DOES NOT RECLINE - HIGH SPECIFICATION SEAT ONLY
TEST
CONDITIONS
E1: CHECK THE LH FRONT SEAT BACKREST MOTOR FOR CORRECT OPERATION
Operate the LH seat control switch to the REARWARD RECLINE position.
Is the LH seat recline adjustment inoperative?
Yes
GO to E2. .
No
GO to E6. .
E2: CHECK THE LH FRONT SEAT BACKREST MOTOR CIRCUITS
Disconnect the seat backrest motor electrical connector LS6.
Operate the seat control switch to the REARWARD RECLINE position.
Measure the voltage between the seat backrest motor electrical connector LS6 pin 2, (WR), and LS6 pin 1, (YR).
Yes
INSTALL a new seat backrest motor. For additional information, refer to MotorFront Seat Backrest.
No
GO to E3. .
E3: CHECK THE LH FRONT SEAT BACKREST MOTOR CIRCUIT
Measure the voltage between the seat backrest motor electrical connector LS6 pin 2, (WR), and ground.
Yes
GO to E4. .
No
GO to E5. .
E4: CHECK THE LH FRONT SEAT BACKREST MOTOR CIRCUIT FOR OPEN
Measure the resistance between the seat backrest motor electrical connector LS6 pin 1, (YR), and the seat control
switch electrical connector LS1 pin 7, (YR).
Yes
No
E5: CHECK THE LH FRONT SEAT BACKREST MOTOR CIRCUIT FOR OPEN
Measure the resistance between the seat backrest motor electrical connector LS6 pin 2, (WR), and the seat control
switch electrical connector LS1 pin 12, (WR).
Yes
No
E6: CHECK THE RH FRONT SEAT BACKREST MOTOR CIRCUITS
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Disconnect the seat backrest motor electrical connector RS6.
Measure the voltage between the seat backrest motor electrical connector RS6 pin 2, (YR), and RS6 pin 1, (WR).
Yes
INSTALL a new seat backrest motor. For additional information, refer to MotorFront Seat Backrest.
No
GO to E7. .
E7: CHECK THE RH FRONT SEAT BACKREST MOTOR CIRCUIT
Measure the voltage between the seat backrest motor electrical connector RS6 pin 2, (YR), and ground.
Yes
GO to E8. .
No
GO to E9. .
E8: CHECK THE RH FRONT SEAT BACKREST MOTOR CIRCUIT FOR OPEN
Measure the resistance between the seat backrest motor electrical connector RS6 pin 1, (WR), and the seat control
switch electrical connector RS1 pin 7, (WR).
Yes
No
E9: CHECK THE RH FRONT SEAT BACKREST MOTOR CIRCUIT FOR OPEN
Measure the resistance between the seat backrest motor electrical connector RS6 pin 2, (YR), and the seat control
switch electrical connector RS1 pin 12, (YR).
Yes
No
PINPOINT TEST F : THE POWER LUMBAR IS INOPERATIVE
TEST
CONDITIONS
F1: CHECK THE LH FRONT SEAT LUMBAR ASSEMBLY OPERATION - HIGH SPECIFICATION SEAT ONLY
Operate the LH seat lumbar control switch to the INFLATE position.
Is the LH seat lumbar adjustment inoperative?
Yes
GO to F2. .
No
GO to F10. .
F2: CHECK THE LH SEAT LUMBAR CONTROL SWITCH POWER SUPPLY
Yes
GO to F3. .
No
F3: CHECK THE LH SEAT LUMBAR CONTROL SWITCH GROUND CIRCUIT
Measure the resistance between the seat control switch electrical connector LS16 pin 3, (B), and ground and
between LS16 pin 6, (B), and ground.
Yes
GO to F4. .
No
F4: CHECK THE LH SEAT LUMBAR ASSEMBLY CIRCUITS
Disconnect the seat lumbar assembly electrical connector LS19.
Operate the seat lumbar control switch to the INFLATE position.
Measure the voltage between the seat lumbar motor electrical connector LS19 pin 1, (YG), and LS19 pin 2, (B).
Yes
GO to F5. .
No
GO to F7. .
F5: CHECK THE LH SEAT LUMBAR ASSEMBLY DEFLATE CIRCUIT
Operate the seat lumbar control switch to the DEFLATE position.
Measure the voltage between the seat lumbar assembly electrical connector LS19 pin 3, (WG), and ground.
Yes
INSTALL a new lumbar assembly. For additional information, refer to Lumbar Assembly.
No
GO to F6. .
F6: CHECK THE LH SEAT LUMBAR ASSEMBLY DEFLATE CIRCUIT FOR OPEN
Disconnect the seat lumber control switch electrical connector LS16.
Measure the resistance between the seat lumbar assembly electrical connector LS19 pin 3, (WG), and the seat
lumbar control switch electrical connector LS16 pin 7, (WG).
Yes
INSTALL a new seat lumbar control switch. TEST the system for normal operation.
No
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F7: CHECK THE LH SEAT LUMBAR ASSEMBLY INFLATE CIRCUIT
Measure the voltage between the seat lumbar motor electrical connector LS19 pin 1, (YG), and ground.
Yes
GO to F8. .
No
GO to F9. .
F8: CHECK THE LH SEAT LUMBAR ASSEMBLY GROUND CIRCUIT
Measure the resistance between the seat lumbar assembly electrical connector LS19 pin 2, (B), and ground.
Yes
No
F9: CHECK THE LH SEAT LUMBAR ASSEMBLY INFLATE CIRCUIT
Disconnect the seat lumber control switch electrical connector LS16.
Measure the resistance between the seat lumbar assembly electrical connector LS19 pin 1, (YG), and the seat
lumbar control switch electrical connector LS16 pin 1, (YG).
Yes
No
F10: CHECK THE RH SEAT LUMBAR CONTROL SWITCH POWER SUPPLY
Yes
GO to F11. .
No
F11: CHECK THE RH SEAT LUMBAR CONTROL SWITCH GROUND CIRCUIT
Measure the resistance between the seat control switch electrical connector RS16 pin 3, (B), and ground and
between RS16 pin 6, (B), and ground.
Yes
GO to F12. .
No
F12: CHECK THE RH SEAT LUMBAR ASSEMBLY CIRCUITS
Disconnect the seat lumbar assembly electrical connector RS19.
Measure the voltage between the seat lumbar motor electrical connector RS19 pin 1, (WG), and RS19 pin 2, (B).
Yes
GO to F13. .
No
GO to F15. .
F13: CHECK THE RH SEAT LUMBAR ASSEMBLY DEFLATE CIRCUIT
Operate the seat lumbar control switch to the DEFLATE position.
Measure the voltage between the seat lumbar assembly electrical connector RS19 pin 3, (YG), and ground.
Yes
INSTALL a new lumbar assembly. For additional information, refer to Lumbar Assembly.
No
GO to F14. .
F14: CHECK THE RH SEAT LUMBAR ASSEMBLY DEFLATE CIRCUIT FOR OPEN
Disconnect the seat lumber control switch electrical connector RS16.
Measure the resistance between the seat lumbar assembly electrical connector RS19 pin 3, (YG), and the seat
lumbar control switch electrical connector RS16 pin 7, (YG).
Yes
No
F15: CHECK THE RH SEAT LUMBAR ASSEMBLY INFLATE CIRCUIT
Measure the voltage between the seat lumbar motor electrical connector RS19 pin 1, (WG), and ground.
Yes
GO to F16. .
No
GO to F17. .
F16: CHECK THE RH SEAT LUMBAR ASSEMBLY GROUND CIRCUIT
Measure the resistance between the seat lumbar assembly electrical connector RS19 pin 2, (B), and ground.
Yes
No
F17: CHECK THE RH SEAT LUMBAR ASSEMBLY INFLATE CIRCUIT
Disconnect the seat lumber control switch electrical connector RS16.
Measure the resistance between the seat lumbar assembly electrical connector RS19 pin 1, (WG), and the seat
lumbar control switch electrical connector RS16 pin 1, (WG).
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Seating - Front Seat
Removal
WARNINGS:
An RCM module only requires replacement if the system has incurred five separate deployments. At no time change an RCM for less
than five separate deployments.
Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag
module. Failure to follow this instruction may result in personal injury.
Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the
event of an accidental deployment. Failure to follow this instruction may result in personal injury.
Do not set a live air bag module down with the trim cover face down. Failure to follow this instruction may result in personal injury.
After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is
irritating to the skin. Wash your hands with soap and water afterwards. Failure to follow this instruction may result in personal injury.
Never probe the connectors on the air bag module. Doing so may result in air bag deployment. Failure to follow this instruction may
Air bag modules with discolored or damaged trim covers must be replaced.
Vehicle sensor orientation is critical for correct system operation. If a vehicle equipped with an air bag supplemental restraint system
(SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. If damaged, install a new sensor
whether or not the air bag is deployed. If the body work is damaged this will have to be addressed.
To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing
any air bag supplemental restraint system (SRS) components. To deplete the backup power supply energy, disconnect the battery ground
cable and wait one minute. Failure to follow this instruction may result in personal injury.
NOTE: Repair is made by replacement only. If a part is replaced and the new part does not correct the condition, install the original part
and carry out the diagnostic procedure again.
NOTE: When installing a new air bag module, a prepaid return postcard is provided with the replacement air bag module. The serial
number for the new part and the vehicle identification number (VIN) must be recorded and sent to Jaguar Cars Ltd.
1. Inspect the front seat to check if a front seat stabilization spring is
installed. If a front seat stabilization spring is installed. REFER to
SERVICE ACTION S948 before carrying out any work on the seat.
2. Move the seat fully rearwards.
3. Remove the seat front retaining bolts.
4. Move the seat fully forwards.
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6. Remove the seat rear retaining bolt covers.
7. Remove the seat.
.
Installation
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Tighten to 20 Nm.
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Seating - Front Seat Backrest
Removal
1. Remove the front seat.
For additional information, refer to: Front Seat (501-10 Seating,
2. Detach the outer side trim panel.
5. Remove the outer side trim panel.
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6. Detach the inner side trim panel.
7. Remove the inner side trim panel.
8. Remove and discard the cable tie.
9. Detach the recliner motor electrical connector.
10. Disconnect the recliner motor electrical connector.
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11. Detach the recliner motor wiring harness.
12. Detach the seat harness electrical connector.
13. Disconnect the side air bag module electrical connector.
14. Detach the side airbag module wiring harness.
15. Remove the front seat backrest retaining bolts.
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16. Remove the front seat backrest.
Installation
1. To install, reverse the removal procedure
Tighten to 25 Nm.
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Seating - Front Seat Cushion
Removal
1. CAUTION: The front seat cushion is calibrated to the occupant
classification sensor, and can only be replaced as part of the service kit.
For additional information, refer to Section 501-20A Safety Belt System
/ 501-20B Supplemental Restraint System.
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Seating - Front Seat Front Height Adjustment Motor
Removal
2. Cut and discard the cable tie.
3. Detach the front height adjustment motor electrical connector.
4. Disconnect the front height adjustment motor electrical connector.
5. Remove the front height adjustment motor roll pin.
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6. Remove the front seat front height adjustment motor.
Installation
Tighten to 10 Nm.
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Seating - Front Seat Rear Height Adjustment Motor
Removal
4. Disconnect the front seat rear height adjustment motor electrical
connector.
5. Remove the front seat rear height adjustment motor roll pin.
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6. Remove the trim finisher.
7. Remove the front seat rear height adjustment motor.
Installation
Tighten to 10 Nm.
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Seating - Front Seat Recliner Motor
Removal
For additional information, refer to: Front Seat Backrest (501-10
Seating, Removal and Installation).
2. Remove the front seat head restraint.
Press the retaining tangs.
3. Detach the front seat backrest cover.
Detach the retaining strip.
4. Detach the front seat backrest cover tension cords from the front seat
backrest.
Remove and discard the hog rings.
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6. Disconnect the front seat backrest motor electrical connector.
7. Detach the front seat backrest recliner bar from the motor.
1. Remove the recliner bar retaining clip.
2. Detach the front seat backrest recliner bar from the motor.
8. Remove the front seat recliner motor.
Remove the retaining screw.
Installation
1. NOTE: Install new hog rings. Use hog ring pliers to close the hog rings.
Do not use any other tool. The hog rings must be closed to overlap as
illustrated.
NOTE: Install a new front seat recliner bar retaining clip.
To assemble, reverse the disassembly procedure.
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Seating - Front Seat Track Motor
Removal
3. Detach the front seat track motor electrical connector.
4. Disconnect the front seat track motor electrical connector.
5. Remove the front seat track motor.
Installation
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1. NOTE: Make sure the front seat track motor control rods are correctly
located.
Tighten to 10 Nm.
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Seating - Lumbar Assembly
Removal
1. Remove the front seat backrest. For additional information, refer to
Front Seat Backrest.
2. Remove the head restraint.
Press the tangs.
3. Detach the backrest cover.
4. Detach the backrest cover tension cords from the backrest.
Cut the hog rings.
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Cut the hog rings.
Cut the hog rings.
8. Roll the backrest cover up the backrest.
9. Detach the lumbar motor from the seat backrest frame.
Cut the cable ties.
10. Remove the lumbar assembly.
Cut the cable ties.
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Installation
1. NOTE: Install new cable ties and hog rings. Use hog ring pliers to close
the hog rings. Do not use any other tool. The hog rings must be closed to
overlap as illustrated.
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Seating - Rear Seat Backrest4-Door
Removal
1. Remove the rear seat cushion. For additional information, refer to Rear
Seat Cushion.
2. Remove the rear center safety belt and buckle.
3. Remove the rear seat backrest.
Installation
Tighten to 55 Nm.
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Seating - Rear Seat Backrest4-Door, Vehicles With: 70/30 Split Seat
Removal
1. Detach the rear seat backrest.
Installation
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Seating - Rear Seat BackrestWagon, Vehicles With: 70/30 Split Seat
Removal
3. Detach the rear seat backrest center hinge plate.
4. Raise the rear seat backrest.
5. Remove the rear seat backrest centre hinge plate.
6. Detach the rear centre safety belt buckle.
Remove the rear seat backrest.
Installation
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Tighten to 55 Nm.
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Seating - Rear Seat Backrest LatchWagon
Removal
1. Disassemble the rear seat backrest.
For additional information, refer to: Rear Seat Backrest - Wagon,
Vehicles With: 70/30 Split Seat (501-10 Seating, Disassembly and
Assembly).
2. Detach the centre safety belt release cable.
3. Remove the rear seat backrest latch.
Installation
Tighten to 32 Nm.
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Seating - Rear Seat Bolster4-Door
Removal
2. Detach the rear seat backrest bolster.
Press the tang.
3. Remove the rear seat backrest bolster.
Installation
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Seating - Rear Seat BolsterWagon
Removal
1. Remove the loadspace cover.
3. Detach the loadspace cover retaining bracket finisher trim.
4. Detach the rear seat bolster.
1. Press the seat bolster upper retaining latch.
2. Detach the rear seat bolster.
5. Remove the rear seat bolster.
Installation
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Seating - Rear Seat Cushion
Removal
1. NOTE: Remove and discard old retaining clips.
Remove the rear seat cushion.
1. Detach the rear seat cushion front retaining clips.
2. Slide the rear seat cushion out of the retaining hooks.
Installation
1. NOTE: Make sure the safety belt buckles are located through the
cushion.
NOTE: Install new seat cushion front retaining clips
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Seating - Seat Base
Removal
2. Detach the electrical connectors.
3. Remove the safety belt buckle and pretensioner.
4. Detach the seat motor electrical connectors.
5. Remove the seat base.
Installation
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Tighten to 15 Nm.
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Seating - Seat Control Switch
Removal
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6. Remove the seat control switch.
Installation
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Seating - Front Seat Backrest
Disassembly
2. Remove the front seat head restraint.
Press the retaining tangs.
4. Detach the front seat backrest cover tension cords from the front seat
backrest.
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6. Detach the front seat backrest cover retaining hook.
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11. Remove the front seat head restraint guides.
Using a suitable tool, press the locking tangs.
Detach the front seat backrest cover tension cords from the front seat
backrest.
13. Remove the front seat backrest cover.
Assembly
illustrated.
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Seating - Front Seat Cushion
Disassembly
1. Remove the front seat cushion. For additional information, refer to Front
Seat Cushion.
2. Remove the seat cushion cover.
Unclip the seat cushion from the seat base.
Cut the hog rings.
Assembly
illustrated.
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Seating - Rear Seat Backrest4-Door, Vehicles With: 70/30 Split Seat
Disassembly
1. Remove the rear seat backrest - folding. For additional information,
refer to Rear Seat BackrestFolding.
2. Remove the head restraint(s).
3. Detach the backrest cover from the backrest.
4. NOTE: The armrest pivot pins are held in place by split pins. The
armrest should be lifted to gain access to the split pins.
NOTE: Moving the armrest left and right assists in the removal of the
pivot pins.
Remove the armrest.
5. Remove the head restraint guides.
1. Using a suitable screwdriver, press the locking tangs.
6. Remove the backrest cover.
Cut the hog rings.
Assembly
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illustrated.
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Seating - Rear Seat BackrestWagon, Vehicles With: 70/30 Split Seat
Disassembly
Vehicles With: 70/30 Split Seat (501-10 Seating, Removal and
Installation).
2. Remove the rear seat head restraints (if equipped).
3. Remove the rear seat backrest hinge bracket.
4. NOTE: Raise the armrest to assist in removal.
NOTE: Moving the armrest left and right assists in the removal of the
pivot pins.
Remove the armrest.
5. Remove the rear seat backrest latch finisher.
6. Detach the rear seat backrest cover from the backrest.
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7. Detach the rear centre safety belt guide finisher.
8. Remove the rear centre safety belt guide finisher.
9. Detach the rear seat backrest cover.
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15. Detach the rear seat backrest cover from the backrest latch.
16. Remove the rear sear head restraint guides.
Using a suitable tool, press the locking tangs.
Remove the rear seat head restraint guides.
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17. Remove the rear seat backrest cover.
Pass the centre safety belt through the rear seat backrest cover.
Assembly
illustrated.
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Seating - Rear Seat Backrest
Disassembly
1. Remove the rear seat backrest - fixed. For additional information, refer
to Rear Seat BackrestFixed.
2. Remove the head restraints.
Cut the hog rings.
Detach the retaining strips.
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1. Using a suitable screwdriver, press the locking tang.
2. Remove the head restraint guide.
6. Remove the backrest frame from the backrest cushion and cover.
7. Detach the backrest cover from the cushion.
Cut the hog rings.
8. Remove the backrest cover.
Cut the hog rings.
Assembly
illustrated.
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Seating - Rear Seat Bolster
Disassembly
1. Remove the rear seat backrest - bolster. For additional information,
refer to Rear Seat BackrestBolster.
2. Remove the backrest bolster cover.
Cut the hog rings.
Assembly
illustrated.
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Seating - Rear Seat Cushion
Disassembly
1. Remove the rear seat cushion. For additional information, refer to Rear
Seat Cushion.
2. Detach the seat cushion cover.
Cut the hog rings.
3. Cut the seat cushion cover tension cord retaining hog rings.
4. Detach the seat cushion cover tension cords from the seat cushion.
5. Detach the seat cushion cover from the seat cushion.
6. Detach the seat cushion cover.
Cut the hog rings.
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7. Remove the seat cushion cover.
Cut the hog rings.
Assembly
illustrated.
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Glass, Frames and Mechanisms -
Adhesive
Windshield Adhesive WSS-M2G379-A6A
Front window glass retaining bolts 8 - 71
Rear quarter light retaining screws 7 - 62
Rear window glass guide rail retaining nut 7 - 62
Window regulator retaining screws 7 - 62
Liftgate window glass to liftgate window glass hinge retaining bolts 9 - 80
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Glass, Frames and Mechanisms - Glass, Frames and Mechanisms
This vehicle has a fully bonded, laminated front windshield glass glazed directly to the body. The front windshield glass is available in six
versions:
Standard mirror non heated windshield glass.
Standard mirror with heated windshield glass.
Electrochromic mirror non heated windshield glass.
Electrochromic mirror with heated windshield glass.
Electrochromic mirror non heated windshield glass with rain sensor.
Electrochromic mirror with heated windshield glass and rain sensor.
The rear windshield glass on 4-door vehicles is a fully bonded toughened glass that combines the antenna for the audio unit within the rear
defrost grid. The rear windshield glass is available in two versions:
Heated with integrated AM/FM antenna
Heated with integrated AM/FM antenna and TV antenna
The liftgate window glass on wagon is toughened glass, bonded to a mounting bracket which in turn is bolted to the liftgate hinge
assembly. The liftgate window glass can be opened independently of the liftgate, and incorporates an electrically operated liftgate window
glass release switch and also the rear wiper pivot arm. The liftgate window glass has integral circuits for the liftgate window glass release
switch and the defrost grid. The liftgate window glass must be adjusted for correct body clearance.
For additional information, refer to: Liftgate Window Glass Adjustment (501-11 Glass, Frames and Mechanisms, General Procedures).
The heated windshield glass is controlled by the dual automatic temperature control module when the ignition is in the RUN position and
the heated windshield glass switch has been activated. Four minutes after activation, the heated windshield glass will automatically switch
off. The function is also turned off if the customer deselects before the four minute time has elapsed.
The heated rear windshield glass is controlled by the dual automatic temperature control when the rear windshield glass defrost button is
operated. When the switch is operated an indicator in the switch will illuminate indicating that the system is operative. Ten minutes after
activation, the heated rear windshield glass will automatically turn off. The function is also turned off if the customer deselects before the
ten minute time has elapsed.
The front windows are electrically operated and the rear can be electrically or manually operated. Each electrically powered window can be
operated individually or from the main window control switch unless the rear window override switch is active which prevents operation of
the rear window control switches.
All switches have two positions enabling either proportional (first position) or automatic ("one-touch" or second position) window activation
in the upward or downward direction.
If the system detects an obstacle while the "one-touch" up function is activated the window will stop motion and reverse to a position at
least 200 mm (7.87 in) open this is known as "bounce back".
If the system has not been initialized (battery disconnected etc.) then the "one touch" up function will not be active, however "one-touch"
down will be active.
The rear quarter window glass on wagon is a fully bonded toughened glass that incorporates the antenna for TV and, for Japan, vehicle
information and communication system (VICS). The rear quarter window glass is available in three versions:
Without antenna.
With integrated TV antenna.
With integrated TV and VICS antenna.
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Glass, Frames and Mechanisms - Glass, Frames and Mechanisms
Window glass
Window regulator
Blown fuse(s)
Window motor
Damaged wiring harness
Loose or corroded connectors
Circuitry open/shorted
step.
3.
4. If the concern is not visually evident, verify the symptom and refer to the approved Jaguar diagnostic system. 4.
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Glass, Frames and Mechanisms - Door Window Motor Initialization
General Procedures
1. NOTE: After the battery has been disconnected it is necessary to
initialize each door window motor separately to operate the "one-touch"
up function.
Operate the window control switch until the door window glass is in the
fully closed position, continue to operate the window control switch for a
further two seconds.
2. Release the window control switch.
3. Operate the window control switch in the closed position and continue
to operate the window control switch for a further two seconds.
4. Operate the window control switch until the door window glass is in the
fully open position ("one-touch" down).
5. NOTE: If the door window motor initialization has been completed
correctly, when the window control switch is operated, the door window
glass should move to the fully closed position ("one-touch" up)
automatically.
NOTE: If the door window glass does not fully close automatically ("one-
touch" up), repeat the complete procedure.
Operate the window control switch once to the close position.
6. Repeat the door window motor initialization for each door window
motor.
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Glass, Frames and Mechanisms - Liftgate Window Glass Adjustment
General Procedures
1. Make sure the rear wiper mounting arm is in the parked position.
7. NOTE: The aid of an assistant in the loadspace will be required to align
the rear wiper motor to the liftgate window glass.
Make sure the liftgate glass latch and rear wiper mounting arm locate
9. CAUTIONS:
the vehicle.
Tighten the rear wiper retaining bolts in the order shown.
1. Tighten to 8 Nm.
10. Visually check the liftgate window glass for correct alignment.
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Glass, Frames and Mechanisms - Front Door Window Glass
Removal
1. Lower the front door window glass approximately 290 mm (11.41 in).
2. Remove the front door trim panel.
For additional information, refer to: Front Door Trim Panel (501-05
3. CAUTION: Do not touch the adhesive surface as rebonding will be
impaired.
Detach the front door weathershield.
4. Remove the front door window glass.
Loosen the retaining bolts.
Installation
1. Install the front door window glass, but do not tighten the retaining
bolts.
2. Connect the window control switch electrical connector.
3. Power the front door window glass to the fully closed position.
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4. Tighten to 8 Nm.
impaired.
Attach the front door weathershield.
6. Install the front door trim panel.
For additional information, refer to: Front Door Trim Panel (501-05
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Glass, Frames and Mechanisms - Front Door Window Regulator and Motor
Removal
For additional information, refer to: Front Door Window Glass (501-11
Glass, Frames and Mechanisms, Removal and Installation).
3. Remove the front door motor and window regulator.
Installation
2. Tighten to 7 Nm.
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Glass, Frames and Mechanisms - Liftgate Window Glass
Removal
1. Remove the rear spoiler.
2. Detach the navigation system antenna electrical connector.
3. Disconnect the navigation system antenna electrical connector.
4. Detach the defrost grid wire electrical connector.
5. Disconnect the defrost grid wire electrical connector.
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6. Detach the liftgate window glass release switch electrical connector.
7. Disconnect the liftgate window glass release switch electrical connector.
8. Detach the liftgate window glass wiring harness retaining clips.
9. Detach the liftgate window glass wiring harness grommet.
Pass the wiring harness through the aperture.
10. CAUTION: Make sure the liftgate window glass is in the open
position before removing the retaining bolts. Failure to follow this
NOTE: Make sure the liftgate window glass is supported before removing
the retaining bolts.
NOTE: Liftgate window glass shown closed for clarity.
Remove the liftgate window glass.
