2008 XF Workshop Manual PDF

Workshop Manual
X250 - XF
2008 to 2009MY
VIN R00019 to VIN R47514

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

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
2: Chassis
204: Suspension
204-00: Suspension System - General Information

Specification
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
Component Location
Overview
System Operation and Component Description
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
Component Location
Overview
Rear Suspension
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
Component Location
Overview
Wheels and Tires
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

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
Vehicle Dynamic Suspension
Adaptive Damping Module
Front Suspension Vertical Accelerometer
Rear Suspension Vertical Accelerometer
204-06: Ride and Handling Optimization

Component Location
Overview
205: Driveline
205-00: Driveline System - General Information

Driveline System
General Procedures
Driveline Angle Inspection
205-01: Driveshaft
Specification
Component Location
Overview
Driveshaft
General Procedures
Driveshaft Runout and Balancing
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
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
Rear Drive Axle and Differential
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
Component Location
Overview
Rear Drive Halfshafts
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
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
Component Location
Overview
Front Disc Brake
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
Component Location
Overview
Rear Disc Brake
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
Component Location
Overview
Parking Brake
General Procedures
Parking Brake Cable Tension Release
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
Component Location
Overview
Hydraulic Brake Actuation
Brake Fluid Reservoir (70.30.16)
Brake Master Cylinder (70.30.08)
206-07: Power Brake Actuation

Specification
Component Location
Overview
Power Brake System
Brake Booster (70.50.17)
Brake Vacuum Pump - 2.7L V6 - TdV6
206-09: Anti-Lock Control - Stability Assist

Specification
Component Location
Overview
Anti-Lock Control - Stability Assist
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
Steering System
General Procedures
Power Steering System Bleeding (57.15.02 )
211-02: Power Steering

Specification
Component Location
Overview
Power Steering
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
Component Location
Overview
Steering Linkage
Tie Rod End (57.55.02)
211-04: Steering Column

Specification
Component Location
Overview
Steering Column
Steering Column
Steering Column Flexible Coupling
Steering Wheel (57.60.01)
211-05: Steering Column Switches

Component Location
Overview
Steering Column Switches
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

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
Component Location
Overview
Engine
General Procedures
Engine Oil Draining and Filling
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
Component Location
Overview
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 (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)
Intake Manifold
Lower Intake Manifold
Removal
Engine (12.41.01)
Installation
Engine (12.41.01)
303-01C: Engine - 4.2L NA V8 - AJV8

Specification
Component Location
Overview
Engine
General Procedures
Valve Clearance Adjustment (12.29.48)
Valve Clearance Check (12.29.47)
In-Vehicle Repair
Camshafts RH (12.13.18)
Cylinder Head LH (12.29.02)
Engine Mount RH (12.45.03)
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
Oil Filter Housing
Crankshaft Main Bearing Carrier
Removal
Engine (12.41.01)
Installation
Engine (12.41.01)
303-01D: Engine - 4.2L SC V8 - AJV8

Specification
Component Location
Overview
Engine
General Procedures
In-Vehicle Repair
Cylinder Head LH (12.29.02)
Engine Mount RH (12.45.03)
Oil Filter Housing
Oil Pan (12.60.44)
Oil Pump (12.60.26)
Twin Oil Coolers
Crankshaft Main Bearing Carrier
Removal
Engine (12.41.01)
Installation
Engine (12.41.01)
303-03A: Engine Cooling - TDV6 2.7L Diesel

Specification
Component Location
Overview
Engine Cooling
General Procedures
Cooling System Draining, Filling and Bleeding
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
Component Location
Overview
Engine Cooling
General Procedures
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
Component Location
Overview
Engine Cooling
General Procedures
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
Component Location
Overview
Supercharger Cooling
Radiator
303-04A: Fuel Charging and Controls - TDV6 2.7L Diesel

Specification
Component Location
Overview
Fuel Charging and Controls
General Procedures
Fuel Injection Component Cleaning
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
Component Location
Overview
Turbocharger
Turbocharger LH
Turbocharger RH
303-04C: Fuel Charging and Controls - V6 3.0L Petrol

Specification
Component Location
Overview
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
Component Location
Overview
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

Component Location
Overview
Fuel Injectors
Fuel Rail
Throttle Body
303-05A: Accessory Drive - TDV6 2.7L Diesel
Specification
Component Location
Overview
Accessory Drive
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
Component Location
Overview
Accessory Drive
303-05C: Accessory Drive - 4.2L NA V8 - AJV8

Specification
Component Location
Overview
Accessory Drive
303-05D: Accessory Drive - 4.2L SC V8 - AJV8
Specification
Component Location
Overview
Accessory Drive
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
Component Location
Overview
Starting System
Starter Motor (86.60.01)
303-06B: Starting System - V6 3.0L Petrol

Specification
Component Location
Overview
Starting System
303-06C: Starting System - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8
Specification
Component Location
Overview
Starting System
303-07A: Engine Ignition - V6 3.0L Petrol

Specification
Component Location
Overview
Engine Ignition
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
Component Location
Overview
Engine Ignition
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
Component Location
Overview
Glow Plug System
303-08A: Engine Emission Control - TDV6 2.7L Diesel

Specification
Component Location
Overview
Engine Emission Control
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
Component Location
Overview
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
Component Location
Overview
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
Component Location
Overview
Intake Air Distribution and Filtering
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
Component Location
Overview
Air Cleaner
Air Cleaner Outlet Pipe
Air Cleaner Element
303-12C: Intake Air Distribution and Filtering - 4.2L NA V8 - AJV8

Specification
Component Location
Overview
Air Cleaner
Air Cleaner Element
303-12D: Intake Air Distribution and Filtering - 4.2L SC V8 - AJV8

Specification
Component Location
Overview
Air Cleaner LH
Air Cleaner RH
Air Cleaner Element
Charge Air Cooler
Supercharger
Supercharger Outlet Pipe
303-13A: Evaporative Emissions - V6 3.0L Petrol

Specification
Component Location
Overview
Evaporative Emissions
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
Component Location
Overview
Evaporative Emissions
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
Component Location
Overview
Electronic Engine Controls
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
Component Location
Overview
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 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)
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
Component Location
Overview
General Procedures
Powertrain Control Module (PCM) Long Drive Cycle Self-Test
Powertrain Control Module (PCM) Short Drive Cycle Self-Test
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 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)
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
Component Location - Vehicles With: ZF 6HP26
Overview - Vehicles With: ZF 6HP26
System Operation and Component Description - Vehicles With: ZF 6HP26
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
Transmission Cooling
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
External Controls
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
Component Location
Overview
Exhaust System
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
Component Location
Overview
Exhaust System
Exhaust System
Rear Muffler
309-00C: Exhaust System - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8

Specification
Component Location
Overview
Exhaust System
Exhaust System
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
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
Component Location
Overview
Fuel Tank and Lines
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
Component Location
Overview
Fuel Tank and Lines
Fuel Filter
Fuel Level Sender LH
Fuel Level Sender RH
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
Component Location
Overview
Fuel Tank and Lines
Fuel Filter
Fuel Level Sender LH
Fuel Level Sender RH
Fuel Tank
Fuel Tank Filler Pipe (19.55.33)
Fuel Transfer Unit
310-02: Acceleration Control

Specification
Acceleration Control
Accelerator Pedal
310-03A: Speed Control - TDV6 2.7L Diesel

Specification
Component Location
Overview
Speed Control
General Procedures
Speed Control Sensor Adjustment
Speed Control Deactivator Switch
Speed Control Module
Speed Control Sensor
Speed Control Switch
310-03B: Speed Control - V6 3.0L Petrol
Specification
Component Location
Overview
Speed Control
General Procedures
310-03C: Speed Control - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8

Specification
Component Location
Overview
Speed Control
General Procedures
4: Electrical
412: Climate Control System
412-00: Climate Control System - General Information

Specification
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
Air Distribution and Filtering
Component Location
Overview
Heating and Ventilation
Component Location
Overview
Air Conditioning
Component Location
Overview
Control Components
Component Location
Overview
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
Air Conditioning
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
Component Location
Overview
Instrument Cluster
Instrument Cluster
413-06: Horn
Specification
Horn
Horn Switch
413-08: Information and Message Center

Component Location
Overview
Information and Message Center
413-09: Warning Devices

Warning Devices
413-13: Parking Aid

Component Location
Overview
Parking Aid
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

Charging System
414-01: Battery, Mounting and Cables

Component Location
Overview
Battery
General Procedures
Battery Disconnect and Connect
Battery
414-02C: Generator and Regulator - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8

Specification
Component Location
Overview
Generator
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
Information and Entertainment System
Cellular Phone
Navigation System
415-01: Information and Entertainment System

Specification
Audio System
Component Location
Overview
Speakers
Component Location
Overview
Cellular Phone
Component Location
Overview
Navigation System
Component Location
Overview
Video System
Component Location
Overview
Information and Entertainment System
Audio Unit
Audio Unit Antenna Amplifier
Audio and Climate Control Assembly
Front Door Speaker
Information and Entertainment Display
Information and Entertainment Module
Instrument Panel Speaker
Rear Door Speaker
Steering Wheel Audio Controls
Subwoofer Amplifier
Subwoofer Speaker
417: Lighting
417-01: Exterior Lighting

Specification
Component Location
Overview
Headlamps
Approach Lamp
Headlamp Assembly
Headlamp Leveling Front Sensor
Headlamp Leveling Rear Sensor
High Mounted Stoplamp
Rear Fog Lamp
Rear Lamp Assembly
Side Turn Signal Lamp
417-02: Interior Lighting

Component Location
Overview
Interior Lighting
417-04: Daytime Running Lamps (DRL)

Overview
418: Electrical Distribution
418-00: Module Communications Network

Overview
Communications Network
Central Junction Box (CJB)
418-02: Wiring Harnesses

Wiring Harness
General Procedures
Wiring Harness Repair
Engine Wiring Harness - TDV6 2.7L Diesel
Luggage Compartment Lid Wiring Harness
419: Electronic Feature Group
419-01A: Anti-Theft - Active

Component Location
Overview
Anti-Theft - Active
Anti-Theft Alarm Horn (86.52.03)
419-01B: Anti-Theft - Passive

Component Location
Overview
Anti-Theft Passive
419-07: Navigation System

Navigation System Antenna (86.62.06)
Navigation System Module (86.62.05)
419-08: Cellular Phone

Bluetooth Module
419-10: Multifunction Electronic Modules

Specification
Component Location
Overview
Driver Door Module (DDM)
Remote Keyless Entry (RKE) Module
Passenger Door Module (PDM)
Driver Seat Module (DSM)
Passenger Door Module (PDM)
Rear Door Module (RDM)
501: Body and Paint
501-02: Front End Body Panels

Specification
Air Deflector
Cowl Vent Screen (76.10.01)
Engine Rear Undershield
Fender Splash Shield
Radiator Splash Shield
Secondary Bulkhead Center Panel
Secondary Bulkhead Panel LH - 2.7L V6 - TdV6/3.0L NA V6 - AJ27/4.2L NA V8
Secondary Bulkhead Panel RH - 2.7L V6 - TdV6/3.0L NA V6 - AJ27/4.2L NA V8
501-03: Body Closures

Front Door
Fuel Filler Door
Fuel Filler Door Assembly
Luggage Compartment Lid (76.19.01)
Rear Door
501-05: Interior Trim and Ornamentation

Specification
A-Pillar Trim Panel
B-Pillar Lower Trim Panel
B-Pillar Upper Trim Panel
C-Pillar Lower Trim Panel
C-Pillar Trim Panel
Cowl Side Trim Panel
Engine Cover (76.11.35) - 4.2L NA V8 - AJV8
Engine Cover (76.11.35) - TDV6 2.7L Diesel
Engine Cover - 4.2L SC V8 - AJV8
Front Door Trim Panel (76.34.01)
Front Scuff Plate Trim Panel
Instrument Panel Speaker Grille
Headliner
Loadspace Scuff Plate Trim Panel
Loadspace Trim Panel
Loadspace Trim Panel LH
Loadspace Trim Panel RH
Luggage Compartment Lid Trim Panel
Parcel Shelf
Rear Door Trim Panel
Rear Scuff Plate Trim Panel
Sun Visor (76.10.48)
501-08: Exterior Trim and Ornamentation

