Jaguar X 250 - XF - Service Manual / Repair Manual - Electrical Information View larger

Jaguar X 250 - XF - Service Manual / Repair Manual - Electrical Information

English Service Manual / Repair Manual and Electrical Information to vehicles Jaguar X 250 - XF.

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LANGUAGE: English.
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PAGES: 3504
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JAGUAR X 250 - XF - WORKSHOP, SERVICE, REPAIR MANUAL - ELECTRICAL

- English Service Manual and Electrical Information to vehicles Jaguar X 250 - XF.



TABLE OF CONTENTS

1: GENERAL INFORMATION

100: Service Information
100-00: General Information
- Description and Operation
- About This Manual
- Application and Use of Specifications
- Battery and Battery Charging Health and Safety Precautions
- Brake System Health and Safety Precautions
- General Service Information
- Health and Safety Precautions
- How To Use This Manual
- Important Safety Instructions
- Petrol and Petrol-Ethanol Fuel Systems Health and Safety Precautions
- Solvents, Sealants and Adhesives
- Standard Workshop Practices
- Symbols Glossary
- Supplemental Restraint System (SRS) Health and Safety Precautions
- Road/Roller Testing
100-01: Identification Codes
- Description and Operation
- Identification Codes
100-02: Jacking and Lifting
- Description and Operation
- Jacking
- Lifting
100-04: Noise, Vibration and Harshness
- Description and Operation
- Noise, Vibration and Harshness (NVH)
- Diagnosis and Testing
- Noise, Vibration and Harshness (NVH)
- General Procedures
- Exhaust System Neutralizing

2: CHASSIS

204: Suspension
204-00: Suspension System - General Information
- Specification
- Diagnosis and Testing
- Suspension System
- General Procedures
- Camber and Caster Adjustment
- Four-Wheel Alignment
- Front Toe Adjustment (57.65.01)
- Rear Toe Adjustment (57.65.08)
204-01: Front Suspension
- Specification