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Installation
1. CAUTION: Make sure the liftgate window glass does not contact
the vehicle body work when the liftgate window glass is closed. Failure to
NOTE: Align the liftgate window glass retaining bolts centrally to the
liftgate window glass retaining bolt holes.
Install the liftgate window glass.
1. Tighten to 9 Nm.
2. Attach the liftgate window glass wiring harness grommet.
Pass the wiring harness through the aperture.
3. Attach the liftgate window glass wiring harness retaining clips.
4. Connect the liftgate window glass release switch electrical connector.
5. Attach the liftgate window glass release switch electrical connector.
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6. Connect the defrost grid wire electrical connector.
7. Attach the defrost grid wire electrical connector.
8. Connect the navigation system antenna electrical connector.
9. Attach the navigation system antenna electrical connector.
10. Loosen the liftgate window glass retaining bolts.
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11. Align the liftgate window glass to the liftgate window glass aperture.
12. Tighten the liftgate window glass retaining bolts.
Tighten to 9 Nm.
13. CAUTION: Make sure the rear spoiler does not contact the vehicle
roof panel when the liftgate window glass is opened. Failure to follow this
Install the rear spoiler.
14. Visually check the alignment of the rear spoiler to the liftgate window
glass aperture.
16. Close the liftgate window glass.
17. Make sure the rear wiper pivot arm is in the parked position.
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23. NOTE: The aid of an assistant in the loadspace will be required to
align the rear wiper motor to the liftgate window glass.
Make sure the liftgate glass latch and rear wiper mounting arm locate
25. CAUTIONS:
the vehicle.
Tighten the rear wiper motor retaining nuts in the order shown.
Tighten to 8 Nm.
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Glass, Frames and Mechanisms - Rear Door Fixed Window Glass
Removal
1. Remove the rear door trim panel. For additional information, refer to
impaired.
Peel back the weathershield.
3. Detach the window glass surround trim.
4. CAUTION: Do not bend or deform the interior weatherstrip.
Remove the door interior weatherstrip.
5. CAUTION: Do not bend or deform the exterior weatherstrip.
Remove the door exterior weatherstrip.
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6. Detach the window glass aperture seal.
7. Remove and discard the rivets.
8. Detach the rear quarter window glass guide rail retaining bracket.
10. CAUTION: Use care when removing the rear quarter window
glass. Failure to follow these instructions may result in damage to the
window glass and the exterior trim.
Remove the rear quarter window glass.
11. Remove any Butyl adheasive from around the rear quarter window
glass door aperature.
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Installation
1. CAUTION: Use care when installing the rear quarter window glass.
Failure to follow these instructions may result in damage to the window
glass and the exterior trim.
NOTE: When refitting the original rear quarter glass, apply new bead of
Butyl adhesive.
Tighten to 7 Nm.
2. Tighten to 7 Nm.
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Glass, Frames and Mechanisms - Rear Door Window Glass
Removal
1. Remove the rear quarter window glass. For additional information, refer
to Window GlassRear Quarter.
2. Lower the door window glass until the pin is visible in the access hole.
3. Reposition the rear window guide rail.
4. Detach the window glass from the regulator.
1. Remove the pin.
2. Remove the sleeve.
5. Remove the window glass.
Installation
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1. CAUTION: Use care when installing the sleeve and the pin into the
window glass. Failure to follow these instructions may result in damage to
the window glass.
Install the pin.
1. CAUTION: Make sure the sleeve is fitted central in the
window glass.
1. Install the sleeve.
1. CAUTION: Make sure the sleeve stays central in the
window glass.
2. Install the pin.
2. Install the window glass.
3. NOTE: Insert the glass into the regulator glass clamp and firmly pushed
down. Check both sides of the clamp have snapped over the spacer
bracket pin.
Attach the window glass into the regulator clamp.
4. Reposition the rear window guide rail.
5. Install the rear quarter window glass. For additional information, refer
to Window GlassRear Quarter.
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Glass, Frames and Mechanisms - Rear Door Window Regulator
Removal
1. Remove the door trim panel.
For additional information, refer to Section 501-05 Interior Trim and
Ornamentation.
For additional information, refer to Section 415-03 Speakers.
impaired
4. Lower the door window glass until the pin is visible in the access hole.
1. Remove the pin.
2. Remove the sleeve.
6. Secure window glass in the fully raised position.
Apply suitable protective tape to the top of the window glass.
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7. Remove the rear door window regulator.
Installation
1. Install the rear door window regulator.
Tighten to 7 Nm.
2. CAUTION: Support the window glass prior to removal of the
protective tape.
Remove the protective tape from the top of the window glass.
3. CAUTION: Use care when installing the sleeve and pin into the
window glass. Failure to follow these instructions may result in damage to
the window glass.
Install the pin.
3. CAUTION: Make sure the sleeve is fitted central in the
window glass.
1. Install the sleeve.
3. CAUTION: Make sure the sleeve stays central in the
window glass.
2. Install the pin.
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4. NOTE: Insert the glass into the regulator glass clamp and firmly pushed
down. Check both sides of the clamp have snapped over the spacer
bracket pin.
Attach the window glass into the regulator clamp.
impaired
Install the weathershield.
6. Install the rear door speaker.
For additional information, refer to Section 415-03 Speakers.
7. Install the door trim panel.
Ornamentation.
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Glass, Frames and Mechanisms - Rear Door Window Regulator and Motor
Removal
1. Remove the rear door window glass.
For additional information, refer to: Rear Door Window Glass (501-11
2. Remove the rear motor and window regulator.
3. Remove the rear motor and window regulator.
Installation
2. Tighten to 7 Nm.
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Glass, Frames and Mechanisms - Rear Quarter Window Glass
Special Tool(s)
Spray Bottle
WK9
Lubricant Concentrate
WK9L
Power Cutting Tool
WK10HD
Cutting Blade - Side
WK4ZS
Adhesive Removal Blade - Body
WK6
Betagun application gun
Betagun 111
Removal
1. Remove the rear quarter window glass weatherstrip.
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2. Remove the rear quarter window glass finisher trim.
4. Apply a suitable protective tape to the edge of the headliner above the
rear quarter glass.
5. Dispense 20ml of WK9L lubricant into the WK9 spray bottle, fill the
spray bottle with water and mix.
6. CAUTION: Make sure cutting lubricant does not contact any
electrical components. Failure to follow this instruction may result in
Apply cutting lubricant to the rear quarter window glass adhesive.
7. Install the cutting tool blade BTB-WK4ZS to the cutting tool
BTB-WK10HD.
8. WARNING: When removing the rear quarter window glass,
personal protection must be worn. Failure to follow this instruction may
CAUTIONS:
Make sure the rear quarter glass edge seal is not damaged when
cutting the rear quarter window glass adhesive.
Support the rear quarter window glass when cutting the rear quarter
window glass adhesive.
NOTE: Apply cutting lubricant to the cutting tool frequently throughout
the cutting process.
Using the special tool cut through the rear quarter window glass
adhesive.
9. Remove the rear quarter window glass.
Installation
1. WARNINGS:
If the rear quarter window glass is being installed at a temperature
of 23C (73F) or above make sure the vehicle is not driven for at least 1
hour after installation.
of 11C (52F) make sure the vehicle is not driven for at least 1.5 hours
after installation.
of 5C (41F) make sure the vehicle is not driven for at least 2 hours after
installation.
below 5C (41F) use heat and make sure the windshield glass adhesive
has set before the vehicle is driven.
Using the special tool, remove any residual adhesive from the body
aperture.
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2. If the original rear quarter window glass is to be installed remove any
residual adhesive from the rear quarter window glass using the special
tool.
3. Thoroughly clean rear quarter window glass surface using Betawipe
spirit.
4. Thoroughly clean the mating face of the body using Betawipe spirit.
5. Apply primer to the mating face of the glass.
6. Apply primer to the mating face of the body.
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7. Cut the nozzle of the JLM20452 glass bonding adhesive to achieve a
triangular section bead 8 mm (0.32 in) wide by 10 mm (0.4 in) high.
8. Using the special tool, apply a uniform bead of adhesive to the rear
quarter window glass edge commencing at the bottom center and
overlapping the ends approximately 14 mm (0.56 in).
9. CAUTIONS:
When installing the rear quarter window glass, do not strike it in
any way as this will crack the rear quarter window glass.
Make sure the rear quarter window glass does not move out of
position in the body aperture.
Install the rear quarter window glass into the aperture and press firmly
in to place.
10. CAUTION: Make sure the rear quarter window glass does not
move out of position in the rear quarter window glass aperture.
Apply suitable tape to the rear quarter window glass.
11. Remove protective tape from the edge of the headliner.
12. Install the loadspace trim panel.
13. NOTE: Make sure the rear quarter window glass adhesive has cured
before installing the rear quarter window glass finisher trim.
Install the rear quarter window glass finisher trim.
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14. NOTE: Make sure the rear quarter window glass adhesive has set
before installing the rear quarter window glass exterior weatherstrip.
Install the rear quarter window glass weatherstrip.
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Glass, Frames and Mechanisms - Rear Window Glass Using Cheese Wire
Removal
1. Remove the high level stop lamp. For additional information, refer to
Section 417-01 Exterior Lighting.
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9. Apply suitable protective tape around the windshield glass aperture.
10. Place a protective sheet over the parcel shelf and place a protective
board over the sheet.
11. Apply suitable protective tape to inner edge of the roof panel.
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12. Prepare the cheese wire and the cutting handle.
Position the cutting handle central tube fully upwards in the
handle.
Cut a suitable length of cheese wire and pass one end through the
handle tube and the locating aperture.
Move the cutting handle central tube downwards to secure the
cheese wire.
13. Using a suitable long bladed tool, penetrate the windshield glass
adhesive.
14. Remove the tool, pass the free end of the cheese wire through the
penetration and install the second cutting handle.
15. With assistance and exercising care to avoid damaging the paintwork,
cut around the windshield glass commencing downwards and along the
bottom.
16. With assistance remove the windshield glass.
Attach the lifting handles to the windshield glass.
17. Remove the lifting handles from the windshield glass.
18. Remove the cheese wire cutting tool from the windshield glass
aperture, separate the handles by moving center tubes upwards and
discard the cheese wire.
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19. Apply suitable protective tape to the windshield glass aperture.
20. NOTE: To aid bonding of a new windshield glass, make sure at least 1
mm (0.3 in) of residual adhesive remains on the body flange.
Using a suitable tool remove residual adhesive from the body flange.
21. Remove the protective tape from the windshield glass aperture.
Installation
1. Make sure the new windshield glass surface is clean using Betawipe
spirit.
2. Apply glass primer to the mating face of the windshield glass.
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3. Apply glass primer to the mating face of the body flange.
4. Cut the adhesive nozzle to achieve a triangular section bead 8 mm
(0.31in) wide by 13 mm (0.51 in) high.
5. NOTE: Apply windshield adhesive WSS-M2G379-A6A or equivalent
meeting Jaguar specification around the windshield glass edge.
Using a suitable pneumatic application gun, apply a uniform bead of
adhesive to the windshield glass edge commencing at the bottom center
and overlapping the ends approximately 14 mm (0.55 in).
6. WARNINGS:
If the windshield glass is being installed at 23C (73F) or above
make sure the vehicle is not driven for at least 1 hour after installation.
If the windshield glass is being installed at a temperature of 11C
(52F) to 23C (73F) make sure the vehicle is not driven for at least 1.5
hours after installation.
(41F) to 11C (52F) make sure the vehicle is not driven for at least 2
If the windshield glass is being installed at a temperature below
5C (41F) use heat and make sure the windshield glass adhesive has set
before the vehicle is driven.
CAUTION: When installing the windshield glass, do not strike it in
any way as this will crack the glass.
Install the lifting handles and with assistance, carefully position the
windshield glass in the aperture.
Align the windshield glass and press firmly into place.
Remove the lifting handles.
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7. CAUTION: Make sure the windshield glass does not move out of
position in the windshield glass aperture.
Apply suitable protective tape to the top of the windshield glass.
8. Remove the tape from the inner edge of the roof panel.
9. Remove the protective sheet and the protective board from the parcel
shelf.
10. Remove the protective tape from around the windshield glass
aperture.
11. CAUTION: Do not connect the electrical connector for at least 1
hour after installation of the windshield glass. Failure to follow these
instructions may result in damage to the windshield glass adhesive.
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13. CAUTION: Do not connect the electrical connectors for at least 1
15. Attach the parcel shelf trim panel.
16. Install the rear seat backrest latch covers.
17. Attach the seat belt reel trim panels.
18. Install the high level stop lamp. For additional information, refer to
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19. CAUTION: Make sure the windshield glass adhesive is set before
removing the protective tape.
Remove the protective tape from the top of the windshield glass.
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Glass, Frames and Mechanisms - Rear Window Glass Using Cutting Tool
Special Tool(s)
Lubricant concentrate
BTB-WK9L
Spray bottle
BTB-WK9
Cutting tool
BTB-WK10HD
Serrated general purpose 'Z' cutting blade
BTB-WK24ZSC
Cutting blade controller arm
BTB-WK11B
Reverse powered cold knife blade cutting tool
BTB-WK27RM
Pinchweld scraper blade
BTB-WK6
Removal
1. Remove the high level stop lamp. For additional information, refer to
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9. Apply suitable protective tape around the windshield glass aperture.
10. Place a protective sheet over the parcel shelf and place a protective
11. Apply suitable protective tape to inner edge of the roof panel.
12. Apply cutting lubricant to the lower part of the inner windshield glass
adhesive.
13. Install the cutting tool blade BTB-WK24ZS to the cutting tool
BTB-WK10HD.
14. Using the cutting tool cut through the lower windshield glass
adhesive.
15. Using the cutting tool cut through the lower windshield glass
adhesive.
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16. Apply cutting lubricant to both sides of the inner C-pillar windshield
glass adhesive.
17. Install the cutting tool controller arm BTB-WK11B to the cutting tool
BTB-WK10HD.
Set the cutting controller arm to 45 mm.
NOTE: Start cutting the windshield glass adhesive from the top of the
C-piller downwards.
Using the cutting tool cut through both sides of the inner C-pillar
windshield glass adhesive.
19. Apply cutting lubricant to the top of the inner windshield glass
adhesive.
20. Set the cutting controller arm to 15 mm.
21. Apply suitable protective tape to the top of the windshield glass.
22. NOTE: Start cutting from either corner of the windshield glass into the
center of the windshield glass and continue the cut all the way through to
the other corner of the windshield glass. Do not cut from each corner of
the windshield glass into the center of the windshield glass as the
pressure on the center of the windshield glass could cause breakage.
Using the special tool cut through the top of the inner windshield glass
adhesive.
Using the special tool cut through any remaining adhesive on the
C-pillars.
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24. Remove the windshield glass.
Attach lifting handles to the windshield glass.
Using the special tool remove the residual adhesive from the body
flange.
Installation
spirit.
2. Apply glass primer to the mating face of the windshield glass.
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6. WARNINGS:
If the windshield glass is being installed at 23 C (73 F) or above
If the windshield glass is being installed at a temperature of 11 C
(52 F) to 23 C (73 F) make sure the vehicle is not driven for at least
1.5 hours after installation.
If the windshield glass is being installed at a temperature of 5 C
(41 F) to 11 C (52 F) make sure the vehicle is not driven for at least 2
If the windshield glass is being installed at a temperature below 5
C (41 F) use heat and make sure the windshield glass adhesive has set
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8. Remove the tape from the inner edge of the roof panel.
9. Remove the protective sheet and the protective board from the parcel
shelf.
10. Remove the protective tape from around the windshield glass
aperture.
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15. Attach the parcel shelf trim panel.
16. Install the rear seat backrest latch covers.
17. Attach the seat belt reel trim panels.
18. Install the high level stop lamp. For additional information, refer to
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Glass, Frames and Mechanisms - Window Control Switch
Removal
2. Remove the window control switch.
Installation
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Glass, Frames and Mechanisms - Windshield Glass Using Cheese Wire
Removal
1. Remove the sun visors.
Ornamentation.
2. Remove the cowl vent screen cover.
For additional information, refer to Section 501-02 Front End Body
Panels.
For additional information, refer to Section 501-09 Rear View Mirrors.
Disconnect the heated windshield glass electrical connectors.
5. Remove the A-pillar exterior trim.
6. Apply suitable protective tape around the windshield glass aperture to
protect the paintwork.
7. Place a suitable protective sheet over the fascia and place a protective
8. Apply suitable protective tape to the leading inner edge of the roof
panel.
9. Prepare the cheese wire and the cutting handle.
Position the cutting handle central tube fully upwards in the
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handle.
Cut a suitable length of cheese wire and pass one end through the
handle tube and the locating aperture.
Move the cutting handle central tube downwards to secure the
cheese wire.
10. Using a suitable long bladed tool, penetrate the windshield glass
adhesive approximately 150 mm (0.59 in) from the top of one A-pillar.
11. Remove the tool, pass the free end of the cheese wire through the
penetration and install the second cutting handle.
12. With assistance and exercising care to avoid damaging the paintwork,
cut around the windshield glass commencing downwards and along the
bottom.
15. Remove the cheese wire cutting tool from the windshield glass
aperture, separate the handles by moving center tubes upwards and
discard the cheese wire.
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Using a suitable tool remove the residual adhesive from the body flange.
Installation
spirit.
2. Apply glass primer to mating face of the windshield glass.
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6. WARNINGS:
5C (41F) use heat and make sure the windshield glass adhesive has set
8. Remove the protective tape from the inner leading edge of the roof
panel.
9. Remove the protective sheet and the protective board from the fascia.
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Connect the the heated windshield glass electrical connectors.
12. Install the A-pillar exterior trim.
13. Install the rear view mirror.
14. Install the cowl vent screen cover.
Panels.
15. Install the sun visors.
Ornamentation.
16. CAUTION: Make sure the windshield glass adheasive is set
before removing the protective tape.
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Glass, Frames and Mechanisms - Windshield Glass Using Cutting Tool
Special Tool(s)
Lubricant concentrate
BTB-WK9L
Spray bottle
BTB-WK9
Cutting tool
BTB-WK10HD
Serrated extra long flat cutting blade
BTB-WK1SC
Serrated general purpose 'Z' cutting blade
BTB-WK24ZSC
Cutting blade controller arm
BTB-WK11B
Reverse powered cold knife blade cutting tool
BTB-WK27RM
Pinchweld scraper blade
BTB-WK6
Removal
1. Remove the sun visors.
Ornamentation.
Panels.
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Disconnect the heated windshield glass electrical connectors.
5. Remove the A-pillar exterior trim.
6. Apply suitable protective tape around the windshield glass aperture to
protect the paintwork.
7. Place a suitable protective sheet over the fascia and place a protective
8. Apply suitable protective tape to the leading inner edge of the roof
panel.
9. Dispense 20 ml of WK9L lubricant into the WK9 spray bottle, fill the
spray bottle with water and mix.
10. Apply cutting lubricant to the lower windshield glass adhesive and
approximately 150 mm (5.9 in) up the A-pillar.
11. Install the cutting tool blade BTB-WK1SC to the cutting tool
BTB-WK10HD.
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Using the cutting tool, cut through the lower windshield glass adhesive
and approximately 150 mm (5.9 in) up the A-pillar.
13. Apply cutting lubricant to both sides of the inner A-pillar windshield
glass adhesive.
14. NOTE: Remove the cutting tool blade BTB-WK1SC from the cutting tool
BTB-WK10HD.
Install the cutting tool side cutting blade BTB-WK24ZS and the cutting
tool controller arm BTB-WK11B to the cutting tool BTB-WK10HD.
Set the cutting tool controller arm to 20 mm.
NOTE: Start cutting the windshield glass adhesive from the top of the
A-piller downwards.
Using the cutting tool, cut through A-pillar windshield glass adhesive.
16. Apply cutting lubricant to the top of the inner windshield glass
adhesive.
17. Apply suitable protective tape to the top of the windshield glass.
18. NOTE: Start cutting from either corner into the center and continue the
cut all the way through to the other corner. Do not cut from each corner
into the center of the windshield glass as the pressure on the center of
the windshield glass could cause breakage.
Using the cutting tool, cut through the top of the inner windshield glass
adhesive.
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Using the special tool cut through any remaining windshield glass
adhesive on the A-pillars.
Using the special tool remove the residual adhesive from the body
flange.
Installation
spirit.
2. Apply glass primer to mating face of the windshield glass.
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6. WARNINGS:
5C (41F) use heat and make sure the windshield glass adheasive has
set before the vehicle is driven.
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8. Remove the protective tape from the inner leading edge of the roof
panel.
9. Remove the protective sheet and the protective board from the fascia.
Connect the the heated windshield glass electrical connectors.
12. Install the A-pillar exterior trim.
13. Install the interior mirror.
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14. Install the cowl vent screen. For additional information, refer to
Section 501-02 Front End Body Panels.
15. Install the sun visors. For additional information, refer to Section
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Instrument Panel and Console - Instrument Panel
1 Left hand side register
3 Center register
4 Passenger air bag module
5 Glovebox
6 Right hand side register
7 J-gate surround
8 Arm rest
9 Rear ashtray
10 Front ashtray
The instrument panel assembly houses the main instrument cluster, passenger air bag module, glovebox, and air distribution registers, all
of which can be readily removed without disturbing the instrument panel. The instrument panel wiring harness is located behind the
instrument panel assembly to facilitate easy installation in vehicle. The instrument panel must be removed from the vehicle to gain access
to the wiring harness.
Console
The floor console is located between the front seats and, depending upon trim level, consists of the ashtray, cigar lighter and armrest. The
center section of the console forms a deep stowage box with a secondary cupholder. The optional telephone is incorporated within the
armrest. In both cases the center console utilizes a rear hinged lid which is padded to form a central arm rest. A dynamic stability control
'ON/OFF' selector switch, if fitted, is situated immediately in front of the stowage box. Situated in the rear of the center console is a rear
passenger ashtray.
The roof console is located between the front sun visors and, depending upon vehicle options, consists of the front overhead courtesy light,
two reading/map lights, remote convenience buttons, sunroof switch, emergency messaging buttons and a microphone.
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Instrument Panel and Console - Floor Console
Removal
All vehicles
1. Detach the electronic passive anti-theft system (PATS) light.
2. Remove the PATS light.
3. Remove the hand brake lever surround.
1. Detach the hand brake lever surround.
2. Remove the hand brake lever surround.
4. Remove the console stowage compartment non slip mat.
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6. Remove the center console trim panel.
7. Remove the center console trim panel.
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9. Remove the J-gate surround.
All vehicles
12. Disconnect the bluetooth upgrade module electrical connector.
All vehicles
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Installation
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Instrument Panel and Console - Instrument Panel
Removal
All vehicles
1. Remove the console.
2. Remove the climate control panel.
For additional information, refer to: Climate Control Assembly (412-04
Control Components, Removal and Installation).
3. Remove the navigation system display module (if equipped).
For additional information, refer to: Navigation System Display Module
(419-07 Navigation System, Removal and Installation).
For additional information, refer to: Instrument Cluster (413-01
Instrument Cluster, Removal and Installation).
5. Remove the passenger air bag module.
For additional information, refer to: Passenger Air Bag Module (501-20B
For additional information, refer to: Steering Column (211-04 Steering
For additional information, refer to: Headlamp Switch (417-01 Exterior
Lighting, Removal and Installation).
8. Remove the gear selector knob.
10. Remove the gear selector surround.
1. Detach the reverse gear interlock mechanism.
2. Remove the gear selector surround.
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All vehicles
11. Remove the right hand end panel.
1. Detach the front door opening weather strip.
2. Remove the right hand end panel.
12. Remove support panel.
14. Remove the instrument panel retaining screws.
15. Detach the electrical harness.
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16. Remove the instrument panel retaining screw.
18. Remove the left hand end panel.
1. Detach the front door opening weather strip.
2. Remove the left hand end panel.
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21. Detach the electrical harness.
22. Remove the instrument panel retaining screw.
24. Remove and discard the pop rivets.
25. Remove the instrument panel.
Installation
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Instrument Panel and Console - Overhead Console
Removal
1. Detach the roof console.
2. Remove the roof console.
Disconnect the electrical connector(s).
Installation
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Instrument Panel and Console - Overhead Console Switch Moulding
Removal
2. NOTE: Where installed.
Remove the front intrusion sensor.
3. NOTE: Where installed.
Remove the garage door opener module.
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4. CAUTION: Make sure that only the head of the fixing is removed.
Do not drill any deeper than necessary. Failure to follow this instruction
may result in damage to the component.
Remove the printed circuit board (PCB) cover.
Using a 5mm drill bit, carefully drill out and remove the 4 plastic
fixing heads.
5. Remove the PCB.
6. Remove the two switch mouldings.
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7. Remove the foam pad.
8. Carefully remove sunroof rocker switch for reuse in the new rear switch
moulding.
Installation
1. Select the correct switch moulding for the vehicle from the parts kit.
2. Remove any unnecessary switch buttons from the rear moulding using a
suitable sharp knife. Take care not to remove any required switches.
3. Install the sunroof rocker switch.
4. Install the front switch moulding.
5. Install the foam pad.
6. Install the rear switch moulding.
7. Install the PCB.
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8. Install the cover.
Install the 4 Torx screws
Tighten to 1.5 Nm.
9. Install the garage door opener module.
10. Install the front intrusion sensor.
11. Install the overhead console.
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Handles, Locks, Latches and Entry Systems -
Door latch actuator retaining screws 7 - 62
Door latch striker retaining bolts 25 18 -
Door exterior handle retaining screws 5 - 44
Luggage compartment lid latch actuator retaining screws 10 - 89
Luggage compartment lid latch striker retaining bolts 25 18 -
Liftgate latch actuator retaining bolts 20 15 -
Liftgate window latch actuator retaining bolts 8 - 71
Rear window wiper pivot arm retaining nut 7 - 62
Rear wiper mounting arm retaining nuts 8 - 71
Liftgate window glass release switch retaining nut 9 - 80
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Handles, Locks, Latches and Entry Systems - Handles, Locks, Latches and Entry
Systems
1 Rear door exterior handle
2 Door interior handle
3 Generic electronics module (GEM)
4 Hood latch release handle
5 Integrated key remote entry transmitter
6 Front door exterior handle
7 Rear door latch and actuator
8 Luggage compartment lid latch and actuator
9 Luggage compartment release switch
10 Front door latch and actuator
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1 - Liftgate window glass release switch
2 - Liftgate window latch actuator
3 - Liftgate latch actuator
4 - Liftgate release switch
For most markets excluding North America and Japan, the remote central locking system incorporates a double locking facility for optimum
security. All locks use the Tibbe key system, using 6 elements and 4 cuts. The keys include 'in-key' transponders which are programmed to
the vehicle engine immobilization system by using the Jaguar approved diagnostic system.