Specification
Radiator Grille
Luggage Compartment Lid Moulding
501-09: Rear View Mirrors

Specification
Component Location
Overview
Rear View Mirrors
Exterior Mirror
Exterior Mirror Cover
Exterior Mirror Glass
Exterior Mirror Motor
Interior Rear View Mirror
501-10: Seating
Specification
Component Location
Overview
Seats
Front Seat (76.70.01)
Front Seat Backrest (76.70.06)
Front Seat Backrest Cover (76.70.15)
Front Seat Cushion Cover
Front Seat Track Motor
Memory Seat Position Switch
Seat Base
Rear Seat Backrest Cover (76.70.48) (78.90.12)
Rear Seat Cushion (76.70.37)
Front Seat Height Adjustment Motor
Front Seat Control Switch
Rear Seat Bolster
501-11: Glass, Frames and Mechanisms

Specification
Component Location
Overview
Glass, Frames and Mechanisms
General Procedures
Door Window Motor Initialization
Door Window Regulator Motor (86.25.04)
Driver Door Window Control Switch (86.25.03) (86.25.08)
Front Door Window Glass
Front Door Window Regulator and Motor (76.31.45)
Passenger Door Window Control Switch
Rear Door Fixed Window Glass
Rear Door Window Glass
Rear Door Window Regulator and Motor
Rear Window Glass
Windshield Glass
501-12: Instrument Panel and Console

Specification
Component Location
Overview
Floor Console
Floor Console Cup Holder
Floor Console Double Cup Holder
Floor Console Side Trim Panel
Glove Compartment
Instrument Panel Console
Instrument Panel Lower Trim Panel
Overhead Console
501-14: Handles, Locks, Latches and Entry Systems

Specification
Component Location
Overview
Locks, Latches and Entry Systems
Exterior Front Door Handle
Exterior Luggage Compartment Lid Release Switch
Exterior Rear Door Handle
Front Door Latch
Front Door Lock Cylinder
Interior Front Door Handle
Luggage Compartment Lid Latch Actuator
Luggage Compartment Lid Lock Cylinder
Rear Door Latch
501-16: Wipers and Washers

Specification
Component Location
Overview
Wipers and Washers
Headlamp Washer Jet
Headlamp Washer Pump
Rain Sensor
Windshield Washer Reservoir
Windshield Wiper Motor
Windshield Washer Pump
501-17: Roof Opening Panel

Specification
Component Location
Overview
Roof Opening Panel
General Procedures
Roof Opening Panel Alignment
Motor Synchronization (76.82.48)
Roof Opening Panel Front Drain Hose
Roof Opening Panel Frame
Roof Opening Panel Glass
Roof Opening Panel Motor
Roof Opening Panel Rear Drain Hose
Roof Opening Panel Weatherstrip
501-19: Bumpers
Specification
Front Bumper Cover
Front Bumper Cover Insert
Rear Bumper Cover
Rear Bumper
501-20A: Safety Belt System

Specification
Component Location
Overview
Safety Belt System
Front Safety Belt Buckle
Front Safety Belt Retractor
Rear Center Safety Belt Retractor
Rear Safety Belt Buckle
Rear Safety Belt Retractor
Safety Belt Shoulder Height Adjuster
501-20B: Supplemental Restraint System

Specification
Component Location
Overview
Air Bag and Safety Belt Pretensioner Supplemental Restraint System (SRS)
General Procedures
Air Bag Disposal
B-Pillar Side Impact Sensor
Clockspring
C-Pillar Side Impact Sensor
Crash Sensor
Driver Air Bag Module
Front Door Side Impact Sensor
Occupant Classification Sensor
Passenger Air Bag Module
Restraints Control Module (RCM)
501-20C: Pedestrian Protection System
Pedestrian Protection System
Component Location
Overview
Pedestrian Protection System
Pedestrian Impact Sensor
Pedestrian Protection Hood Actuator LH
Pedestrian Protection Hood Actuator RH
Pedestrian Protection Module
501-25A: Body Repairs - General Information

Body Repairs
501-25B: Body Repairs - Corrosion Protection

Corrosion Protection
501-25C: Body Repairs - Water Leaks

Water Leaks
501-26: Body Repairs - Vehicle Specific Information and Tolerance Checks

Body and Frame
501-27: Front End Sheet Metal Repairs

Front End Sheet Metal
Fender Apron Closing Panel Front Section
Fender Apron Panel
Fender Apron Panel Closing Panel
Fender Apron Panel Front Extension
Fender Apron Panel Front Section
Front Bumper Mounting
Front Fender
Front Fender Support Bracket
Front Side Member
Front Side Member and Suspension Top Mount Assembly
Front Side Member Closing Panel
Front Side Member Closing Panel Section
Front Side Member Section
Front Wheelhouse Section
Hood Latch Panel
Hood Latch Panel Mounting Bracket
501-28: Roof Sheet Metal Repairs

Roof
Roof Panel - Vehicles With: Sliding Roof Opening Panel
Roof Panel - Vehicles Without: Sliding Roof Opening Panel
501-29: Side Panel Sheet Metal Repairs

Side Panel Sheet Metal
A-Pillar Outer Panel
A-Pillar Reinforcement
B-Pillar Inner Panel
B-Pillar Reinforcement
Front Door Skin Panel
Rear Door Skin Panel
Rocker Panel
Rocker Panel and B-Pillar Outer Panel
Rocker Panel Front Section
Rocker Panel Inner Reinforcement
Rocker Panel Rear Section
501-30: Rear End Sheet Metal Repairs

Back Panel
Quarter Panel
Quarter Panel Lower Extension
Rear Bumper Mounting
502: Frame and Mounting
502-00: Uni-Body, Subframe and Mounting System

Specification
Front Subframe (76.10.05) - TDV6 2.7L Diesel
Front Subframe (76.10.05) - V6 3.0L Petrol
Front Subframe (76.10.05) - 4.2L NA V8 - AJV8
Front Subframe (76.10.05) - 4.2L SC V8 - AJV8
Rear Subframe (64.25.01)
Rear Subframe Rear Bushing (64.25.36)
Published: 11-May-2011
General Information - About This Manual
Introduction
This manual covers diagnosis and testing and repair procedures.
It is structured into groups and sections, with specific system sections collected together under their relevant group.
A group covers a specific portion of the vehicle. The manual is divided into five groups, General Information, Chassis,
Powertrain, Electrical and Body and Paint. The number of the group is the first number of a section number.
Within Etis, the navigation tree will list the groups. After selecting a group the navigation tree will then list the sections
within that group. Each section has a contents list detailing Specifications, Description and Operation, Diagnosis and
Testing, General Procedures, Disassembly and Assembly, Removal and Installation.
References to LH (left-hand) and RH (right-hand)
All LH and RH references to the vehicle are taken from a position sitting in the driver seat looking forward.
Vehicle LH and RH definition
Item Part Number Description

1 - LH
2 - RH
All LH and RH references to the engine are taken from a position at the flywheel looking towards the crankshaft front
pulley.
Powertrain LH and RH definition

1 - front
2 - right
3 - rear
4 - left
How to use Repair Procedures

This manual has been written in a format that is designed to meet the needs of technicians worldwide. It provides general
descriptions for accomplishing repair work with tested and effective techniques.
Important Safety Instructions
Appropriate service methods and correct repair procedures are essential for the safe, reliable operation of all motor
vehicles as well as the personal safety of the individual carrying out the work.
Anyone who departs from the instructions provided in this manual must first establish that personal safety or vehicle
integrity is not compromised by the choice of method, tools or components.
Warnings, Cautions and Notes in This Manual
WARNING: Warnings are used to indicate that failure to follow a procedure correctly may result in personal injury.
CAUTION: Cautions are used to indicate that failure to follow a procedure correctly may result in damage to the
vehicle or equipment being used.
NOTE: Notes are used to provide additional essential information required to carry out a complete and satisfactory
repair.
Generic warnings or cautions are in their relevant description and operation procedure within section 100-00. If the generic
warnings or cautions are required for a procedure, there will be a referral to the appropriate description and operation
procedure.
If a warning, caution or note only applies to one step, it is placed at the beginning of the specific step.
Trustmark Authoring Standards (TAS) Repair Procedures
NOTE: TAS style procedures can be identified by steps that have no accompanying step text and the magenta color of
the electrical connectors and fasteners such as nuts, bolts, clamps or clips.
A TAS removal and installation procedure uses a sequence of color illustrations to indicate the order to be followed when
removing/disassembling or installing/assembling a component.
Many of the TAS procedures will have the installation information within the removal steps. These procedures will have the
following note at the beginning of the procedure:
NOTE: Removal steps in this procedure may contain installation details.
Reuse of fasteners and seals and gaskets
The following list details the general policy for the reuse of fasteners and seals and gaskets.
Types of self-locking nuts and bolts
NOTE: There are more types of self-locking fasteners available than shown in following illustration.

1 - Completely coated self-locking bolt
2 - Partially coated self-locking bolt
3 - Self-locking bolt with a locking washer
4 - Self-locking nut with a plastic locking insert
5 - Self-locking nut with thread deformation (3 dents)
6 - Self-locking nut with thread deformation (squeeze of thread to oval shape)
7 - Self-locking nut with integrated locking ring
All types of seals and gaskets must be discarded and new seals and gaskets installed unless otherwise stated
within the procedure.
Nuts and bolts with a chemical coating for locking and/or sealing and/or antiseize must be discarded unless the
procedure advises to reapply the coating with a specified material.
Nuts and bolts with a mechanical locking such as thread inserts, thread deformation or locking washers must be
discarded and new nuts and bolts installed unless otherwise stated within the procedure.
Torque to yield bolts must be discarded and new torque to yield bolts installed unless otherwise stated within the
procedure, recognizable by a tightening torque with more than one stage together with a torque angle.
Specification data
Specification procedures will only contain technical data that is not already part of a repair procedure.
Sequence of tasks
If components must be removed or installed in a specific sequence, the sequence will be identified numerically in a graphic
and the corresponding text will be numbered accordingly.
Special Tools, Equipment, Materials and Torque Figures
Special tools will be shown with the tool numbers in the illustration. The special tool numbers, general equipment,
materials and torque figures used for the procedure step will be shown in the text column.
TAS Graphics
Colors used in the graphic are as follows:
Blue - Component to be removed/installed or disassembled/assembled.