- Description and Operation
- Component Location
- Overview
- System Operation and Component Description
- Diagnosis and Testing
- Front Suspension
- Removal and Installation
- Front Shock Absorber (60.30.04)
- Front Lower Arm (60.35.53)
- Rear Lower Arm (60.35.54)
- Rear Lower Arm Bushing (60.35.56)
- Shock Absorber Bushing (60.30.16) (60.30.23)
- Front Stabilizer Bar (60.10.01) - TDV6 2.7L Diesel
- Front Stabilizer Bar (60.10.01) - V6 3.0L Petrol
- Front Stabilizer Bar (60.10.01) - V8 4.2L Petrol/V8 S/C 4.2L Petrol
- Front Stabilizer Bar Link (60.10.02)
- Stabilizer Bar Link Bushing (60.10.03)
- Upper Arm LH (60.35.41)
- Upper Arm RH (60.35.42)
- Front Wheel Bearing and Wheel Hub (60.25.03)
- Wheel Knuckle (60.25.23)
204-02: Rear Suspension
- Specification
- Description and Operation
- Component Location
- Overview
- System Operation and Component Description
- Diagnosis and Testing
- Rear Suspension
- Removal and Installation
- Upper Arm (64.25.31)
- Lower Arm (64.35.43)
- Shock Absorber and Spring Assembly
- Shock Absorber Lower Bushing (64.30.39)
- Rear Stabilizer Bar (64.35.08)
- Rear Wheel Bearing
- Disassembly and Assembly
- Shock Absorber and Spring Assembly
204-04: Wheels and Tires
- Specification
- Description and Operation
- Component Location
- Overview
- System Operation and Component Description
- Diagnosis and Testing
- Wheels and Tires
- Removal and Installation
- Tire Low Pressure Sensor
- Tire Pressure Monitoring System (TPMS) Front Antenna
- Tire Pressure Monitoring System (TPMS) Rear Antenna
- Tire Pressure Monitoring System (TPMS) Module
- Tire Pressure Monitoring System (TPMS) Receiver
- Wheel and Tire
204-05: Vehicle Dynamic Suspension
- Description and Operation
- Component Location - V8 4.2L Petrol/V8 S/C 4.2L Petrol
- Overview - V8 4.2L Petrol/V8 S/C 4.2L Petrol
- System Operation and Component Description - V8 4.2L Petrol/V8 S/C 4.2L Petrol
- Diagnosis and Testing
- Vehicle Dynamic Suspension
- Removal and Installation
- Adaptive Damping Module
- Front Suspension Vertical Accelerometer
- Rear Suspension Vertical Accelerometer
204-06: Ride and Handling Optimization
- Description and Operation
- Component Location
- Overview
- System Operation and Component Description
205: Driveline
- 205-00: Driveline System - General Information
- Diagnosis and Testing
- Driveline System
- General Procedures
- Driveline Angle Inspection
205-01: Driveshaft
- Specification
- Description and Operation
- Component Location
- Overview
- System Operation and Component Description
- Diagnosis and Testing
- Driveshaft
- General Procedures
- Driveshaft Runout and Balancing
- Removal and Installation
- Driveshaft
205-02: Rear Drive Axle/Differential
- Specification - 2.7L V6 - TdV6/3.0L NA V6 - AJ27/4.2L NA V8 - AJV8/4.2L SC V8 - AJV8
- Description and Operation
- Component Location - V8 4.2L Petrol/V8 S/C 4.2L Petrol
- Overview - V8 4.2L Petrol/V8 S/C 4.2L Petrol
- System Operation and Component Description - V8 4.2L Petrol/V8 S/C 4.2L Petrol
- Diagnosis and Testing
- Rear Drive Axle and Differential
- Removal and Installation
- Axle Assembly (51.25.13) - 2.7L V6 - TdV6/3.0L NA V6 - AJ27/4.2L NA V8 -
- AJV8/4.2L SC V8 - AJV8, Vehicles Without: Differential Drain Plug
- Axle Housing Bushing (64.25.30) - 2.7L V6 - TdV6/3.0L NA V6 - AJ27/4.2L NA V8 -
- AJV8/4.2L SC V8 - AJV8
205-05: Rear Drive Halfshafts
- Specification
- Description and Operation
- Component Location
- Overview
- System Operation and Component Description
- Diagnosis and Testing
- Rear Drive Halfshafts
- Removal and Installation
- Rear Halfshaft (47.10.13)
- Inner Constant Velocity (CV) Joint Boot (47.10.33)
- Outer Constant Velocity (CV) Joint Boot (47.10.32)
206: Brake System
206-00: Brake System - General Information
- Specification
- Diagnosis and Testing
- Brake System
- General Procedures
- Brake Disc Runout Check
- Brake System Bleeding (70.25.03)
206-03: Front Disc Brake - 2.7L V6 - TdV6/3.0L NA V6 - AJ27/4.2L NA V8 - AJV8/4.2L SC V8
- AJV8
- Specification
- Description and Operation
- Component Location
- Overview
- Diagnosis and Testing
- Front Disc Brake
- Removal and Installation
- Brake Caliper (70.55.02) - Vehicles With: Standard Brakes
- Brake Caliper (70.55.02) - Vehicles With: High Performance Brakes
- Brake Disc (70.10.10) - Vehicles With: Standard Brakes
- Brake Disc (70.10.10) - Vehicles With: High Performance Brakes
- Brake Disc Shield (70.10.18) - Vehicles With: Standard Brakes
- Brake Disc Shield (70.10.18) - Vehicles With: High Performance Brakes
- Brake Pads (70.40.02) - Vehicles With: Standard Brakes
- Brake Pads (70.40.02) - Vehicles With: High Performance Brakes
206-04: Rear Disc Brake - 2.7L V6 - TdV6/3.0L NA V6 - AJ27/4.2L NA V8 - AJV8/4.2L SC
- V8 - AJV8
- Specification
- Description and Operation
- Component Location
- Overview
- Diagnosis and Testing
- Rear Disc Brake
- Removal and Installation
- Brake Caliper (70.55.03) (70.55.25)
- Brake Disc (70.10.11)
- Brake Pads (70.40.03)
- Brake Disc Shield (70.10.19)
206-05: Parking Brake and Actuation
- Description and Operation
- Component Location
- Overview
- System Operation and Component Description
- Diagnosis and Testing
- Parking Brake
- General Procedures
- Parking Brake Cable Tension Release
- Removal and Installation
- Parking Brake Cable LH - 2.7L V6 - TdV6/3.0L NA V6 - AJ27/4.2L NA V8 - AJV8/4.2L
- SC V8 - AJV8
- Parking Brake Cable RH - 2.7L V6 - TdV6/3.0L NA V6 - AJ27/4.2L NA V8 - AJV8/4.2L
- SC V8 - AJV8
- Parking Brake Module
- Parking Brake Switch
- Parking Brake Release Actuator (70.35.45) - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8
206-06: Hydraulic Brake Actuation
- Specification
- Description and Operation
- Component Location
- Overview
- System Operation and Component Description
- Diagnosis and Testing
- Hydraulic Brake Actuation
- Removal and Installation
- Brake Fluid Reservoir (70.30.16)
- Brake Master Cylinder (70.30.08)
206-07: Power Brake Actuation
- Specification
- Description and Operation
- Component Location
- Overview
- Diagnosis and Testing
- Power Brake System
- Removal and Installation
- Brake Booster (70.50.17)
- Brake Vacuum Pump - 2.7L V6 - TdV6
206-09: Anti-Lock Control - Stability Assist
- Specification
- Description and Operation
- Component Location
- Overview
- System Operation and Component Description
- Diagnosis and Testing
- Anti-Lock Control - Stability Assist
- Removal and Installation
- Anti-Lock Brake System (ABS) Module (70.60.02)
- Front Wheel Speed Sensor
- Rear Wheel Speed Sensor (70.60.04)
- Steering Wheel Rotation Sensor
- Yaw Rate Sensor and Accelerometer
211: Steering System
211-00: Steering System - General Information
- Specification
- Diagnosis and Testing
- Steering System
- General Procedures
- Power Steering System Bleeding (57.15.02 )
211-02: Power Steering
- Specification
- Description and Operation
- Component Location
- Overview
- System Operation and Component Description
- Diagnosis and Testing
- Power Steering
- Removal and Installation
- Steering Gear (57.10.01)
- Power Steering Fluid Cooler (57.15.11) - 3.0L NA V6 - AJ27/4.2L NA V8 - AJV8/4.2L
- SC V8 - AJV8
- Power Steering Fluid Reservoir (57.15.08)
- Power Steering Pump - TDV6 2.7L Diesel
- Power Steering Pump - V6 3.0L Petrol
- Power Steering Pump (57.20.14) - 4.2L NA V8 - AJV8
211-03: Steering Linkage
- Specification
- Description and Operation
- Component Location
- Overview
- System Operation and Component Description
- Diagnosis and Testing
- Steering Linkage
- Removal and Installation
- Tie Rod End (57.55.02)
211-04: Steering Column
- Specification
- Description and Operation
- Component Location
- Overview
- System Operation and Component Description
- Diagnosis and Testing
- Steering Column
- Removal and Installation
- Steering Column
- Steering Column Flexible Coupling
- Steering Wheel (57.60.01)
211-05: Steering Column Switches
- Description and Operation
- Component Location
- Overview
- System Operation and Component Description
- Diagnosis and Testing
- Steering Column Switches
- Removal and Installation
- Hazard Flasher Switch
- Steering Column Multifunction Switch LH
- Steering Column Multifunction Switch RH
- Steering Column Lock Actuator