The central locking system employs single key access to the driver door, ignition switch and steering column lock.
When the vehicle is not locked, each door latch can be externally released by the corresponding exterior door handle which is operated by a
single rod. When unlocked, or central locked, the door latches can also be released by the interior door handles, each of which are operated
by a single cable. Operation of the front door interior handles will also unlock the rear doors. Use of the key in the driver door lock cylinder
operates the lock by a short rod to provide locking of the door latch. This in turn locks all other doors and the luggage compartment through
the central locking system. These locking functions can also be achieved by use of the integrated key remote entry transmitter.
For most markets, vehicles with 2.0L, 2.5L and 3.0L engines have a 'drive-away door locking' feature which automatically central locks all
doors and the luggage compartment when the vehicle exceeds 7 km/h (4 mile/h).
Key operation
To central unlock or lock the vehicle, the key is inserted in the driver door lock cylinder, turned towards the front or rear of the vehicle
respectively, and released. Holding the key in the lock position for 1.5 seconds will close all windows. Releasing the key stops all
operations. Central locking of the vehicle locks all doors and the luggage compartment and sets the alarm system. In addition to all of the
above functions, double locking prevents the doors opening from the interior. To 'double lock' the vehicle, the key is inserted in the driver
door lock cylinder and turned to the unlock (forward) position, then within three seconds, turned to the lock (rearward) position and
released. The same procedure is required to unlock a 'double locked' vehicle as with a central locked vehicle. The key is inserted in the
driver door lock cylinder and turned to the unlock (forward) position. This function can also be activated using the remote transmitter.
If an attempt is made to lock the vehicle from either front doors through the driver or passenger interior door handles, when a door, hood or
luggage compartment is ajar, will result in all doors being locked and then unlocked. If an attempt is made to lock the vehicle from either
rear doors through the interior door handles, or when the hood, a door or the luggage compartment is ajar or open, will result in only that
specific rear door to lock.
The fuel filler flap release lever is used to allow the driver to release the fuel filler flap from inside the vehicle. This function can be used at
all times.
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Keyless Entry
The integrated key remote transmitter operates the following functions:
unlocking the driver door
unlocking/locking all doors
releasing the luggage compartment lid
activate/deactivate the double locking
arms/disarms the anti-theft alarm system, interior scanning system and the inclination sensor (if equipped)
activates global closing
deactivates a triggered alarm
headlamp convenience
remote panic alarm (standard on North American specification vehicles and as a dealer option in other markets)
Inputs and Outputs
The keyless entry/computer operated lock system receives inputs from the following:
ignition switch (ACC and ON positions)
door ajar switches
hood switch
luggage compartment switch
remote transmitter
The Generic electronics module (GEM) distributes outputs to the following:
door lock actuators
double locking motors
turn signals
alarm horn
luggage compartment latch
power window motors for global closing
Transmitter, Keyless Entry Remote
The keyless entry/remote operated lock system is completely independent in function but fully integrated within the GEM. The remote
control system consists of a transmitter and an antenna (radio frequency system).
The remote control transmitter for the radio frequency system will operate without the transmitter being directed at the vehicle. The normal
range between the transmitter and the antenna will be up to 10 meters for the USA, Canada and the rest of the world. The normal range
between transmitter and antenna will be up to five meters for the UK and Europe and three meters for Japan.
Before the remote control system can be used, each transmitter must be initialized to the vehicle. A maximum number of four transmitters
can be initialized to any vehicle. All remote transmitters must be initialized at the same time.
The keyless entry/remote operated locks will not operate when the ignition key is in the ignition switch.
Locking and Unlocking
The remote transmitter is integrated into the key and contains four buttons (lock, unlock, trunk release, headlamp convenience). To operate
the system:
Press the lock button once to activate the central locking system and the alarm system (if enabled).
Press the lock button twice within three seconds to activate the central locking system, double locking system, alarm system and the
interior scanning system (if equipped).
Press the unlock button once to deactivate the double locking, the alarm system is deactivated and only the driver door is fully unlocked
(this is programmable using the Jaguar approved diagnostic system or by pressing and holding the lock and unlock buttons simultaneously
for 4 seconds, the direction indicators will then flash to show the change of status from single point entry to central unlock).
Pressing the unlock button twice within three seconds will unlock the remaining doors (this is programmable using the Jaguar approved
diagnostic system).
Pressing the luggage compartment release button once releases the trunk. The vehicle must be unlocked and at vehicles speeds below 7
km/h (4 mile/h).
Press the headlamp convenience button once to activate the headlamp main beam function, press the headlamp convenience button again
to deactivate the headlamp main beam function. This function will automatically deactivate after 30 seconds.
Press the headlamp convenience button three times within three seconds to activate the alarm, press the headlamp convenience button
again three times within 3 seconds to deactivate the alarm.
Double Locking
Double locking prevents the interior door handles from unlocking the door.
Double locking is activated by turning the key in the driver door lock to the unlock position and then to the lock position within three
seconds or by pressing the lock button twice within three seconds on the remote transmitter.
Successful double locking is indicated by the turn signals flashing twice, one short flash followed by a long flash.
Double locking will be inhibited if the GEM senses the hood, a door or the luggage compartment is ajar or open. The GEM receives its input
from the door ajar switches.
If the vehicle battery becomes discharged after the double locking has been activated, opening the drivers door with the key will
mechanically deactivate the double locking on the drivers door only.
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Handles, Locks, Latches and Entry Systems - Locks, Latches and Entry Systems
Door locks
Latch(es)
Handle(s)
Rods/linkages
Relay(s)
Module (GEM)
Actuator(s)
step.
3.
NOTE: Check frequently asked questions 4461 prior to door latch replacement.
NOTE: Key transmitters will not operate if the key is in the ignition switch.
NOTE: Carry out the checks in the table and pinpoint tests before installing a new latch.
Symptom Chart
Symtom
(General) Symptom (Specific) Possible Source Action
The car or a door
fails to lock
The car or a door
fails to lock from a
transmitter
A door luggage compartment
lid or hood is ajar
Transmitter battery
Signal failure
Latch motor failure(s)
For transmitter tests, GO to Pinpoint Test A. .
Drive away locking
does not function
Function disabled
Signal failure
Check the central locking function using the transmitter. If this
functions correctly, check that the drive away locking function is
enabled using the Jaguar approved diagnostic system. Carry out
a system test using the Jaguar approved diagnostic system.
The car or a door
fails to lock from a
key
Linkage rod
disconnected/damaged
Lock barrel operating lever
Check for resistance when the key is operated, remove the
suspect door casing and examine the components listed.
The car or a door
fails to lock from the
interior paddle(s)
Cable disconnected/damaged
Locking paddle damaged
Remove the suspect door casing and examine the components
listed.
The car or a door
fails to unlock
The car or a door
fails to unlock from
a transmitter
Transmitter battery
Signal failure
For transmitter tests, GO to Pinpoint Test A. , carry out a
system test using the Jaguar approved diagnostic system.
The car or a door
a key
Linkage rod
Lock barrel operating lever
Check for resistance when the key is operated, remove the
suspect door casing and examine the components listed.
The car or a door
the interior
paddle(s)
Double locking engaged
Incorrect interior door handle
fitted
Check that the vehicle is not double-locked. Remove the suspect
door casing and examine the components listed. Check that the
paddles work when the interior release is pulled (Federal
vehicles, front doors only). Check that a double-locking latch is
not fitted to a central lock specification vehicle.
The car or a door
a rear interior
paddle
Child locks engaged
Check that the vehicle is not double-locked. Check the child lock
engagement (see owner's handbook). Remove the suspect door
casing and examine the components listed.
Door fails to
latch fully (does
not stay closed)
Door ajar Pawl fails to latch
Striker is too far inboard
Check the pawl operation with the door open, if the pawl fails to
latch fully, install a new latch. Check/adjust the striker(s)
Door(s) difficult
to open
An individual door is
difficult to open from
the exterior handle
Striker adjustment
Operating rod
Pawl sticking
Check the adjustment of the striker(s), remove the suspect door
casing and inspect the operating linkage. Check the pawl for
correct operation.
An individual door is
difficult to open from
the interior handle
Striker adjustment
Operating cable
Pawl sticking
Check the adjustment of the striker(s), remove the suspect door
casing and inspect the operating linkage. Check the pawl for
correct operation.
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1
1
1
1
2
1
1
2
1
Symtom
(General) Symptom (Specific) Possible Source Action
Door(s) fail to
open
An individual door
fails to open from
the exterior handle
Exterior release handle
failure
Operating rod
Pawl sticking
Check the pawl for correct operation. Check if the door opens
from the interior handle. Remove the suspect door casing and
inspect the operating linkage (pay particular attention to the
linkage clips).
An individual door
fails to open from
the interior handle
Interior release handle
failure
Operating cable
Pawl sticking
Wrong interior handle fitted
Check that the vehicle is not double-locked. Check the pawl for
correct operation. Check if the door opens from the exterior
handle. Remove the suspect door casing and inspect the
operating linkage. Check that the interior paddle operates when
the interior release is pulled (Federal vehicles only).
An individual rear
door fails to open
from the interior
handle
Child locks engaged
Interior release handle
failure
Operating cable
Pawl sticking
Check that the vehicle is not double-locked. Check the child lock
engagement (see owner's handbook). Check the pawl for correct
operation. Check if the door opens from the exterior handle.
Remove the suspect door casing and inspect the operating
linkage.
Vehicle locks
without request
The vehicle locks
without the
transmitter or key
being operated
Locking barrel operating lever
or linkage rod is
disconnected
Latch failure
Check that the lock functions with a key. If the system
locks/unlocks normally with a key, carry out a system test using
the Jaguar approved diagnostic system.
Vehicle unlocks
without request
The vehicle unlocks
without the
transmitter or key
being operated
Locking barrel operating lever
or linkage rod is
disconnected
Latch failure
Check the lock function with a key. If the system locks/unlocks
normally with a key, carry out a system test using the Jaguar
approved diagnostic system.
Pinpoint Tests
PINPOINT TEST A : CAR OR DOOR FAILS TO LOCK FROM A TRANSMITTER
NOTE: Make sure all transmitters are available before testing.
TEST
CONDITIONS
A1: CHECK TRANSMITTER FUNCTION
Operate the remote headlight function with the transmitter.
Do the headlights operate?
Yes
GO to A2.
No
REPEAT the test with the spare transmitters. If none of the transmitters function, GO to A2. . If spare transmitters
function correctly, check/replace the battery in the suspect transmitter.
A2: CHECK THE LOCKING FUNCTION WITH THE KEY
Operate the lock with the key.
Does the central locking function correctly?
Yes
CARRY OUT transmitter tests using the Jaguar approved diagnostic system.
No
GO to A3.
A3: CHECK THE MECHANICAL FUNCTION OF THE LOCK
Operate the lock with a key.
Is resistance felt when turning the key?
Yes
GO to A4.
No
REMOVE the door casing and check the linkage rod connection from lock barrel to latch.
A4: CHECK THE FUNCTION OF THE INTERIOR LOCKING PADDLES
Operate the lock with a key.
Observe the operation of the interior locking paddles whilst operating the key.
Do all the interior operating paddles move freely?
Yes
CARRY OUT functional tests using the Jaguar approved diagnostic system.
No
GO to A5.
A5: CHECK LATCH FUNCTION (CLOSED)
Check that all the doors, luggage compartment and hood are firmly latched.
Do all the doors, luggage compartment and hood latch correctly?
Yes
No
GO to A6.
A6: CHECK LATCH FUNCTION (OPEN)
Fully open whichever of the body openings did not latch correctly.
Manually operate the body opening pawl.
Does the body opening pawl latch correctly?
Yes
CHECK and adjust the body opening striker. Recheck for correct latching with the door closed.
No
GO to A7.
A7: CHECK THE INTERIOR LOCKING PADDLE CABLES
Remove the door casing and check interior locking cable(s) for connection/damage.
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Are any of the cables disconnected or damaged?
Yes
RECTIFY as necessary. For additional information, refer to removal and installation in this section.
No
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Handles, Locks, Latches and Entry Systems - Remote Transmitter Programming
General Procedures
1. NOTE: All remote transmitters are programmable and must be
programmed at the same time.
NOTE: If an attempt is made to program a fifth remote transmitter after
four remote transmitters have already been programmed, the generic
electronic module (GEM) will exit the remote transmitter learn mode. If the
remote transmitter learn mode is entered again, the attempt shall erase
all remote entry device associations and start a new set of four remote
entry device associations with this fifth remote transmitter programming
attempt.
The complexity of the electronics involved with the remote keyless
entry, of which the GEM is a part, and the multiplexed communication
network which are connected to it, exclude the use of workshop general
Jaguar Approved Diagnostic System for programming the remote
transmitters.
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Handles, Locks, Latches and Entry Systems - Exterior Front Door Handle
Removal
For additional information, refer to: Front Door Window Glass (501-11
2. Remove the front door security shield.
2. Remove and discard the retaining clips.
3. Remove the front door security shield.
3. Disconnect the front door exterior handle connecting rod and the door
lock cylinder connecting rod.
4. Remove the front door motor and window regulator upper and lower rear
securing scews.
5. Remove the front door exterior handle retaining screws.
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6. Remove the front door exterior handle.
Installation
1. NOTE: Install new front door security shield retaining clips.
Tighten to 5 Nm.
2. Tighten to 7 Nm.
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Handles, Locks, Latches and Entry Systems - Front Door Lock Actuator
Removal
1. Remove the front door trim panel. For additional information, refer
toSection 501-05 Interior Trim and Ornamentation.
2. CAUTION: Do not touch the adhesive surface as re-bonding will be
impaired.
3. Remove the door security shield.
2. Remove and discard the retaining clips.
3. Remove the door security shield.
4. Disconnect the front door exterior handle connecting rod and the door
lock cylinder connecting rod.
5. Detach the front door latch.
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6. Disconnect the front door latch actuator electrical connectors.
7. Remove the front door latch actuator.
1. Detach the front door latch actuator release cable.
2. Disconnect the front door latch actuator release cable.
3. Remove the front door latch actuator.
Installation
1. NOTE: Install new front door security shield retaining clips.
Tighten to 7 Nm.
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Handles, Locks, Latches and Entry Systems - Front Door Lock Cylinder
Removal
1. Remove the front door exterior handle. For additional information, refer
to HandleFront Door Exterior.
2. Remove the door lock cylinder.
Installation
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Handles, Locks, Latches and Entry Systems - Fuel Filler Door Release Handle and
Cable4-Door
Removal
NOTE: The procedure shown is for LHD vehicles. The procedure is similar for RHD vehicles.
All vehicles
2. Remove the rear seat bolster cushion.
For additional information, refer to: Rear Seat Bolster - 4-Door (501-10
.
3. Remove the driver side front scuff plate trim panel.
For additional information, refer to: Front Scuff Plate Trim Panel (501-05
.
4. Remove the driver side rear scuff plate trim panel.
5. Reposition the floor covering to one side.
1. Lift the fuel filler door release handle.
6. Detach the fuel filler door release handle and cable.
7. Remove the fuel filler door release handle.
1. Detach the fuel filler door release cable.
2. Rotate the fuel filler door release cable counter clockwise.
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9. Detach the rear door opening weatherstrip and position to one side.
10. Reposition the wiring harness to one side.
Loosen the retaining screws.
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Vehicles built up to VIN:J38978
Vehicles built from VIN:J38979
15. Remove the luggage compartment floor covering.
16. Detach and reposition the LH rear quarted trim panel.
17. Remove the rear panel.
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All vehicles
20. Detach and reposition the RH rear quarter trim panel.
21. Remove the fuel filler door release cable.
1. Rotate the fuel filler door release cable clockwise.
2. Remove the fuel filler door release cable.
Installation
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Handles, Locks, Latches and Entry Systems - Fuel Filler Door Release Handle and
CableWagon
Removal
For additional information, refer to: Rear Seat Bolster - Wagon (501-10
3. Remove the driver front scuff plate trim panel.
For additional information, refer to: Front Scuff Plate Trim Panel (501-05
4. Remove the driver rear scuff plate trim panel.
6. Remove the right-hand front retaining hook.
7. Detach the right-hand loadspace side trim panel.
8. Remove the right-hand loadspace trim panel.
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9. Disconnect the subwoofer enclosure electrical connector (if equipped).
10. Remove the subwoofer enclosure (if equipped).
1. Rotate the fuel filler door release cable clockwise.
12. Remove the fuel filler door latch retainer.
13. Remove the fuel filler door latch and spring.
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14. Reposition the cable through the boot.
15. NOTE: To aid installation, note the routing of the fuel filler door
release cable.
Detach fuel filler door release cable.
16. Detach fuel filler door release cable.
1. Lift the fuel filler door release handle.
18. Detach the fuel filler door release handle and cable.
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1. Detach the fuel filler door release cable from the handle.
20. NOTE: To aid installation, note the routing of the fuel filler door
release cable.
Remove the fuel filler door release cable.
Installation
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Handles, Locks, Latches and Entry Systems - Liftgate Latch Actuator
Removal
1. Remove the tailgate trim panel.
2. Disconnect the liftgate latch actuator electrical connector.
3. Remove the liftgate latch actuator.
Installation
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Handles, Locks, Latches and Entry Systems - Liftgate Window Glass Release Switch
Removal
1. Remove the rear window wiper pivot arm retaining nut cover.
2. Remove the rear window wiper pivot arm.
3. Remove the liftgate window glass release switch retaining nut.
4. Remove the rear wiper mounting arm cover retaining nut trim covers.
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5. Remove the rear wiper mounting arm cover.
6. Remove the rear wiper mounting arm.
7. Remove the liftgate window glass release switch.
Disconnect the liftgate window glass release switch electrical
connector.
Installation
1. Install the liftgate window glass release switch.
Connect the liftgate window glass release switch electrical
connector.
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2. Install the rear wiper mounting arm.
Tighten to 8 Nm.
3. Install the rear wiper mounting arm cover.
4. Install the rear wiper mounting arm cover retaining nut trim covers.
5. Install the liftgate window glass release switch retaining nut.
Tighten to 9 Nm.
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7. Install the rear window wiper pivot arm retaining nut.
Tighten to 7 Nm.
8. Install the rear window wiper pivot arm retaining nut cover.
12. NOTE: The aid of an assistant in the loadspace will be required to
align the rear wiper motor to the liftgate window glass.
Make sure that the liftgate glass latch and rear wiper mounting arm
locate correctly into the liftgate latch actuator and rear wiper motor.
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14. CAUTIONS:
the vehicle.
Tighten to 8 Nm.
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Handles, Locks, Latches and Entry Systems - Luggage Compartment Lid Latch Actuator
Removal
1. Remove the luggage compartment lid latch actuator trim panel.
2. Disconnect the luggage compartment lid latch actuator electrical
connector.
3. Remove the luggage compartment lid latch actuator.
Installation
Tighten to 10 Nm.
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Handles, Locks, Latches and Entry Systems - Rear Door Lock Actuator
Removal
1. Remove the rear door trim panel. For additional information, refer
2. CAUTION: Do not touch the adhesive surface as re-bonding will be
impaired.
3. Remove the rear door window glass run retaining bracket.
4. Disconnect the rear door latch exterior handle connecting rod.
5. Detach the rear door latch.
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7. Remove the rear door latch actuator.
1. Detach the rear door latch actuator release cable.
2. Disconnect the rear door latch actuator release cable.
3. Remove the rear door latch actuator.
Installation
Tighten to 7 Nm.
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Wipers and Washers -
Front mounting arm and pivot shaft retaining bolts 8 - 71
Front wiper motor retaining screws 8 - 71
Front wiper motor shaft retaining nut 18 13 -
Front wiper arm retaining nuts 17 13 -
Rear window wiper pivot arm retaining nut 7 - 62
Rear wiper motor retaining nuts 8 - 71
Liftgate window glass latch actuator retaining bolts 8 - 71
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Wipers and Washers - Wipers and Washers
All vehicles
1 Moisture sensor
2 Wiper pivot arms/wiper blades
3 Mounting arm and pivot shaft
4 Windscreen washer jets
5 Reservoir
6 Reservoir level switch
7 Windsheild washer pump
8 Headlamp washer assembly (if equipped)
9 Rain sensor module
The wipers and washers system consist of the following components, wipers and washers, mounting arm and pivot shaft, wiper motor,
reservoir and washer pump, a headlamp washing system is available as an additional option.
The wipers have two speed control, low and high, and an intermittent wipe mode. The wipers will park automatically irrespective of their
position when the OFF position of the ignition or control switch is selected.
Within wiper and washer system the following features can be attained, adjustable interval intermittent wiping, programmable wash and
wipe sequencing and moisture sensitive wiping. The system and features are centrally controlled by the GEM (generic electronics module).
The intermittent wiping has seven speed settings, 3, 6, 9, 12, 15, 18 seconds and speed dependent. The driver also has the capacity to
adjust these via a switch with seven settings.
The programmable wash and wipe sequence is driver controlled. With a depression of the wash/wipe switch between 40 milliseconds and
1.2 seconds the wash pump will be activated for a duration of 1.2 seconds. When the wash/wipe switch is depressed for longer than 1.2
seconds the wash pump will be activated for the duration of switch depression, a 10 second duration is the maximum available. The wiping
system is automatically activated with the depression of the wash switch.
Where fitted, moisture sensitive wiping will be initiated when the vehicle is running and not in the PARK or NEUTRAL gear selection (gear
engaged on manual vehicles). The wiper switch must be in the AUTO position.
Wagon
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1 - Rear window washer jet
2 - Reservoir
3 - Windsheild and rear window washer motor
4 - Rear window wiper motor
5 - Rear wiper mounting arm
6 - Rear window wiper pivot arm/wiper blade
The rear wiper and washer system consist of the following components, wipers and washers, pivot arm, wiper motor, reservoir (uses
standard front washer reservoir) and washer pump.
The washer pump directs the washer fluid to the rear washer jet or the front washer jets via a directional valve.
The wiper motor has a rotating disk with a slot. The pivot arm has a pin. The movement of the arm is ensured through the engagement of
the pin in the slot when the glass is closed. The latch actuator is fixed with 2 fixings on the latch bracket. It is driven electrically by switch
on rear glass handle.
The rear wiper and washer is controlled by pushing the wash/wipe stalk forward, position one for the wipers and position two for the
washers.
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Wipers and Washers - Wipers and Washers
Wiper arms for damage
Wiper linkage for damage
Wiper blades for cuts
Pipe(s) for blockages
Switch(s)
Motor(s)
Relay(s)
Fuse(s)
Module
step.
3.
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Wipers and Washers - Headlamp Washer Pump
Removal
3. Remove the undertray. For additional information, refer toSection
4. Disconnect the headlamp washer supply hose.
5. Remove the headlamp washer pump.
1. Disconnect the headlamp washer pump electrical connector.
2. Remove the headlamp washer pump.
Installation
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Wipers and Washers - Rain Sensor
Removal
1. Remove the interior rear view mirror. For additional information, refer to
Section 501-09 Rear View Mirrors.
2. Remove the moisture sensor.
1. Disconnect the moisture sensor electrical connector.
2. Remove the moisture sensor.
Installation
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Wipers and Washers - Rain Sensor Module
Removal
1. Remove the cowl side trim panel. For additional information, refer
2. Remove the rain sensor module.
1. Disconnect the rain sensor module electrical connector.
2. Remove the rain sensor module.
Installation
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Wipers and Washers - Rear Window Wiper Motor
Removal
2. Disconnect the liftgate window glass latch actuator electrical connector.
3. Remove the liftgate window glass latch actuator.
4. Disconnect the rear window wiper motor electrical connector.
5. Remove the rear window wiper motor.
Installation
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1. NOTE: Do not tighten the rear window wiper motor retaining nuts at
this stage.
Install the rear window wiper motor.
2. Connect the rear window wiper motor electrical connector.
3. NOTE: Do not tighten the liftgate window glass actuator retaining bolts
at this stage.
Install the liftgate window glass latch actuator.
4. Connect the liftgate window glass latch actuator electical connector.
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7. NOTE: The aid of an assistant in the loadspace will be required to align
the rear wiper motor to the liftgate window glass.
Make sure that the liftgate glass latch and rear wiper mounting arm
locate correctly into the liftgate latch actuator and rear wiper motor.
9. Tighten the liftgate window glass actuator retaining bolts.
Tighten to 8 Nm.
10. CAUTIONS:
the vehicle.
Tighten to 8 Nm.
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Wipers and Washers - Windshield and Rear Window Washer Pump
Removal
1. Remove the right-hand front wheel and tire.
2. Detach the fender splash shield.
4. Remove the windshield and rear window washer pump.
1. Disconnect the windshield washer supply hose.
2. Disconnect the rear window washer supply hose.
3. Remove the windshield and rear window washer pump.
Installation
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Wipers and Washers - Windshield Washer Pump
Removal
3. Remove the washer pump.
1. Disconnect the washer pump electrical connector.
2. Disconnect the washer pump supply hose.
3. Remove the washer pump.
Installation
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Wipers and Washers - Windshield Washer Reservoir
Removal
1. Disconnect the ABS electrical connector.
2. Detach the ABS module.
3. Remove the ABS module support bracket retaining bolts.
4. Remove the ABS module support bracket.
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5. Remove the reservoir filler neck.
Section 501-19 Bumpers.
7. Disconnect the headlamp washer supply hose.
8. Remove the reservoir.
1. Disconnect the washer pump, headlamp washer pump and fluid
level switch electrical connectors.