Green and Brown - Additional components that need to be removed/installed or disassembled/assembled prior to
the target component.
Yellow - Component that is touched or affected in a way but remains in the vehicle. It may be detached, attached,
moved, modified, checked, adjusted etc.
Magenta - Electrical connectors and fasteners such as nuts, bolts, clamps and clips.
Pale Blue - Special tool(s) and general equipment.
One illustration may have multiple steps assigned to it.
Numbered pointers are used to indicate the number of electrical connectors and fasteners such as nuts, bolts, clamps and
clips.
Items in the illustration can be transparent or use cutouts to show hidden details.
TAS Symbols
Symbols are used inside the graphics and in the text area to enhance the information display. The following paragraphs
describe the various types and categories of symbols.
For additional information, refer to: Symbols Glossary (100-00 General Information, Description and Operation).
Prohibition symbols advise on prohibited actions to either avoid damage or health and safety related risks. These symbols
are
Health and Safety symbols recommend the use of particular protection equipment to avoid or at least reduce the risk or
severity of possible injuries.
Warning symbols are used to indicate potential risks resulting from a certain component or area.
Instruction symbols are used to apply sealer, lubricant, weight, tape or cleaning detergent to a component.
Location symbols are used to show the location of a component or system within the vehicle.
Gearshift lever or selector lever position symbols are used to show which gearshift lever or selector lever position is to be
set.
Pointer symbols are used to draw attention to components and give special instructions such as a required sequence or
number of components. The number of components is reflected by the value inside the luty arrow. A sequence number is
located inside the circle. Numbers inside circles are also used to allocate special information such as tightening torques or
chemicals to a particular component.
Movement arrows are used to show three dimensional or rotational movements. These movements can include specific
values inside the symbol if required.
Standard tool symbols recommend the use of certain standard tools. These tools can include dimension values if required.
The following graphic illustrates a set of symbols that are used to provide detailed information on where to apply a
material.
Measurement symbols provide detailed information on where to carry out a specific measurement. These symbols can
include specific values if required.
How to use Diagnosis and Testing procedures

Inspection and Verification
Visual Inspection Charts, Symptom Charts and other information charts (such as diagnostic routines) or supplement test
procedures with technical specifications will navigate the user to a specific test procedure.
Symptom Chart
The symptom chart indicates symptoms, sources and actions to address a condition.
Pinpoint Tests
For electrical systems, pinpoint test steps are used to identify the source of a concern in a logical, step-by-step manner.
Pinpoint tests have two columns: CONDITIONS and DETAILS/RESULTS/ACTIONS.
The CONDITIONS column is used exclusively for graphics and icons (with or without captions) and the DETAILS/RESULTS
/ACTIONS column provides direction to another test step or specific corrective actions.
The boxed numbers indicate the order in which the described action is to be carried out.
Component Tests
A component test is used when a component is tested in multiple pinpoint tests, or if a procedure is too complicated to be
formatted within a single page of the pinpoint test.
Graphics
Test graphics show the measurement or test to be carried out in a test step.
A representative tester graphic is used for voltmeters and ohmmeters.
If multiple measurements are made in a single graphic, the test leads are drawn with a solid line until the test lead splits
to indicate the multiple measurements, at which point dashed lines are used.
Breakout box type testers are represented by a double circle test pin. Test pins are labeled with the pin number.
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.
General Information - Battery and Battery Charging Health and Safety
Precautions
W ARNINGS:
Batteries contain sulphuric acid, avoid contact with skin, eyes or clothing. Wear safety goggles when working near
the battery to protect against possible splashing of the acid solution.
EYE CONTACT: If acid comes into contact with the eyes, flush immediately with plenty of running water for a
minimum of 15 minutes. Seek immediate medical attention.
SKIN CONTACT: If acid comes into contact with the skin, flush immediately with plenty of running water for a
minimum of 15 minutes. Seek immediate medical attention.
SWALLOWED: If acid is swallowed, rinse the mouth with plenty of water and then drink plenty of water or milk. Do
not induce vomiting. Seek immediate medical attention.
Batteries normally produce explosive gases. Do not allow naked flames, sparks or lighted substances to come near
the battery.
W hen charging the battery shield your face and wear safety goggles. Provide adequate ventilation.
CAUTION: Boost charging with excessive current or voltage above 16 volts will damage the battery.
General Information - Brake System Health and Safety Precautions
W ARNINGS:
EYE CONTACT: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with the eyes. Wash hands
thoroughly after handling. If brake fluid comes into contact with the eyes, flush the eyes with plenty of cold running water
for 15 minutes. Seek medical attention for any persistent eye irritation or abnormality.
SWALLOWED: Brake fluid contains polyglycol ethers and polyglycols. If swallowed, drink plenty of water. Seek
immediate medical attention.
INHALED: Dust from friction materials can be harmful if inhaled.
Only use new specified brake fluid from airtight containers.
CAUTION: If brake fluid is spilled on the paintwork, the affected area must be immediately washed down with cold
water.
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 installation of replacement parts and accessories:
Safety features embodied in the vehicle may be impaired if other than genuine parts are installed. In certain
territories, legislation prohibits the installation 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 installed. 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 installed
location on the vehicle conform to mandatory requirements existing in their country of origin.
The vehicle warranty may be invalidated by the installation 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).
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, when not working on the Air Bag or Fuel systems. W ith 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 installed) and set it to the correct time.
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 will allow the ECM to relearn idle
and drive values, and may cause driveability concerns if the procedure is not carried out.
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 discharged 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 circuits are switched off. This can cause arcing when the jump
leads are connected.
W hilst 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, 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 generator to restore a discharged battery. For a generator 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.
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 installed. 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 ensure 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 oil ways,
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, oil ways and fluid passages with compressed air.
WARNING: 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 reinstalled 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. W ire 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 component may be reinstalled 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 that 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 rectification of the
vehicle without recourse to the Jaguar approved diagnostic system.
The diagnosis and testing sections within the manual cover:
System principles of operation with links to the relevant Description and Operation sections
Self tests (where appropriate)
Inspection and Verification - manual checks, symptom and Diagnostic Trouble Code (DTC) driven diagnostic charts
with actions required to rectify concerns
Component tests (where appropriate)
Circuit Diagrams
To understand the relationship between the vehicle electrical system and the system circuit diagrams, Refer to the
Electrical Guide.
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.
Acronym/Unit
Term(s) /Abbreviation Definition
Air Conditioning A/C
Accelerator Pedal Position APP Is a multitrack sensor which inputs the drivers demand into the engine
control module (ECM)
After Bottom Dead Center ABDC Event occurring after bottom dead center
After Top Dead Center ATDC Event occurring after top dead center
Anti-lock Brake System ABS 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)
Alternating Current ac
Amplitude Modulation AM
Automatic Temperature Control ATC
Automatic Transmission Fluid ATF
Ampere A SI unit of current
Ampere hour Ah
Barometric Pressure BARO 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 bottom dead center
Before Top Dead Center BTDC Event occurring before top dead center
Bottom Dead Center BDC Lowest point of piston travel in a reciprocating engine
Battery Junction Box BJB
Brake Pedal Position BPP
Brake Horsepower BHP Effective horsepower developed by an engine or motor, as measured by
a brake applied to its output shaft
British Standard BS Standard specification issued by the British Standards Institution
Brake Traction Control System BTCS
Bus Topology of a
communication
network
Coast Clutch Solenoid CCS
Camshaft Position CMP Indicates camshaft position
Carbon dioxide CO 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
Chlorofluorocarbon CFC
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
Compact Disc CD
Cylinder Head Temperature CHT Sensor A sensor for measuring the temperature of the cylinder head
Sensor
Central Junction Box CJB
Crankshaft Position CKP Indicates crankshaft position
Clutch Pedal Position CPP Indicates clutch pedal position
Acronym/Unit
Controller Area Network CAN A communication system which allows control modules to be linked
together
Constant Velocity CV
Cubic centimeter cm
Central Security Module CSM Electronic module to support security system functionality
Data Link Connector DLC Connector providing access and/or control of the vehicle information,
operating conditions, and diagnostic information
Driver Door Module DDM Electronic module to support driver door functionality
Driver Seat Module DSM Electronic module to support driver seat functionality
Daytime Running Lamps DRL
Deutsche Institut fur Normung DIN German standards regulation body
Diagnostic Trouble Code DTC An alpha/numeric identifier for a fault condition identified by the
On-Board Diagnostic (OBD) system
Direct current dc Current which flows in one direction only, though it may have
appreciable pulsations in its magnitude
Domestic Data Bus D2B
Digital Versatile Disc DVD
Electronic Automatic EATC
Temperature Control
Exhaust Gas Recirculation EGR
Exhaust Gas Recirculation EGRT Sensing EGR function based on temperature change
Temperature Sensor
Electronic Brake Force EBD
Distribution
Engine Control Module ECM Electronic module to support engine functionality
Electronic Crash Sensor ECS Sensor to measure severity of impact
Engine Coolant Temperature ECT
Engine Oil Pressure EOP
European On-Board Diagnostic EOBD
Electronic Pressure Control EPC
Electrically Erasable EEPROM
Programmable Read-Only
Memory
Erasable Programmable EPROM
Read-Only Memory
Evaporative Emission EVAP System designed to prevent fuel vapor from escaping into the
atmosphere. Typically includes a charcoal filled canister to absorb fuel
vapor
Flash Electrically Erasable FEEPROM
Programmable Read-Only
Memory
Front Electronic Module FEM
Flash Erasable Programmable FEPROM
Read-Only Memory
Frequency Modulation FM
Fuel Pump Driver Module FPDM
Fuel Rail Pressure FRP
Generic Electronic Module GEM
Ground GND Electrical conductor used as a common return for an electrical circuit or
circuits, and with a relative zero potential
Global Positioning System GPS
Global System for Mobile GSM
Communication
Gross Vehicle Weight GVW
Heated Oxygen Sensor HO2S Electrically heated oxygen sensor which induces fuelling corrections
Hydrofluorocarbon HFC
High tension HT
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
Intake Air Temperature IAT Temperature of intake air
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
Input Shaft Speed ISS Indicates input shaft speed
Key On, Engine Off KOEO
Key On, Engine Running KOER
Kilogram (mass) kg
Kilogram (force) kgf
Kilogram force per square kgf/cm
centimeter
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 ignition
Acronym/Unit
Liquid Crystal Display LCD Optical digital display system, to which applied voltage varies the way
the crystals reflect light, thereby modifying the display
Lighting Control Module LCM
Light Emitting Diode LED
Low Tension LT Primary circuit of the ignition system, linking the battery to the primary
winding in the ignition coil
Left-Hand LH
Left-Hand Drive LHD
Mass Air Flow MAF System which provides information on the mass flow rate of the intake
air to the engine
Manifold Absolute Pressure MAP Absolute pressure of the intake manifold air
Manifold Absolute Pressure MAPT
and Temperature
Malfunction Indicator Lamp MIL A required on-board indicator to alert the driver of an emission related
malfunction
Meter (measurement) m
Metric (screw thread, e.g. M8) M
Farad F Unit of electrical capacitance
Millimeter mm
Millimeter of mercury mmHg
Millisecond ms
Model year MY
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)
Negative Temperature NTC
Coefficient
Naturally aspirated N/A Fuelling system using intake air at atmospheric pressure; not
supercharged or turbocharged
Noise, Vibration and NVH
Harshness
North American Specification NAS Vehicles for sale in the USA and Canadian markets
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
Oxides of Nitrogen Nox
Oxygen Sensor O2S A sensor which detects oxygen content in the exhaust gases
On-board Refuelling Vapour ORVR
Recovery
Output State Control OSC
Output Shaft Speed OSS
Passenger Air Bag Deactivation PAD
Pulsed Secondary Air Injection PAIR
Passive Anti-Theft System PATS
Positive Crankcase Ventilation PCV
Parameter Identification PID An index number referring to a parameter within a module without
knowledge of its storage location
Park/Neutral Position PNP
Pulse W idth Modulation PW M
Programmable Electronic PECUS Process whereby a common ECM is programmed on the production line
Control Units System to suit the market requirements of a particular vehicle
Programmable Read-only PROM ROM with some provision for setting the stored data after manufacture
Memory
Portable Support Electronics PSE
Power Steering Pressure PSP
Polytetrafluoroethylene PTFE
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
Restraints Control Module RCM Electronic module to support functionality of the Supplemental
Restraints System
Radio Data System RDS
Rear Electronic Module REM
Remote Keyless Entry RKE
Right-hand RH
Right-hand drive RHD
Research Octane Number RON
Rear Seat Module RSM Electronic module to support functionality of rear seats
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)
Serial Communications Link SCL
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
Supplemental Restraints SRS
System
Shift Solenoid SS Controls shifting in an automatic transmission
Acronym/Unit
Seat Control Module SCM Module controlling the seat motor systems (not electric
raise/lower-only seats)
Secondary Air Injection 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
Service Repair Operation SRO Number generated by Jaguar Methods & Techniques system which
(number) 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'
Society of Automotive SAE
Engineers
Timing/Coast Clutch Solenoid T/CCS
Torque Converter Clutch TCC
Transmission Control Indicator TCIL
Lamp
Throttle Position TP
Top Dead Center TDC
Transmission Control Module TCM Controls the shifting pattern of the (automatic) transmission
Transmission Control Switch TCS Modifies the operation of electronically controlled transmissions
Transmission Fluid TFT Indicates temperature of transmission fluid
Temperature
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
Variable Assist Power Steering VAPS
Variable Camshaft Timing VCT A system by which the relationship of the crankshaft and camshaft
may be altered during engine running
Vehicle Identification Number VIN Number assigned to the vehicle by the manufacturer, primarily for
licensing and identification purposes
Vehicle Speed Sensor VSS Sensor which provides vehicle speed information
W orldwide Diagnostic System W DS Jaguar approved diagnostic system
W ide Open Throttle W OT Full throttle position
General Information - Health and Safety Precautions
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. W ear 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 part of the Supplemental Restraint System (SRS), mounted in various positions around the vehicle.
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
WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted
before repairing or replacing any SRS components. To deplete the backup power supply energy, disconnect the battery
negative cable and wait for one minute. Failure to follow this instruction may result in personal injury.
NOTE: The storage, transportation, disposal and/or recycling of air bag modules 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.
Air Bags - Do's
Do store in an air bag safe when not installed 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
Do wear safety glasses when carrying out repairs to the SRS or when handling an air bag module
Only carry out a system test with the air bag modules fully installed
Do inspect the condition of the impact sensor mounting bracket and sensor flylead if the vehicle has been involved
in an impact. Replace if damaged, even if there has been no deployment.
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 handle a deployed device or gas generator for at least 20 minutes
Do not probe air bag module electrical connectors or any other SRS component
Air Conditioning Refrigerant

