Jaguar X-Type (2001-2009) - Service Manual / Repair Manual

JAGUAR X-TYPE (2001-2009) - WORKSHOP MANUAL

- English Service Manual to vehicles Jaguar X-Type.
 

CONTENTS:

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
- 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
- Description and Operation
- Wheel Alignment Angles
- Diagnosis and Testing
- Suspension System
- General Procedures
- Front Toe Adjustment (57.65.01)
- Rear Toe Adjustment (57.65.08)
- Wheel Bearing Inspection
- 204-01: Front Suspension
- Specification
- Description and Operation
- Front Suspension
- Diagnosis and Testing
- 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
- Description and Operation
- Rear Suspension
- Diagnosis and Testing
- Rear Suspension
- Removal and Installation
- 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
- Description and Operation
- Safety Precautions
- Wheels and Tires
- Diagnosis and Testing
- Wheels and Tires
- Removal and Installation
- 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
- Description and Operation
- Driveline System
- Diagnosis and Testing
- Driveline System
- 205-01: Driveshaft

- Specification
- Description and Operation
- Driveshaft
- Diagnosis and Testing
- Driveshaft
- General Procedures
- Driveshaft Runout and Balancing
- Removal and Installation
- Driveshaft (47.15.01)
- 205-02: Rear Drive Axle/Differential
- Specification
- Description and Operation
- Rear Drive Axle and Differential
- Diagnosis and Testing
- 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)
- Removal and Installation
- Axle Assembly (51.25.13)
- 205-04: Front Drive Halfshafts
- Specification
- Description and Operation
- Front Drive Halfshafts
- Diagnosis and Testing
- Front Drive Halfshafts
- Removal and Installation
- 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
- 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
- Description and Operation
- Rear Drive Halfshafts
- Diagnosis and Testing
- Rear Drive Halfshafts
- Removal and Installation
- Rear Halfshaft (47.10.13)
- Outer Constant Velocity (CV) Joint Boot (47.10.32)
- 206: Brake System
- 206-00: Brake System - General Information
- Specification
- Description and Operation
- Brake System
- Diagnosis and Testing
- Brake System
- General Procedures
- Brake Disc Runout Check
- Brake System Bleeding (70.25.03)
- 206-03: Front Disc Brake
- Specification
- Description and Operation
- Front Disc Brake
- Diagnosis and Testing
- Front Disc Brake
- Removal and Installation
- Brake Caliper (70.55.02)
- Brake Disc (70.10.10)
- Brake Pads (70.40.02)
- 206-04: Rear Disc Brake
- Specification
- Description and Operation
- Rear Disc Brake
- Diagnosis and Testing
- Rear Disc Brake
- Removal and Installation

- 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
- Description and Operation
- Parking Brake
- Diagnosis and Testing
- Parking Brake
- General Procedures
- Removal and Installation
- 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
- Description and Operation
- Hydraulic Brake Actuation
- Diagnosis and Testing
- Hydraulic Brake Actuation
- Removal and Installation
- Brake Fluid Reservoir (70.30.16)
- Brake Master Cylinder (70.30.08)
- Brake Pedal and Bracket (70.35.03)
- Brake Pedal Cross-Shaft
- 206-07: Power Brake Actuation
- Specification
- Description and Operation
- Brake Booster
- Diagnosis and Testing
- Power Brake System
- Removal and Installation
- 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
- Description and Operation
- Anti-Lock Control - Stability Assist
- Diagnosis and Testing
- Anti-Lock Control - Stability Assist - VIN Range: C00344->J12991
- Anti-Lock Control - Stability Assist - VIN Range: J12992->V99999
- Removal and Installation
- 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
- 211: Steering System
- 211-00: Steering System - General Information
- Specification
- Description and Operation
- Steering System
- Diagnosis and Testing
- Steering System
- General Procedures
- Power Steering System Filling
- Power Steering System Flushing (57.15.08)
- 211-02: Power Steering
- Specification
- Description and Operation
- Power Steering
- Diagnosis and Testing
- Power Steering
- General Procedures
- Start Up Procedure After Power Steering Pump/Gear Overhaul