3: POWERTRAIN

303: Engine
303-00: Engine System - General Information
- Diagnosis and Testing
- Engine - 3.0L NA V6 - AJ27/4.2L NA V8 - AJV8/4.2L SC V8 - AJV8
- Engine - TDV6 2.7L Diesel
- General Procedures
- Bearing Inspection
- Camshaft Bearing Journal Clearance
- Camshaft Bearing Journal Diameter
- Camshaft End Play
- Camshaft Lobe Lift
- Camshaft Surface Inspection
- Connecting Rod Cleaning
- Connecting Rod Large End Bore
- Crankshaft End Play
- Crankshaft Main Bearing Journal Clearance - 3.0L NA V6 - AJ27
- Crankshaft Main Bearing Journal Clearance - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8
- Cylinder Bore Out-of-Round
- Cylinder Head Distortion
- Exhaust Manifold Cleaning and Inspection
- Piston Inspection
- Piston Pin Diameter
- Piston Pin to Bore Diameter
- Piston Ring End Gap
- Piston Ring-to-Groove Clearance
- Valve Spring Free Length
- Valve Stem Diameter
303-01A: Engine - TDV6 2.7L Diesel
- Specification
- Description and Operation
- Component Location
- Overview
- System Operation and Component Description
- Diagnosis and Testing
- Engine
- General Procedures
- Engine Oil Draining and Filling
- Removal and Installation
- Camshaft Front Seal
- Camshaft LH
- Camshaft Rear Seal
- Crankshaft Front Seal
- Crankshaft Pulley
- Crankshaft Rear Seal
- Crankshaft Vibration Damper
- Cylinder Head LH
- Engine Mount LH
- Engine Mount RH
- Exhaust Manifold
- Flexplate
- Oil Filter Element
- Oil Pan
- Oil Pan Extension
- Oil Pump
- Timing Belt
- Timing Cover
- Valve Cover
- Valve Cover LH
- Valve Cover RH
- Removal
- Engine (12.41.01)
- Installation
- Engine (12.41.01)
303-01B: Engine - V6 3.0L Petrol
- Specification
- Description and Operation
- Component Location
- Overview
- System Operation and Component Description
- Diagnosis and Testing
- Engine
- General Procedures
- Engine Oil Draining and Filling
- 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 (12.29.01)
- Engine Front Cover (12.65.01)
- Engine Mount LH (12.45.01)
- Exhaust Manifold LH (30.15.55)
- Flexplate (12.53.13)
- Oil Cooler (12.60.68)
- Oil Pan (12.60.44)
- Oil Pump (12.60.26)
- Timing Drive Components (12.65.13)
- Valve Cover LH (12.29.43)
- Valve Cover RH (12.29.44)
- Removal and Installation
- Intake Manifold
- Lower Intake Manifold
- Removal
- Engine (12.41.01)
- Installation
- Engine (12.41.01)
303-01C: Engine - 4.2L NA V8 - AJV8
- Specification
- Description and Operation
- Component Location
- Overview
- System Operation and Component Description
- Diagnosis and Testing
- Engine
- General Procedures
- Engine Oil Draining and Filling
- Valve Clearance Adjustment (12.29.48)
- Valve Clearance Check (12.29.47)
- In-Vehicle Repair
- Camshafts LH (12.13.19)
- Camshafts RH (12.13.18)
- 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 Mount LH (12.45.01)
- Engine Mount RH (12.45.03)
- Exhaust Manifold LH (30.15.55)
- Flexplate (12.53.13)
- Exhaust Manifold RH (30.15.56)
- Intake Manifold (30.15.01)
- Oil Pan (12.60.44)
- Oil Pan Extension (12.60.48)
- Oil Pump (12.60.26)
- Secondary Timing Chain Tensioner
- Timing Drive Components (12.65.13)

- Valve Cover LH (12.29.43)
- Valve Cover RH (12.29.44)
- Oil Filter Housing
- Removal and Installation
- Crankshaft Main Bearing Carrier
- Removal
- Engine (12.41.01)
- Installation
- Engine (12.41.01)
303-01D: Engine - 4.2L SC V8 - AJV8
- Specification
- Description and Operation
- Component Location
- Overview
- System Operation and Component Description
- Diagnosis and Testing
- Engine
- General Procedures
- Engine Oil Draining and Filling
- 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 Mount LH (12.45.01)
- Engine Mount RH (12.45.03)
- Exhaust Manifold LH (30.15.55)
- Flexplate (12.53.13)
- Oil Filter Housing
- Oil Pan (12.60.44)
- Oil Pump (12.60.26)
- Timing Drive Components (12.65.13)
- Twin Oil Coolers
- Valve Cover LH (12.29.43)
- Valve Cover RH (12.29.44)
- Removal and Installation
- Crankshaft Main Bearing Carrier
- Removal
- Engine (12.41.01)
- Installation
- Engine (12.41.01)
303-03A: Engine Cooling - TDV6 2.7L Diesel
- Specification
- Description and Operation
- Component Location
- Overview
- System Operation and Component Description
- Diagnosis and Testing
- Engine Cooling
- General Procedures
- Cooling System Draining, Filling and Bleeding
- Removal and Installation
- Coolant Expansion Tank (26.15.01)
- Cooling Fan Motor and Shroud (26.25.25)
- Coolant Pump