See also Chlorofluorocarbon, Chemical Materials
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 with 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 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 W arning 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.
Brake Fluids (Polyalkylene Glycols)

See also Fire.
Splashes to the skin and eyes may cause irritation. Avoid skin and eye contact as far as possible. Vapor inhalation 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, and the breathing in of
vapors, aerosols, dusts or fumes
Do wash before breaks, before eating, smoking, drinking or using toilet facilities when handling chemical materials
Do keep work areas clean, uncluttered and free from 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
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 W elding, 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 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. W ear 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.
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/in) 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 UK are listed. Similar laws exist for other territories:
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 W heels 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 with oil
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 enable easier removal of dirty oil and grease from
the skin
Wash with soap and water to make sure all oil is removed (skin cleansers and nail brushes will help). Preparations
containing lanolin 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, 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, batteries should also be disposed off under similar arrangements. 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 a mixture 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 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 de-waxing 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 to 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. W ear 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 installed 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
See also Fire, Electric Shock, Gas Cylinders.
Welding processes include Resistance Welding (Spot Welding), Arc Welding and Gas Welding (and cutting).
Resistance Welding (Spot W elding)
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 ultraviolet 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 W HEN ARC W ELDING 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 ultraviolet 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. 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.
2. 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.
3. 3. Jaguar vehicles and replacement parts which contain asbestos are identified by this symbol. See Asbestos in this
subsection.
4. 4. Components or assemblies displaying this symbol give warning that the component contains a corrosive
substance. See Acids and Alkalis in this subsection.
5. 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.
6. 6. All vehicles with the passenger air bag installed 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.
White Spirit
See Solvents.
Safety Precautions
W ARNINGS:
W orking 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 CO fire extinguisher is close at hand
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. W hen 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 is 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. W ear 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 installed.
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.
General Information - How To Use This Manual
Copyright Statement
Copyright. Jaguar Cars Ltd. 2005
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 from the Service Division
of Jaguar Cars Ltd.
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 [Air Conditioning] covers air conditioning, which is part of the climate control system.
The first digit of the section number indicates the group (in the above example this being Electrical). 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 (12 in the above example being Climate
Control).
The last two digits of the section number indicate the part of the system covered by the section (03 in the example
denotes Air Conditioning).
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.
General Information - Petrol and Petrol-Ethanol Fuel Systems Health and
Safety Precautions
W ARNINGS:
Fuel may not give adequate warning before toxic or harmful effects arise.
Exposure to fuel can be harmful and can cause severe health damage or death.
Extreme care must be exercised when handling hot fluids. Always wash off spilled fluids from affected areas of skin
immediately.
Highly flammable mixtures are always present and may ignite when working on fuel systems. Do not allow naked
flames, sparks or lighted substances to come near fuel related components.
Fuel must not be used as a cleaning agent.
Keep fuel containers tightly closed, out of direct sunlight and in a cool area. Keep away from heat sources, ignition
sources and oxidizing agents.
SKIN CONTACT: Excessive or prolonged skin contact with diesel fuel may cause serious skin disorders including skin
cancer.
SKIN CONTACT: Fuel is mildly irritating to the skin and may cause dermatitis due to defatting effect. Remove
contaminated clothing. W ash affected areas of skin with soap and water. Seek medical attention for any persistent skin
irritation or abnormality. W ash contaminated clothing before reuse.
EYE CONTACT: Fuel is mildly irritating to the eyes. Flush with plenty of running water, blinking as often as possible.
Do not force the eyelid open. Seek medical attention for any persistent eye irritation or abnormality.
SWALLOWED: Fuel is moderately toxic and tends to foam on vomiting. If drawn into the lungs, inflammation may
develop. Do not induce vomiting. If spontaneous vomiting occurs place the victim in a forward position to reduce the risk
of fuel being drawn into the lungs. Give nothing by mouth. If breathing but unconscious, place in the recovery position. If
breathing has stopped, apply artificial respiration. Seek immediate medical attention.
INHALED: Fuel is toxic to the respiratory and other body systems. Exposure may result in various symptoms
including drowsiness, unconsciousness or severe health damage. Move a victim to fresh air. Keep a victim warm and at
rest. If unconscious, place in the recovery position. If not breathing, apply artificial respiration. Give cardiac massage if
necessary. Seek immediate medical attention.
CAUTIONS:
Fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is essential that absolute
cleanliness is observed when working with these components.
Make sure that the workshop area in which the vehicle is being worked on is as clean and as dust free as possible.
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.

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: W hen 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.
General Information - Symbols Glossary
Symbols are used inside the graphics and in the text area to enhance the information display.
Movement Symbols
Movement symbols provide detailed information to a required component movement. These component movements can be
rotational or 1-3 dimensional movements.

1 - Minor component movement clockwise/counterclockwise
2 - Major component movement clockwise/counterclockwise
3 - Component movement to the left/right/up/down
4 - Component movement towards/away
5 - 3 dimensional component movement
6 - 2 dimensional component movement
7 - 3 dimensional component rotation
8 - 3 dimensional component cycling
Turn Symbols
Turn symbols are used to provide further information on the direction or angle of component turns.
1 - Turn the component clockwise through 45
2 - Turn the component counterclockwise through 45
7 - Turn the component clockwise through 2 complete turns
8 - Turn the component counterclockwise through 2 complete turns
Steering W heel Symbols
Steering wheel symbols are used to provide further information to a required steering wheel position or steering column
lock status.
1 - Steering wheel in straight ahead position
2 - Steering column lock locked
3 - Steering column lock unlocked
4 - Turn the steering wheel to the 90 left position
5 - Turn the steering wheel to the 90 right position
6 - Turn the steering wheel to the left-hand end position
7 - Turn the steering wheel to the right-hand end position
1 - 3, 4, 5-door body style
2 - Wagon body style
3 - Sports utility vehicle body style
4 - Coupe body style
5 - Convertible body style
6 - Van body style
7 - 3, 4, 5-door body style - Top View
8 - Wagon body style - Top View
9 - Underview
10 - Right-hand drive (RHD) vehicle
11 - Left-hand drive (LHD) vehicle
Gearshift lever and selector lever position symbols
Gearshift lever and selector lever position symbols are used to show the lever position that is required to be selected to
carry out a procedure step.
1 - Set the selector lever to the park (P) position
2 - Set the selector lever to the reverse ) position
3 - Set the selector lever to the neutral (N) position
4 - Set the selector lever to the drive (D) position
5 - Set the selector lever with manual shift pattern to the park (D) position
6 - Set the selector lever with manual shift pattern to the manual (M) position
7 - Set the selector lever with manual shift pattern to the shift down (-) position
8 - Set the selector lever with manual shift pattern to the shift up (+) position
9 - Set the gearshift lever to the neutral (N) position
10 - Further gearshift lever positions that may appear in illustrations
Screwdriver symbols
The screwdriver symbols are used to show which screwdriver bit is recommended to carry out a procedure step.
1 - Screwdriver
2 - Cross bladed screwdriver
3 - Flat bladed screwdriver
4 - Hexagonal screwdriver
5 - TORX screwdriver
Pliers symbols
The pliers symbols are used to show which pliers is recommended to carry out a procedure step.
1 - Combination pliers
2 - Side cutter pliers
3 - Securing ring pliers - inner
4 - Securing ring pliers - outer
5 - Hose clamp pliers
6 - Locking pliers
7 - Long nose pliers
Drill symbols
The drill symbols are used to show which type and size of drill bit is recommended to carry out a procedure step.
1 - Drill bit with a specified diameter
2 - Hole saw with a specified diameter
3 - Stepped drill bit with a specified diameter
4 - Tap with a specified diameter
5 - Die with a specified diameter
6 - Scraper for circular holes
7 - Scraper for straight edges
Cutting tool symbols
The cutting tool symbols are used to show which type of cutting tool is recommended to carry out a procedure step.
1 - Cutting knife
2 - Air body saw
3 - Scissors
4 - Grinder
5 - Jig saw
6 - Plasma cutter
7 - Sanding Paper
8 - Drill through the shown number of body panel layers with a specified diameter
9 - Drill through the shown number of body panel layers with a suitable diameter
10 - Drill through 1 body panel layer with a specified diameter
11 - Drill through 1 body panel layer with a suitable diameter
12 - Wire brush
Apply Chemical or load symbols
The apply chemical or load symbols are used to show where to apply which type of chemical or load to carry out a
procedure step.

1 - Apply a bead from the specified tube
2 - Apply a bead from the specified cartridge
3 - Apply the specified chemical with a brush
4 - Apply the specified load to the specified component
5 - Apply a bead with a specific diameter from the specified tube
6 - Apply a bead with a specific diameter from the specified cartridge
7 - Apply the specified chemical with a roller
8 - Apply hot glue to the specified component
9 - Apply the specified amount of fluid from the fluid can
10 - Apply fluid from the fluid can
11 - Clean the specified component with the specified material
12 - Apply a broken bead from the specified tube
13 - Apply the specified chemical from a spray can
14 - Apply the specified lubricant to the specified component
15 - Apply spot welds to the specified component
16 - Apply a continuous weld to the specified component
17 - Handle the fluid using a syringe
18 - Extract the specified amount of fluid using a syringe
Measurement symbols
The measurement symbols are used to show where to measure which type of measurement to carry out a procedure step.
1 - Measure the current using a digital multimeter
2 - Measure the voltage using a digital multimeter
3 - Measure the resistance using a digital multimeter
4 - Measure the length/distance
5 - Check that the specified pressure is available using a suitable pressure gauge
6 - Measure the pressure at the specified port using a suitable pressure gauge
7 - Measure the time using a suitable stopwatch
8 - W ait for the specified period of time
9 - The specified task requires the specified minimum temperature
10 - The specified task requires the specified maximum temperature not to be exceeded
11 - The specified task requires the specified temperature range
12 - The specified task requires the specified temperature
13 - Measure and check for the specified value using a dial indicator gauge
14 - Measure and check for the specified MAX value using a dial indicator gauge
15 - Measure and check for the specified MIN value using a dial indicator gauge
General equipment symbols
The general equipment symbols are used to show where to use which type of general equipment to carry out a procedure
step.
1 - Hot air gun
2 - Soldering iron
3 - Scraper
4 - Scriber
5 - Securing strap
6 - File with a specified size
7 - Center punch
8 - Marker
9 - Metal inert gas (MIG) welding equipment
10 - Hose clamp
11 - Interior trim remover
12 - Vacuum cleaner
13 - Strap wrench
14 - W edge
15 - Pin Punch
Material symbols
The material symbols are used to show where to use which type of material to carry out a procedure step.