- Removal and Installation
- 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
- (110kW/150PS) - Puma
- Steering Gear (57.10.01) - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi
- (110kW/150PS) - Puma
- Steering Gear (57.10.01) - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 –
- AJ27
- 211-03: Steering Linkage
- Specification
- Description and Operation
- Steering Linkage
- Diagnosis and Testing
- Steering Linkage
- Removal and Installation
- Steering Gear Boot (57.10.29)
- Tie Rod End (57.55.02)
- 211-04: Steering Column
- Specification
- Description and Operation
- Steering Column
- Diagnosis and Testing
- Steering Column
- Removal and Installation
- 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
- Description and Operation
- Steering Column Switches
- Diagnosis and Testing
- Steering Column Switches
- Removal and Installation
- Steering Column Multifunction Switch LH (86.65.78)
- Steering Column Multifunction Switch RH (86.65.41)
- 3: Powertrain
- 303: Engine
- 303-00: Engine System - General Information
- Specification
- Description and Operation
- Engine
- Diagnosis and Testing
- 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
- 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
- Description and Operation
- Engine
- Diagnosis and Testing
- 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
- 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
- Description and Operation
- 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
- 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
- Description and Operation
- Engine Cooling
- Diagnosis and Testing
- Engine Cooling
- General Procedures
- Cooling System Backflushing
- Cooling System Draining, Filling and Bleeding
- Cooling System Flushing
- Removal and Installation
- 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
- Description and Operation
- Engine Cooling
- General Procedures
- Cooling System Draining, Filling and Bleeding
- Cooling System Draining and Vacuum Filling
- Removal and Installation
- Cooling Fan Motor and Shroud (26.25.25)
- 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
- Description and Operation
- Fuel Charging and Controls
- Diagnosis and Testing
- 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
- Removal and Installation
- 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
- (110kW/150PS) - Puma
- Specification
- Description and Operation
- Fuel Charging and Controls
- Diagnosis and Testing
- Fuel Charging and Controls
- General Procedures
- Fuel Injection Component Cleaning
- Removal and Installation
- Fuel Injection Pump
- Fuel Injection Supply Manifold (19.60.13)
- Fuel Injector (18.10.01)
- Fuel Metering Valve
- Fuel Return Line Venturi
- 303-04C: Fuel Charging and Controls - Turbocharger
- Specification
- Description and Operation
- Turbocharger
- Diagnosis and Testing
- Turbocharger
- Removal and Installation
- Turbocharger
- 303-05: Accessory Drive
- Specification
- Description and Operation
- Accessory Drive
- Diagnosis and Testing
- Accessory Drive
- Removal and Installation
- Accessory Drive Belt (12.10.40) - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi
- (110kW/150PS) - Puma
- 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 –
- AJV6/3.0L NA V6 - AJ27
- Power Steering Pump Belt - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi
- (110kW/150PS) - Puma
- Power Steering Pump Belt Tensioner - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi
- (110kW/150PS) - Puma
- 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 –
- AJV6/3.0L NA V6 - AJ27
- 303-06: Starting System
- Specification
- Description and Operation
- Starting System
- Diagnosis and Testing
- Starting System - 2.0L NA V6 - AJV6
- Starting System - 2.5L NA V6 - AJV6/3.0L NA V6 - AJ27
- Removal and Installation
- 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
- Description and Operation
- Engine Ignition
- Diagnosis and Testing
- Engine Ignition - 2.0L NA V6 - AJV6
- Engine Ignition - 2.5L NA V6 - AJV6/3.0L NA V6 - AJ27
- Removal and Installation
- Ignition Coil-On-Plug LH (18.20.44)
- Ignition Coil-On-Plug RH (18.20.43)
- 303-07B: Glow Plug System
- Specification
- Description and Operation
- Glow Plug System
- Diagnosis and Testing
- Glow Plug System