- Radiator (26.40.01)
- Thermostat (26.45.07)
303-03B: Engine Cooling - V6 3.0L Petrol
- Specification
- Description and Operation
- Component Location
- Overview
- System Operation and Component Description
- Diagnosis and Testing
- Engine Cooling
- General Procedures
- Cooling System Draining, Filling and Bleeding
- Removal and Installation
- Coolant Expansion Tank (26.15.01)
- Cooling Fan Shroud
- Cooling Module (26.40.16)
- Thermostat (26.45.07)
- Radiator (26.40.01)
- Water Pump (26.50.01)
303-03C: Engine Cooling - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8
- Specification
- Description and Operation
- Component Location
- Overview
- System Operation and Component Description
- Diagnosis and Testing
- Engine Cooling
- General Procedures
- Cooling System Draining, Filling and Bleeding
- Removal and Installation
- Coolant Expansion Tank (26.15.01)
- Cooling Fan Motor and Shroud - 4.2L SC V8 - AJV8
- Cooling Fan Motor and Shroud (26.25.25) - 4.2L NA V8 - AJV8
- Coolant Manifold - 4.2L SC V8 - AJV8
- Cooling Module (26.40.16) - 4.2L SC V8 - AJV8
- Cooling Module (26.40.16) - 4.2L NA V8 - AJV8
- Coolant Pump - 4.2L SC V8 - AJV8
- Coolant Pump - 4.2L NA V8 - AJV8
- Radiator (26.40.01) - 4.2L SC V8 - AJV8
- Radiator (26.40.01) - 4.2L NA V8 - AJV8
- Thermostat (26.45.07) - 4.2L SC V8 - AJV8
- Thermostat (26.45.07) - 4.2L NA V8 - AJV8
- Thermostat Housing - 4.2L SC V8 - AJV8
- Thermostat Housing - 4.2L NA V8 - AJV8
303-03D: Supercharger Cooling - 4.2L SC V8 - AJV8

- Specification
- Description and Operation
- Component Location
- Overview
- System Operation and Component Description
- Diagnosis and Testing
- Supercharger Cooling
- Removal and Installation
- Radiator
- 303-04A: Fuel Charging and Controls - TDV6 2.7L Diesel
- Specification
- Description and Operation
- Component Location
- Overview
- System Operation and Component Description
- Diagnosis and Testing
- Fuel Charging and Controls
- General Procedures
- Fuel Injection Component Cleaning
- Removal and Installation
- Fuel Injector (18.10.01)
- Fuel Injection Pump
- Intake Air Shutoff Throttle
- Swirl Plate Actuator Diaphragm
303-04B: Fuel Charging and Controls - Turbocharger - TDV6 2.7L Diesel
- Specification
- Description and Operation
- Component Location
- Overview
- System Operation and Component Description
- Diagnosis and Testing
- Turbocharger
- Removal and Installation
- Turbocharger LH
- Turbocharger RH
303-04C: Fuel Charging and Controls - V6 3.0L Petrol