1 - Remove/Install the specified blind rivet
2 - Apply tape to the specified component/area
3 - Remove/Install the specified cable tie
Miscellaneous symbols
These symbols provide further information that is required to carry out a procedure step.
1 - Set the ignition switch to the 0 position
2 - Set the ignition switch to the II position
3 - The procedure step requires the aid of the specified number of supporting technicians
4 - Self contained breathing apparatus
5 - General prohibition used in combination with another symbol
6 - Do not use power tools
7 - Visual check
8 - Noise check
9 - Dispose the specified component
10 - Replaced by item 9 (Dispose the specified component)
11 - Set the engine speed to the specified value
12 - Fully apply the parking brake lever
13 - Fully release the parking brake lever
14 - Do not dispose of batteries into the waste bin
15 - Visual check using a mirror
16 - Area/component must be dry
Mandatory Protective equipment - Health and safety symbols
The protective equipment symbols advise to use a mandatory protective equipment to avoid or at least reduce possible
health and safety risks.

1 - Wear protective gloves
2 - Wear face guard
3 - Wear safety goggles
4 - Wear ear protectors
5 - Wear safety goggles and ear protectors
6 - Wear a respirator
Prohibition - Health and safety symbols and component damage
The prohibition symbols are used to prohibit the specified actions to avoid or at least reduce possible component damage
and health and safety risks.
1 - General prohibition symbol
2 - No naked flames
3 - No smoking
4 - No water
5 - Do not touch
6 - Do not switch
7 - No grinding
Warning symbols - Health and safety and component damage
The warning symbols are used to advise on hazardous conditions to avoid or at least reduce possible component damage
and health and safety risks.
1 - Hazardous voltage/Electrical shock/Electrocution
2 - Fire Hazard/Highly flammable
3 - Burn hazard/Hot surface
4 - Automatic start-up
5 - Toxic
6 - Explosive material
7 - Battery hazard
8 - Corrosive material
9 - Lifting hazard
10 - Hand crush/Force from above
11 - Cutting of fingers or hand
12 - Pressure hazard
Control Diagram symbols - Description and Operation procedures
These symbols provide further information on the type of connectivity, direction of flow or type of data bus of a system.
1 - Mid-speed Controller Area Network (CAN)
2 - High-speed Controller Area Network (CAN)
3 - Local Interconnect Network (LIN)
4 - W ires crossing not connected
General Information - Supplemental Restraint System (SRS) Health and
Safety Precautions
W ARNINGS:
Only qualified technicians are allowed to work on pyrotechnic components.
INHALED: Exposure to pyrotechnic residue may cause low blood pressure, severe headache, irritation of mucous
membranes, fainting, shortness of breath or rapid pulse. Move a victim to fresh air. Seek immediate medical attention.
EYE CONTACT: Exposure to unburned pyrotechnic residue may cause irritation, burning and etching of the eyes. Flush
immediately with plenty of cold running water for at least 15 minutes. Seek immediate medical attention.
EYE CONTACT: Exposure to burned pyrotechnic residue may cause irritation, burning and etching of the eyes. Flush
immediately with diluted boric acid solution. Seek immediate medical attention.
SKIN CONTACT: Unburned pyrotechnic residue may be rapidly absorbed through the skin in toxic quantities. Wash
immediately with plenty of soap and water. Seek medical attention.
SKIN CONTACT: Burned pyrotechnic residue may be rapidly absorbed through the skin in toxic quantities. W ash with
plenty of water. Do not use soap. Seek medical attention.
SWALLOWED: Unburned pyrotechnic residue is extremely toxic. If conscious drink plenty of water then induce
vomiting. Seek immediate medical attention. If unconscious, or in convulsions do not attempt to induce vomiting or give
anything by mouth. Seek immediate medical attention.
SWALLOWED: Burned pyrotechnic residue is extremely toxic. Drink plenty of water and seek immediate medical
attention.
The deployment key must only be accessible to authorized personnel.
Make sure that the deployment key remains removed from the deployment equipment except during deployment.
If permenantly disabling or enabling the passenger air bag a new seat belt for vehicles without or with a passenger
air bag must be installed.
Undeployed pyrotechnic components must not be deployed in the vehicle.
Pyrotechnic components must be deployed following local regulations.
Check thoroughly that no loose objects can be spread during the deployment of pyrotechnic components.
Pyrotechnic components must be transported following local regulations.
Never carry out any electrical measurement on disconnected, undeployed pyrotechnic components.
Pyrotechnic components must not be disassembled.
Pyrotechnic components are not interchangeable between vehicles.
Always carry a live air bag module away from the body with the air bag or trim cover pointing upwards.
Live air bag modules must be placed in a suitable cage when removed from the vehicle. The air bag or trim cover
must be facing upwards.
Do not install a rearward facing child safety seat to the passenger seat with an activated passenger air bag.
CAUTIONS:
Pyrotechnic components must not be subjected to temperatures higher than 110C.
Never install aftermarket accessories to the vehicle on or adjacent to the supplemental restraint system module.
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 in this section.
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
CAUTION: 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 parking brake is applied

The transmission selector lever is in Park
All instrument gauges (except fuel gauge) read zero
With the ignition switched on, check:
Ignition controlled warning lamps come on

Engine coolant temperature gauge registers a reading compatible with the engine coolant temperature
Fuel gauge registers a reading appropriate to the fuel level in the tank
The operation of the parking brake and brake fluid level warning lamps
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.
Initial gear engagement is smooth

Parking brake control operates smoothly and the parking brake releases quickly and completely
Transmission takes up the drive smoothly, without 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, 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 register the correct readings
or operate correctly
Switches and controls operate smoothly and positively, warning lamps 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

Abnormal temperature of any moving components or assemblies, e.g. wheel hubs, transmission, axle etc., which
might indicate over tightness or lack of lubrication
Identification Codes - Identification Codes
Vehicle Identification Number (VIN)

The official Vehicle Identification Number (VIN) for title and registration purposes is stamped on a metal plate and
fastened to the instrument panel. It is positioned close on the left-hand side of the vehicle and is visible from the outside.
The VIN is also located on the vehicle certification label.

1 VIN (stamped)
2 Bar code label (USA)
3 VIN label (Europe/Rest of World shown)
4 VIN plate
Vehicle Identification Number (Typical)

1 World manufacturer identifier
2 Market, air bag specification
3 Transmission and steering code
4 Body code
5 Emission control system
6 Check digit
7 Model year
8 Assembly plant, model line
9 Production sequence number
World Manufacturer Identifier

VIN Positions 1
Codes Manufacturer Make Type
SAJ Jaguar Cars Limited, England Jaguar Passenger Car
Market, Air Bag Specification

VIN position 2
VIN code Description
A Rest of W orld 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 3
VIN Code Description
A Automatic LHS
C Automatic RHS
Body Code - All except USA and Canada 2010 model year
VIN Position 4
05 Luxury
06 Premium luxury
07 Sport luxury/Portfolio/SV8
08 'R'
Body Code (USA and Canada) - 2010 model year

VIN Position 4
0F Luxury
0G Premium luxury
0H Portfolio/SV8
0J 'R'
Engine Emission System - 2009 model year

VIN Position 5
NOTE: *1 EU. Includes the following markets; Austria, Belgium, Bulgaria, Cyprus, Czech Rep, Denmark, Eire, Estonia,
Finland, France, Germany, Greece, Holland, Hungary, Italy, Latvia, Lithuania, Luxembourg, Malta, Poland, Portugal,
Romania, Slovenia, Slovakia, Spain (incl. Canary Islands), Sweden and UK.
NOTE: *2 East Europe. Includes the following markets; Albania, Bosnia, Croatia, Former Yugoslav Republic of Macedonia,
Kosovo, Montenegro 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, Qatar
and Saudi Arabia.
NOTE: *5 Caribbean. Includes the following markets; Bahamas, Barbados, Grand Cayman, Grenada and Trinidad and
Tobago.
VIN
Code Engine Market
D 3.0L *5 Caribbean, Chile, Dominican Rep, Guatemala, Indonesia, Malaysia, *4 Middle East, Morocco,
F 4.2L Panama, Phillipines, Singapore, Sri Lanka and Uruguay
G 4.2L
Supercharged
N/A 2.7L Diesel
M 3.0L China
N/A 4.2L
N/A 4.2L
Supercharged
N/A 2.7L Diesel
M 3.0L *2 East Europe, *1 EU, Israel, Norway, *3 Russia, Switzerland and Turkey
P 4.2L
R 4.2L
Supercharged
1 2.7L Diesel
W 3.0L Brazil
X 4.2L
Y 4.2L
Supercharged
N/A 2.7L Diesel
S 3.0L Egypt and Syria
U 4.2L
V 4.2L
Supercharged
N/A 2.7L Diesel
H 3.0L Japan
K 4.2L
L 4.2L
Supercharged
N/A 2.7L Diesel
N/A 3.0L USA
B 4.2L
C 4.2L
Supercharged
N/A 2.7L Diesel
N/A 3.0L Canada
B 4.2L
C 4.2L
Supercharged
N/A 2.7L Diesel
N/A 3.0L Mexico
K 4.2L
L 4.2L
Supercharged
N/A 2.7L Diesel
N/A 3.0L South Korea
B 4.2L
C 4.2L
Supercharged
1 2.7L Diesel
D 3.0L South Africa
F 4.2L
VIN
Code Engine Market
G 4.2L
Supercharged
1 2.7L Diesel
M 3.0L Argentina, Australia, Cyprus, Hong Kong, Malta, New Zealand, Taiwan, Thailand and UK (and
P 4.2L Eire)
R 4.2L
Supercharged
1 2.7L Diesel
Engine Emission System - 2010 model year

VIN Position 5
NOTE: *1 EU. Includes the following markets; Austria, Belgium, Bulgaria, Cyprus, Czech Rep, Denmark, Eire, Estonia,
Finland, France, Germany, Greece, Holland, Hungary, Italy, Latvia, Lithuania, Luxembourg, Malta, Poland, Portugal,
Romania, Slovenia, Slovakia, Spain (incl. Canary Islands), Sweden and UK.
NOTE: *2 East Europe. Includes the following markets; Albania, Bosnia, Croatia, Former Yugoslav Republic of Macedonia,
Kosovo, Montenegro 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, Qatar
and Saudi Arabia.
NOTE: *5 Caribbean. Includes the following markets; Bahamas, Barbados, Grand Cayman, Grenada and Trinidad and
Tobago.
VIN
Code Engine Market
D 3.0L Algeria, Brunei, *5 Caribbean, Dominican Rep, Guatemala, Indonesia, Libya, *4 Middle East,
F 5.0L Morrocco, Pakistan, Panama, Phillipines, Sri Lanka, Tunisia and Uruguay
G 5.0L
Supercharged
H 3.0L China
P 5.0L
R 5.0L
Supercharged
H 3.0L Chile
P 5.0L
R 5.0L
Supercharged
H 3.0L Argentina
P 5.0L
R 5.0L
Supercharged
H 3.0L *1 EU, *2 East Europe, Israel, Norway, Switzerland and Turkey
P 5.0L
R 5.0L
Supercharged
2 3.0L Diesel
W 3.0L Brazil
X 5.0L
Y 5.0L
Supercharged
S 3.0L - Egypt Egypt and Syria
only
F 5.0L
G 5.0L
Supercharged
H 3.0L Japan
P 5.0L
R 5.0L
Supercharged
A 4.2L USA
B 5.0L
C 5.0L
Supercharged
A 4.2L Canada
B 5.0L
C 5.0L
Supercharged
A 4.2L Mexico
B 5.0L
C 5.0L
Supercharged
B 5.0L South Korea
C 5.0L
Supercharged
VIN
Code Engine Market
2 3.0L Diesel
H 3.0L Malaysia
P 5.0L
R 5.0L
Supercharged
D 3.0L South Africa
F 5.0L
G 5.0L
Supercharged
2 3.0L Diesel
H 3.0L Taiwan
P 5.0L
R 5.0L
Supercharged
2 3.0L Diesel
D 3.0L Thailand
F 5.0L
G 5.0L
Supercharged
D 3.0L Singapore
F 5.0L
G 5.0L
Supercharged
H 3.0L Australia, Cyprus, Hong Kong, Malta, New Zealand and UK (and Eire)
P 5.0L
R 5.0L
Supercharged
2 3.0L Diesel
Check Digit
VIN Position 6
0 - 9 or X Calculated in accordance with American standard CFR part 565
Model Year
VIN Position 7
9 2009 model year
A 2010 model year
Assembly Plant and Model Line