- Removal and Installation
- Glow Plugs
- 303-08: Engine Emission Control - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi
- (110kW/150PS) - Puma
- Specification
- Description and Operation
- Engine Emission Control
- Diagnosis and Testing
- Engine Emission Control
- Removal and Installation
- 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 –
- AJV6/3.0L NA V6 - AJ27
- Description and Operation
- Intake Air Distribution and Filtering
- Diagnosis and Testing
- Intake Air Distribution and Filtering
- Removal and Installation
- Air Cleaner (19.10.05)
- Air Cleaner Element (19.10.08)
- 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
- Description and Operation
- Intake Air Distribution and Filtering
- Diagnosis and Testing
- Intake Air Distribution and Filtering
- Removal and Installation
- Air Cleaner (19.10.05)
- Air Cleaner Element (19.10.08)
- 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
- Description and Operation
- Evaporative Emissions
- Diagnosis and Testing
- Evaporative Emissions - 2.0L NA V6 - AJV6
- Evaporative Emissions - 2.5L NA V6 - AJV6/3.0L NA V6 - AJ27
- Removal and Installation
- 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
- Description and Operation
- Electronic Engine Controls
- Diagnosis and Testing
- 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
- Electronic Engine Controls - 2.5L NA V6 - AJV6/3.0L NA V6 - AJ27, VIN Range:
- J28493->V99999
- 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 (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
- (110kW/150PS) - Puma
- Specification
- Description and Operation
- Electronic Engine Controls
- Diagnosis and Testing
- Electronic Engine Controls
- Removal and Installation
- 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
- Description and Operation
- Transmission Description - Vehicles With: 5-Speed Automatic Transaxle - JATCO
- Diagnosis and Testing
- 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)
- Transmission Control Module (TCM) (44.15.32)
- Transmission Range (TR) Sensor
- Removal
- Transaxle (44.20.01)
- Disassembly and Assembly of Subassemblies
- Input Shaft Seal (44.32.07)
- Installation
- Transaxle (44.20.01)
- 307-01B: Automatic Transmission/Transaxle - Vehicles With: 6-Speed Automatic
- Transaxle - AWF21
- Specification
- Description and Operation
- Transmission Description - Vehicles With: 6-Speed Automatic Transaxle - AWF21
- Transmission Electronic Control System - Vehicles With: 6-Speed Automatic
- Transaxle - AWF21
- Diagnosis and Testing
- 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)
- Removal and Installation
- Torque Converter
- Torque Converter Seal
- Turbine Shaft Speed (TSS) Sensor
- Removal
- Transmission (44.20.01)
- Installation
- Transmission (44.20.01)
- 307-02A: Transmission/Transaxle Cooling - Vehicles With: 5-Speed Automatic
- Transaxle - JATCO
- Specification
- Description and Operation
- Transmission Cooling - Vehicles With: 5-Speed Automatic Transaxle - JATCO
- Diagnosis and Testing
- Transmission Cooling
- Removal and Installation
- 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
- Description and Operation
- Transmission Cooling - Vehicles With: 6-Speed Automatic Transaxle - AWF21
- Diagnosis and Testing
- Transmission Cooling
- Removal and Installation
- 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
- Description and Operation
- External Controls - Vehicles With: 5-Speed Automatic Transaxle - JATCO
- Diagnosis and Testing
- External Controls
- General Procedures
- Selector Lever Cable Adjustment (44.15.07)
- Removal and Installation
- Selector Lever Cable and Bracket (44.15.08)
- Selector Lever Assembly (44.15.04)
- 307-05B: Automatic Transmission/Transaxle External Controls - Vehicles With:
- 6-Speed Automatic Transaxle - AWF21
- Specification
- Description and Operation
- External Controls - Vehicles With: 6-Speed Automatic Transaxle - AWF21
- Diagnosis and Testing
- External Controls
- General Procedures
- Selector Lever Cable Adjustment (44.15.07)
- Removal and Installation
- 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
- Description and Operation
- Manual Transmission and Clutch
- Diagnosis and Testing
- 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
- Description and Operation