- Specification
- Description and Operation
- Component Location
- Overview
- System Operation and Component Description
- Diagnosis and Testing
- Fuel Charging and Controls
- Removal and Installation
- Fuel Charging Wiring Harness (86.70.22)
- Fuel Injection Supply Manifold (19.60.13)
- Fuel Injectors (18.10.02)
- Fuel Pressure Regulator (19.45.11)
- Throttle Body (19.70.04)
303-04D: Fuel Charging and Controls - 4.2L NA V8 - AJV8
- Specification
- Description and Operation
- Component Location
- Overview
- System Operation and Component Description
- Diagnosis and Testing
- Fuel Charging and Controls
- Removal and Installation
- Fuel Injectors (18.10.02)
- Fuel Injection Supply Manifold (19.60.13)
- Fuel Pressure Regulator (19.45.11)
- Throttle Body (19.70.04)
303-04E: Fuel Charging and Controls - 4.2L SC V8 - AJV8
- Description and Operation
- Component Location
- Overview
- System Operation and Component Description
- Diagnosis and Testing
- Fuel Charging and Controls
- Removal and Installation
- Fuel Injectors
- Fuel Rail
- Throttle Body
303-05A: Accessory Drive - TDV6 2.7L Diesel
- Specification
- Description and Operation
- Component Location
- Overview
- Diagnosis and Testing
- Accessory Drive
- Removal and Installation
- Accessory Drive Belt (12.10.40)
- Accessory Drive Belt Idler Pulley (12.10.43)
- Accessory Drive Belt Tensioner (12.10.41)
- Fuel Injection Pump Belt
- Fuel Injection Pump Pulley
303-05B: Accessory Drive - V6 3.0L Petrol
- Specification
- Description and Operation
- Component Location
- Overview
- Diagnosis and Testing
- Accessory Drive
- Removal and Installation
- Accessory Drive Belt (12.10.40)
- Accessory Drive Belt Idler Pulley (12.10.43)
- Accessory Drive Belt Tensioner (12.10.41)
303-05C: Accessory Drive - 4.2L NA V8 - AJV8
- Specification
- Description and Operation
- Component Location
- Overview
- Diagnosis and Testing
- Accessory Drive
- Removal and Installation
- Accessory Drive Belt (12.10.40)
- Accessory Drive Belt Tensioner (12.10.41)
- Accessory Drive Belt Idler Pulley (12.10.43)
303-05D: Accessory Drive - 4.2L SC V8 - AJV8
- Specification
- Description and Operation
- Component Location
- Overview
- Diagnosis and Testing
- Accessory Drive
- Removal and Installation
- Accessory Drive Belt (12.10.40)
- Accessory Drive Belt Tensioner (12.10.41)
- Accessory Drive Belt Idler Pulley (12.10.43)
- Supercharger Belt (18.50.08)
- Supercharger Belt Tensioner (18.50.24)
- Supercharger Belt Idler Pulley (18.50.09)
303-06A: Starting System - TDV6 2.7L Diesel
- Specification
- Description and Operation
- Component Location
- Overview
- Diagnosis and Testing
- Starting System
- Removal and Installation
- Starter Motor (86.60.01)
303-06B: Starting System - V6 3.0L Petrol
- Specification
- Description and Operation
- Component Location
- Overview
- Diagnosis and Testing
- Starting System
- Removal and Installation
- Starter Motor (86.60.01)
303-06C: Starting System - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8
- Specification
- Description and Operation
- Component Location
- Overview
- Diagnosis and Testing
- Starting System
- Removal and Installation
- Starter Motor (86.60.01)
303-07A: Engine Ignition - V6 3.0L Petrol
- Specification
- Description and Operation
- Component Location
- Overview
- System Operation and Component Description
- Diagnosis and Testing
- Engine Ignition
- Removal and Installation
- Ignition Coil-On-Plug LH (18.20.44)
- Ignition Coil-On-Plug RH (18.20.43)
303-07B: Engine Ignition - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8
- Specification
- Description and Operation
- Component Location
- Overview
- System Operation and Component Description
- Diagnosis and Testing
- Engine Ignition
- Removal and Installation
- Ignition Coil-On-Plug (18.20.40) - 4.2L NA V8 - AJV8
- Ignition Coil-On-Plug (18.20.40) - 4.2L SC V8 - AJV8
303-07C: Glow Plug System
- Specification
- Description and Operation
- Component Location
- Overview
- System Operation and Component Description
- Diagnosis and Testing
- Glow Plug System
303-08A: Engine Emission Control - TDV6 2.7L Diesel
- Specification
- Description and Operation
- Component Location
- Overview
- System Operation and Component Description
- Diagnosis and Testing
- Engine Emission Control
- Removal and Installation
- Crankcase Vent Oil Separator
- Exhaust Gas Recirculation (EGR) Valve Outlet Tube (17.45.11)
- Exhaust Gas Recirculation (EGR) Valve LH
- Exhaust Gas Recirculation (EGR) Valve RH
303-08B: Engine Emission Control - V6 3.0L Petrol
- Specification
- Description and Operation
- Component Location
- Overview
- System Operation and Component Description
- Diagnosis and Testing
- Engine Emission Control
- Removal and Installation
- Secondary Air Injection (AIR) Control Valve
- Secondary Air Injection (AIR) Control Valve to Exhaust Manifold Tube LH
- Secondary Air Injection (AIR) Control Valve to Exhaust Manifold Tube RH
- Secondary Air Injection (AIR) Pump
303-08C: Engine Emission Control - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8
- Specification
- Description and Operation
- Component Location
- Overview
- System Operation and Component Description
- Diagnosis and Testing
- Engine Emission Control
- Removal and Installation
- Exhaust Gas Recirculation (EGR) Valve (17.45.01) - 4.2L NA V8 - AJV8
- Exhaust Gas Recirculation (EGR) Valve - 4.2L SC V8 - AJV8
- Exhaust Manifold to Exhaust Gas Recirculation (EGR) Valve Tube (17.45.11) - 4.2L
- NA V8 - AJV8
- Exhaust Manifold to Exhaust Gas Recirculation (EGR) Valve Tube - 4.2L SC V8 - AJV8
- Secondary Air Injection (AIR) Control Valve to Exhaust Manifold Tube
- Secondary Air Injection (AIR) Control Valve - 4.2L NA V8 - AJV8
- Secondary Air Injection (AIR) Control Valve - 4.2L SC V8 - AJV8
- Secondary Air Injection (AIR) Pump
- Secondary Air Injection Manifold Absolute Pressure Sensor
303-12A: Intake Air Distribution and Filtering - TDV6 2.7L Diesel
- Specification
- Description and Operation
- Component Location
- Overview
- System Operation and Component Description
- Diagnosis and Testing
- Intake Air Distribution and Filtering
- Removal and Installation
- Air Cleaner (19.10.05)
- Air Cleaner Element (19.10.08)
- Charge Air Cooler
303-12B: Intake Air Distribution and Filtering - V6 3.0L Petrol
- Specification
- Description and Operation
- Component Location
- Overview
- System Operation and Component Description
- Diagnosis and Testing
- Intake Air Distribution and Filtering
- Removal and Installation
- Air Cleaner
- Air Cleaner Outlet Pipe
- Air Cleaner Element
303-12C: Intake Air Distribution and Filtering - 4.2L NA V8 - AJV8
- Specification
- Description and Operation
- Component Location
- Overview
- System Operation and Component Description
- Diagnosis and Testing
- Intake Air Distribution and Filtering
- Removal and Installation
- Air Cleaner
- Air Cleaner Outlet Pipe
- Air Cleaner Element
303-12D: Intake Air Distribution and Filtering - 4.2L SC V8 - AJV8
- Specification
- Description and Operation
- Component Location
- Overview
- System Operation and Component Description
- Diagnosis and Testing
- Intake Air Distribution and Filtering
- Removal and Installation
- Air Cleaner LH
- Air Cleaner RH
- Air Cleaner Element
- Air Cleaner Outlet Pipe
- Charge Air Cooler
- Supercharger
- Supercharger Outlet Pipe
303-13A: Evaporative Emissions - V6 3.0L Petrol
- Specification
- Description and Operation
- Component Location