VIN Position 8
F Castle Bromwich 3.0L
H Castle Bromwich 4.2L Normally aspirated
1 Castle Bromwich 4.2L Supercharged
7 Castle Bromwich 2.7L Diesel
K Castle Bromwich 3.0L Diesel (low power)
L Castle Bromwich 5.0L Normally aspirated
M Castle Bromwich 5.0L Supercharged
N Castle Bromwich 3.0L Diesel
P Castle Bromwich 5.0L Supercharged (low power)
Production Sequence Number

VIN Position 9
Sequence Number
R00001 - R99999
VIN Label
VIN Label (Europe and Rest of world)
1 Whole Vehicle Type Approval (WVTA) - Only shown for certain markets
2 VIN
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
VIN Label (North America)
5 VIN
6 Type
8 Paint code
VIN Label (Saudi Arabia and Gulf States)

2 VIN
4 Paint code
VIN Label (Canada)
5 VIN
6 Paint code
8 Type
VIN Label (China)

1 Occupant number
2 Engine specification (Type/Capacity/Power)
3 VIN
4 Trade mark
5 Vehicle type
8 Manufacturer name
VIN Label (Argentina)
1 VIN
2 Trade mark and manufacturer adress (in Spanish)
4 Gross train weight
9 Paint code
Automatic Transmission Number

The serial number of the transmission unit is displayed on a metal label or bar code (if equipped) attached to the
transmission casing.
Engine Number(s)
Engine Number - 2.7L Diesel
The serial number is stamped on an engine web on the right-hand side of the cylinder block behind the engine mounting.
Engine Number - 3.0L Diesel
The serial number is stamped on an engine web on the right-hand side of the cylinder block behind the engine mounting.
Engine Number - 3.0L
The engine number is contained on a bar code label on the front cover and is also stamped in the cylinder block casting on
the left-hand side of the engine below the engine mounting.
Engine Number - 4.2L and 4.2L Supercharged
The serial number is stamped on an engine web on the left-hand side of the cylinder block behind the engine mounting.
The emission code is also located here, on the transmission flange.
Engine Number - 5.0L and 5.0L Supercharged
The serial number is stamped on an engine web on the left-hand side of the cylinder block behind the engine mounting.
Jacking and Lifting - Jacking
Safety Precautions
WARNING: 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 may 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. Always 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.
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.
W hen using a floor jack, a cushioned pad must be utilized to avoid body damage.
Vehicle Support Points

Vehicle Recovery
NOTE: Prior to vehicle recovery, make sure the vehicle keys are available and the security system is disarmed.
Vehicle recovery methods are:
By flat-bed transporter.
By rear suspended tow.
By rear 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.
Rear Suspended Tow
When the vehicle is being recovered by rear suspended tow:
The ignition key must be removed from the ignition switch to lock the steering.
The rear wheels must be correctly positioned in the lifting cradle and securely tied down.
Emergency Towing
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 rear suspended tow.
When the vehicle is being towed on its own wheels:
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 position II to release the steering lock and make the direction indicators, horn and
stop lamps operate.
A distance of 0,8 km (0.5 mile) 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.
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.
Noise, Vibration and Harshness - Noise, Vibration and Harshness (NVH)
Principle of Operation
For a detailed description of Noise, Vibration and Harshness issues, refer to the Description and Operation section of the
workshop manual.
REFER to: Noise, Vibration and Harshness (NVH) (100-04 Noise, Vibration and Harshness, Description and Operation).

1. 1. Verify the customer's concerns by operating the vehicle to duplicate the condition.
2. 2. Visually inspect the vehicle to determine any obvious cause(s) of the concern(s).
3. 3. If the inspection reveals obvious causes that can be readily identified, repair as necessary.
4. 4. If the concern(s) remains after the inspection, determine the symptom(s) and refer to the Symptom Chart.
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 problems usually occur 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)
transmission
engine
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
tear down and diagnosis.
Under 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 approximately 64 km/h (40 miles/h) 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 tear down
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 CV joint boots resulting in inadequate or contaminated lubricant in the outboard or inboard CV
joint bearing housings
Loose CV joint boot clamps
Another component contacting the rear 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: Rear drive half shafts are not balanced and are not likely to contribute to rotational vibration disturbance.
Shudder or vibration during acceleration (including from rest) may be caused by the following:
Driveline alignment
Excessively worn or damaged outboard or inboard CV joint 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
Excessively worn driveshaft components
Leakage Conditions
1. 1. Inspect the CV joint boots for evidence of cracks, tears or splits.
2. 2. Inspect the underbody for any indication of grease splatter in the vicinity of the rear drive half shaft, outboard
and inboard CV joint boot locations, which is an indication of CV joint boot or CV joint boot clamp damage.
3. 3. Inspect the inboard CV joint bearing housing seal for leakage.
Inoperative Conditions
If a CV joint or rear drive 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 rear drive 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. 1. Make notes throughout the diagnosis routine. Make sure to write down even the smallest piece of information,
because it may turn out to be the most important.
2. 2. Do not touch anything until a road test and a thorough visual inspection of the vehicle 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.
3. 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.
4. 4. Road test the vehicle and define the condition by reproducing it several times during the road test.
5. 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.
Road Test Quick Checks

1. 1. 24-80 km/h (15-50 miles/h): 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.
2. 2. Acceleration/deceleration: W ith 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.
3. 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
brake discs, wheel hubs or front wheel bearings. Refer to High Speed Shake in the Symptom Chart.
4. 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 torque converter which turns
at engine speed when the vehicle is stopped. Refer to High Speed Shake in the Symptom Chart.
5. 5. Noise/vibration while turning: Clicking, popping, or grinding noises may be due to a worn, damaged, or
incorrectly installed front wheel bearing, rear drive half shaft or CV joint.
6. 6. Noise/vibration that is road speed relative: This noise/vibration can be diagnosed independent of engine speed
or gear selected (engine speed varies but torque and road speed remain constant). The cause may be a rear drive
axle/differential whine.
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 miles/h) indicated on
the speedometer since actual wheel speed will be twice that indicated on the speedometer. Speed exceeding 55 km/h (35
miles/h) or allowing the drive wheel to hang unsupported could result in tire disintegration, differential failure, constant
velocity joint and drive half shaft 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. W hen the CV joint is run at a very high angle, extra
vibration as well as damage to the seals and joints can occur.
The rear suspension lower arm 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. REFER to: (100-02 Jacking and Lifting)
Jacking (Description and Operation),

Lifting (Description and Operation).
1. 1. Raise and support the vehicle. REFER to: (100-02 Jacking and Lifting)

2. 2. Explore the speed range of interest using the Road Test Quick Checks as previously described.
3. 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.
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.
Exhaust Neutralization Procedure

1. 1. Raise vehicle on lift and slacken all exhaust fixings.
2. 2. With all fixings loose, neutralize the exhaust system.
3. 3. Tighten all fixings to correct torque, starting at the rear-most point working towards the front of the vehicle.
Symptom Chart
Symptom Possible Cause Action

High-speed shake Wheel end vibration GO to Pinpoint Test A.
Engine/transmission
Driveline
Tip-in moan Air cleaner GO to Pinpoint Test B.

Power steering
Powertrain
Engine mounts
Exhaust system
Idle boom/shake/vibration, or shudder Cable(s)/hoses(s) GO to Pinpoint Test C.

Intake air distribution and filtering system
Engine mounts
Exhaust system
Belt/pulleys
W heel end vibration analysis Suspension/rear drive halfshaft and CV joints GO to Pinpoint Test D.
Tires/wheels
Wheel bearings
CV joint boots
Non-axle noise Trim/mouldings GO to Pinpoint Test E.

A/C system
Accessories
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 DETAILS/RESULTS/ACTIONS
CONDITIONS
A1: NEUTRAL COAST
1 Carry out the neutral coast test.
Does the vibration disappear during the neutral coast test?
Yes
Check and install/re-balance wheels and tires and driveshaft. Check and install new
engine/transmission mounts as necessary. Repeat Road Test as outlined.
No
GO to D1.
PINPOINT TEST B : TIP-IN MOAN

CONDITIONS
B1: CHECK THE AIR CLEANER
1 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
1 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
1 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 Section 211-00.
No
Check and install new engine/transmission mounts as necessary. Repeat Road Test as outlined.
PINPOINT TEST C : IDLE BOOM/SHAKE/VIBRATION/SHUDDER

CONDITIONS
C1: CHECK CABLE/HOSES
1 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 COOLING RADIATOR
1 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 C3.
No
C3: CHECK THE EXHAUST SYSTEM
1 Carry out the exhaust system neutralizing procedure in this section.
Is the exhaust system OK?
Yes
Check and install new engine/transmission mounts as necessary. Repeat Road Test as outlined.
No
Repair as necessary. Repeat Road Test.
PINPOINT TEST D : WHEEL END VIBRATION ANALYSIS

TEST CONDITIONS DETAILS/RESULTS/ACTIONS
D1: INSPECT THE TIRES
1 Inspect the tires.
Raise and support the vehicle. REFER to: (100-02 Jacking and Lifting)
Inspect the tires for:
Correct tire size
Tire/wheel compatibility
Wear or damage
Tire beads correctly seated
Are the tires OK?

Yes
GO to D2.
No
Inspect the wheels. For additional information, refer to Section 204-00.
D2: INSPECT WHEEL BEARINGS
1 Inspect the wheel bearings. For additional information, refer to Section 204-00.
Are the wheel bearings OK?
Yes
GO to D3.
No
Repair as necessary. Repeat the Road Test as outlined.
D3: INSPECT THE CONSTANT VELOCITY (CV) JOINT BOOTS
1 Inspect the CV joint boots.
Spin the rear tire by hand
Inspect for evidence of cracks, tears, splits or splattered grease
Are the CV joint boots OK?

Yes
GO to D4.
No
Repair as necessary. Repeat the Road Test as outlined.
D4: INSPECT WHEEL AND TIRE RUNOUT
1 Inspect the wheel and tire runout.
Carry out the W heel and Tire Check procedure.

REFER to: W heels and Tires (204-04 W heels 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
Repair as necessary.
REFER to: W heels and Tires (204-04 Wheels and Tires, Diagnosis and Testing).
Repeat the Road Test as outlined.
PINPOINT TEST E : NON-AXLE NOISE

CONDITIONS
E1: INSPECT VEHICLE TRIM
1 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 Section 501-08.
No
GO to E2.
E2: CHECK THE A/C SYSTEM FOR NOISE
1 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.
REFER to: Climate Control System (412-00 Climate Control System - General Information,
Diagnosis and Testing).
No
GO to E3.
E3: CHECK NON-FACTORY ACCESSORIES
1 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.
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 converter and heat shield 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
Suspension System - General Information -
Vehicle Ride Height
Description Measurement
Description Front/Rear Kerb mm (inch) Tolerance mm (inch)
Vehicles without supercharger Front 387 (15.23) 15 (0.6)
Rear 392 (15.11) 15 (0.6)
Vehicles with supercharger Front 386 (15.19) 15 (0.6)
Rear 387 (15.23) 15 (0.6)
Ride height is measured from the centre of the wheel to the apex of the wheel arch, through the wheel centre line.
Kerb - with all fluids at full and a full tank of fuel, no occupants/luggage.
Wheel Alignment - Front Camber

Description Left-hand Right-hand Balance*1
Markets Degrees/MinutesNominalTolerance NominalTolerance NominalTolerance
All right-hand drive and Japan Degrees/Minutes -0 36' 45' -0 12' 45' -0 24' 45'
Decimal Degrees -0.6 0.75 -0.2 0.75 -0.4 0.75
USA, Canada, Mexico and Dominican Republic Degrees/Minutes -0 12' 45' -0 33' 45' 0 21' 45'
(Federal) Decimal Degrees -0.2 0.75 -0.55 0.75 0.35 0.75
Rest of world Degrees/Minutes -0 12' 45' -0 24' 45' 0 12' 45'
Decimal Degrees -0.2 0.75 -0.4 0.75 0.2 0.75
All above figures are at "Kerb" height - For additional information, refer to Vehicle Ride Height.
Tires must be inflated to normal pressure -
For additional information, refer to: Specifications (204-04, Specifications).
Wheel Alignment - Front Caster