2. Disconnect the washer pump supply hose.
3. Remove the reservoir.
Installation
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Wipers and Washers - Windshield Wiper Motor
Removal
1. Remove the mounting arm and pivot shaft assembly. For additional
information, refer to Mounting Arm and Pivot Shaft.
2. Remove the wiper motor.
Installation
Tighten to 8 Nm.
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Wipers and Washers - Wiper Mounting Arm and Pivot Shaft
Removal
1. Remove the plenum cover. For additional information, refer toSection
2. Detach the mounting arm and pivot shaft assembly.
3. Remove the mounting arm and pivot shaft assembly.
Installation
Tighten to 8 Nm.
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Wipers and Washers - Wiper Pivot Arm
Special Tool(s)
Remover - windscreen wiper
501-065
Removal
1. Remove the wiper arm nut covers
2. Remove the wiper arm nuts.
3. Using the special tool, detach the wiper arms.
4. Remove the wiper arms
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Installation
Tighten to 17 Nm.
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Roof Opening Panel -
Roof opening panel frame retaining bolts 9 - 80
Roof opening panel bracket retaining bolts 9 - 80
Roof opening panel motor retaining bolts 3 - 27
Roof opening panel glass retaining screws 3 - 27
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Roof Opening Panel - Roof Opening Panel
1 Roof opening panel shield
2 Lifter arms
3 Air deflector
4 Roof opening panel frame
5 Roof opening panel motor
6 Roof opening panel glass
The roof opening panel is available as an option. The roof opening panel control module controls the roof opening panel. The roof opening
panel motor and module are not available separately. The roof opening panel may be operated from the roof opening panel switch or the
global close function.
Roof Opening Panel Switch Operation
The system operates as follows from the roof opening panel switch:
Press the rear of the switch to the first detent with the roof opening glass in the closed position.
- The roof opening glass opens rearward until the roof opening panel switch is released or the roof opening panel glass reaches
the full open position.
Press the rear of the switch to the second detent with the roof opening panel glass in the closed position.
- Activates the express open feature.
- The roof opening glass will slide rearward until the roof opening panel switch is pressed in any direction or the roof opening
glass reaches the full open position.
Press the front of the switch to the first detent with the roof opening panel glass in the closed position.
- The roof opening panel glass will vent up until the roof opening panel switch is released or the roof opening panel glass reaches
the full vent up position.
Press the front of the switch to the second detent with the roof opening glass in the closed position.
- The roof opening glass will vent up until the roof opening glass reaches the full vent up position or the switch is pressed in any
direction.
Press the front of the switch to the first detent with the roof opening glass in a rearward open position.
- The roof opening glass will slide forward until the roof opening glass reaches the fully closed position or the switch is released.
Press the front of the switch to the second detent with the roof opening glass in a rearward position.
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- The roof opening glass will close until the roof opening panel switch is pressed i n any direction or the roof opening glass
reaches the full closed position.
Press the rear of the switch to the first detent with the roof opening glass in a vent up position.
- The roof opening glass will close until the roof opening panel switch is released or the roof opening glass reaches the full closed
position.
Press the rear of the switch to the second detent with the roof opening glass in a vent up position.
- The roof opening glass will close until the roof opening panel switch is pressed i n any direction or the roof opening glass
reaches the full closed position.
Global Closing Operation
The roof opening panel is included in the global close operation. This function closes the power windows and the roof opening panel
automatically. For additional information on the global close feature for the power windows, refer to Section 501-11 Glass, Frames and
Mechanisms.
The global close function is activated by:
turning the driver door lock cylinder to the lock position and holding.
Global close operation is only available with the ignition in the OFF position and the ignition key removed.
When the global close operation is selected, the roof opening panel switch is not recognized by the roof opening panel control module
throughout the operation and for five seconds after the operation is completed.
Global close will operate as follows.
With the roof opening glass in the open position, activating global close will close the roof opening glass to the flush position.
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Roof Opening Panel - Roof Opening Panel
Roof Opening Panel Control Module
Battery power is continuously supplied to the roof opening panel control module. However, the roof opening panel will only operate from the
roof opening panel switch with the ignition switch in the RUN or ACCY position. The global close feature is controlled by two circuits from
the generic electronics control module (GEM). The two circuits must be at ground potential before the roof opening panel control module will
acknowledge the roof opening panel switch. When the ignition switch is turned to RUN or ACCY, the GEM provides ground to these circuits.
The roof opening panel control module incorporates soft stops at the end of all travel positions. The roof opening panel control module
monitors the internal switches to determine the roof opening glass position and the soft stops. The internal switches are activated by the
roof opening panel motor rotation.
The roof opening panel control module supplies the power and ground to the roof opening panel motor depending on the ordered function.
Power is supplied to the roof opening panel for a maximum of 12 seconds. Under normal operation, position is monitored by the roof
opening panel control module and power is removed from the roof opening panel motor as soon as the roof opening panel reaches the
commanded position.
Roof Opening Panel Switch
Two circuits connect the roof opening panel switch to the roof opening panel control module. One circuit controls open and down operation.
The other circuit controls the tilt and close operation. The roof opening panel control module monitors these lines for voltage fluctuation to
determine which function was selected.
With the ignition switch in the RUN or ACCY position, the roof opening panel supplies a five volt reference voltage to three control lines.
Activation of the roof opening panel switch connects one or more of these lines to the common return which pulls the line low. The roof
opening panel control module will sense the line or lines being connected to the common line and carry out the appropriate function.
The express open function connects the open and tilt circuits to the common return when the roof opening panel switch is moved rearward
to the second detent position. The operator-controlled open function connects the open circuit to the common return. The close function
connects the close circuit to the common causing the roof opening panel to close from a slide or vent position.
Global Close
One circuit connects the GEM to the roof opening panel control module for this function. Global close operation for the roof opening panel is
controlled by this circuit being grounded by the GEM.
When the ignition switch is in the RUN or ACCY position, the GEM grounds this circuit allowing normal operation of the roof opening panel
from the roof opening panel switch. Global close operation is only available with the ignition in the OFF position and the ignition key
removed.
When global close operation is selected, the roof opening panel switch is not recognized by the roof opening panel control module
throughout the operation and for five seconds after the operation is completed.
With the ignition switch in the OFF position, the roof opening panel control module supplies a constant voltage to this circuit. The roof
opening panel control module monitors these lines for a low state, caused by the GEM grounding the line, to determine the ordered global
function by the GEM.
Global close is commanded by the GEM grounding control line one. Line two will remain at previous voltage.
If both lines have voltage, the roof opening panel will be inoperative.
Roof opening panel track and rail assembly
Roof opening panel glass seal
Roof opening panel glass adjustment
Roof opening panel synchronization
Central junction box (CJB) fuse 73 (15A)
Wiring harness
Roof opening panel switch
Roof opening panel motor
Roof opening panel control module
step.
3.
Symptom Chart
Refer to the Wiring Diagram manual for the connectors cited in the pinpoint tests.
SYMPTOM CHART
The roof opening panel has excessive wind noise Incorrect adjustment.
Roof opening panel glass seal.
The roof opening panel leaks Incorrect adjustment.
Roof opening panel frame drain
hoses.
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1
2
1
1
1
1
1
1
The roof opening panel is noisy during operation Roof opening panel glass.
Roof opening panel.
Roof opening panel motor.
The roof opening panel does not open or close Roof opening panel.
Roof opening panel control
module.
Roof opening panel motor.
Generic electronics module (GEM).
Roof opening panel switch.
Circuitry.
GO to the approved Jaguar diagnostic
system.
The roof opening panel does not open or close in vent
position
module.
Circuitry.
system.
The roof opening panel does not stop in flush from any
position.
Roof opening panel adjustment.
module.
The express open is inoperative Roof opening panel control
module.
Circuitry.
system.
PINPOINT TEST A : THE ROOF OPENING PANEL HAS EXCESSIVE WIND NOISE
TEST
CONDITIONS
A1: CHECK THE ROOF OPENING GLASS FIT
Cycle the roof opening glass from the full-open to the full-closed position.
Inspect the roof opening glass seal for proper fit or damage.
Is the roof opening glass seal OK?
Yes
GO to A2.
No
INSTALL a new roof opening glass seal. REFER to Seal. Test the system for normal operation.
A2: CHECK THE ROOF OPENING GLASS OPERATION
Does the roof opening glass travel to the full-open and the full-closed position?
Yes
ADJUST the roof opening glass. REFER to Roof Opening Panel Alignment. If the roof opening glass closes unevenly,
CHECK the roof opening panel syncronization. REFER to Section 100-00 General InformationMotor Synchronization
Calibration. Test the system for normal operation.
No
CHECK the roof opening panel glass seal. If necessary, INSTALL a new roof opening panel glass seal. REFER to Seal.
PINPOINT TEST B : THE ROOF OPENING PANEL LEAKS
TEST
CONDITIONS
B1: CHECK THE ROOF OPENING PANEL OPERATION
Cycle the roof opening panel glass from the full-open position to the full-closed position.
Does the roof opening glass operate smoothly and close tightly?
Yes
GO to B2.
No
CHECK the roof opening panel glass alignment. REFER to Roof Opening Panel Alignment. Test the system for
normal operation.
B2: CHECK THE ROOF OPENING PANEL FRAME DRAIN TUBES
Gain access to the roof opening panel drain tubes.
Is there blockage or damage to the roof opening panel drain tubes?
Yes
Clear the blockage or if necessary, INSTALL a new drain tube. TEST the system for normal operation.
No
GO to B3.
B3: CHECK THE ROOF OPENING PANEL GLASS SEAL
Actuate the roof opening panel glass to the full open position.
Is the roof opening panel glass seal damaged?
Yes
INSTALL a new roof opening panel glass seal. REFER to Seal. TEST the system for normal operation.
No
REPAIR as necessary. TEST the system for normal operation.
PINPOINT TEST C : THE ROOF OPENING PANEL IS NOISY DURING OPERATION
TEST
CONDITIONS
C1: CHECK THE OPERATION OF THE ROOF OPENING PANEL GLASS
Cycle the roof opening panel glass from the full-open to the full-closed position.
Is the roof opening panel glass loose?
Yes
ADJUST the roof opening panel glass. REFER toRoof Opening Panel Alignment
No
GO to C2.
C2: CHECK FOR OBSTRUCTIONS
Check the roof opening panel track and rail for foreign material, damage or looseness.
Is the roof opening panel obstructed or damaged?
Yes
REMOVE the obstruction. If necessary, INSTALL a new roof opening panel frame. REFER to Roof Opening Panel Frame.
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No
GO to C3.
C3: CHECK THE ROOF OPENING PANEL MOTOR
Does the roof opening panel motor make excessive noise?
Yes
CHECK the roof opening panel motor for correct mounting. If necessary, INSTALL a new roof opening panel motor .
REFER toRoof Opening Panel MotorTEST the system for normal operation. If the roof opening panel opens or closes
unevenly, ADJUST the roof opening panel motor syncronization. REFER toMotor SynchronizationCalibration
No
REFER to Roof Opening Panel Alignment ADJUST the roof opening panel glass as necessary. TEST the system for
normal operation.
PINPOINT TEST D : THE ROOF OPENING PANEL DOES NOT STOP IN FLUSH FROM ANY POSITION
TEST
CONDITIONS
D1: CHECK THE ROOF OPENING PANEL GLASS ADJUSTMENT
Check the roof opening panel glass alignment. For additional information, refer to Roof Opening Panel Alignment.
Is the roof opening panel glass adjusted correctly?
Yes
GO to D2.
No
ADJUST the roof opening panel glass as necessary. TEST the system for normal operation.
D2: CHECK THE ROOF OPENING GLASS SEAL
Inspect the roof opening panel glass seal for looseness, damage and correct installation.
Is the roof opening panel glass seal OK and installed correctly?
Yes
GO to D3.
No
REPAIR or INSTALL a new roof opening panel glass seal as necessary. For additional information, refer to Seal. TEST
D3: CHECK FOR OBSTRUCTION IN THE ROOF OPENING PANEL
Inspect the roof opening panel assembly for obstructions in the track.
Are any obstructions found?
Yes
REMOVE the obstruction. If necessary, INSTALL a new roof opening panel track and rail assembly. For additional
information, refer to Roof Opening Panel Frame. TEST the system for normal operation.
No
INSTALL a new roof opening panel control module. For additional information, refer toRoof Opening Panel Motor
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Roof Opening Panel - Motor Synchronization
General Procedures
New Roof Opening Panel Motor Synchronization Procedure
NOTE: The roof opening panel and roof opening panel motor must be installed and the roof opening panel alignment checked prior to
synchronizing the motor.
NOTE: This procedure is for a new roof opening panel motor.
1. Operate the roof opening panel to the fully vent position.
2. Release the roof opening panel control switch, press the roof opening
panel control switch again in the same direction within 0.5 seconds and
hold until the glass panel stops after a complete opening and closing
cycle.
Roof Opening Panel De-Synchronization Procedure
NOTE: This procedure is to be followed when the roof opening panel motor is detached or removed from the roof opening panel and before
it is re-installed.
1. Connect the roof opening panel motor electrical connector.
2. Connect the roof opening panel control switch electrical connector.
3. Operate the roof opening panel control switch to the vent position until
the roof opening panel motor stops.
4. Release the roof opening panel control switch. Operate the roof opening
panel control switch again in the same direction until the roof opening
panel motor stops.
5. Release the roof opening panel control switch, operate the roof opening
panel control switch within 0.5 seconds in the same direction and hold
for 30 seconds.
6. After 30 seconds the roof opening panel motor will start to turn in one
direction.
7. Operate the roof opening panel control switch in the opposite (open)
direction. The de-synchronization procedure is successful if the roof
opening panel motor does not turn.
De-Synchronized Roof Opening Panel Synchronization Procedure
NOTE: The roof opening panel and roof opening panel motor must be installed and the roof opening panel alignment checked prior to
synchronizing the motor.
NOTE: This procedure is for a roof opening panel motor that has been previously installed and has been de-synchronized.
1. Operate the roof opening panel to the fully vent position.
2. Release the roof opening panel control switch, press the roof opening
panel control switch again in the same direction and hold for 30 seconds
until the glass moves slightly.
3. Release the roof opening control switch, press the roof opening panel
control switch again within 0.5 seconds in the same direction until the
glass panel stops after a complete opening and closing cycle.
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Roof Opening Panel - Roof Opening Panel Alignment
General Procedures
1. Place a suitable 1.0 - 1.2 mm thick plastic spacer between the roof
opening panel and the roof panel.
2. Adjust the rear edge of the roof opening panel.
1. Loosen the rear screws on both sides.
2. Push the rear edge up/down to give correct alignment (flush to
+ 1 mm).
3. Adjust the front edge of the roof opening panel.
1. Loosen the front screws on both sides.
2. Push the front edge up/down to give correct alignment (flush
to - 1 mm).
4. Tighten to 3 Nm.
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Roof Opening Panel - Air Deflector
Removal
1. Move the roof opening panel glass fully rearward.
2. Detach the air deflector.
Installation
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Roof Opening Panel - Lifter Arms
Removal
1. Remove the roof opening panel glass. For additional information, refer
to Roof Opening Panel Glass.
2. Detach the control arm.
3. Remove the lifter arm retaining plate.
4. Detach the lifter arm.
5. Remove the lifter arm.
Installation
2. Check, and if necessary, adjust the roof opening panel alignment. For
additional information, refer to Roof Opening Panel Alignment.
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Roof Opening Panel - Roof Opening Panel Control Switch
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Roof Opening Panel - Roof Opening Panel Drain Hose
Removal
1. Detach the rear quarter trim panel.
2. Detach the drain hose from the retaining clip.
3. Detach the drain hose from the grommet.
4. Remove the headliner. For additional information, refer toSection
5. Detach the drain hose from the retaining clip.
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6. Remove the drain hose.
Installation
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Roof Opening Panel - Roof Opening Panel Frame
Removal
2. Detach the roof opening panel shield.
1. Position the center of the roof opening panel shield upwards.
2. Detach the roof opening panel shield guide pads.
3. Remove the roof opening panel shield.
Rotate the roof opening panel shield.
4. Remove the headliner. For additional information refer to Section
5. Disconnect the roof opening panel motor electrical connector.
6. Detach the roof opening panel front drain hoses.
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7. Detach the roof opening panel rear drain hoses.
8. Detach the roof opening panel frame.
9. Remove the roof opening panel frame retaining brackets.
10. CAUTION: Take care to support roof opening panel frame as final
bolts are removed.
Detach the roof opening panel frame.
11. Remove the roof opening panel frame.
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12. Remove the roof opening panel motor.
14. Detach the control arms.
15. Remove the lifter arm retaining plates.
16. Detach the lifter arms.
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17. Remove the lifter arms.
Installation
Tighten to 9 Nm.
2. Tighten to 9 Nm.
3. Tighten to 9 Nm.
4. Tighten to 3 Nm.
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5. CAUTION: If motor oscillation is detected, loosen the motor
screws, operate the roof opening panel, then retighten the motor screws.
If necessary repeat this procedure.
Syncronize the roof opening panel motor. Refer to Motor Synchronization
Calibration.
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Roof Opening Panel - Roof Opening Panel Glass
Removal
NOTE: Make sure the roof opening panel glass is in the closed position.
1. Remove the roof opening panel glass screws.
2. Remove the roof opening panel glass.
Installation
Tighten to 3 Nm.
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Roof Opening Panel - Roof Opening Panel Motor
Removal
2. Detach the roof opening panel motor.
3. Remove the roof opening panel motor.
Installation
1. CAUTION: If motor oscillation is detected, loosen the motor
screws, operate the roof opening panel, then retighten the motor screws.
If necessary repeat this procedure.
Syncronize the roof opening panel motor. Refer to Motor Synchronization
Calibration.
Tighten to 3 Nm.
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Roof Opening Panel - Roof Opening Panel Shield
Removal
1. Partially open the roof opening panel.
2. Detach the front of the roof opening panel shield.
1. Position the center of the roof opening panel shield
downwards.
2. Position the roof opening panel shield forwards.
3. Fully open the roof opening panel.
4. Detach the roof opening panel shield.
1. Position the center of the roof opening panel shield upwards.
2. Detach the roof opening panel shield guide pads.
5. Remove the roof opening panel shield.
Rotate the roof opening panel shield.
Installation
1. CAUTION: To prevent damage to the roof opening panel shield use
a steel rule to compress the guide pads.
To install reverse the removal procedure.
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Roof Opening Panel - Roof Opening Panel Weatherstrip
Removal
2. Remove the roof opening panel glass seal.
Installation
1. CAUTION: Make sure the roof opening panel glass seal is fully
seated in the glass channel.
Position the roof opening panel seal seam in the center of the rear
facing side of the roof opening glass.
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Bumpers -
Front bumper cover upper securing bolts 7 5 -
Front bumper cover side securing bolts 7 5 -
Rear bumper cover side securing nuts 7 5 -
Rear bumper cover securing nuts 7 5 -
Rear bumper securing bolts 17 13 -
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Bumpers - Bumpers
This vehicle is fitted with a chassis mounted aluminium beam and is covered by a one piece color co-ordinated front bumper cover which
incorporates the energy absorbing foam. The bumper construction includes air management and brake cooling ducts. The fog lamps are
mounted via brackets to the bumper covers. Chrome or body color inserts, side marker lights/reflex (Federal specification vehicles only), and
a color co-ordinated removable cover for towing eye access are fitted as standard. Telescopic headlamp washers are optional. The color
co-ordinated parking aid sensors are mounted through the bumper cover and are optional with the front parking aid system.
The rear bumper beam is of aluminium construction and is covered by a two piece colour co-ordinated rear bumper cover which incorporates
the energy absorbing foam and lower black out panel. Chrome or body color inserts are fitted as standard, and on 4-door vehicles side
marker lights/reflex are fitted as standard to Federal specification vehicles. The parking aid sensors are mounted in the lower black out
panel and are optional with the parking aid system.
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Bumpers - Front Bumper Cover
Removal
All vehicles
1. Remove the radiator splash shield retaining bolts.
Detach the wheel arch liner.
3. Disconnect the bumper wiring harness electrical connector.
Detach the bumper cover.
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Apply suitable tape to the bumper cover to prevent damage to the
bumper cover.
Reposition the headlamp washers to the fully open position.
Remove the headlamp washer cover.
All vehicles
Detach the side of the bumper cover from the retaining clips.
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9. CAUTION: Make sure the bumper cover is supported before
removing the securing bolts.
Remove the bumper cover.
Remove the bumper cover securing bolts.
Installation
Tighten to 7 Nm.
2. Tighten to 7 Nm.
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Bumpers - Front Bumper Cover Insert
Removal
1. Remove the front bumper cover. For additional information, refer
toSection 501-19 Bumpers.
2. Remove the energy absorbing foam.
1. Remove the energy absorbing foam retaining clips.
3. Remove the bumper insert retaining clips.
4. Using a suitable thin lever to avoid damaging the paintwork,
progressively ease the moulding away from the front bumper.
Installation
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Bumpers - Rear Bumper4-Door
Removal
1. Remove the rear bumper cover. For additional information, refer to
Bumper CoverRear .
2. Remove the bumper insulator.
3. Remove the rear bumper.
Installation
Tighten to 17 Nm,
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Bumpers - Rear BumperWagon
Removal
1. Remove the rear bumper cover.
For additional information, refer to: Rear Bumper Cover - Wagon (501-19
Remove the rear bumper insulators.
3. Remove the rear bumper retaining bolts.
4. Remove the rear bumper.
Installation
Tighten to 17 Nm,
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Bumpers - Rear Bumper Cover4-Door
Removal
All Vehicles
2. Detach the rear wheel arch liner.
3. Detach the side of the bumper cover.
4. Detach the boot liner.
5. Remove the luggage compartment rear trim panel.
6. Remove the spare wheel.
Vehicles with parking aid
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All vehicles
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removing the securing nuts.
Remove the bumper cover securing nuts.
13. Remove the bumper cover.
Installation
2. Tighten to 7 Nm.
3. Tighten to 7 Nm.
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4. Tighten to 7 Nm.
5. Tighten to 7 Nm.
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Bumpers - Rear Bumper CoverWagon
Removal
All Vehicles
Detach both rear fender splash shields.
Detach the bumper cover.
4. Detach the right-hand bumper cover.
5. Remove the rear lamp assemblies.
For additional information, refer to: Rear Lamp Assembly - Wagon
(417-01 Exterior Lighting, Removal and Installation).
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7. Detach the load space floor covering.
11. Disconnect the navigation system module electrical connectors (if
equipped).
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12. Disconnect the compact disc (CD) changer electrical connectors (if
equipped).
13. Disconnect the voice activated control (VACM) module electrical
connectors (if equipped).
14. Disconnect the cellular phone module electrical connectors (if
equipped).
15. Detach the bumper cover.
16. Remove the right-hand front retaining hook.
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17. Detach the right-hand loadspace side trim panel.
18. Remove the right-hand loadspace side trim panel.
19. Disconnect the subwoofer enclosure electrical connector (if equipped) .
20. Remove the subwoofer enclosure (if equipped).
21. Detach the bumper cover.
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removing the retaining nuts.
Remove the bumper cover retaining nuts.
Vehicles with parking aid
All vehicles
25. Remove the bumper cover.
Installation
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2. Tighten to 4 Nm.
3. Tighten to 4 Nm.
4. Tighten to 4 Nm.
5. Tighten to 4 Nm.
6. Tighten to 4 Nm.
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7. Tighten to 8 Nm.
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Bumpers - Rear Bumper Cover Insert4-Door
Removal
1. Remove the rear bumper cover. For additional information, refer
toSection 501-19 Bumpers.
1. Remove the energy absorbing foam retaining clips.
3. Remove the bumper insert retaining clips.
progressively ease the moulding away from the front bumper.
Installation
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Bumpers - Rear Bumper Cover InsertWagon
Removal
1. Remove the rear bumper cover.
For additional information, refer to: Rear Bumper Cover - Wagon (501-19
2. Detach the bumper cover insert.
progressively ease the bumper cover insert away from the bumper cover.
Installation
1. NOTE: Attach the bumper cover insert to the front of the bumper cover
and install towards the rear.
Install the bumper cover insert.
2. Make sure the bumper cover insert tangs are correctly seated.
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Safety Belt System -
Front safety belt buckle and pretensioner retaining bolt 50 37 -
Front safety belt lower anchor retaining bolt 55 41 -
Front safety belt upper retaining bolt 25 18 -
Front safety belt guide retaining bolt 5 - 44
Front safety belt retractor retaining bolt 55 41 -
Front safety shoulder height adjuster retaining bolts 25 18 -
Rear safety belt anchor retaining bolts 55 41 -
Rear safety belt and buckle retaining bolt 55 41 -
Rear safety belt retractor retaining bolt 55 41 -
Rear center safety belt retractor retaining bolt - 4-Door 55 41 -
Rear center safety belt retractor retaining bolt - Wagon 38 28 -
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Safety Belt System - Safety Belt System
WARNINGS:
any air bag occupant restraints system (ORS) components. To deplete the backup power supply energy, disconnect the battery ground cable
and wait one minute. Failure to follow this instruction may result in personal injury.
Never probe the connectors on the air bag module or pretensioners. Doing so may result in deployment. Failure to follow this
All safety belt assemblies including retractors, buckles, front safety belt buckle support assemblies (slider bar), if equipped, child
safety seat tether brackets (if equipped) and attaching hardware should be inspected after any collision. New safety belt assemblies should
be fitted unless a qualified technician finds the assemblies, show no damage and operate correctly. New safety belt assemblies should also
be fitted where safety belt assemblies not in use during a collision, are inspected and damage or incorrect operation is noted. Failure to
CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result.
WARNING: All vehicles fitted with the passenger air bag from the factory have a WARNING sticker attached to the instrument panel,
PROHIBITING the use of rear facing child seats in the front seating position. Failure to follow this instruction may result in personal injury.
NOTE: The front seat belts, which incorporate the seat belt retractors and pretensioners are supplied as an assembly and not serviceable
components.
The safety belt system fitted to the vehicle utilizes the conventional lap and diagonal three point fixing. The front and rear safety belts use
a conventional static type buckle which is attached to the seat frame of each front seat and directly to the floor pan underneath the rear
seats.