- Clutch
- Diagnosis and Testing
- Clutch
- Removal and Installation
- Clutch Disc and Pressure Plate (12.53.13) (33.10.01)
- 308-02: Clutch Controls
- Specification
- Description and Operation
- Clutch Controls
- Diagnosis and Testing
- Clutch Controls
- Removal and Installation
- 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
- Description and Operation
- Manual Transaxle - Vehicles With: 5-Speed Manual Transmission - MT75
- Manual Transaxle - Vehicles With: 6-Speed Manual Transaxle - MMT6
- Diagnosis and Testing
- 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
- 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
- Description and Operation
- External Controls
- Diagnosis and Testing
- External Controls
- Removal and Installation
- 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
- Description and Operation
- 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)
- 309: Exhaust System
- 309-00: Exhaust System
- Specification
- Description and Operation
- Exhaust System
- Diagnosis and Testing
- Exhaust System
- Removal and Installation
- Catalytic Converter (17.50.05) - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi
- (110kW/150PS) - Puma
- 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
- (110kW/150PS) - Puma
- Front Muffler (30.10.18) - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi
- (110kW/150PS) - Puma
- 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
- Description and Operation
- Fuel System
- Diagnosis and Testing
- Fuel System
- 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
- Description and Operation
- Fuel Tank and Lines
- Diagnosis and Testing
- Fuel Tank and Lines
- Removal and Installation
- 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
- (110kW/150PS) - Puma
- 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
- 310-02: Acceleration Control
- Specification
- Description and Operation
- Acceleration Control
- Diagnosis and Testing
- Acceleration Control
- General Procedures
- Accelerator Cable Adjustment (12.20.05) - 2.0L NA V6 - AJV6
- Removal and Installation
- Accelerator Cable (19.20.06) - 2.0L NA V6 - AJV6
- Accelerator Pedal (19.20.01)
- 310-03: Speed Control
- Specification
- Description and Operation
- Speed Control
- Diagnosis and Testing
- Speed Control - 2.0L NA V6 - AJV6
- Speed Control - 2.5L NA V6 - AJV6/3.0L NA V6 - AJ27
- Removal and Installation
- 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
- Description and Operation
- Climate Control System
- Diagnosis and Testing
- Climate Control System
- General Procedures
- Air Conditioning (A/C) Compressor Leak Detection
- 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
- Description and Operation
- Air Distribution and Filtering
- Diagnosis and Testing
- Air Distribution and Filtering
- Removal and Installation
- 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
- Description and Operation
- Heating and Ventilation
- Diagnosis and Testing
- Heating and Ventilation
- Removal and Installation
- Blower Motor (82.25.66)
- Evaporator Core Housing (80.20.01)
- Heater Core (80.20.29)
- Disassembly and Assembly
- Evaporator Core Housing
- 412-02B: Auxiliary Heating
- Specification
- Description and Operation
- Electric Booster Heater
- Fuel Fired Booster Heater
- Diagnosis and Testing
- Auxiliary Heater
- Fuel Fired Booster Heater
- Removal and Installation
- Electric Booster Heater
- Fuel Fired Booster Heater
- 412-03: Air Conditioning
- Specification
- Description and Operation
- Air Conditioning
- Diagnosis and Testing
- Air Conditioning
- Removal and Installation
- Air Conditioning (A/C) Compressor (82.10.20) - 2.0L NA V6 - AJV6/2.5L NA V6 –
- AJV6/3.0L NA V6 - AJ27
- 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 –
- AJV6/3.0L NA V6 - AJ27
- 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
- Description and Operation
- Control Components
- Diagnosis and Testing
- Control Components
- Removal and Installation
- Air Discharge Temperature Sensor (82.20.64)
- Ambient Air Temperature Sensor (82.20.02)
- Climate Control Assembly (82.20.07)
- 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
- Diagnosis and Testing
- Instrument Cluster and Panel Illumination
- 413-01: Instrument Cluster
- Description and Operation