Description Left-hand Right-hand Balance*2
Markets Degrees/MinutesNominalTolerance NominalTolerance NominalTolerance
All right-hand drive and Japan Degrees/Minutes 6 53' 45' 6 20' 45' 0 33' 45'
Decimal Degrees 6.88 0.75 6.33 0.75 0.55 0.75
USA, Canada, Mexico and Dominican Republic Degrees/Minutes 6 36' 45' 6 45' 45' -0 8' 45'
(Federal) Decimal Degrees 6.61 0.75 6.74 0.75 -0.14 0.75
Rest of world Degrees/Minutes 6 36' 45' 6 36' 45' 0 0' 45'
Decimal Degrees 6.61 0.75 6.61 0.75 0 0.75
Wheel Alignment - Front Toe

Description Total Toe
Markets Degrees/Minutes Nominal Tolerance
All right-hand drive and Japan Degrees/Minutes 0 13' 12'
Decimal Degrees 0.22 0.20
USA, Canada, Mexico and Dominican Republic (Federal) Degrees/Minutes 0 13' 12'
Rest of world Degrees/Minutes 0 13' 12'
Wheel Alignment - Rear Camber

Description Left-hand Right-hand
Markets Degrees/Minutes Nominal Tolerance Nominal Tolerance
All Markets Degrees/Minutes -0 41' 45' -0 41' 45'
Decimal Degrees -0.69 0.75 -0.69 0.75
Wheel Alignment - Rear Toe

Description Left-hand Right-hand Thrust Angle*5 Total Toe
Markets Degrees/Minutes Nominal Tolerance Nominal Tolerance Nominal Tolerance Nominal Tolerance
All Markets Degrees/Minutes 0 5' 8' 0 5' 8' 0 0' 8' 0 10' 12'
Decimal Degrees 0.09 0.14 0.09 0.14 0 0.14 0.17 0.20
*1 Camber balance = LH camber - RH camber
*2 Caster balance = LH caster - RH caster
*5 Thrust angle = Crab angle = (LH rear toe - RH rear toe)2
General Specifications
Item Specification
Item Specification
Clear Vision
Clear vision (negative value is counterclockwise) 0 3
Ball Joint Radial Play
Lower ball joint maximum 0.8 mm (1/32 in)
Upper ball joint maximum 0.8 mm (1/32 in)
Suspension System - General Information - Suspension System
For a detailed description of the suspension system, refer to the relevant Description and Operation section of the
workshop manual. REFER to:
Front Suspension (204-01 Front Suspension, Description and Operation),

Rear Suspension (204-02 Rear Suspension, Description and Operation),
Rear Suspension (204-02 Rear Suspension, Description and Operation),
Rear Suspension (204-02 Rear Suspension, Description and Operation).

1. 1. Verify the customer 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.
2. 2. Visually inspect for obvious signs of damage and system integrity.
Visual Inspection Chart

Mechanical
Damaged tires
W heel bearing(s)
Loose or damaged front or rear suspension components
Loose, damaged or missing suspension fastener(s)
Incorrect spring usage
Damaged or sagging spring(s)
Damaged or leaking shock absorber(s)
Damaged or leaking strut(s)
W orn or damaged suspension bushing(s)
Loose, worn or damaged steering system components
Damaged axle components
3. 3. If an obvious cause for an observed or reported condition is found, correct the cause (if possible) before
proceeding to the next step.
4. 4. If the fault is not visually evident, verify the symptom and refer to the following Symptom Chart.
Symptom Chart
Symptom Possible Sources Action

Crabbing * Incorrect rear thrust angle. * Check the rear toe adjustment.
REFER to: Rear Toe Adjustment (204-00 Suspension System -
General Information, General Procedures).
* Front or rear suspension * Inspect the front and rear suspension systems. Repair or install
components. new suspension components as necessary.
* Drive axle damaged. * Install a new rear drive axle/differential.
REFER to: Axle Assembly - 2.7L V6 - TdV6/3.0L NA V6 - AJ27/4.2L
NA V8 - AJV8/4.2L SC V8 - AJV8, Vehicles W ithout: Differential
Drain Plug (205-02 Rear Drive Axle/Differential, Removal and
Installation).
Drift/Pull * Unequal tire pressure. * Check and adjust the tire pressures. Inspect the tire for excessive
wear.
REFER to: Specifications (204-04 W heels and Tires, Specifications).
* Incorrect wheel alignment. * Check and adjust the wheel alignment. REFER to: (204-00
Suspension System - General Information)
Front Toe Adjustment (General Procedures),
Rear Toe Adjustment (General Procedures),
Camber and Caster Adjustment (General Procedures).
* Tires. * Check and adjust the tire pressures. Inspect the tire for excessive
wear.
* Unevenly loaded or * Notify the customer of incorrect vehicle loading.
overloaded vehicle.
* Damaged steering * Check the steering system.
components.
* Brake drag. * Check the brakes.
REFER to: Brake System (206-00 Brake System - General
Information, Diagnosis and Testing).
Front Bottoming or * Coil springs. * Check the ride height. Install new springs as necessary. REFER to:
Riding Low Front Shock Absorber (204-01 Front Suspension, Removal and
Installation),
Shock Absorber and Spring Assembly (204-02 Rear
Suspension, Removal and Installation).
Incorrect Tire Wear * Incorrect tire pressure * Check and adjust the tire pressure. Inspect the tire for excessive
(rapid center rib or inner wear.
and outer edge wear). REFER to: Specifications (204-04 W heels and Tires, Specifications).
* Excessive front or rear toe * Check and adjust the wheel alignment. REFER to: (204-00
(rapid inner or outer edge Suspension System - General Information)
wear). Front Toe Adjustment (General Procedures),
* Excessive negative or * Check and adjust the wheel alignment. REFER to: (204-00
positive camber (rapid inner Suspension System - General Information)
or outer edge wear). Front Toe Adjustment (General Procedures),
* Tires out of balance (tires * Balance the tires.
cupped or dished).
Rough ride * Spring(s) * Check and install new spring(s) as necessary. REFER to:
Front Shock Absorber (204-01 Front Suspension, Removal and
Installation),
Shimmy or Wheel * Loose wheel nut(s). * Check and tighten the wheel nuts to specification.
Tramp REFER to: Specifications (204-04 W heels and Tires, Specifications).
* Loose front suspension * Check and tighten the suspension fasteners to specification.
fasteners. REFER to: Specifications (204-00 Suspension System - General
Information, Specifications).
* Front wheel bearing(s). * Check the wheel bearings.
* W orn or damaged * Check and install new components as necessary.
suspension component
bushing.
* W heel/tires. * Check the wheels/tires. Balance or install new wheel/tires as
necessary.
REFER to: W heels and Tires (204-04 Wheels and Tires, Diagnosis
and Testing).
* Loose, worn or damaged * Check the Ball Joint(s).
ball joint(s).
* Loose, worn or damaged * Check and install new components as necessary.
steering components.
* Front wheel alignment. * Check and adjust the wheel alignment. REFER to: (204-00
Suspension System - General Information)
* Shock absorber(s). * Check and install new shock absorber(s) as necessary. REFER to:
Installation),
* Spring(s). * Check and install new springs as necessary. REFER to:
Installation),
Poor self center * Ball joints. * Check the Ball Joints.
action of the
* Steering components. * Check and install new components as necessary.
steering
Steering wheel * Unequal front or rear toe * Check and adjust the wheel alignment. REFER to: (204-00
off-center settings. Suspension System - General Information)
* Steering components. * Check and install new components as necessary.
Sway or roll * Overloaded, unevenly or * Notify the customer of incorrect vehicle loading.
incorrectly loaded vehicle.
* Loose wheel nut(s). * Check and tighten the wheel nut(s) to specification.
* Coil spring(s). * Check and install new coil springs as necessary. REFER to:
Installation),
* Loose front stabilizer bar or * Check and tighten the stabilizer bar to specification. REFER to:
rear stabilizer bar. Specifications (204-01 Front Suspension, Specifications),
Specifications (204-02 Rear Suspension, Specifications).
* W orn lower suspension arm * Install new lower suspension arm stabilizer bar as necessary.
stabilizer bar insulators. REFER to:
Front Stabilizer Bar - 2.7L Diesel (204-01, Removal and
Installation),
Front Stabilizer Bar - 3.0L (204-01, Removal and Installation),
Front Stabilizer Bar - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8
(204-01 Front Suspension, Removal and Installation),
Rear Stabilizer Bar (204-02 Rear Suspension, Removal and
Installation).
Installation),
Vehicle Leans to * Unevenly loaded or * Notify the customer of incorrect vehicle loading.
One Side overloaded vehicle.
* Front or rear suspension * Inspect the front and rear suspension systems. Repair or install
components. new suspension components as necessary.
Installation),
* Coil spring(s). * Check and install new spring(s) as necessary. REFER to:
Installation),
* Incorrect ride height. * Check the ride height. Install new spring(s) as necessary. REFER
Lateral tilt out of to:
specification. Front Shock Absorber (204-01 Front Suspension, Removal and
Installation),
Vibration/Noise * Tires/wheels. * Check and install new components as necessary.
* W heel bearings.
* W heel hubs.
* Brake components.
* Suspension components.
* Steering components.
W ander * Unevenly loaded or * Notify the customer of incorrect vehicle loading.
overloaded vehicle.
* Ball joint(s). * Check the Ball Joint(s).
* Front wheel bearing(s). * Check the wheel bearings.
* Loose, worn or damaged * Check and install new suspension components as necessary.
suspension components.
* Loose suspension * Check and tighten the suspension fasteners to specification.
fasteners. REFER to: Specifications (204-00 Suspension System - General
* Steering components. * Check and install new steering components.
* W heel alignment (excessive * Check and adjust the wheel alignment. REFER to: (204-00
total front toe-out). Suspension System - General Information)
Component Tests
Ball Joint Inspection
NOTE: The front suspension is shown in the following procedures. The inspection of the rear suspension upper ball joint
is similar.
1. 1. Raise and support the vehicle. REFER to: (100-02 Jacking and Lifting)

2. 2. Prior to carrying out any inspection of the ball joints, inspect the front wheel bearings.
3. CAUTION: The safety stand beneath the suspension lower arm must only support the weight of the
suspension and not the full weight of the vehicle. Failure to follow this instruction may result in damage to the
components.
3. Position a safety stand beneath the front suspension lower arm or rear suspension lower arm to be tested.
4. 4. While an assistant pulls and pushes the top and bottom of the tire, observe the relative movement between the
ball joint and the front suspension lower arm. Any movement at or exceeding the specification indicates a worn or
damaged ball joint. Install a new wheel knuckle as necessary.
REFER to: Wheel Knuckle (204-01 Front Suspension, Removal and Installation).
5. 5. While an assistant pulls and pushes the top and bottom of the tire, observe the relative movement between the
ball joint and the front suspension upper arm or rear suspension upper arm. Any movement at or exceeding the
specification indicates a worn or damaged ball joint. Install a new upper arm as necessary. REFER to: (204-01
Front Suspension)
Upper Arm LH (Removal and Installation),

Upper Arm RH (Removal and Installation).
6. 6. Remove the safety stand.
7. 7. Lower the vehicle.