The safety belt buckle and pretensioner which is attached to the driver seat is fitted with a switch, which is connected through a wiring
harness to a warning indicator which is housed within the instrument cluster. When the ignition is first turned on the warning indicator will
illuminate only if the safety belt is not fastened. If the safety belt is fastened before the ignition is turned on the circuit is broken and the
indicator will remain off. The safety belt buckle pretensioners will deploy at the same time as the front or side air bags. The air bag control
module receives information on the status of the safety belt buckles from a switch contained in the buckle.
The front safety belt retractors incorporate a load limiting device, which reduces occupant injury in the event of a crash. The safety belt
retractors, which are mounted within the base of the 'B' pillars, incorporate a torsion bar load limiting device. This device consists of a
retractor reel which is mounted onto a spindle (torsion bar) which once the sensor has locked the retractor reel and a predetermined load is
applied, twists and allows additional webbing into the system. The deceleration force required to initiate this sequence is approximately the
same as that required to initiate air bag deployment. The torsion bar load limiting device will only react if the safety belt is in use at the
time of the impact.
It should be considered that during any event that utilizes the full capability of the safety belts, the webbing may have been elongated and
the torsion bar may have twisted. For this reason, if a vehicle is involved in an accident which results in the deployment of the airbag (s),
all the safety belts that were in use at the time of the accident MUST NOT be reused, NEW safety belts MUST be installed.
EMERGENCY LOCKING RETRACTOR (ELR)
The retractors in all seat positions feature ELR. During any period of sudden deceleration, or under lateral load when cornering at speed, a
sensor weight within the safety belt retractor moves a locking pawl against the teeth on the retractor reel, which then locks the retractor
preventing any further release of webbing. As soon as the load applied onto the retractor through the safety belt webbing is removed the
locking pawl releases the retractor reel and normal movement is returned to the retractor.
AUTOMATIC LOCKING RETRACTOR (ALR)
Automatic Locking Retractors (ALR) are not fitted in all markets (currently only in the U.S.A., Dominican Republic and Mexico) and are
installed in all passenger seat positions. The safety belt webbing on these are clearly marked to show their operating feature. The ALR
feature is initiated by pulling all of the webbing from the retractor with the buckl e fastened, when the webbing is then released as it
retracts the retractor locks allowing travel in only one plane thus producing a fixed length restraint and preventing the safety belt from
introducing slack, making any child seat it may be restraining insecure. The ALR mode of the retractor is disengaged by allowing the
unfastened webbing to fully retract on to the reel.
BELT MINDER - JAPAN ONLY - VEHICLES FROM 2009MY
The belt minder function is an additional warning to the seat belt warning reminder for the driver's seat only. Under conditions where the
driver is unbelted or becomes unbelted and the vehicle is moving above 10 km/h (6 mph) then an additional warning (generated by the GEM
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(generic electronic module)) of an intermittent tone will start or resume accompanied by the seat belt warning lamp flashing in the
instrument cluster. The intermittent tone and flashing lamp will last for 10 seconds, followed by a 10 second period with no tone or flashing
lamp. This cycle of 10 seconds on and 10 seconds off is repeated for up to 190 seconds. The warnings will stop when the driver has the seat
buckle fastened or the vehicle speed is less than 5 km/h (3 mph) .
The RCM (restraints control module) monitors the status of the driver's seat buckle and transmits this status to the GEM. The GEM uses the
seat buckle status and compares it with vehicle speed and driver seat occupancy (ignition on signal determines driver's seat is occupied). If
the driver's seat belt is not buckled and the vehicle speed is above 10 km/h (6 mph) then the GEM initiates the belt minder warning.
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Safety Belt System - Safety Belt System
Visual inspection
Damaged/frayed webbing
Damaged buckles
Damaged tongues
3. If the fault is not visually evident determine the symptom(s) and proceed to the diagnostic trouble code (DTC) flash code index. 3.
Safety information
WARNINGS:
any air bag SRS components. To deplete the backup power supply energy, disconnect the battery ground cable and wait for one minute.
Always wear safety glasses when repairing an air bag SRS vehicle and when handling an air bag module. Failure to follow this
1. These warnings should be observed whenever working on the SRS and/or it's components. 1.
Flash codes
Self check
1. Turn the ignition switch to the ON position. 1.
2. Observe the airbag warning light function. 2.
Warning light ON solid for six seconds.
Warning light goes off and stays off.
Fault on system
Warning light goes off for two seconds.
Warning light flashes the appropriate number of times for the fault logged (see below).
The sequence is repeated five times.
Warning light stays ON until the ignition is switched OFF.
Example
Flash code 16 would be shown as lamp ON for one occurence of 0.5 seconds, then lamp OFF for one second, followed by six occurences of
lamp flashing ON/OFF for 0.5 seconds each (1 - 6).
Poor Retraction
WARNINGS:
In the event of an incident in which the air bags have been deployed, ALL safety belts that were in use at the time of the incident
must be removed and new safety belts must be installed. Failure to follow this instruction may result in personal injury.
After five incidents involving the deployment of SRS components, the restraints control module must be replaced. Failure to follow
If a safety belt does not retract correctly, check that the anchor covers and trim bezels are correctly installed and not rubbing against the
safety belt webbing. Where necessary, check that the safety belt webbing is not rubbing at one end of the retractor cover slot and , if so,
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correct by loosening the retaining bolt, aligning the retractor to centralize the safety belt webbing and retighten the bolt.
The vehicle is equipped with two front and three rear inertia reel safety belts. These safety belts are dual sensitive which means that they
have:
a vehicle motion sensor, which locks the safety belt webbing under braking, cornering, on steep hills and in adverse camber
conditions
a webbing motion sensor, which locks when the safety belt webbing is quickly extracted.
Both systems should be fully operational and can be checked by the tests below.
Vehicle Motion Sensor Test
Either of the following two procedures may be used to check correct operation of the vehicle motion sensor.
Both methods require two people, but note that people of larger than normal size should not be asked to conduct these tests. This is to
avoid the possibility of a fully unrolled safety belt webbing being mistaken for a correctly locked safety belt retractor.
Test Method 1 (braking)
WARNING: It is important that during this test, the wearer allows the safety belt to provide the restraint, the wearer should not
attempt to anticipate the sudden deceleration. However, both the driver and the passenger must prepare themselves for the possibility that
the safety belt will not lock. Failure to follow this instruction may result in personal injury.
Select a suitable road. Make sure that the road is clear and that full visibility is maintained at all times.
Both driver and passenger should adopt normal, comfortable seating positions, with safety belts worn in a normal fashion.
Do not exceed 6 mph (10 km/h) for this test.
Make sure that all passengers are aware of when the driver will brake.
Apply the foot brake sharply to stop the vehicle. If the vehicle motion sensitive lock mechanism is operating correctly, the safety
belt webbing will lock and restrain the wearer.
Conduct the test twice in each front and rear passenger seat position.
Any safety belt retractor which does not restrain the wearer during this test must not be reused. A new safety belt must be
installed.
Test Method 2 (turning circle)
This method requires a flat open area, sufficient for the vehicle to be driven in a continuous circle on full lock.
The passenger should occupy a rear seat with the safety belt correctly adjusted.
With the steering on full lock, drive the vehicle in a continuous circle at 10 mph (16 km/h). Do not exceed 10 mph (16 km/h).
When the speed is stable, the passenger should attempt to slowly extract the safety belt webbing from each safety belt retractor in
turn. If the vehicle motion sensitive lock mechanism is operating correctly, it will not be possible to extract the webbing.
Any safety belt retractor from which it is possible to extract the webbing during this test must not be used. A new safety belt must
be installed.
Safety Belt Webbing Sensor Test
With the vehicle stationary and on level ground take firm hold of the safety belt webbing and pull out quickly. The retractor should lock
within 0.25 metre (10 inches), preventing further webbing pay out. Any safety belt retractor from which it is possible to extract further
webbing must not be used. A new safety belt must be installed.
Diagnostic trouble code (DTC) flash code index
B2292 Safety belt pretensioner
circuit fault
Pretensioner resistance low on squib For driver side pretensioner circuit
tests, GO to Pinpoint Test A.
Flash code 33 - driver
side
PID $5954/5961 (bit 7)
circuit fault
Pretensioner circuit; open circuit For driver side pretensioner circuit
tests, GO to Pinpoint Test A. Flash code 33 - driver
side
PID $5954/5961 (bit 6)
circuit fault
Pretensioner circuit; short circuit to
battery
For driver side pretensioner circuit
tests, GO to Pinpoint Test A.
side
PID $5954/5961 (bit 5)
circuit fault
ground
For driver side pretensioner circuit
tests, GO to Pinpoint Test A. Flash code 33 - driver
side
PID $5954/5961 (bit 4)
circuit fault
Pretensioner resistance low on squib For passenger side pretensioner circuit
tests, GO to Pinpoint Test B.
Flash code 34 - front
passenger side
PID $5954/5961 (bit 3)
circuit fault
Pretensioner circuit; open circuit For passenger side pretensioner circuit
tests, GO to Pinpoint Test B. Flash code 34 - front
passenger side
PID $5954/5961 (bit 2)
circuit fault
battery
For passenger side pretensioner circuit
tests, GO to Pinpoint Test B.
Flash code 34 - front
passenger side
PID $5954/5961 (bit 1)
circuit fault
ground
For passenger side pretensioner circuit
tests, GO to Pinpoint Test B. Flash code 34 - front
passenger side
PID $5954/5961 (bit 0)
B2292 Safety belt reel Retractor pretensioner resistance low on For driver side reel pretensioner circuit
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1
2
3
4
5
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7
8
pretensioner circuit fault squib tests, GO to Pinpoint Test E. Flash code 38 - driver
side
PID $5954/5961 (bit 7)
B2292 Safety belt reel
pretensioner circuit fault
Retractor pretensioner circuit; open
circuit
For driver side reel pretensioner circuit
tests, GO to Pinpoint Test E. Flash code 38 - driver
side
PID $5954/5961 (bit 6)
Retractor pretensioner circuit; short
circuit to battery
side
PID $5954/5961 (bit 5)
circuit to ground
side
PID $5954/5961 (bit 4)
Retractor pretensioner resistance low on
squib
For passenger side reel pretensioner
circuit tests, GO to Pinpoint Test F. Flash code 39 - front
passenger side
PID $5954/5961 (bit 3)
Retractor pretensioner circuit; open
circuit
passenger side
PID $5954/5961 (bit 2)
circuit to battery
passenger side
PID $5954/5961 (bit 1)
circuit to ground
passenger side
PID $5954/5961 (bit 0)
B2434 Driver safety belt switch
circuit fault
Driver safety belt switch circuit: short
circuit to ground
For driver safety belt switch circuit
tests, GO to Pinpoint Test C.
Flash code 51
circuit fault
Driver safety belt switch circuit:
resistance out of range
Flash code 51
circuit fault
Driver safety belt switch circuit; open
circuit or short circuit to battery
Flash code 51
B2692 Passenger safety belt
switch circuit fault
Passenger safety belt switch circuit;
open circuit or short circuit to battery
For passenger safety belt switch circuit
tests, GO to Pinpoint Test D.
Flash code 52
B2438 Front passenger safety belt
Passenger safety belt switch circuit:
Flash code 52
B2439 Front passenger safety belt
Passenger safety belt switch circuit:
resistance out of range
Flash code 52
Additional tests for changes to be introduced
B2909 Front passenger belt tension
sensor fault
Belt tension sensor circuit; open circuit or
short circuit to battery
For belt tension sensor circuit tests, GO
to Pinpoint Test G. Flash code 16
PID $5939/593A
(bit 7)
B2909 Front passenger belt tension
sensor fault
Belt tension sensor circuit; short circuit to
ground
For belt tension sensor circuit tests, GO
to Pinpoint Test G. Flash code 16
PID $5939/593A
(bit 5)
Pinpoint tests
PINPOINT TEST A : B2292 (FLASH CODE 33): DRIVER SAFETY BELT PRETENSIONER CIRCUIT FAULT
WARNING: DO NOT attempt to measure the resistance across the pretensioner. Failure to follow this instruction may result in
personal injury.
A1: CHECK THE SAFETY BELT PRETENSIONER CIRCUIT WITH A SIMULATOR IN PLACE
WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing
or replacing any air bag SRS components. To deplete the backup power supply energy, disconnect the battery ground cable and wait for one
minute. Failure to follow this instruction may result in personal injury.
Wait one minute for the backup power supply to deplete.
Disconnect the driver safety belt pretensioner connector, CA65.
Connect the simulator in place of the pretensioner.
Clear the DTC.
Recheck the DTCs and flash codes.
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2
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1
1
1
1
1
1
2
3
Are there any DTCs and/or flash codes set with the simulator(s) in place?
Yes
GO to A2.
No
INSTALL a new pretensioner.
REFER to: Safety Belt Buckle and Pretensioner (501-20A Safety Belt System, Removal and Installation).
A2: CHECK THE PRETENSIONER SUPPLY CIRCUIT FOR HIGH RESISTANCE
Disconnect the simulator.
Disconnect the RCM connector,
For vehicles with 2.0L engine;
CA165.
For vehicles with 2.5/3.0L engine;
CA450.
Measure the resistance between the RCM connector, pin 31 (WR) and CA65, pin 07 (WR)
Yes
No
GO to A3.
A3: CHECK THE PRETENSIONER GROUND CIRCUIT FOR HIGH RESISTANCE
Measure the resistance between the RCM connector, pin 32 (NW) and CA65, pin 08 (NW).
Yes
No
GO to A4.
A4: CHECK THE PRETENSIONER SUPPLY CIRCUIT FOR SHORT CIRCUIT TO BATTERY
Measure the resistance between CA65, pin 07 (WR) and the battery positive terminal.
Yes
REPAIR the short circuit. For additional information, refer to the wiring diagrams. Clear the DTC, test the
No
GO to A5.
A5: CHECK THE PRETENSIONER GROUND CIRCUIT FOR SHORT CIRCUIT TO BATTERY
Measure the resistance between CA65, pin 08 (NW) and the battery positive terminal.
Yes
No
GO to A6.
A6: CHECK THE PRETENSIONER SUPPLY CIRCUIT FOR SHORT CIRCUIT TO GROUND
Measure the resistance between CA65, pin 07 (WR) and GROUND.
Yes
No
GO to A7.
A7: CHECK THE PRETENSIONER GROUND CIRCUIT FOR SHORT CIRCUIT TO GROUND
Measure the resistance between CA65, pin 08 (NW) and GROUND.
Yes
No
PINPOINT TEST B : B2292 (FLASH CODE 34): PASSENGER SAFETY BELT PRETENSIONER CIRCUIT FAULT
personal injury.
B1: CHECK THE SAFETY BELT PRETENSIONER CIRCUIT WITH A SIMULATOR IN PLACE
Disconnect the passenger safety belt pretensioner connector, CA70
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7
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2
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1
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1
1
Clear the DTC.
Yes
GO to B2.
No
B2: CHECK THE PRETENSIONER SUPPLY CIRCUIT FOR HIGH RESISTANCE
CA165.
CA450.
Measure the resistance between the RCM connector, pin 33 (GO) and CA70, pin 07 (GO)
Yes
No
GO to B3.
B3: CHECK THE PRETENSIONER GROUND CIRCUIT FOR HIGH RESISTANCE
Measure the resistance between the RCM connector, pin 34 (BR) and CA70, pin 08 (BR).
Yes
REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. Clear the DTC, test
No
GO to B4.
B4: CHECK THE PRETENSIONER SUPPLY CIRCUIT FOR SHORT CIRCUIT TO BATTERY
Measure the resistance between CA70, pin 07 (GO) and the battery positive terminal.
Yes
No
GO to B5.
B5: CHECK THE PRETENSIONER GROUND CIRCUIT FOR SHORT CIRCUIT TO BATTERY
Measure the resistance between CA70, pin 08 (BR) and the battery positive terminal.
Yes
No
GO to B6.
B6: CHECK THE PRETENSIONER SUPPLY CIRCUIT FOR SHORT CIRCUIT TO GROUND
Measure the resistance between CA70, pin 07 (GO) and GROUND.
Yes
No
GO to B7.
B7: CHECK THE PRETENSIONER GROUND CIRCUIT FOR SHORT CIRCUIT TO GROUND
Measure the resistance between CA70, pin 08 (BR) and GROUND.
Yes
No
PINPOINT TEST C : B2434, B2435, B2691 (FLASH CODE 51): DRIVER SAFETY BELT SWITCH CIRCUIT FAULT
C1: CHECK THE DRIVER SAFETY BELT SWITCH SUPPLY CIRCUIT FOR HIGH RESISTANCE
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3
4
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4
5
1
CA165.
CA450.
Disconnect the driver safety belt switch connector, CA65.
Measure the resistance between CA65, pin 14 (O) and the RCM connector, pin 25 (O).
Yes
No
GO to C2.
C2: CHECK THE DRIVER SAFETY BELT SWITCH SUPPLY CIRCUIT FOR SHORT CIRCUIT TO BATTERY
Measure the resistance between CA65, pin 14 (O) and the battery positive terminal.
Yes
No
GO to C3.
C3: CHECK THE DRIVER SAFETY BELT SWITCH SUPPLY CIRCUIT FOR SHORT CIRCUIT TO GROUND
Measure the resistance between CA65, pin 14 (O) and GROUND.
Yes
No
GO to C4.
C4: CHECK THE DRIVER SAFETY BELT SWITCH GROUND CIRCUIT FOR HIGH RESISTANCE
Yes
No
GO to C5.
C5: CHECK THE DRIVER SAFETY BELT SWITCH GROUND CIRCUIT FOR SHORT CIRCUIT TO BATTERY
Measure the resistance between CA65, pin 13 (B) and the battery positive terminal.
Yes
No
INSTALL a new driver safety belt switch,
Clear the DTC, test the system for normal operation. If the DTC is repeated, install a new RCM,
Installation).
PINPOINT TEST D : B2438, B2439, B2692 (FLASH CODE 52): PASSENGER SAFETY BELT SWITCH CIRCUIT FAULT
D1: CHECK THE PASSENGER SAFETY BELT SWITCH SUPPLY CIRCUIT FOR HIGH RESISTANCE
CA165.
CA450.
Disconnect the passenger safety belt switch connector, CA70.
Measure the resistance between CA70, pin 14 (R) and the RCM connector, pin 26 (R).
Yes
No
GO to D2.
D2: CHECK THE PASSENGER SAFETY BELT SWITCH SUPPLY CIRCUIT FOR SHORT CIRCUIT TO BATTERY
Measure the resistance between CA70, pin 14 (R) and the battery positive terminal.
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1
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1
2
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7
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1
2
3
4
5
1
Yes
No
GO to D3.
D3: CHECK THE PASSENGER SAFETY BELT SWITCH SUPPLY CIRCUIT FOR SHORT CIRCUIT TO GROUND
Measure the resistance between CA70, pin 14 (r) and GROUND.
Yes
No
GO to D4.
D4: CHECK THE PASSENGER SAFETY BELT SWITCH GROUND CIRCUIT FOR HIGH RESISTANCE
Yes
No
GO to D5.
D5: CHECK THE PASSENGER SAFETY BELT SWITCH GROUND CIRCUIT FOR SHORT CIRCUIT TO BATTERY
Yes
No
INSTALL a new passenger safety belt switch,
Installation).
PINPOINT TEST E : B2292 (FLASH CODE 38) DRIVER SIDE RETRACTOR PRETENSIONER CIRCUIT FAULT
personal injury.
E1: CHECK THE RETRACTOR PRETENSIONER CIRCUIT WITH A SIMULATOR IN PLACE
Disconnect the retractor pretensioner connector, CA421.
Clear the DTC.
Are there any DTCs and/or flash codes set with the simulator in place?
Yes
GO to E2.
No
INSTALL a new pretensioner,
REFER to: Front Safety Belt Retractor (501-20A Safety Belt System, Removal and Installation).
E2: CHECK THE RETRACTOR PRETENSIONER SUPPLY CIRCUIT FOR HIGH RESISTANCE
CA165.
CA450.
Measure the resistance between CA421, pin 01 (WR) and the RCM connector, pin 35 (WR).
Yes
No
GO to E3.
E3: CHECK THE RETRACTOR PRETENSIONER GROUND CIRCUIT FOR HIGH RESISTANCE
Measure the resistance between CA421, pin 03 (NW) and the RCM connector, pin 36 (NW).
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2
3
4
5
Yes
No
GO to E4.
E4: CHECK THE RETRACTOR PRETENSIONER SUPPLY CIRCUIT FOR SHORT CIRCUIT TO BATTERY
Measure the resistance between CA421, pin 01 (WR) and the battery positive terminal.
Yes
No
GO to E5.
E5: CHECK THE RETRACTOR PRETENSIONER GROUND CIRCUIT FOR SHORT CIRCUIT TO BATTERY
Measure the resistance between CA421, pin 03 (NW) and the battery positive terminal.
Yes
No
GO to E6.
E6: CHECK THE RETRACTOR PRETENSIONER SUPPLY CIRCUIT FOR SHORT CIRCUIT TO GROUND
Measure the resistance between CA421, pin 01 (WR) and GROUND.
Yes
No
GO to E7.
E7: CHECK THE RETRACTOR PRETENSIONER GROUND CIRCUIT FOR SHORT CIRCUIT TO GROUND
Measure the resistance between CA421, pin 03 (NW) and GROUND.
Yes
No
PINPOINT TEST F : B2292 (FLASH CODE 39) PASSENGER SIDE RETRACTOR PRETENSIONER CIRCUIT FAULT
personal injury.
F1: CHECK THE RETRACTOR PRETENSIONER CIRCUIT WITH A SIMULATOR IN PLACE
Disconnect the retractor pretensioner connector, CA422.
Clear the DTC.
Are there any DTCs and/or flash codes set with the simulator in place?
Yes
GO to F2.
No
REFER to: Front Safety Belt Retractor (501-20A Safety Belt System, Removal and Installation).
F2: CHECK THE RETRACTOR PRETENSIONER SUPPLY CIRCUIT FOR HIGH RESISTANCE
CA165.
CA450.
Measure the resistance between CA422, pin 01 (GO) and the RCM connector, pin 37 (GO).
Yes
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1
1
1
1
1
1
2
3
1
1
1
1
No
GO to F3.
F3: CHECK THE RETRACTOR PRETENSIONER GROUND CIRCUIT FOR HIGH RESISTANCE
Measure the resistance between CA422, pin 03 (BR) and the RCM connector, pin 38 (BR).
Yes
No
GO to F4.
F4: CHECK THE RETRACTOR PRETENSIONER SUPPLY CIRCUIT FOR SHORT CIRCUIT TO BATTERY
Measure the resistance between CA422, pin 01 (GO) and the battery positive terminal.
Yes
No
GO to F5.
F5: CHECK THE RETRACTOR PRETENSIONER GROUND CIRCUIT FOR SHORT CIRCUIT TO BATTERY
Measure the resistance between CA422, pin 03 (BR) and the battery positive terminal.
Yes
No
GO to F6.
F6: CHECK THE RETRACTOR PRETENSIONER SUPPLY CIRCUIT FOR SHORT CIRCUIT TO GROUND
Measure the resistance between CA422, pin 01 (GO) and GROUND.
Yes
No
GO to F7.
F7: CHECK THE RETRACTOR PRETENSIONER GROUND CIRCUIT FOR SHORT CIRCUIT TO GROUND
Measure the resistance between CA422, pin 03 (BR) and GROUND.
Yes
No
PINPOINT TEST G : C2909 (FLASH CODE 16): BELT TENSION SENSOR FAULT
TEST
CONDITIONS
G1: CHECK THE BELT TENSION SENSOR SIGNAL CIRCUIT FOR HIGH RESISTANCE
Disconnect the belt tension sensor connector, WS19.
Disconnect the occupant classification sensor connector, WS17.
Measure the resistance between WS19, pin 02 (Y) and WS17, pin A (Y).
Yes
REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. Clear the DTC, test the
No
GO to G2.
G2: CHECK THE BELT TENSION SENSOR VCC CIRCUIT FOR HIGH RESISTANCE
Measure the resistance between WS19, pin 01 (O) and WS17, pin B (O).
Yes
No
GO to G3.
G3: CHECK THE BELT TENSION SENSOR GROUND CIRCUIT FOR HIGH RESISTANCE
Measure the resistance between WS19, pin 03 (G) and WS17, pin C (G).
Yes
No
GO to G4.
G4: CHECK THE BELT TENSION SENSOR SIGNAL CIRCUIT FOR SHORT CIRCUIT TO BATTERY
Measure the resistance between WS19, pin 02 (Y) and the battery positive terminal.
Yes
REPAIR the short circuit. For additional information, refer to the wiring diagrams. Clear the DTC, test the system for
normal operation.
No
GO to G5.
G5: CHECK THE BELT TENSION SENSOR VCC CIRCUIT FOR SHORT CIRCUIT TO BATTERY
Measure the resistance between WS19, pin 01 (O) and the battery positive terminal.
Yes
normal operation.
No
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1
1
1
1
GO to G6.
G6: CHECK THE BELT TENSION SENSOR GROUND CIRCUIT FOR SHORT CIRCUIT TO BATTERY
Measure the resistance between WS19, pin 03 (G) and the battery positive terminal.
Yes
normal operation.
No
GO to G7.
G7: CHECK THE BELT TENSION SENSOR SIGNAL CIRCUIT FOR SHORT CIRCUIT TO GROUND
Measure the resistance between WS19, pin 02 (Y) and GROUND.
Yes
normal operation.
No
GO to G8.
G8: CHECK THE BELT TENSION SENSOR VCC CIRCUIT FOR SHORT CIRCUIT TO GROUND
Measure the resistance between WS19, pin 01 (O) and GROUND.
Yes
normal operation.
No
GO to G9.
G9: CHECK THE BELT TENSION SENSOR GROUND CIRCUIT FOR SHORT CIRCUIT TO GROUND
Measure the resistance between WS19, pin 03 (G) and the battery positive terminal.
Yes
normal operation.
No
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Safety Belt System - Front Safety Belt Retractor
Removal
components.