- Instrument Cluster
- Diagnosis and Testing
- Instrument Cluster
- Removal and Installation
- Instrument Cluster (88.20.01)
- 413-06: Horn
- Description and Operation
- Horn
- Diagnosis and Testing
- Horn
- Removal and Installation
- Horn (86.30.02) (86.30.10)
- Horn Switch (86.30.01)
- 413-08: Information and Message Center
- Description and Operation
- Information and Message Center
- Diagnosis and Testing
- Information and Message Center
- Removal and Installation
- Message Center
- Message Center Switch (86.66.11)
- 413-09: Warning Devices
- Description and Operation
- Warning Devices
- Diagnosis and Testing
- Warning Devices
- General Procedures
- Oil Change Indicator Reset
- Removal and Installation
- Low Washer Fluid Warning Indicator Switch (84.10.17)
- 413-13: Parking Aid
- Description and Operation
- Parking Aid
- Diagnosis and Testing
- Parking Aid
- Removal and Installation
- 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
- Description and Operation
- Charging System
- Battery Care
- Quiescent Drain
- Diagnosis and Testing
- 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
- Description and Operation
- Battery and Cables
- Diagnosis and Testing
- Battery
- General Procedures
- Battery Connect (86.15.15)
- Battery Disconnect and Connect
- Removal and Installation
- 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
- (110kW/150PS) - Puma
- Battery Tray (86.15.11)
- 414-02: Generator and Regulator
- Specification
- Description and Operation
- Generator
- Diagnosis and Testing
- Generator
- Removal and Installation
- 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
- 415: Information and Entertainment Systems
- 415-00: Information and Entertainment System - General Information
- Diagnosis and Testing
- Audio System
- 415-01: Audio Unit
- Description and Operation
- Audio System
- Diagnosis and Testing
- Audio System
- Removal and Installation
- 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
- Description and Operation
- Antenna
- Diagnosis and Testing
- Antenna
- Removal and Installation
- Antenna (86.51.17.60) - Wagon
- Module
- 415-03: Speakers
- Description and Operation
- Speakers
- Diagnosis and Testing
- Speakers
- Removal and Installation
- Front Door Speaker (86.50.13)
- Front Door Tweeter Speaker (86.50.63)
- 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
- Description and Operation
- Exterior Lighting
- Diagnosis and Testing
- Headlamps
- General Procedures
- Headlamp Adjustment (86.40.18)
- Removal and Installation
- 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
- Description and Operation
- Interior Lighting
- Diagnosis and Testing
- Interior Lighting
- Removal and Installation
- Front Interior Lamp (86.45.12)
- Rear Interior Lamp (86.46.03)
- 417-04: Daytime Running Lamps (DRL)
- Description and Operation
- Daytime Running Lamps (DRL)
- Diagnosis and Testing
- Daytime Running Lamps (DRL)
- 418: Electrical Distribution
- 418-00: Module Communications Network
- Description and Operation
- Communications Network
- Diagnosis and Testing
- Communications Network - VIN Range: E96603->J28492
- Communications Network - VIN Range: J28493->V99999
- 418-01: Module Configuration
- Diagnosis and Testing
- Module Configuration
- General Procedures
- Module Configuration
- 418-02: Wiring Harnesses
- Description and Operation
- Wiring Harness
- General Procedures
- Wiring Harness Repair
- 419: Electronic Feature Group
- 419-01A: Anti-Theft - Active
- Description and Operation
- Anti-Theft - Active
- Diagnosis and Testing
- Anti-Theft - Active
- Removal and Installation
- Anti-Theft Alarm Horn (86.52.03)
- 419-01B: Anti-Theft - Passive
- Description and Operation
- Anti-Theft - Passive
- Diagnosis and Testing
- Anti-Theft - Passive
- General Procedures
- Anti-Theft Security Access
- Key Programming Using Diagnostic Equipment
- Removal and Installation
- Passive Anti-Theft System (PATS) Transceiver (86.52.30)
- 419-02: Remote Convenience
- Description and Operation
- Universal Transmitter
- Diagnosis and Testing
- Universal Transmitter
- General Procedures
- Universal Transmitter Programming
- 419-07: Navigation System

- Description and Operation
- Navigation System
- Diagnosis and Testing
- Navigation System</strong