- Overview
- System Operation and Component Description
- Diagnosis and Testing
- Evaporative Emissions
- Removal and Installation
- Evaporative Emission Canister (17.15.13)
- Evaporative Emission Canister Purge Valve (17.15.30)
- Evaporative Emission Canister Vent Solenoid (17.15.45)
303-13B: Evaporative Emissions - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8
- Specification
- Description and Operation
- Component Location
- Overview
- System Operation and Component Description
- Diagnosis and Testing
- Evaporative Emissions
- Removal and Installation
- Evaporative Emission Canister (17.15.13)
- Evaporative Emission Canister Purge Valve (17.15.30) - 4.2L NA V8 - AJV8
- Evaporative Emission Canister Purge Valve - 4.2L SC V8 - AJV8
303-14A: Electronic Engine Controls - TDV6 2.7L Diesel
- Specification
- Description and Operation
- Component Location
- Overview
- System Operation and Component Description
- Diagnosis and Testing
- Electronic Engine Controls
- Removal and Installation
- Camshaft Position (CMP) Sensor (18.30.63)
- Crankshaft Position (CKP) Sensor (18.30.12)
- Crankshaft Position (CKP) Sensor Ring
- Engine Control Module (ECM) (18.30.01)
- Engine Coolant Temperature (ECT) Sensor (18.30.10)
- Engine Oil Pressure (EOP) Sensor
- Fuel Rail Pressure (FRP) Sensor (18.30.98)
- Fuel Temperature Sensor (18.30.99)
- Knock Sensor (KS) LH (18.30.92)
- Knock Sensor (KS) RH (18.30.93)
- Intake Air Temperature (IAT) Sensor
- Manifold Absolute Pressure (MAP) Sensor (18.30.86)
- Mass Air Flow (MAF) Sensor (18.30.15)
- Oil Temperature Sensor (18.31.01)
303-14B: Electronic Engine Controls - V6 3.0L Petrol
- Specification
- Description and Operation
- Component Location
- Overview
- System Operation and Component Description
- Diagnosis and Testing
- Electronic Engine Controls
- Removal and Installation
- Camshaft Position (CMP) Sensor LH (18.31.12)
- Camshaft Position (CMP) Sensor RH (18.31.11)
- Catalyst Monitor Sensor (18.30.66)
- Crankshaft Position (CKP) Sensor (18.30.12)
- Engine Control Module (ECM) (18.30.01)
- Engine Coolant Temperature (ECT) Sensor
- Fuel Temperature Sensor
- Heated Oxygen Sensor (HO2S)
- Intake Manifold Tuning (IMT) Valve LH (19.70.30)
- Knock Sensor (KS) LH (18.30.92)
- Knock Sensor (KS) RH (18.30.93)
- Manifold Absolute Pressure (MAP) Sensor (18.30.86)
- Mass Air Flow (MAF) Sensor (18.30.15)
- Oil Temperature Sensor (18.31.01)
- Variable Camshaft Timing (VCT) Oil Control Solenoid (18.30.90)
303-14C: Electronic Engine Controls - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8
- Specification
- Description and Operation
- Component Location
- Overview
- System Operation and Component Description
- Diagnosis and Testing
- Electronic Engine Controls
- General Procedures