Remove the lower B-pillar trim panel for additional information, refer to
3. Detach the safety belt upper retaining bolt.
4. Remove the safety belt guide retaining bolt.
5. Remove the front safety belt retractor assembly.
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Installation
components.
Tighten to 55 Nm.
2. Tighten to 5 Nm.
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Safety Belt System - Front Safety Belt Shoulder Height Adjuster
Removal
1. Remove the upper B-pillar trim panel for additional information, refer to
2. Detach the safety belt upper retaining bolt.
3. Remove the front safety belt shoulder height adjuster retaining bolt.
Installation
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Safety Belt System - Rear Center Safety Belt Retractor4-Door
Removal
1. Remove the rear seat backrest for additional information, refer to
2. Remove the center rear safety belt and buckle.
3. Detach and remove the center rear safety belt upper trim cover.
4. Remove the parcel shelf trim panel.
5. Remove the center rear safety belt retractor.
Installation
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3. NOTE: Make sure the anti rotation pins on the body and safety belt
anchor plate are located correctly before tightening the bolt.
Tighten to 55 Nm.
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Safety Belt System - Rear Center Safety Belt RetractorWagon
Removal
1. Disassemble the rear seat backrest.
Vehicles With: 70/30 Split Seat (501-10 Seating, Removal and
Installation).
2. Detach the release cable from the rear center safety belt retractor.
3. Remove the rear center safety belt retractor.
Installation
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Safety Belt System - Rear Safety Belt Buckle
Removal
1. Remove the rear seat cushion for additional information, refer to
2. Remove the left-hand rear safety belt buckles.
3. Remove the right-hand rear safety belt and buckle.
Installation
NOTE: Make sure the anti rotation pins on the body and safety belt
Tighten to 55 Nm.
2. NOTE: Make sure the anti rotation pins on the body and safety belt
Tighten to 55 Nm.
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Safety Belt System - Rear Safety Belt Retractor4-Door
Removal
1. Remove the rear seat backrest for additional information, refer to
2. NOTE: Left-hand shown right-hand similar.
Remove the rear safety belt anchor retaining bolt.
3. Remove and detach the rear safety belt upper trim cover.
4. Remove the rear safety belt retractor trim panel.
5. Remove the rear safety belt retractor assembly.
Installation
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Tighten to 55 Nm.
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Safety Belt System - Rear Safety Belt RetractorWagon
Removal
For additional information, refer to: Rear Seat Bolster - Wagon (501-10
3. Remove the rear safety belt anchor retaining bolt.
4. Remove the rear safety belt retractor retaining bolt.
5. Remove the rear safety belt retractor.
Installation
Tighten to 55 Nm
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Safety Belt System - Safety Belt Buckle and Pretensioner
Removal
WARNINGS:
any air bag occupant restraints system (ORS) components. To deplete the backup power supply energy, disconnect the battery ground cable
and wait one minute. Failure to follow this instructions may result in personal injury.
components.
1. Disconnect the battery ground cable. For additional information, refer
toSection 414-01 Battery, Mounting and Cables.
2. Remove the front seat. For additional information, refer to Section
501-10 Seating.
3. Disconnect the safety belt pretensioner electrical connector.
4. Disconnect the safety belt buckle electrical connector.
5. Detach the safety belt buckle and pretensioner wiring harness.
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6. Remove the safety belt buckle and pretensioner.
Installation
WARNINGS:
any air bag ORS components. To deplete the backup power supply energy, disconnect the battery ground cable and wait one minute. Failure
to follow this instructions may result in personal injury.
components.
Tighten to 50 Nm.
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Supplemental Restraint System -
Description Nm Lb/Ft Lb/In
Restraints control module (RCM) retaining bolts 12 9 -
Driver air bag module retaining bolts 5 - 44
Passenger air bag module retaining bolts 9 - 80
Side air curtain module retaining bolts 9 - 80
Side impact sensor retaining bolt 12 9 -
Crash sensor retaining bolt 12 9 -
Driver lower air bag module retaining bolts 11 8 -
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Supplemental Restraint System - Air Bag Supplemental Restraint System (SRS)
WARNING: All pyrotechnic devices are dangerous. Before performing any procedures on any pyrotechnic device, read all information
contained within the Standard Workshop Practices section of this manual.
For additional information, refer to: Standard Workshop Practices (100-00 General Information, Description and Operation).
The SRS is designed to provide increased collision protection for front seat occupants in addition to that provided by the three-point safety
belt system. Safety belt use is necessary to obtain the best occupant protection and to receive the full advantages of the SRS.
Air Bag Supplemental Restraint System (SRS) Components
1 Side air curtain module
2 Restraints control module (RCM)
3 Side air curtain module
4 Side air bag module
5 Passenger air bag deactivation (PAD) indictor
6 Passenger air bag module
7 Crash sensor
8 Side impact sensor
9 Passenger weight sensor
10 Driver lower air bag module
11 Seat track position sensor
12 Driver air bag module
13 Air bag sliding contact
14 Side impact sensor
15 - Side air bag module
Restraints Control Module (RCM)
The restraints control module (RCM):
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The primary purpose of the restraints control system is to discriminate between an event that warrants supplemental restraints
system deployment and an event that does not. The air bag control module, located under the floor console, governs the operation
of the whole system and performs continual system diagnostics. Information on the severity of an impact is received from the crash
sensor. In the event of a side impact, in excess of a predetermined limit, the air bag control module will evaluate the signal received
from either of the side impact sensors against stored data and deploy the corresponding side air bag module and the side air curtain
module. In the event of a frontal impact, in excess of a predetermined limit, the air bag control module will evaluate the signal
received from the front crash sensor against stored data and deploy the front air bag modules and the safety belt buckle
pretensioners. Variations in the deployment of the front air bag modules are dependent on the status of the driver seat track
position, passenger weight sensor and the front safety belt buckles.
Driver Air bag Module
The drivers air bag module:
The driver air bag module is replaced as an assembly.
There is no routine maintenance required for this part and there are no serviceable parts.
The driver air bag module is fitted to the steering wheel, the cover forming the outer surface of the steering wheel boss. The cover
has invisible split lines molded in its surface allowing the air bag to easily exit through the cover when the system deploys.
Passenger Air Bag Module
The passenger air bag module:
The passenger air bag module is replaced as an assembly.
The passenger air bag module is located above the glove compartment behind the finish panel. The air bag control module will only
deploy the passenger air bag provided that the passenger weight sensor senses that the seat is occupied.
Deployment Door
The deployment door:
Is an integral part of the instrument panel with a textured finish.
The deployment door is tethered and moves out of the way when the air bag inflates, and hinges out of the way during deployment.
Must not be repainted for any reason.
Inflator
The inflator:
Both driver and passenger air bag inflators have a two stage inflation system, this means there are two air bag connections to be
made. The two connectors are coded to ensure that the connection is made correctly.
Receives electrical charge when the air bag sensor is activated.
Contains an igniter that converts the electrical signal to thermal energy (heat), causing the ignition of the inflator gas generant.
Inflates the air bag after the sodium azide/copper oxide combustion occurs.
Is a component of the driver air bag module and passenger air bag module and is not replaced separately.
Side Air Curtain Module
The side air curtain module:
Is replaced as an assembly.
The side air curtain modules are fixed between the A-pillar and C-pillar under the headliner and deployed at the same time as the
corresponding seat mounted side air bag. If the passenger air bag is deactivated the corresponding side air bag is also deactivated.
When deployed, the side air curtain module extends down to approximately shoulder height to protect both the front and rear
occupants heads. The side air curtain module is stabilized at the A-pillar and C-pil lar by tethers. The side curtain module uses
compressed argon to inflate the air bag.
Side Air Bag Module - Front Seat
The side air bag module:
Is replaced as an assembly.
The side air bag module is mounted in the outboard bolster of each front seat and uses compressed argon to inflate. It provides
protection for the thorax (the part of the torso between the neck and the abdomen). To ensure that the air bag emerges at the same
point, a chute has been designed into the inside of the seat trim cover and wrapped around the air bag module. In a side air bag
module deployment situation, the air bag module deploys through a stitched seam in the side bolster.
Air Bag Sliding Contact
The air bag sliding contact:
The air bag sliding contact does not contain any serviceable components.
The air bag sliding contact is mounted on the steering column, behind the steering wheel.
The air bag sliding contact continuously transfers electrical signals from the driver air bag module to the air bag sensor.
Side Impact Sensors
The side impact sensors:
The side impact sensors are mounted at the base of the B-pillars to facilitate lateral impact sensing. In the event of a side impact,
the air bag control module processes the crash data sent by the side impact sensor against stored data. The air bag control module
will deploy the side air bag and, if equipped, the side air curtain on the side the deployment request was initiated.
Crash Sensor
The crash sensor:
The front crash sensor is located under the grill opening panel to facilitate impact sensing along the longitudinal axis. The air bag
control module processes the crash data sent by the front crash sensor against stored data, and deploys the front air bags.
Seat Track Position Sensor
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The seat track position sensor:
The seat track position sensor is located on the driver seat track. The seat position sensor determines the position of the driver
seat, which is then communicated to the restraints control module. If the driver seat is in the forward position, the driver air bag
second stage is disabled.
Passenger Weight Sensor
The passenger weight sensor:
The occupant classification sensor detects, by integrated pressure sensors, the presence of a passenger or object on the seat
cushion. The occupant classification sensor cannot discriminate between a passenger and an object. The electronic control unit
processes the pressure information and, if the pressure exceeds a threshold, an occupied seat state is communicated through the
wiring harness to the air bag control module. If the seat is empty or occupied by a very light object an empty seat state is
transmitted to the air bag control module and the passenger air bag will be deactivated to avoid unnecessary repair costs. If the
seat is empty and the safety belt is buckled the passenger air bag deactivation indicator will be illuminated. The occupant
classification sensor system is not affected by the position of the passenger seat.
Driver lower air bag module
The driver lower air bag module:
The driver lower air bag module is replaced as an assembly.
The driver lower air bag module is fitted to enhance lower limb protection. The driver lower air bag module is located below the
steering wheel in the instrument panel and is retained by two bolts and two spring clips.
Passenger Air Bag Deactivation (PAD) Indictor
The Passenger air bag deactivation (PAD) Indictor:
The passenger air bag deployment door has a built in lens that displays the passenger air bag module deactivated symbol. The
symbol is backlit by the PAD indicator. The illumination of the symbol informs the front seat occupants whether or not the passenger
air bag has been deactivated by the occupancy sensing system. The PAD indicator is located under the vent finish panel in front of
the passengers seat.
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Supplemental Restraint System - Air Bag Supplemental Restraint System (SRS)
The SRS is an intelligent system, in that it deploys the appropriate airbag module for any impact event, based on information provided by
the sensors around the vehicle.
Working in conjunction with the safety belt system, the SRS will provide the maximum protection for the vehicle occupants wherever the
impact occurs.
In the event of a severe frontal impact, the restraints control module (RCM) will deploy the safety belt pretensioners and/or the front
airbags as necessary, by measuring the impact via the crash sensor and comparing the measurement against data stored in it's memory.
In the event of a side impact, the RCM uses information from the side impact sensors to determine if the thoracic and/or curtain airbags
should be deployed.
Occupancy classification sensor
In addition to determining the best deployment of the airbags from impact data, the system uses information from the occupancy
classification sensor to control the two-stage airbag used in the passenger airbag module, and relays this information to the occupants via
the passenger airbag deactivation (PAD) lamp.
PAD lamp strategy
Passenger seat status Passenger airbag status PAD lamp status
Empty OFF OFF
Empty, but safety belt fastened OFF ON
Occupied (small occupant) OFF ON
Occupied (large occupant) ON OFF
Seat track position sensor
To determine the level of deployment of the front airbag modules, the system also uses inputs from the seat track position sensor.
The system will not deploy the second stage of the airbag if the front occupants are too close to the front airbag modules.
Safety information
WARNINGS:
any air bag SRS components. To deplete the backup power supply energy, disconnect the battery ground cable and wait for one minute.
Always wear safety glasses when repairing an air bag SRS vehicle and when handling an air bag module. Failure to follow this
In the event of an incident in which the air bags have been deployed, ALL safety belts that were in use at the time of the incident
must be removed and new safety belts must be installed. Failure to follow this instruction may result in personal injury.
After five incidents involving the deployment of SRS components, the restraints control module must be replaced. Failure to follow
1. These warnings should be observed whenever working on the SRS and/or it's components. 1.
Flash codes
Self check (no fault on system)
Warning light goes off and stays off.
Fault on system
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Warning light flashes the appropriate number of times for the fault logged (see below).
The sequence is repeated five times.
Warning light stays ON until the ignition is switched OFF.
Example
Flash code 16 would be shown as lamp ON for one occurence of 0.5 seconds, then lamp OFF for one second, followed by six occurences of
lamp flashing ON/OFF for 0.5 seconds each (1 - 6).
Warning tones
In the event of a second fault occurring whilst there is a warning light fault, there will be an audible warning, initiated by the instrument
cluster.
This secondary warning will be activated when the SRS system detects any additional fault, other than a warning light fault.
The secondary warning will consist of five sets of five tone bursts, each set of five tones being separated by a five second silence.
This sequence will be repeated approximately every 30 minutes.
Preliminary inspection
Check all visible SRS components for
damage/security
Carry out self-check as above
Check fuses (for additional information, refer to the wiring diagrams)
Only after checking fuses, check connections and harnesses to SRS components for
correct fitment/damage
For module power and ground circuit tests,
REFER to: Communications Network - VIN Range: E96603->J28492 (418-00 Module
Communications Network, Diagnosis and Testing).
Diagnostic trouble code (DTC) flash code index
NOTE: Other DTCs and flash codes may be stored, relating to the safety belt system,
REFER to: Safety Belt System (501-20A Safety Belt System, Diagnosis and Testing).
DTC/Flash code Condition Possible source Action
B1231 Crash data memory
full
Restraints control
module (RCM) fault
Stored impact data
Please check part is not on any form of prior authorisation
before replacement.
Flash code 13
B1317 Battery voltage
high
Module input voltage
greater than 15 volts
Suspect charging system fault. Refer to charging system
tests.
Continuous lamp
B1318 Battery voltage low Module input voltage
less than 10.4 volts
Suspect charging system fault. Refer to charging system
tests.
Continuous lamp
B1342 RCM internal fault RCM fault Please check part is not on any form of prior authorisation
before replacement.
B1869 Note, If a system fault
occurs at the same time as a
MIL fault, a tone will sound as
well as the MIL illumination
(see 'warning tones' above).
Airbag MIL circuit
fault
Airbag MIL circuit;
open circuit, short
circuit to ground
For MIL circuit tests, GO to Pinpoint Test A.
B1870 Airbag MIL circuit
fault
Airbag MIL circuit;
short circuit to
battery
For MIL circuit tests, GO to Pinpoint Test A.
B1884 Passenger airbag
deactivated (PAD)
indicator lamp
circuit fault
PAD indicator lamp
circuit; open circuit,
short circuit to
ground
For PAD circuit tests, GO to Pinpoint Test B.
Flash code 18
B1890 Passenger airbag
deactivated (PAD)
indicator lamp
circuit fault
PAD indicator lamp
to battery
For PAD circuit tests, GO to Pinpoint Test B.
Flash code 18
B1921 RCM internal airbag
diagnostic monitor
ground circuit fault
RCM mounting
bracket contact; open
circuit, high
resistance
WARNING: To avoid accidental deployment and
possible personal injury, the backup power supply must be
depleted before repairing or replacing any air bag SRS
components. To deplete the backup power supply energy,
disconnect the battery ground cable and wait for one
minute. Failure to follow this instruction may result in
personal injury.
Ensure a clean electrical contact between the RCM and
ground. Ensure the fasteners are correctly torqued.
Flash code 14
B2293 Airbag circuit
status fault
Driver airbag circuit
fault
For airbag circuit tests, GO to Pinpoint Test C.
B2293 Airbag circuit
status fault
Passenger airbag
circuit fault
For airbag circuit tests, GO to Pinpoint Test C.
Flash code 23 - passenger
B2294 Curtain airbag
circuit status fault
Driver curtain airbag
circuit; status fault
For curtain airbag circuit tests, GO to Pinpoint Test D.
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DTC/Flash code Condition Possible source Action
B2294 Curtain airbag
Passenger curtain
airbag circuit; status
fault
For curtain airbag circuit tests, GO to Pinpoint Test D.
B2295 Side airbag circuit
status fault
Driver side airbag
circuit; status fault
For side airbag circuit tests, GO to Pinpoint Test E.
B2295 Side airbag circuit
status fault
Passenger side
airbag circuit; status
fault
For side airbag circuit tests, GO to Pinpoint Test E.
B2988 Knee bolster circuit
open circuit
Knee bolster ground
Knee bolster power
For knee bolster circuit tests, GO to Pinpoint Test K.
Flash code 28
short to battery
Knee bolster ground
to battery
Knee bolster power
to battery
Flash code 28
short to ground
Knee bolster ground
to ground
Knee bolster power
to ground
Flash code 28
B2991 Knee bolster squib
resistance low
Resistance low or
short circuit across
airbag module
Flash code 28
B2296 Front impact sensor
Impact sensor circuit;
status fault
For front impact sensor circuit tests, GO to Pinpoint Test F.
Flash code 42 - front impact
sensor
B2296 Front driver side
impact sensor
status fault
For front driver side impact sensor circuit tests, GO to
Pinpoint Test G.
Flash code 43 - front driver
side impact sensor
B2296 Front passenger
side impact sensor
status fault
For front passenger side impact sensor circuit tests, GO to
Pinpoint Test H. Flash code 44 - front
passenger side impact sensor
B2296 Impact sensor
status fault
For rear driver side impact sensor circuit tests, GO to
Pinpoint Test I. Flash code 45 - rear driver
side impact sensor
B2296 Impact sensor
status fault
For rear passenger side impact sensor circuit tests, GO to
Pinpoint Test J. Flash code 46 - rear passenger
side impact sensor
B2477 RCM configuration
fault
RCM configuration
fault
Reconfigure the module using the Jaguar approved
diagnostic system Flash code 54 (continuous
lamp)
C1947 Driver seat track
position sensor
circuit fault
Driver seat track
position sensor
to ground
For driver seat track position sensor circuit tests, GO to
Pinpoint Test L.
Flash code 49
position sensor
circuit fault
Current out of range
Feature present, but
not expected
Check configuration using the Jaguar approved diagnostic
system. For driver seat track position sensor circuit tests,
GO to Pinpoint Test L. Flash code 49
position sensor
circuit fault
Driver seat track
position sensor
circuit; open circuit,
short circuit to
battery
For driver seat track position sensor circuit tests, GO to
Pinpoint Test L.
Flash code 49
Additional tests for changes to be introduced
C2200 Passenger seat track position
sensor circuit fault
Passenger seat track position
sensor circuit; open circuit
sensor circuit; short circuit to
battery
For passenger seat track position sensor circuit tests,
Flash code 48
sensor circuit short circuit to
ground
sensor circuit; short circuit to
ground
For passenger seat track position sensor circuit tests,
Flash code 48
sensor circuit resistance out
of range
Current out of range
Feature present, but not
expected
Check configuration using the Jaguar approved
diagnostic system. For passenger seat track position
sensor circuit tests, GO to Pinpoint Test M. Flash code 48
B2290 Occupant classification
sensor (OCS) system fault
OCS module fault Check the power and ground to the module, GO to
Pinpoint Test N. Please check part is not on any form of
prior authorisation before replacement.
Flash code 16
PID
$5952/5959
(bit 3)
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1
2
3
4
5
1
2
1
2
1
2
1
2
1
2
OCS module communications
fault
For communication circuit tests, GO to Pinpoint Test N.
For more detailed CAN circuit tests,
Flash code 16
PID
$5952/5959
(bit 2)
OCS module calibration fault Check that the OCS is the correct unit for the vehicle.
Please check part is not on any form of prior
authorisation before replacement.
Flash code 16
PID
$5952/5959
(bit 1)
OCS module sensing element
fault
Install a new OCS,
REFER to: Occupant Classification Sensor (501-20B
Supplemental Restraint System, Removal and
Installation).
Flash code 16
PID
$5952/5959
(bit 0)
Pinpoint tests
PINPOINT TEST A : B1869, B1870: AIRBAG MIL CIRCUIT FAULT
A1: CHECK THE AIRBAG WARNING LIGHT CIRCUIT FOR HIGH RESISTANCE
Disconnect the instrument cluster connector, IP11.
Measure the resistance between IP74, pin 19 (U) and IP11, pin 19 (U).
Yes
No
GO to A2.
A2: CHECK THE AIRBAG WARNING LIGHT CIRCUIT FOR SHORT CIRCUIT TO B+
Measure the voltage between IP74, pin 19 (U) and GROUND.
Yes
REPAIR the short circuit. For additional information, refer to the wiring diagrams. Clear the DTC, test the system
No
The LEDs in the instrument cluster are not serviceable. Install a new instrument cluster. Clear the DTC, test the
system for normal operation. If the fault is still apparent, install a new RCM.
REFER to: Restraints Control Module (RCM) (501-20B Supplemental Restraint System, Removal and Installation).
PINPOINT TEST B : B1884, B1890: PASSENGER AIRBAG DEACTIVATION (PAD) LAMP CIRCUIT FAULT
TEST
CONDITIONS
B1: CHECK THE PAD LAMP LED
Disconnect the PAD lamp connector, IP140.
Measure the resistance between IP140, pins 01 (GR) and 03 (O).
Yes
GO to B2.
No
INSTALL a new PAD lamp LED.
REFER to: Passenger Air Bag Deactivation (PAD) Indicator (501-20B Supplemental Restraint System, Removal and
Installation).
Clear the DTC, test the system for normal operation.
B2: CHECK THE PAD LAMP SUPPLY CIRCUIT FOR OPEN CIRCUIT
Yes
REPAIR the circuit between the PAD lamp and battery. This circuit includes the primary junction box, fuses 31 and 41,
the ignition switch, and the front power distribution box, fuse 39. For additional i nformation, refer to the wiring
diagrams. Clear the DTC, test the system for normal operation.
No
GO to B3.
B3: CHECK THE PAD LAMP SUPPLY CIRCUIT FOR SHORT CIRCUIT TO B+
Measure the voltage between IP74, pin 15 (O) and GROUND.
Yes
normal operation.
No
GO to B4.
B4: CHECK THE PAD LAMP TRIGGER CIRCUIT FOR HIGH RESISTANCE
Measure the resistance between IP140, pin 03 (O) and IP74, pin 15 (O).
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Yes
No
GO to B5.
B5: CHECK THE PAD LAMP TRIGGER CIRCUIT FOR SHORT CIRCUIT TO GROUND
Measure the resistance between IP40, pin 03 (O) and GROUND.
Yes
normal operation.
No
INSTALL a new RCM.
REFER to: Restraints Control Module (RCM) (501-20B Supplemental Restraint System, Removal and Installation).
PINPOINT TEST C : B2293 (FLASH CODE 19 AND/OR 23): AIRBAG CIRCUIT STATUS FAULT
C1: CHECK THE AIRBAG CIRCUIT STATUS WITH SIMULATORS IN PLACE
For flash code 19
Disconnect the driver airbag module connectors, SW01 and SW02.
For flash code 23
Disconnect the passenger airbag module connectors, IP36 and IP37.
Connect the simulators in place of the airbag modules.
Clear the DTC.
Are there any DTCs and/or flash codes set with the simulators in place?
Yes
GO to C2.
No
INSTALL a new airbag module for the relevant side,
REFER to: Driver Air Bag Module (501-20B Supplemental Restraint System, Removal and Installation) /
Passenger Air Bag Module (501-20B Supplemental Restraint System, Removal and Installation).
C2: CHECK THE STAGE 1 CIRCUIT BETWEEN THE AIRBAG MODULE AND THE RCM FOR OPEN CIRCUIT
CA165.
CA450.
Disconnect the simulators.
For flash code 19
SW02, pin 01 (G) and the RCM connector, pin 01 (G)
SW02, pin 02 (B) and the RCM connector, pin 02 (B)
For flash code 23
IP36, pin 01 (RW) and the RCM connector, pin 03 (RW)
IP36, pin 02 (BW) and the RCM connector, pin 04 (BW)
Are any of the resistances greater than 5 ohms?
Yes
GO to C4.
No
GO to C3.
C3: CHECK THE STAGE 2 CIRCUIT BETWEEN THE AIRBAG MODULE AND THE RCM FOR OPEN CIRCUIT
For flash code 19
SW01, pin 01 (G) and the RCM connector, pin 05 (G)
SW01, pin 02 (B) and the RCM connector, pin 06 (B)
For flash code 23
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IP37, pin 01 (RW) and the RCM connector, pin 13 (RW)
IP37, pin 02 (BW) and the RCM connector, pin 14 (BW)
Yes
GO to C4.
No
INSTALL a new RCM.
Installation).
C4: CHECK THE CIRCUITS BETWEEN THE CLOCKSPRING AND THE RCM FOR OPEN CIRCUIT
Disconnect the clockspring connector, IP34.
IP34, pin 10 (B) and the RCM connector, pin 02 (B)
IP34, pin 09 (G) and the RCM connector, pin 01 (G)
IP34, pin 02 (B) and the RCM connector, pin 06 (B)
IP34, pin 01 (G) and the RCM connector, pin 05 (G)
Yes
No
GO to C5.
C5: CHECK THE CIRCUITS THROUGH THE CLOCKSPRING FOR HIGH RESISTANCE
SW01, pin 01 (G) and IP34, pin 01 (G)
SW01, pin 02 (B) and IP34, pin 02 (G)
SW02, pin 01 (G) and IP34, pin 01 (G)
SW02, pin 02 (B) and IP34, pin 02 (B)
Yes
INSTALL a new clockspring.
REFER to: Clockspring (501-20B Supplemental Restraint System, Removal and Installation).
No
INSTALL a new RCM.
Installation).
PINPOINT TEST D : B2294: (FLASH CODE 24 AND/OR 25): CURTAIN AIRBAG CIRCUIT STATUS FAULT
D1: CHECK THE CURTAIN AIRBAG CIRCUIT STATUS WITH SIMULATORS IN PLACE
For flash code 24
Disconnect the driver curtain airbag module connector, CA144.