- Powertrain Control Module (PCM) Long Drive Cycle Self-Test
- Powertrain Control Module (PCM) Short Drive Cycle Self-Test
- Removal and Installation
- Camshaft Position (CMP) Sensor LH (18.31.12)
- Camshaft Position (CMP) Sensor RH (18.31.11)
- Catalyst Monitor Sensor (18.30.66)
- Crankshaft Position (CKP) Sensor (18.30.12) - 4.2L NA V8 - AJV8
- Engine Control Module (ECM) (18.30.01)
- Engine Coolant Temperature (ECT) Sensor (18.30.10)
- Fuel Temperature Sensor (18.30.99)
- Heated Oxygen Sensor (HO2S)
- Intake Air Temperature (IAT) Sensor (18.30.52)
- Knock Sensor (KS) (18.30.69)
- Manifold Absolute Pressure (MAP) Sensor (18.30.86)
- Mass Air Flow (MAF) Sensor (18.30.15)
- Oil Temperature Sensor (18.31.01)
- Variable Camshaft Timing (VCT) Oil Control Solenoid (18.30.90)
307: Automatic Transmission/Transaxle
307-01: Automatic Transmission/Transaxle - 2.7L V6 - TdV6/3.0L NA V6 - AJ27/4.2L NA
- V8 - AJV8/4.2L SC V8 - AJV8
- Specification
- Description and Operation
- Component Location - Vehicles With: ZF 6HP26
- Overview - Vehicles With: ZF 6HP26
- System Operation and Component Description - Vehicles With: ZF 6HP26
- Component Location - Vehicles With: ZF 6HP26
- Overview - Vehicles With: ZF 6HP26
- System Operation and Component Description - Vehicles With: ZF 6HP26
- Diagnosis and Testing
- Diagnostic Strategy
- General Procedures
- Transmission Fluid Drain and Refill (44.24.02)
- Transmission Fluid Level Check
- In-Vehicle Repair
- Extension Housing Seal (44.20.18)
- Transmission Fluid Pan, Gasket and Filter (44.24.07)
- Transmission Control Module (TCM) and Main Control Valve Body
- Removal
- Transmission (44.20.01) - TDV6 2.7L Diesel
- Transmission (44.20.01) - V6 3.0L Petrol
- Transmission (44.20.01) - V8 4.2L Petrol/V8 S/C 4.2L Petrol
- Installation
- Transmission (44.20.01) - TDV6 2.7L Diesel
- Transmission (44.20.01) - V6 3.0L Petrol
- Transmission (44.20.01) - V8 4.2L Petrol/V8 S/C 4.2L Petrol
307-02: Transmission/Transaxle Cooling - 2.7L V6 - TdV6/3.0L NA V6 - AJ27/4.2L NA V8
- AJV8/4.2L SC V8 - AJV8
- Description and Operation
- Component Location - Vehicles With: ZF 6HP26
- Overview - Vehicles With: ZF 6HP26
- System Operation and Component Description - Vehicles With: ZF 6HP26
- Diagnosis and Testing
- Transmission Cooling
- Removal and Installation
- Transmission Fluid Cooler (44.24.10) - TDV6 2.7L Diesel
- Transmission Fluid Cooler Tubes (44.24.19) - TDV6 2.7L Diesel
307-05: Automatic Transmission/Transaxle External Controls
- Specification
- Description and Operation
- Component Location - Vehicles With: ZF 6HP26
- Overview - Vehicles With: ZF 6HP26
- System Operation and Component Description - Vehicles With: ZF 6HP26
- Diagnosis and Testing
- External Controls
- Removal and Installation
- Transmission Control Switch (TCS)
- Transmission Control Switch (TCS) Knob
- Emergency Park Position Release Lever
- Upshift Paddle Switch
- Downshift Paddle Switch
309: Exhaust System
- 309-00A: Exhaust System - TDV6 2.7L Diesel
- Specification
- Description and Operation
- Component Location
- Overview
- System Operation and Component Description
- Diagnosis and Testing
- Exhaust System
- Removal and Installation
- Catalytic Converter (17.50.05)
- Exhaust System
- Diesel Particulate Filter (DPF)
- Diesel Particulate Filter (DPF) Differential Pressure Sensor
- Front Muffler (30.10.18)
- Rear Muffler
309-00B: Exhaust System - V6 3.0L Petrol
- Specification
- Description and Operation
- Component Location
- Overview
- System Operation and Component Description
- Diagnosis and Testing
- Exhaust System
- Removal and Installation
- Catalytic Converter (17.50.05)
- Exhaust System
- Front Muffler (30.10.18)
- Rear Muffler
309-00C: Exhaust System - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8
- Specification
- Description and Operation
- Component Location
- Overview
- System Operation and Component Description
- Diagnosis and Testing
- Exhaust System
- Removal and Installation
- Catalytic Converter (17.50.05)
- Exhaust System
- Front Muffler (30.10.18)
- Rear Muffler
310: Fuel System - General Information
310-00: Fuel System - General Information
- Specification
- General Procedures
- Fuel System Pressure Check - 3.0L NA V6 - AJ27/4.2L NA V8 - AJV8/4.2L SC V8 –
- AJV8
- Fuel System Pressure Release (19.50.02) - 3.0L NA V6 - AJ27/4.2L NA V8 –
- AJV8/4.2L SC V8 - AJV8
- Fuel Tank Draining
- Low-Pressure Fuel System Bleeding - TDV6 2.7L Diesel
- Spring Lock Couplings
- Quick Release Coupling
- Quick Release Coupling - Push Connect
- 310-01A: Fuel Tank and Lines - TDV6 2.7L Diesel
- Specification
- Description and Operation
- Component Location
- Overview
- System Operation and Component Description
- Diagnosis and Testing
- Fuel Tank and Lines
- Removal and Installation
- Fuel Cooler
- Fuel Filter
- Fuel Tank
- Fuel Pump Module (19.45.08)
- Fuel Transfer Unit
310-01B: Fuel Tank and Lines - V6 3.0L Petrol
- Specification
- Description and Operation
- Component Location
- Overview
- System Operation and Component Description
- Diagnosis and Testing
- Fuel Tank and Lines
- Removal and Installation
- Fuel Filter
- Fuel Level Sender LH
- Fuel Level Sender RH
- Fuel Pump Module (19.45.08)
- Fuel Tank
- Fuel Tank Filler Pipe (19.55.33)
- Fuel Transfer Unit
310-01C: Fuel Tank and Lines - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8
- Specification
- Description and Operation
- Component Location
- Overview
- System Operation and Component Description
- Diagnosis and Testing
- Fuel Tank and Lines
- Removal and Installation
- Fuel Filter
- Fuel Level Sender LH
- Fuel Level Sender RH
- Fuel Pump Module (19.45.08)
- Fuel Tank
- Fuel Tank Filler Pipe (19.55.33)
- Fuel Transfer Unit
310-02: Acceleration Control
- Specification
- Diagnosis and Testing
- Acceleration Control
- Removal and Installation
- Accelerator Pedal
310-03A: Speed Control - TDV6 2.7L Diesel
- Specification
- Description and Operation
- Component Location
- Overview
- System Operation and Component Description
- Diagnosis and Testing
- Speed Control
- General Procedures
- Speed Control Sensor Adjustment
- Removal and Installation
- Speed Control Deactivator Switch
- Speed Control Module
- Speed Control Sensor
- Speed Control Switch
310-03B: Speed Control - V6 3.0L Petrol
- Specification
- Description and Operation
- Component Location
- Overview
- System Operation and Component Description
- Diagnosis and Testing
- Speed Control
- General Procedures