For flash code 25
Disconnect the passenger curtain airbag module connector, CA145.
Connect the simulator(s) in place of the airbag module(s).
Clear the DTC.
Yes
GO to D2.
No
INSTALL a new curtain airbag module for the relevant side,
REFER to: Side Air Curtain Module - 4-Door (501-20B Supplemental Restraint System, Removal and Installation)
/
Side Air Curtain Module - Wagon (501-20B Supplemental Restraint System, Removal and Installation).
D2: CHECK THE CIRCUITS BETWEEN THE CURTAIN AIRBAG MODULE AND THE RCM FOR OPEN CIRCUIT
Disconnect the simulator(s).
CA165.
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CA450.
For flash code 24
The RCM connector, pin 03 (RW) and CA144, pin 01 (RW)
The RCM connector, pin 04 (BW) and CA144, pin 02 (BW)
For flash code 25
The RCM connector, pin 05 (RW) and CA145, pin 01 (RW)
The RCM connector, pin 06 (BW) and CA145, pin 02 (BW)
Yes
No
INSTALL a new RCM.
Installation).
PINPOINT TEST E : B2295 (FLASH CODE 22 AND/OR 23): SIDE AIRBAG CIRCUIT STATUS FAULT
E1: CHECK THE SIDE AIRBAG CIRCUIT STATUS WITH SIMULATORS IN PLACE
For flash code 22
Disconnect the driver side airbag module connector, AL01.
For flash code 23
Disconnect the passenger side airbag module connector, AD01.
Connect the simulator(s) in place of the airbag module(s).
Clear the DTC.
Yes
GO to E2.
No
INSTALL a new side airbag module for the relevant side.
REFER to: Side Air Curtain Module - 4-Door (501-20B Supplemental Restraint System, Removal and Installation)
/
Side Air Curtain Module - Wagon (501-20B Supplemental Restraint System, Removal and Installation).
E2: CHECK THE CIRCUITS BETWEEN THE SIDE AIRBAG MODULE AND THE RCM FOR OPEN CIRCUIT
Disconnect the simulator(s).
CA165.
CA450.
For flash code 22
The RCM connector, pin 01 (RW) and AL01, pin 01 (RW)
The RCM connector, pin 02 (BW) and AL01, pin 02 (BW)
For flash code 23
The RCM connector, pin 21 (RW) and AD01, pin 01 (RW)
The RCM connector, pin 22 (BW) and AD01, pin 02 (BW)
Yes
No
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INSTALL a new RCM.
Installation).
PINPOINT TEST F : B2296 (FLASH CODE 42): FRONT IMPACT SENSOR CIRCUIT STATUS FAULT
F1: CHECK THE POWER SUPPLY TO THE FRONT IMPACT SENSOR
Disconnect the front impact sensor connector, JB93.
Measure the voltage between JB93, pin 02 (W) and GROUND.
Yes
GO to F2.
No
GO to F3.
F2: CHECK THE FRONT IMPACT SENSOR SUPPLY CIRCUIT FOR OPEN CIRCUIT
CA165.
CA450.
Measure the resistance between JB93, pin 02 (W) and the RCM connector, pin 19 (W).
Yes
No
GO to F3.
F3: CHECK THE FRONT IMPACT SENSOR RETURN CIRCUIT FOR OPEN CIRCUIT
Measure the resistance between JB93, pin 01 (N) and the RCM connector, pin 20 (N).
Yes
No
INSTALL a new front impact sensor,
REFER to: Crash Sensor.
Clear the DTC, test the system for normal operation. If the fault persists, install a new RCM.
Installation).
PINPOINT TEST G : B2296 (FLASH CODE 43): FRONT DRIVER SIDE IMPACT SENSOR CIRCUIT STATUS FAULT
G1: CHECK THE POWER SUPPLY TO THE FRONT DRIVER SIDE IMPACT SENSOR
Disconnect the front driver side impact sensor connector, CA215.
Measure the voltage between CA215, pin 02 (W) and GROUND.
Yes
GO to G2.
No
GO to G3.
G2: CHECK THE FRONT DRIVER SIDE IMPACT SENSOR SUPPLY CIRCUIT FOR OPEN CIRCUIT
CA165.
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CA450.
Measure the resistance between CA215, pin 02 (W) and the RCM connector, pin 27 (W).
Yes
No
GO to G3.
G3: CHECK THE FRONT DRIVER SIDE IMPACT SENSOR RETURN CIRCUIT FOR OPEN CIRCUIT
Measure the resistance between CA215, pin 01 (N) and the RCM connector, pin 28 (N).
Yes
No
INSTALL a new front driver side impact sensor,
REFER to: Side Impact Sensor (501-20B Supplemental Restraint System, Removal and Installation).
Installation).
PINPOINT TEST H : B2296 (FLASH CODE 44): FRONT PASSENGER SIDE IMPACT SENSOR CIRCUIT STATUS FAULT
H1: CHECK THE POWER SUPPLY TO THE FRONT PASSENGER SIDE IMPACT SENSOR
Disconnect the front passenger side impact sensor connector, CA216.
Yes
GO to H2.
No
GO to H3.
H2: CHECK THE FRONT PASSENGER SIDE IMPACT SENSOR SUPPLY CIRCUIT FOR OPEN CIRCUIT
CA165.
CA450.
Yes
No
GO to H3.
H3: CHECK THE FRONT PASSENGER SIDE IMPACT SENSOR RETURN CIRCUIT FOR OPEN CIRCUIT
Yes
No
INSTALL a new front passenger side impact sensor,
Installation).
PINPOINT TEST I : B2296 (FLASH CODE 45): REAR DRIVER SIDE IMPACT SENSOR CIRCUIT STATUS FAULT
I1: CHECK THE POWER SUPPLY TO THE REAR DRIVER SIDE IMPACT SENSOR
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Disconnect the rear driver side impact sensor connector, CA140.
Yes
GO to I2.
No
GO to I3.
I2: CHECK THE REAR DRIVER SIDE IMPACT SENSOR SUPPLY CIRCUIT FOR OPEN CIRCUIT
CA165.
CA450.
Yes
No
GO to I3.
I3: CHECK THE REAR DRIVER SIDE IMPACT SENSOR RETURN CIRCUIT FOR OPEN CIRCUIT
Yes
No
INSTALL a new rear driver side impact sensor,
Installation).
PINPOINT TEST J : B2296 (FLASH CODE 46): REAR PASSENGER SIDE IMPACT SENSOR CIRCUIT STATUS FAULT
J1: CHECK THE POWER SUPPLY TO THE REAR PASSENGER SIDE IMPACT SENSOR
Disconnect the rear passenger side impact sensor connector, CA131.
Yes
GO to J2.
No
GO to J3.
J2: CHECK THE REAR PASSENGER SIDE IMPACT SENSOR SUPPLY CIRCUIT FOR OPEN CIRCUIT
CA165.
CA450.
PINPOINT TEST K : B2988, B2989, B2990, B2991 (FLASH CODE 28): KNEE BOLSTER CIRCUIT OPEN/SHORT
CIRCUIT
WARNING: DO NOT attempt to measure the resistance across the airbag module. Failure to follow this instruction may result in
personal injury.
K1: CHECK THE KNEE BOLSTER AIRBAG CIRCUIT STATUS WITH A SIMULATOR IN PLACE
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Disconnect the knee bolster connector, CA420.
Connect the simulator in place of the airbag module.
Clear the DTC.
Are there any DTCs and/or flash codes set with the simulators in place?
Yes
GO to K2.
No
INSTALL a new knee bolster airbag module,
REFER to: Driver Lower Air Bag Module (501-20B Supplemental Restraint System, Removal and Installation).
K2: CHECK THE KNEE BOLSTER AIRBAG MODULE SUPPLY CIRCUIT FOR OPEN CIRCUIT
Disconnect the simulator from the knee bolster connector, CA420.
CA165.
CA450.
Measure the resistance between CA420, pin 01 (RW) and the RCM connector, pin 07 (RW).
Yes
No
GO to K3.
K3: CHECK THE KNEE BOLSTER AIRBAG MODULE SUPPLY CIRCUIT FOR SHORT CIRCUIT TO BATTERY
Measure the resistance between CA420, pin 01 (RW) and the battery positive terminal.
Yes
No
GO to K4.
K4: CHECK THE KNEE BOLSTER AIRBAG MODULE SUPPLY CIRCUIT FOR SHORT CIRCUIT TO GROUND
Measure the resistance between CA420, pin 01 (RW) and GROUND.
Yes
No
INSTALL a new knee bolster airbag module,
REFER to: Driver Lower Air Bag Module (501-20B Supplemental Restraint System, Removal and Installation).
PINPOINT TEST L : C1947 (FLASH CODE 49): DRIVER SEAT TRACK POSITION SENSOR CIRCUIT FAULT
NOTE: Check the seat track position sensor for correct fitment before beginning pinpoint tests.
L1: CHECK THE DRIVER SEAT TRACK POSITION SENSOR SUPPLY CIRCUIT FOR HIGH RESISTANCE
Disconnect the driver seat track sensor connector, CA65.
CA165.
CA450.
Measure the resistance between CA65, pin 20 (U) and the RCM connector, pin 23 (U).
Yes
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No
GO to L2.
L2: CHECK THE DRIVER SEAT TRACK POSITION SENSOR SUPPLY CIRCUIT FOR SHORT CIRCUIT TO BATTERY
Measure the resistance between CA65, pin 20 (U) and the battery positive terminal.
Yes
No
GO to L3.
L3: CHECK THE DRIVER SEAT TRACK POSITION SENSOR SUPPLY CIRCUIT FOR SHORT CIRCUIT TO GROUND
Measure the resistance between CA65, pin 20 (U) and GROUND.
Yes
No
GO to L4.
L4: CHECK THE DRIVER SEAT TRACK POSITION SENSOR GROUND CIRCUIT FOR HIGH RESISTANCE
Yes
No
GO to L5.
L5: CHECK THE DRIVER SEAT TRACK POSITION SENSOR GROUND CIRCUIT FOR SHORT CIRCUIT TO BATTERY
Yes
No
INSTALL a new driver seat track position sensor.
REFER to: Seat Position Sensor (501-20B Supplemental Restraint System, Removal and Installation).
Installation).
PINPOINT TEST M : C2200 (FLASH CODE 48): PASSENGER SEAT TRACK POSITION SENSOR CIRCUIT FAULT
NOTE: Check the seat track position sensor for correct fitment before beginning pinpoint tests.
M1: CHECK THE PASSENGER SEAT TRACK POSITION SENSOR SUPPLY CIRCUIT FOR HIGH RESISTANCE
Disconnect the passenger seat track sensor connector, CA70.
CA165.
CA450.
Measure the resistance between CA70, pin 20 (U) and the RCM connector, pin 24 (U).
Yes
No
GO to M2.
M2: CHECK THE PASSENGER SEAT TRACK POSITION SENSOR SUPPLY CIRCUIT FOR SHORT CIRCUIT TO BATTERY
Measure the resistance between CA70, pin 20 (U) and the battery positive terminal.
Yes
No
GO to M3.
M3: CHECK THE PASSENGER SEAT TRACK POSITION SENSOR SUPPLY CIRCUIT FOR SHORT CIRCUIT TO GROUND
Measure the resistance between CA70, pin 20 (U) and GROUND.
Yes
No
GO to M4.
M4: CHECK THE PASSENGER SEAT TRACK POSITION SENSOR GROUND CIRCUIT FOR HIGH RESISTANCE
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Yes
No
GO to M5.
M5: CHECK THE PASSENGER SEAT TRACK POSITION SENSOR GROUND CIRCUIT FOR SHORT CIRCUIT TO BATTERY
Yes
No
INSTALL a new passenger seat track position sensor.
REFER to: Seat Position Sensor (501-20B Supplemental Restraint System, Removal and Installation).
Installation).
PINPOINT TEST N : B2290 (FLASH CODE 16): OCCUPANT CLASSIFICATION SENSOR (OCS) SYSTEM FAULT
NOTE: Refer to the preliminary inspection table for fuse checks, etc before beginning pinpoint tests.
NOTE: For belt tension sensor to OCS circuit tests,
REFER to: Safety Belt System (501-20A Safety Belt System, Diagnosis and Testing).
N1: CHECK THE POWER SUPPLY TO THE OCS
Disconnect the OCS connector, WS17.
Measure the voltage between WS17, pin G (GR) and GROUND.
Yes
REPAIR the circuit between the OCS and battery. For additional information, refer to the wiring diagrams. CLEAR
the DTC, test the system for normal operation.
No
GO to N2.
N2: CHECK THE GEOUND TO THE OCS
Measure the resistance between WS17, pin D and GROUND.
Yes
No
GO to N3.
N3: CHECK THE SIGNAL CIRCUIT BETWEEN THE OCS AND THE SEAT TRANSDUCER FOR HIGH RESISTANCE
Disconnect the seat transducer connector, WS20.
Measure the resistance between WS17, pin K (U) and WS20, pin 02 (U).
Yes
No
GO to N4.
N4: CHECK THE SIGNAL CIRCUIT BETWEEN THE OCS AND THE SEAT TRANSDUCER FOR SHORT CIRCUIT TO BATTERY
Measure the resistance between WS17, pin K (U) and the battery positive terminal.
Yes
No
GO to N5.
N5: CHECK THE SIGNAL CIRCUIT BETWEEN THE OCS AND THE SEAT TRANSDUCER FOR SHORT CIRCUIT TO GROUND
Measure the resistance between WS17, pin K (U) and GROUND.
Yes
No
GO to N6.
N6: CHECK THE 5V CIRCUIT BETWEEN THE OCS AND THE SEAT TRANSDUCER FOR HIGH RESISTANCE
Measure the resistance between WS17, pin J (W) and WS20, pin 01 (W).
Yes
No
GO to N7.
N7: CHECK THE 5V CIRCUIT BETWEEN THE OCS AND THE SEAT TRANSDUCER FOR SHORT CIRCUIT TO BATTERY
Measure the resistance between WS17, pin J (W) and the battery positive terminal.
Yes
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GO to N8.
N8: CHECK THE 5V CIRCUIT BETWEEN THE OCS AND THE SEAT TRANSDUCER FOR SHORT CIRCUIT TO GROUND
Measure the resistance between WS17, pin J (W) and GROUND.
Yes
No
GO to N9.
N9: CHECK THE GROUND CIRCUIT BETWEEN THE OCS AND THE SEAT TRANSDUCER FOR HIGH RESISTANCE
Measure the resistance between WS17, pin H (R) and WS20, pin 03 (R).
Yes
No
GO to N10.
N10: CHECK THE GROUND CIRCUIT BETWEEN THE OCS AND THE SEAT TRANSDUCER FOR SHORT CIRCUIT TO BATTERY
Measure the resistance between WS17, pin H (R) and the battery positive terminal.
Yes
No
GO to N11.
N11: CHECK THE GROUND CIRCUIT BETWEEN THE OCS AND THE SEAT TRANSDUCER FOR SHORT CIRCUIT TO GROUND
Measure the resistance between WS17, pin H (R) and GROUND.
Yes
No
GO to N12.
N12: CHECK THE CONTROLLER AREA NETWORK + CIRCUIT BETWEEN THE RCM AND THE OCS FOR HIGH RESISTANCE
CA165.
CA450.
Measure the resistance between the RCM connector, pin 17 (O) and WS17, pin E (O).
Yes
No
GO to N13.
N13: CHECK THE CONTROLLER AREA NETWORK - CIRCUIT BETWEEN THE RCM AND THE OCS FOR HIGH RESISTANCE
Measure the resistance between the RCM connector, pin 18 (U) and WS17, pin F (U).
Yes
No
For more detailed CAN circuit tests,
www.JagDocs.com
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Supplemental Restraint System - Air Bag Disposal
General Procedures
Deployed Air Bag
1. WARNING: Always wear safety glasses when repairing an air bag
supplemental restraint system (SRS) vehicle and when handling an air bag
Deployed air bag modules are to be disposed of as special waste and
must comply with local environmental requirements, if in doubt, contact
Authority for disposal requirements.
2. NOTE: The storage, transportation, disposal, and/or recycling of air bag
module components must be carried out in accordance with all applicable
federal, state and local regulations including, but not limited to, those
governing building and fire codes, environmental protection, occupational
health and safety, and transportation.
Modules removed and deployed by Jaguar service are to be returned to
the importer for disposal.
Undeployed Air Bag Inoperative
1. WARNINGS:
Carry a live air bag module with the air bag and trim cover or
deployment door pointed away from your body. This will reduce the risk of
injury in the event of an accidental deployment. Failure to follow this
All inoperative air bag modules have been placed on the Mandatory
Return List. All discolored or damaged air bag modules must be treated
the same as any inoperative live air bag being returned. Failure to follow
Remove the inoperative driver air bag module or passenger air bag
module. For additional information see Driver Air Bag Module or
Passenger Air Bag Module in this section.
Undeployed Air Bag Scrapped Vehicle
Remote Deployment
1. WARNINGS:
Always wear safety glasses when repairing an air bag supplemental
restraint system (SRS) vehicle and when handling an air bag module.
Carry a live air bag module with the air bag and trim cover or
deployment door pointed away from your body. This will reduce the risk of
injury in the event of an accidental deployment. Failure to follow this
Remote deployment is to be carried out outdoors with all personnel
at least 6.1 meters (20 feet) away to ensure personal safety. Due to the
loud report which occurs when the air bag is deployed, hearing protection
is required. Failure to follow this instruction may result in personal injury.
Do not place the driver or passenger air bag module with the trim
cover or deployment door facing down, as the forces of the deploying air
bag can cause it to ricochet and cause personal injury. Failure to follow
Equipment required: Universal deployment tool-Part N 418-S135 and
12V Battery.
2. The deployment procedure should be carried out outdoors away from
other personnel.
3. Remove any loose debris from around air bag. Make sure that no
flammable liquids are present.
4. Disconnect the battery ground and positive cables.
5. Disconnect the relevant air bag module electrical connector.
6. Connect the appropriate adaptor lead to the restraint device.
7. Connect the deployment lead to the adaptor lead. Pass wire of the
deployment tool through window, close all doors, leave window with
lead for deployment tool open.
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8. WARNING: Before proceeding, make sure precautions have been
taken to warn personnel of a possible loud noise upon activation. Do not
allow anybody to approach closer to restraint device than six meters.
Move as far from restraint device as possible and connect the tool clips
to a 12V vehicle battery.
9. WARNING: Do not handle the deployed device immediately after
activation - it may be hot. Allow the unit to cool for at least 20 minutes.
Cooling modules should be continuously monitored to make sure heat does
not create a fire with spilled liquids or other debris. Failure to follow this
Deploy the module by depressing both switches on the tool. If activation
does not occur, disconnect battery from tool and seek advise from
Jaguar Engineering and wait for further instructions.
10. Repeat procedure for all air bags in vehicle.
11. The vehicle is now to be scrapped in the normal manner with modules
installed.
Disposal of live air bag modules for driver air bag module, passenger air bag module and side
air bag module, using tyres
1. Equipment required: Deployment tool 418-S135, Battery (12V), Safety
goggles to BS2092 grade 2, Rubber gloves to PrEN 374 class 2, Ear
protectors that have been measured to BS.EN 24869, Particulate
respirator to EN 149 grade FFP2S.
2. The deployment procedure should be carried out outdoors, away from
other personnel.
3. Stack four scrap tyres, securing together with heavy gauge wire or
cable. While disconnected from any electrical power source, connect
deployment harness and place air bag adaptor portion under tyre stack,
ready for connection to air bag.
4. WARNING: Power must not be connected during this step. Failure
CAUTION: Make sure the connector is not in contact with the inflator
or it will be damaged during the test.
Connect air bag to air bag connector, make sure the locking sleeve is
fully engaged. Position the air bag with the cover facing upwards.
5. Make sure battery connections of deployment harness are ten meters
away from the tyre stack
6. Remove any loose parts from around the air bag. Make sure that no
9. Allow the air bag to cool for at least 20 minutes. Cooling modules
should be continuously monitored to make sure heat does not generate
a fire with spilled liquids or other debris.
10. Remove the air bag from the tyre stack and seal in a plastic bag,
ready for disposal.
11. In the event of any problems or queries arising from this procedure,
contact Jaguar Engineering.
Disposal of side curtain air bag module using tyres
1. Equipment required: Deployment tool 418-S135, Battery (12V), Safety
goggles to BS2092 grade 2, Rubber gloves to PrEN 374 class 2, Ear
protectors that have been measured to BS.EN 24869, Particulate
respirator to EN 149 grade FFP2S.
2. The deployment procedure should be carried out outdoors, away from
other personnel.
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3. WARNING: Make sure that the tyre stack is stable before and after
deployment. Failure to follow this instruction my result in personal injury.
Stack scrap tyres of a sufficient height to mask the side curtain air bag
module, securing together with heavy gauge wire or cable. While
disconnected from any electrical power source, connect deployment
harness and place air bag adaptor portion under tyre stack, ready for
connection to air bag.
4. WARNING: Power must not be connected during this step. Failure
CAUTION: Make sure the connector is not in contact with the inflator
or it will be damaged during the test.
Connect air bag to air bag connector, make sure the locking sleeve is
fully engaged. Position the air bag into the tyres with the inflator
canister at the lowest point.
5. Make sure battery connections of deployment harness are ten meters
away from the tyre stack
6. Remove any loose parts from around the air bag. Make sure that no
9. Allow the air bag to cool for at least 20 minutes. Cooling modules
should be continuously monitored to make sure heat does not generate
a fire with spilled liquids or other debris.
10. Remove the air bag from the tyre stack and seal in a plastic bag,
ready for disposal.
11. In the event of any problems or queries arising from this procedure,
contact Jaguar Engineering.
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Supplemental Restraint System - Clockspring
Removal
1. WARNINGS:
restraints system (SRS) vehicle and when handling an air bag module.
Carry a live air bag module with the air bag and trim cover pointed
away from your body. This will reduce the risk of injury in the event of an
accidental deployment. Failure to follow this instruction may result in
personal injury.
Do not set a live air bag module down with the trim cover face
down. Failure to follow this instruction may result in personal injury.
After deployment, the air bag surface can contain deposits of
sodium hydroxide, a product of the gas generant combustion that is
irritating to the skin. Wash your hands with soap and water afterwards.
Never probe the connectors on the air bag module. Doing so may
result in air bag deployment, which may result in personal injury. Failure
Air bag modules with discolored or damaged trim covers must be
replaced, not repainted.
Vehicle sensor orientation is critical for correct system operation. If
a vehicle equipped with an air bag SRS is involved in a collision, inspect
the sensor mounting bracket and wiring pigtail for deformation. If
damaged, replace the sensor whether or not the air bag is deployed.
To avoid accidental deployment and possible personal injury, the
backup power supply must be depleted before repairing or replacing any air
bag SRS components. To deplete the backup power supply energy,
disconnect the battery ground cable and wait one minute. Failure to follow
NOTE: Repair is made by replacement only. If a part is replaced and the
new part does not correct the condition, install the original part and carry
out the diagnostic procedure again.
NOTE: Make sure the front wheels are in the straight-ahead position.
Remove the steering wheel. For additional information, refer to Section
211-04 Steering Column.
1. Remove the steering column lower shroud retaining screws.
2. Remove the ignition lock cylinder grommet.
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4. Disconnect the multifunction switch electrical connectors.
1. Remove the multifunction switch spring.
2. Disconnect the multifunction switch electrical connectors.
5. Remove the multifunction switches.
6. Remove the air bag sliding contact.
Release the retaining tangs.
Installation
1. WARNINGS:
personal injury.
result in air bag deployment. Failure to follow this instruction may result in
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personal injury.
NOTE: A repair is made by replacement only. If a part is replaced and
the new part does not correct the condition, install the original part and
carry out the diagnostic procedure again.
NOTE: The air bag sliding contact has a service lock that prevents
rotation of the air bag sliding contact when the steering wheel is removed.
NOTE: Make sure the front wheels are in the straight-ahead position.
NOTE: Make sure to tighten the retaining bolts to the correct
specification.
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Supplemental Restraint System - Crash Sensor
Removal
1. WARNINGS:
bag or any other supplemental restraints system (SRS) components. To
deplete the backup power supply energy, disconnect the battery ground
cable and wait one minute. Failure to follow this instruction may result in
personal injury.
Never probe the electrical connectors of air bag modules or any
other SRS component. Failure to follow this instruction may result in
personal injury.
2. Remove the hood latch bracket retaining bolts.
3. Disconnect the crash sensor electrical connector.
4. Remove the crash sensor.
Installation
WARNINGS:
Make sure the crash sensor locating tang is correctly located. Failure to follow this instruction may result in personal injury.
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Never probe the electrical connectors of air bag modules or any other supplemental restraint system (SRS) component. Failure to
1. Install the crash sensor.
Tighten to 12 Nm.
2. Connect the crash sensor electrical connector.
3. Tighten the hood latch bracket retaining bolts.
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Supplemental Restraint System - Driver Air Bag Module
Removal
1. WARNINGS:
An RCM module only requires replacement if the system has incurred
five separate deployments. At no time change an RCM for less than five
separate deployments.
personal injury.
personal injury.
replaced.
damaged, install a new sensor whether or not the air bag is deployed. If
the body work is damaged this will have to be addressed.
NOTE: When installing a new air bag module, a prepaid return postcard
is provided with the replacement air bag module. The serial number for the
new part and the vehicle identification number (VIN) must be recorded and
sent to Jaguar Cars Ltd.
2. CAUTION: Make sure the driver air bag module snap fit connectors
are released before removing the driver air bag module.
Detach the driver air bag module.
Using a suitable tool, access the clips from the rear of the steering
wheel.
Rotate the tool and release the three clips.
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3. Disconnect the driver air bag module electrical connector.
4. Remove the driver air bag module.
Disconnect the driver air bag module electrical connector.
Installation
1. WARNINGS:
personal injury.
personal injury.
new part does not correct the condition , install the original part and carry
Connect the driver air bag module electrical connector.
2. Connect the driver air bag module electrical connector.
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3. NOTE: Make sure the driver air bag module snap fit connectors are fully
seated.
Install the driver air bag module.
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Supplemental Restraint System - Driver Lower Air Bag Module
Removal
1. WARNINGS:
A restraints control (RCM) module only requires replacement if the
system has incurred five separate deployments. At no time change an RCM
for less than five separate deployments.
restraints system (SRS) and when handling an air bag module. Failure to
personal injury.
personal injury.
replaced.
damaged, install a new sensor whether or not the air bag is deployed.
2. Remove the driver lower air bag module retaining screws.
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3. Detach the right-hand driver lower air bag module retaining clip.
4. Detach the left-hand driver lower air bag module retaining clip.
5. Remove the driver lower air bag module.
Disconnect the driver lower air bag module electrical connector.
Installation
1. WARNINGS:
Always wear safety glasses when repairing an SRS vehicle and when
handling an air bag module. Failure to follow this instruction may result in
personal injury.
personal injury.
personal injury.
new part does not correct the condition , install the original part and carry
Connect the driver lower air bag module electrical connector.
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2. NOTE: Make sure the driver lower air bag module retaining clips are fully
seated.
Install the driver lower air bag module.
Tighten to 11 Nm.
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Supplemental Restraint System - Occupant Classification Sensor
Removal
1. WARNINGS:
bag supplemental restraint system (SRS) components. To deplete the
backup power supply energy, disconnect the battery ground cable and wait
one minute. Failure to follow this instruction may result in personal injury.
personal injury.
CAUTION: Electronic components in seats are sensitive to impact.
Handle seat with care or damage may result.
NOTE: Sensor is available only as a service kit. No attempt should be
made to replace individual components.
Power seat base to lowest position. Recline seat back to 25 degrees
from vertical.
Remove the passenger seat. For additional information, Section 501-10
Seating.
2. Remove the backrest recliner handwheel (if equipped).
3. Remove the inner side trim panel.
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5. Remove the electronic control unit (ECU).
1. Remove the two clips.
1. Remove the ECU.
6. Disconnect the electrical connector from the sensor.
7. Detach the wiring harness from the seat base by cutting and removing
the cable ties. If a plastic harness connector plate is fitted to the seat,
detach the connectors to free the harness. The plastic carrier plate can
then be removed and discarded.
8. Detach the electrical connector from the electrical connector bracket.
9. Remove the seat buckle.
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10. Remove the seat base retaining nuts.
11. Detach the passenger weight sensor electrical connector from the
retaining clip.
12. Remove the seat cover.
Unclip the seat cover from the seat base.
13. Remove the seat cushion bladder from the seat base.
Remove the two fir tree clips.
14. CAUTION: Swarf may damage the bladder. Make sure the seat
and bladder are free from debris.
Remove the electrical connector bracket.
Installation
1. NOTE: Once the seat base is fully assembled, using the cable ties
supplied with the kit, fully secure the harness to the seat base.
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Supplemental Restraint System - Passenger Air Bag Deactivation (PAD) Indicator
Removal
1. WARNINGS:
bag supplemental restraints system (SRS) components. To deplete the
other supplemental restraint system component. Failure to follow this
Lower and extend the steering column to its maximum rearward
position.
4. Remove the passenger finish panel.
5. Detach the passenger air bag deactivation PAD indicator.
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6. Remove the PAD indicator.
Installation
1. WARNINGS:
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Supplemental Restraint System - Passenger Air Bag Module
Removal
1. WARNINGS:
A restraints control module (RCM) only requires replacement if the
personal injury.
personal injury.
replaced.
sent to Jaguar cars ltd.
2. Lower and extend the steering column to its maximum rearward
position.
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4. Detach the passenger finish panel.
5. Remove the passenger air vent.
6. WARNING: Disconnect the passenger air bag module right-hand
electrical connector before the left-hand electrical connector. Failure to
Disconnect the passenger air bag module right-hand electrical connector.
7. WARNING: Make sure the passenger air bag module right-hand
electrical connector has been disconnected. Failure to follow this
Disconnect the passenger air bag module left-hand electrical connector.
8. Remove the passenger compartment hinge retaining screws.
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9. Remove the passenger compartment finisher trim.
10. Remove the passenger compartment.
Remove the passenger compartment retaining screws.
11. Disconnect the passenger compartment lamp electrical connector.
12. NOTE: Under no circumstances should the air bag be removed from the
re-action can.
NOTE: Support the passenger air bag module.
Remove the passenger air bag module.
Installation
1. WARNINGS:
Make sure the passenger air bag module left-hand electrical
connector is connected before the right-hand electrical connector. Failure
A restraints control module (RCM) only requires replacement if the
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Carry a live air bag module with the air bag and deployment door
pointed away from your body. This will reduce the risk of injury in the
event of an accidental deployment.
personal injury.
Tighten to 9 Nm.
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Supplemental Restraint System - Restraints Control Module (RCM)
Removal
1. WARNINGS:
personal injury.
CAUTION: Electronic modules are sensitive to static electrical
3. Disconnect the RCM electrical connectors.
4. Remove the RCM.
Installation
1. WARNINGS:
The tightening torque of the RCM retaining bolts is critical for correct
system operation and safety.
personal injury.
NOTE: Make sure to tighten the retaining bolts to the correct
specification.
Tighten to 12 Nm.
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Supplemental Restraint System - Seat Position Sensor
Removal
1. WARNINGS:
Remove the driver seat. For additional information, refer to Section
501-10 Seating.
2. Disconnect the seat track position sensor electrical connector.
3. Detach the seat track position sensor wiring harness.
4. Remove the seat track position sensor.
Installation
1. WARNINGS:
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restraint system component. Failure to follow this instruction may result in
personal injury.
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Supplemental Restraint System - Side Air Curtain Module4-Door
Removal
1. WARNINGS:
A restraint control module (RCM) only requires replacement if the
personal injury.
personal injury.
replaced.
2. Remove the headliner. For additional information, refer to Section
3. NOTE: To aid installation, note the routing of the retaining cord.
Remove the side air curtain module cord retaining bolt.
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Detach the side air curtain module cord from the retaining clip.
5. Disconnect the side air curtain module electrical connector.
Remove the side air curtain module retaining bolts.
7. NOTE: To aid installation, note the position of the locating tangs.
Remove the side air curtain module.
Installation
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1. WARNINGS:
An restraint control module (RCM) only requires replacement if the
personal injury.
personal injury.
NOTE: Tighten the retaining bolts to the correct specification and in the
indicated sequence shown.
NOTE: Make sure the side air curtain module tang is correctly located.
Install the side air curtain module retaining bolts.
Tighten to 9 Nm.
2. Tighten to 9 Nm.
3. Connect the side air curtain module electrical connector.
4. Attach the side air curtain module cord.
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5. Install the side air curtain module cord retaining bolt.
Tighten to 9 Nm.
6. Install the headliner. For additional information, refer to Section 501-05
Interior Trim and Ornamentation.
7. Connect the battery ground cable. For additional information, refer to
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Supplemental Restraint System - Side Air Curtain ModuleWagon
Removal
1. WARNINGS:
A restraint control module (RCM) only requires replacement if the
personal injury.
personal injury.
replaced.
3. Remove the sun visor retaining clips.
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Detach the front door opening weatherstrips.
5. Remove the A-pillar trim panels.
Detach the B-pillar upper trim panels.
Detach the B-pillar lower trim panels.
Detach the B-pillar upper trim panels from the B-pillar trim lower trim
panels.
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10. Lever open the covers to expose the screws and remove the driver and
11. Remove the D-pillar trim panels.
Remove the luggage net retaining clip.
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Remove the side air curtain module front cord retaining bolt.
Detach the side air curtain module front cord from the retaining clip.
19. NOTE: To disconnect, slide back the locking tang.
Disconnect the side air curtain module electrical connector.
20. Remove the side air curtain module retaining nuts.
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21. Remove the side air curtain module.
2. Detach the retaining clip.
Installation
WARNINGS:
An restraint control module (RCM) only requires replacement if the system has incurred five separate deployments. At no time change
an RCM for less than five separate deployments.
Always wear safety glasses when repairing an air bag supplemental restraints system (SRS) vehicle and when handling an air bag
NOTE: Tighten the retaining bolts to the correct specification and in the indicated sequence shown.
NOTE: Make sure the side air curtain module tang is correctly located.
1. Tighten to 9 Nm.
2. Tighten to 9 Nm.
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3. Tighten to 9 Nm.
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Supplemental Restraint System - Side Impact Sensor
Removal
1. WARNINGS:
personal injury.
2. Position the seat fully forwards.
3. Remove the B-pillar lower trim panel. For additional information, refer
to Section 501-05 Interior Trim and Ornamentation.
Disconnect the side impact sensor electrical connector.
Remove the side impact sensor.
Installation
1. WARNINGS:
Make sure the side impact sensor locating tangs are correctly
located into the B-pillar. Failure to follow this instruction may result in
personal injury.
personal injury.
Tighten to 12 Nm.
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Uni-Body, Subframe and Mounting System -
Specification
Bush installation lubrication Shell gravex oil 973
Front subframe front mount retaining bolts 142 105 -
Front subframe rear mount retaining bolts 142 105 -
Front subframe reinforcement plate retaining bolts 35 26 -
Front stabilizer bar link arm retaining nuts 47 35 -
Steering gear heat shield retaining bolts 7 - 62
Steering gear to subframe retaining bolts 133 98 -
Steering gear cooling pipe retaining bolts 7 - 62
Engine roll restrictor retaining bolts 80 59 -
Front lower arm ball joint retaining nuts 83 61 -
Rear subframe mounting retaining bolts 126 93 -
Rear shock absorber to wheel knuckle retaining bolts 130 96 -
Wheel knuckle mounting bracket to body retaining bolts 126 93 -
Rear brake caliper retaining bolts 32 24 -
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Uni-Body, Subframe and Mounting System - Frame Assembly
FRONT SUB-FRAME ASSEMBLY
The front sub-frame is bolted to the body and aids in structural support. The front sub-frame provides the mounting surface for the steering
gear, the front suspension lower arm, the stabilizer bar and the engine roll restrictor support bracket.
On vehicles from 2009MY using the 2.2 Diesel engine and the AW F21 6 speed transmission, a dynamic damper is fitted to the front
sub-frame. The damper improves refinement in the 1500-1800 rpm range of the engine. The damper is attached to the rear LH (left-hand)
corner of the sub-frame. An integral stud on the damper is located through a hole in the sub-frame and secured with a flanged nut.
REAR SUB-FRAME ASSEMBLY
The rear sub-frame is bolted to the body and aids in structural support. The rear sub-frame provides the mounting surface for the rear
suspension components, the exhaust hanger insulator and the rear drive differential.
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Uni-Body, Subframe and Mounting System - Underbody Misalignment Check
General Procedures
Special Tool(s)
Alignment equipment
501-081
1. Raise and support the vehicle on a two post ramp. For additional
information, refer to Section 100-02 Jacking and Lifting.
2. Inspect all underbody structural members for cracks, twists or bends.
Check all welded connections for cracks. Inspect the support brackets for
looseness. Perform any necessary service or make replacements as
required.
3. Install the alignment pins supplied with special tool number HTJ1200-2
to the rear of the front subframe for the initial front subframe to vehicle
body alignment check.
4. Remove the alignment pins.
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5. CAUTION: Make sure the measuring equipment is used the right
way up as shown in the illustration.
The Z measurement is set on the special tool before the X measurement
is taken on the vehicle.
6. CAUTION: Make sure the measuring equipment is used the right
way up as shown in the illustration.
NOTE: Make sure the inner part of the measuring bar is fully retracted
and the lock fully tightened before any measurements are taken.
Take the X measurement.
1. Take the X measurement using the middle part of the
measuring bar.
2. If the middle part of the measuring bar locks into its fully
extended position, continue taking the X measurement on the
inner part of the measuring bar.
7. NOTE: The smallest diameter pin and bracket (D) is fitted to vehicles
with automatic transmission. The bracket is marked A.The larger diameter
pin and bracket (D) is fitted to vehicles with manual transmission. The
bracket is marked M.
NOTE: Clean all the special tool mounting surfaces before installing the
special tools.
Install the special tools to the underside of the vehicle.
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8. NOTE: The smallest diameter pin and bracket (D) is fitted to vehicles
with automatic transmission. The larger diameter pin and bracket (D) is
fitted to vehicles with manual transmission.
NOTE: Clean all the special tool mounting surfaces before installing the
special tools.
Install the special tools to the underside of the vehicle.
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9. CAUTION: When installing or removing the special tool make sure
the brake pipes are not damaged or detached from the retaining clips.
Adjust the steady screw to the front of the wheel knuckle to stabilize
the special tool to the underside of the vehicle.
10. Underbody dimension tolerances are 2 mm (0.08 inch).
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Underbody Dimensions
X-Dimension Millimeter Inch
1-All vehicles 674.00 26.28
3-Manual transmission 877.00 34.20
4-Manual transmission 708.00 27.61
3-Automatic transmission924.00 36.04
4-Automatic transmission736.00 28.70
6-All vehicles 1258.00 49.06
7-All vehicles 1258.00 49.06
10-All vehicles 997.00 38.88
Underbody Measurements
Measurement number Z-Measuring heightFrom pointTo point
1-All vehicles 117mm B C
2-All vehicles 117mm E C
3-Manual transmission 126mm B D
4-Manual transmission 126mm E D
3-Automatic transmission126mm B D
4-Automatic transmission126mm E D
5-All vehicles 314mm I H
6-All vehicles 314mm F H
7-All vehicles 314mm I G
8-All vehicles 314mm F G
9-All vehicles 122mm F J
10-All vehicles 122mm I J
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Uni-Body, Subframe and Mounting System - Front Subframe2.0L NA V6 - AJV6/2.5L
NA V6 - AJV6/3.0L NA V6 - AJ27
Special Tool(s)
HTJ1200-2
Removal
All vehicles
All vehicles
flange.
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9. NOTE: If installed, remove and discard the gasket.
Detach the driveshaft from drive pinion flange.
Remove and discard the driveshaft retaining bolts and link washers.
universal joint.
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Using suitable tie straps, secure the driveshaft to the front exhaust
hanger .
Remove the lower arm ball joint nut and bolt.
All vehicles
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15. Detach the front of the steering gear cooling pipe.
16. Detach the rear of the steering gear cooling pipe.
17. Remove the selector cable shield.
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19. Disconnect the selector cable.
20. NOTE: Secure the selector cable using tie straps.
Detach the selector cable.
All vehicles
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Remove the front subframe front mount retaining bolts.
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27. Detach the steering gear supply pipe from the steering gear heat
shield mount bracket.
28. Detach the steering gear heat shield mount bracket.
31. Using suitable securing straps, secure the steering gear to the vehicle
body.
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32. Remove the steering gear heat shield lower retaining bolts.
33. CAUTION: To prevent damage to the lower arm bushing, detach
the lower arm ball joint as the subframe is being lowered. Failure to follow
Detach the lower arm.
Remove the subframe.
Lower the special tool.
Installation
All vehicles
1. WARNING: Raise the special tool platform slowly. Failure to follow
this instruction can result in personal injury.
Install the subframe.
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2. CAUTION: To prevent damage to the lower arm bushing, attach
the lower arm ball joint as the subframe is being raised. Failure to follow
Attach the lower arm.
4. Install the steering gear heat shield lower retaining bolts.
5. Remove the steering gear securing straps.
Tighten to 133 Nm.
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Tighten to 133 Nm.
8. Attach the steering gear heat shield mount bracket.
9. Attach the steering gear supply pipe to the steering gear heat shield
mount bracket.
Loosely install the front subframe front mount retaining bolt.
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Tighten to 142 Nm.
Tighten to 142 Nm.
M8 to 35 Nm.
M10 to 70 Nm.
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17. Attach the selector cable.
18. Connect the selector cable.
Tighten to 10 Nm.
19. Attach the selector cable.
20. Install the selector cable shield.
Tighten to 10 Nm.
All vehicles
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21. Attach the rear of the steering gear cooling pipe.
Tighten to 7 Nm.
22. Attach the front of the steering gear cooling pipe.
Tighten to 7 Nm.
23. Connect the high intensity discharge (H.I.D) sensor drop arm.
All vehicles
Tighten to 48 Nm.
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Install the lower arm ball joint retaining nut and bolt.
Tighten to 83 Nm.
26. Install the muffler inlet pipe.
Cut and remove the tie straps securing the driveshaft to the front
exhaust hanger.
29. CAUTIONS:
INSTALLING A NEW DRIVESHAFT. If a new driveshaft is to be
installed, no gasket is required between the driveshaft and the drive
pinion flange. Failure to follow this instruction may result in damage to
the vehicle.
INSTALLING THE ORIGINAL DRIVESHAFT. If a gasket was removed
from between the driveshaft and the drive pinion flange on the driveshaft
removal procedure, make sure to install a new gasket. If no gasket was
removed from between the driveshaft and the drive pinion flange on the
driveshaft removal procedure, a new gasket is not required. Failure to
Attach the driveshaft universal joint.
3. Install new driveshaft retaining bolts
Tighten to 44 Nm.
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Install the engine roll restrictor retaining bolt.
Tighten to 80 Nm
36. Carry out the front subframe alignment procedure.
37. Calibrate the steering angle sensor, using the Jaguar approved
diagnostic system.
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Uni-Body, Subframe and Mounting System - Front Subframe2.0L Duratorq-TDCi/2.2L
Special Tool(s)
HTJ1200-2
Removal
All vehicles
1. Remove the wheels and tires.
Remove the wheel arch liner access cover.
Remove the lower arm ball joint nut and bolt.
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All vehicles
8. Detach the front of the steering gear cooling pipe.
9. Detach the rear of the steering gear cooling pipe.
10. Detach the electric booster heater electrical connector from the
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11. Detach the coolant hoses from the retaining clips.
Detach the coolant hose.
13. Detach the fuel fired booster heater electrical connector from the
All vehicles
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Remove the roll restrictor retaining bolt.
Remove the front subframe front mount retaining bolts.
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26. Using suitable securing straps, secure the steering gear to the vehicle
body.
27. CAUTION: To prevent damage to the lower arm bushing, detach
the lower arm ball joint as the subframe is being lowered. Failure to follow
Detach the lower arm.
Remove the subframe.
Lower the special tool.
Installation
All vehicles
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1. WARNING: Raise the special tool platform slowly. Failure to follow
this instruction can result in personal injury.
Install the subframe.
2. CAUTION: To prevent damage to the lower arm bushing, attach
the lower arm ball joint as the subframe is being raised. Failure to follow
Attach the lower arm.
4. Remove the steering gear securing straps.
Tighten to 133 Nm.
Tighten to 133 Nm.
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Loosely install the front subframe front mount retaining bolt.
Tighten to 142 Nm.
Tighten to 142 Nm.
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M8 to 35 Nm.
M10 to 70 Nm.
Tighten to 80 Nm.
Tighten to 80 Nm.
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18. Attach the fuel fired booster heater electrical connector to the
20. Attach the coolant hoses from the retaining clips.
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21. Attach the electric booster heater electrical connector to the subframe
retaining tang.
All vehicles
22. Attach the rear of the steering gear cooling pipe.
Tighten to 7 Nm.
23. Attach the front of the steering gear cooling pipe.
Tighten to 7 Nm.
24. Connect the high intensity discharge (H.I.D) sensor drop arm.
All vehicles
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Tighten to 48 Nm.
Install the lower arm ball joint retaining nut and bolt.
Tighten to 83 Nm.
Install the wheel arch liner access cover.
30. Install the wheels and tires.
31. Calibrate the steering angle sensor, using the Jaguar approved
diagnostic system.
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Uni-Body, Subframe and Mounting System - Front Subframe Front Bushing
Special Tool(s)
Adaptor nut
204-274
Forcing screw
204-275
Support
204-305
Installer guide
204-306
Receiver cup
204-307
Bush remover/installer
204-308
Bush remover/installer
204-243
Thrust bearing
JAG-061
Removal
1. Remove the front subframe
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2. NOTE: Note the orientation of the bushing before removal.
Using the special tools, remove the front subframe mounting bushing.
Installation
1. Fit the bushing to the special tool.
2. NOTE: Apply a suitable amount of Shell gravex oil 973 to the bushing
NOTE: Make sure the bushing is correctly orientated.
Using the special tools, engage the bushing into the subframe.
Using suitable clamps, secure the special tool to the subframe.
3. Remove the securing clamps and the special tool.
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4. Using the special tools, fully engage the bushing into the subframe.
5. Install the front subframe
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Uni-Body, Subframe and Mounting System - Front Subframe Rear Bushing
Special Tool(s)
Adaptor nut
204-274
Forcing screw
204-275
Support
204-305
Installer guide
204-306
Receiver cup
204-307
Bush remover
204-308
Bush installer
204-315
Installer guide
204-319
Bush installer
204-243
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Thrust bearing
JAG-061
Removal
1. Remove the front subframe
2. NOTE: Note the orientation of the bushing before removal.
Using the special tools, remove the front subframe mounting bushing.
Installation
1. Fit the bushing to the special tool.
2. CAUTION: Make sure excessive pressure is not used when
installing the bushing. Failure to follow these instructions may result in
damage to the subframe.
NOTE: Apply a suitable amount of Shell gravex oil 973 to the bushing
before installing.
NOTE: Make sure the bushing is correctly orientated.
Using the special tools, partially install the bushing.
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4. Using the special tools, fully seat the bushing.
5. Install the front subframe
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Uni-Body, Subframe and Mounting System - Rear Axle Crossmember Bushing
Special Tool(s)
Forcing nut
204-274
Forcing screw
204-275
Support cup
204-299
Bush remover
204-271
Bush installer
204-245
Removal
1. Remove the drive differential. For additional information, refer to
Section 205-02 Rear Drive Axle/Differential .
3. Detach the wheel knuckle mounting bracket.
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4. Loosen the rear subframe mounting retaining bolts.
5. Using the special tools, remove the rear axle crossmember bush.
Installation
1. Using the special tools, install the rear axle crossmember bush.
2. NOTE: The final tightening of the suspension components must be
carried out with the vehicle on its wheels.
Tighten to 126 Nm.
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Tighten to 126 Nm.
Tighten to 130 Nm.
5. Install the drive differential. For additional information, refer to Section
205-02 Rear Drive Axle/Differential .
6. Carry out the rear subframe alignment procedure. For additional
information, refer to Underbody Misalignment Check .
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Uni-Body, Subframe and Mounting System - Rear Subframe
Special Tool(s)
HTJ1200-2
Removal
All vehicles
1. Remove the wheels and tires.For additional information, refer to: Wheel
and Tire (204-04 Wheels and Tires, Removal and Installation).
2. Remove the driveshaft.For additional information, refer to: Driveshaft
(205-01 Driveshaft, Removal and Installation).
All vehicles
3. Remove the front muffler.For additional information, refer to: (309-00
Exhaust System)
Front Muffler - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS)
- Puma (Removal and Installation),
Front Muffler - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 -
AJ27 (Removal and Installation).
NOTE: 2.5L and 3.0L shown,2.0L similar.
Detach the rear muffler exhaust hanger insulators.
2. Detach the rear parking brake cables.
Detach the parking brake cables and conduits.
1. Release the parking brake conduit retaining tangs.
2. Detach the parking brake cables and conduits.
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Detach the parking brake cables and conduits from the wheel hub
carriers.
Detach the brake calipers and secure to one side.
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Detach the Anti-lock brake system (ABS) wheel speed sensors.
Remove the ABS wheel speed sensor retaining bolts.
Remove the ABS wheel speed sensor wiring harness retaining straps.
All vehicles
Detach the ABS wheel speed sensor wiring harness.
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Detach the dampers.
Position and adjust the special tool front height adjusters.
Position and adjust the special tool rear height adjusters.
Detach the wheel knuckle mounting brackets.
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Detach the rear subframe.
slowly. Failure to follow this instruction can result in personal injury.
Remove the rear subframe.
Installation
All vehicles
4. Install the driveshaft.For additional information, refer to: Driveshaft
(205-01 Driveshaft, Removal and Installation).
All vehicles
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5. CAUTIONS:
Make sure that the piston location mark is in the correct position so
that the locator pin on the brake pad backing plate locates correctly into
the piston.
Tighten to 32 Nm.
6. Install the front muffler.For additional information, refer to: (309-00
Exhaust System)
Front Muffler - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS)
- Puma (Removal and Installation),
Front Muffler - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 -
AJ27 (Removal and Installation).
7. Install the wheels and tires.For additional information, refer to: Wheel
and Tire (204-04 Wheels and Tires, Removal and Installation).
Tighten to 130 Nm.
10. Carry out the rear subframe alignment procedure.For additional
information, refer to: Underbody Misalignment Check (502-00 Uni-Body,
Subframe and Mounting System, General Procedures).
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Uni-Body, Subframe and Mounting System - Rear Subframe Bushing
Special Tool(s)
Bush remover
204-315
Support cup
204-316
Forcing screw
204-320
Support cup
204-318
Installer guide
204-319
Pusher
204-317
All mounting bushes
1. Remove the rear subframe. For additional information, refer to Subframe
Rear.
Rear subframe front mounting bush
2. Note the orientation of the mounting bush.
Rear subframe rear mounting bush
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3. Note the orientation of the mounting bush.
All mounting bushes
4. CAUTION: Make sure the subframe is not damaged during this
procedure.
Cut the edge of the mounting bush.
5. Using the special tools, remove the mounting bush.
Installation
Rear subframe front mounting bush
1. NOTE: Apply a suitable amount of Shell gravex oil 973 to the bush
before installing.
Align the bush to the subframe. The alignment pointer points to the
front of the vehicle.
Rear subframe rear mounting bush
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2. NOTE: Apply a suitable amount of Shell gravex oil 973 to the bush
before installing.
Align the bush to the subframe. The alignment pointer points to the
front and rear of the vehicle.
All mounting bushes
3. Using the special tools, install the mounting bush.
4. Install the rear subframe. For additional information, refer to Subframe
Rear.
www.JagDocs.com
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