- Speed Control Sensor Adjustment
- Removal and Installation
- Speed Control Deactivator Switch
- Speed Control Module
- Speed Control Sensor
- Speed Control Switch
310-03C: Speed Control - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8
- Specification
- Description and Operation
- Component Location
- Overview
- System Operation and Component Description
- Diagnosis and Testing
- Speed Control
- General Procedures
- Speed Control Sensor Adjustment
- Removal and Installation
- Speed Control Deactivator Switch
- Speed Control Module
- Speed Control Sensor
- Speed Control Switch

4: ELECTRICAL

412: Climate Control System
412-00: Climate Control System - General Information
- Specification
- Diagnosis and Testing
- Climate Control System
- General Procedures
- Air Conditioning (A/C) System Recovery, Evacuation and Charging (82.30.30)
- Air Conditioning (A/C) System Flushing
- Contaminated Refrigerant Handling
- Electronic Leak Detection
- Fluorescent Dye Leak Detection
- Inspection and Assembly Requirements
- Manifold Gauge Set Connection
- Refrigerant Oil Adding
- Refrigerant System Tests
412-01: Climate Control
- Specification
- Description and Operation
- Air Distribution and Filtering
- Component Location
- Overview
- System Operation and Component Description
- Heating and Ventilation
- Component Location
- Overview
- System Operation and Component Description
- Air Conditioning
- Component Location
- Overview
- System Operation and Component Description
- Control Components
- Component Location
- Overview
- System Operation and Component Description
- Removal and Installation
- Ambient Air Temperature Sensor
- Blower Motor
- Blower Motor Control Module
- Center Registers
- Climate Control Assembly
- Climate Control Module
- Defrost Vent/Register Blend Door Actuator
- Driver Side Register
- Evaporator
- Floor Console Register
- Footwell Vent/Duct Blend Door Actuator
- Heater Core
- Heater Core and Evaporator Core Housing
- Instrument Panel Register Trim Panel
- In-Vehicle Temperature Sensor
- Passenger Side Register
- Pollen Filter
- Recirculation Blend Door Actuator
- Sunload Sensor
- Thermostatic Expansion Valve
412-03: Air Conditioning
- Specification
- Diagnosis and Testing
- Air Conditioning
- Removal and Installation
- Air Conditioning (A/C) Compressor (82.10.20) - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8
- Condenser Core - 4.2L NA V8 - AJV8
- Condenser Core - 4.2L SC V8 - AJV8
- Pressure Cutoff Switch (82.10.32)
413: Instrumentation and Warning Systems
413-01: Instrument Cluster
- Specification
- Description and Operation
- Component Location
- Overview
- System Operation and Component Description
- Diagnosis and Testing
- Instrument Cluster
- Removal and Installation
- Instrument Cluster
413-06: Horn
- Specification
- Removal and Installation
- Horn
- Horn Switch
413-08: Information and Message Center
- Description and Operation
- Component Location
- Overview
- System Operation and Component Description
- Diagnosis and Testing
- Information and Message Center
413-09: Warning Devices
- Description and Operation
- Diagnosis and Testing
- Warning Devices
413-13: Parking Aid
- Description and Operation
- Component Location
- Overview
- System Operation and Component Description
- Diagnosis and Testing
- Parking Aid
- Removal and Installation
- Front Inner Parking Aid Sensor
- Front Outer Parking Aid Sensor
- Parking Aid Camera
- Parking Aid Module
- Rear Parking Aid Sensor
414: Battery and Charging System
414-00: Charging System - General Information
- Diagnosis and Testing
- Charging System
414-01: Battery, Mounting and Cables
- Description and Operation
- Component Location
- Overview
- System Operation and Component Description
- Diagnosis and Testing
- Battery
- General Procedures
- Battery Disconnect and Connect
- Removal and Installation
- Battery
414-02C: Generator and Regulator - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8
- Specification
- Description and Operation
- Component Location
- Overview
- System Operation and Component Description
- Diagnosis and Testing
- Generator
- Removal and Installation
- Generator (86.10.02) - 4.2L NA V8 - AJV8
- Generator (86.10.02) - 4.2L SC V8 - AJV8
415: Information and Entertainment Systems
415-00: Information and Entertainment System - General Information
- Diagnosis and Testing
- Information and Entertainment System
- Cellular Phone
- Navigation System<b