Suspension System - General Information - Camber and Caster Adjustment
General Procedures
NOTE: The camber and caster adjustment for the left-hand side is shown, the procedure for adjusting the right-hand side
is similar.
NOTE: This procedure must be carried out using a 4-post ramp.
NOTE: Adjustments to the camber will affect the toe settings. Therefore, the camber and toe may need to be adjusted
at the same time to achieve the correct settings.
NOTE: Adjustments to the camber may affect the caster settings. Therefore, the caster will need to be checked, and
adjusted as necessary.
All vehicles
1. Check the rear toe adjustment.
For additional information, refer to: Rear Toe Adjustment
(204-00 Suspension System - General Information, General
Procedures).
Adjust as necessary.
2. Check the front toe adjustment.
For additional information, refer to: Front Toe Adjustment
Procedures).
Adjust as necessary.
3. Check the camber and caster settings. Follow the equipment
manufacturer's instructions.
4. NOTE: Left-hand shown, right-hand similar.
Loosen the tie-rod end lock nut.
Clean and lubricate the lock nut and tie-rod threads.
5. NOTE: Do not allow the tie-rod end or steering gear boot to

twist when the tie-rod is rotated.
NOTE: Left-hand, shown right-hand similar.
Rotate the tie-rod to adjust the toe.
Vehicles requiring camber adjustment

Loosen the rear lower arm lock nut.
Rotate the camber adjustment cam bolt to adjust the camber.
8. Check the camber and toe settings. Follow the equipment

manufacturer's instructions. Adjust as necessary.
9. NOTE: Make sure the camber adjustment cam bolt does not
rotate.
NOTE: Left-hand shown, right-hand similar.
Tighten the rear lower arm lock nut.
Tighten to 175 Nm.
Vehicles requiring caster adjustment

Loosen the front lower arm lock nut.

11. NOTE: Adjustments to the caster will affect the toe settings.
Therefore, the caster and toe may need to be adjusted at the
same time to achieve the correct settings.
Rotate the caster adjustment cam bolt to adjust the caster.
12. NOTE: Make sure the caster adjustment cam bolt does not
rotate.
Tighten the caster adjustment cam bolt lock nut.
Tighten to 175 Nm.
13. NOTE: Make sure the tie-rod or tie-rod end does not rotate.
Tighten the tie-rod end lock nut
Tighten to 55 Nm.
14. NOTE: Make sure that all fixings are torqued to the correct
specification.
Check the caster and toe settings. Follow the equipment

manufacturer's instructions. Adjust as necessary.
Suspension System - General Information - Four-Wheel Alignment
General Procedures
CAUTIONS:
Make sure the vehicle is on a flat level surface.
Make sure the tire pressures are within specification.
Make sure that only the manufacturers' recommended four wheel alignment equipment is used.
Make sure the steering is in the straight ahead position.
1. For wheel alignment information, refer to the suspension

specification section.
For additional information, refer to: Specifications (204-00
Suspension System - General Information, Specifications).
2. Check the tie rod ends, suspension joints, wheel bearings and
wheels and tires for damage, wear and free play.
Adjust or repair any worn, damaged or incorrectly

adjusted components.
3. Check and adjust tire pressures.

4. Position the vehicle on a calibrated, level, vehicle lift.
5. Release the vehicle parking brake.
6. Using only four-wheel alignment equipment approved by
Jaguar, check the wheel alignment.
7. NOTE: LH illustration shown, RH is similar.
To adjust, loosen the toe link locknuts.
8. CAUTION: Do not allow the gaiter to twist.
NOTE: Both tie rods must be rotated by an equal amount.
NOTE: LH illustration shown, RH is similar.
Adjust the rear toe.
9. Tighten the toe link locknuts to 55 Nm (40 lb.ft).

To adjust the caster, loosen the front lower arm lock nuts.
Rotate the caster adjustment cam bolt.
12. CAUTION: Make sure the caster adjustment bolt does

not rotate while the lock nut is being tightened.
Tighten the caster adjustment cam bolt nut.
Tighten the nut and bolt to 175 Nm (129 lb.ft).
13. CAUTION: Adjustments made to the camber setting will

affect the front toe setting. Therefore , the camber and toe may
need to be adjusted at the same time.
To adjust the camber, loosen the rear lower arm lock nuts.
Rotate the camber adjustment cam bolt.
15. CAUTION: Make sure the camber adjustment bolt does

not rotate while the lock nut is being tightened.
Tighten the camber adjustment cam bolt nut.
Tighten the nut and bolt to 175 Nm (129 lb.ft).
To adjust, loosen the tie rod end lock nuts.
Adjust the front toe.
18. Tighten the tie rod end lock nuts to 55 Nm (40 lb.ft).
Suspension System - General Information - Front Toe Adjustment
General Procedures
CAUTIONS:
Make sure the vehicle is on a flat level surface.
Make sure the tire pressures are within specification.
Make sure the steering is in the straight ahead position.
1. For wheel alignment information, refer to the suspension

specification section.
Suspension System - General Information, Specifications).
2. Check the tie rod ends, suspension joints, wheel bearings and
wheels and tires for damage, wear and free play.
Adjust or repair any worn, damaged or incorrectly

adjusted components.
3. Check and adjust tire pressures.

4. Position the vehicle on a 4 post lift.
5. Release the vehicle parking brake.
To adjust, loosen the tie rod end lock nuts.
Adjust the front toe.

Tighten the tie rod end lock nuts to 55 Nm.

Suspension System - General Information - Rear Toe Adjustment
General Procedures
1. Check the toe settings. Follow the equipment manufacturer's

instructions.
2. NOTE: Left-hand, shown right-hand similar.
Loosen the lock nut.
Clean and lubricate the lock nut and toe link threads.
3. Rotate the toe link to adjust the toe settings.
4. Tighten the lock nut.
5. Check the toe settings. Follow the equipment manufacturer's

instructions.
Front Suspension -
Torque Specification
Description Nm lb-ft lb-in
Steering gear to subframe retaining bolts 100 74 -
Toe link ball joint to wheel knuckle retaining nut 133 98 -
Stabilizer bar link to stabilizer bar retaining nut 43 32 -
Stabilizer bar link to lower arm retaining nut and bolt 70 52 -
Stabilizer bar clamp to subframe retaining bolts 55 41 -
Rear lower arm to wheel knuckle ball joint retaining nut 75 55 -
Rear lower arm to subframe retaining nut and bolt 175 129 -
Front lower arm to subframe retaining nut and bolt 175 129 -
Front lower arm to rear lower arm retaining nut and bolt Stage 1 - 60 Stage 2 - Stage 1 - 44 Stage 2 - -
135 degrees 135 degrees
Upper arm ball joint to wheel knuckle retaining nut 90 66 -
Upper arm to body retaining nuts and bolts 47 35 -
Shock absorber and spring assembly upper mounting to body 28 20 -
retaining nuts
Shock absorber and spring assembly to lower arm retaining nut 175 129 -
and bolt
Shock absorber and spring assembly upper mounting retaining nut 50 37 -
(without adaptive damping)
Shock absorber and spring assembly upper mounting retaining nut 27 20 -
(with adaptive damping)
W heel hub and bearing assembly to wheel knuckle retaining bolt 90 66 -
W heel and tire to wheel hub retaining nuts 125 92 -
Front Suspension - Front Suspension - Component Location
COMPONENT LOCATION
ItemDescription
1 Subframe
2 Spring and damper assembly
3 Upper control arm
4 W heel knuckle
5 W heel hub and bearing assembly
6 Lower lateral control arm
7 Lower forward control arm
8 Stabilizer bar
9 Stabilizer bar link
Front Suspension - Front Suspension - Overview
OVERVIEW
The front suspension is a fully independent design assembled on a non-isolated subframe. The wheel knuckle attaches to
the wishbone type upper and lower control arms.
The stabilizer bar attaches to the front of the subframe and varies in shape depending on the engine variant.
The spring and damper assemblies are located between the lower control arm and the front suspension housing in the
inner wing. Dependant on vehicle model there are three types of coil spring and damper available:
a standard oil passive damper (All models except supercharged),

an adaptive damper, also known as Computer Active Technology Suspension (CATS) on 4.2L supercharged vehicles
up to 2010MY,
Refer to: Vehicle Dynamic Suspension - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8 (204-05 Vehicle Dynamic Suspension,
Description and Operation).
a continuously variable adaptive damper, also known as Adaptive Dynamics System on 5.0L supercharged vehicles
from 2010MY.
Refer to: Vehicle Dynamic Suspension - 5.0L (204-05 Vehicle Dynamic Suspension, Description and Operation).
Front Suspension - Front Suspension - System Operation and Component
Description
System Operation
The front suspension is a fully independent design assembled on a non-isolated subframe mounted by four bolts to the
vehicle body. This rigid mounting arrangement provides the driver with optimum steering feel and facilitates towards the
vehicle's sporty dynamic suspension.
The suspension arrangement is a double-wishbone type with the length ratio between the upper and lower wish-bone
control arms calculated to minimize track and camber changes.
An adaptive damping system is available on specified models. For additional information refer to Vehicle Dynamic
Suspension 4.2L or 5.0L.
Component Description
COMPONENTS
ItemDescription
1 Subframe
3 Upper control arm
4 W heel knuckle
7 Lower lateral control arm
8 Lower forward control arm
9 Stabilizer bar
Upper Control Arm

The forged-aluminum upper control arm is a wishbone design and connects to the vehicle body through two plain bushes,
and links to the swan neck wheel knuckle by an integral ball joint. The upper control arm is inclined to provide anti-dive
characteristics under heavy braking, while also controlling geometry for vehicle straight-line stability.
Lower Control Arm

www.JagDocs.com
The forged aluminum lower control arms are of the wishbone design; the arms separate to allow for optimum bush tuning:
The rear lateral control arm is fitted with a bush at its inner end which locates between brackets on the subframe.
The arm is secured with an eccentric bolt which provides the adjustment of the suspension camber geometry. The
outer end of the control arm has a tapered hole which locates on a ball joint fitted to the wheel knuckle. An
integral clevis bracket on the forward face of the lateral control arm allows for the attachment of the forward
control arm. A bush is fitted below the clevis bracket to provide for the attachment of the stabilizer bar link. A
cross-axis joint is fitted to a cross-hole in the control arm to provide the location for the clevis attachment of the
spring and damper assembly.
The forward control arm is fitted with a fluid-block rubber bush at its inner end which locates between brackets on
the subframe. The arm is secured with an eccentric bolt which provides adjustment of the castor and camber
geometry. The outer end of the control arm is fitted with a cross-axis joint and locates in the integral clevis bracket
on the lateral control arm.
Wheel Knuckle
The cast aluminum wheel knuckle is a swan neck design and attaches to the upper control arm and lower lateral control
arm. The lower lateral control arm locates on a non serviceable ball-joint integral with the wheel knuckle. The lower boss
on the rear of the knuckle provides for the attachment of the steering gear tie-rod ball joint.
The wheel knuckle also provides the mounting locations for the:
wheel hub and bearing assembly

the wheel speed sensor (integral to the wheel hub and bearing assembly)
brake caliper and disc shield.
Stabilizer Bar
The stabilizer bar is attached to the front of the subframe with bushes and mounting brackets. The pressed steel mounting
brackets locate over the bushes and are attached to the cross member with bolts screwed into threaded locations in the
subframe. The stabilizer bar has crimped, 'anti-shuffle' collars pressed in position on the inside edges of the bushes. The
collars prevent sideways movement of the stabilizer bar.
The stabilizer bar is manufactured from 32mm diameter tubular steel on supercharged models and 31mm diameter tubular
steel on diesel and normally aspirated models and has been designed to provide particular characteristics in maintaining
roll rates, specifically in primary ride comfort.
Each end of the stabilizer bar curves rearwards to attach to a ball joint on a stabilizer link. Each stabilizer link is secured
to a bush in the lower lateral arm with a bolt and locknut. The links allow the stabilizer bar to move with the wheel travel
providing maximum effectiveness.
The only difference between the front stabilizer bars, in addition to the diameter, is in the shape to accommodate engine
variant:
a slightly curved bar, between bush centers, for V6 diesel (31 mm dia) and V8 gasoline supercharged (32 mm dia),
a straight bar, between bush centers, for V6 and V8 normally aspirated gasoline engines (31 mm dia).
Spring and Damper Assembly

The spring and damper assemblies are located between the lower lateral arm and the front suspension housing in the
inner wing. Dependant on vehicle model there are three types of coil spring and damper available:

up to 2010MY, For additional information refer to Vehicle Dynamic Suspension 4.2L.
from 2010MY. For additional information refer to Vehicle Dynamic Suspension 5.0L.
The dampers are a monotube design with a spring seat secured by a circlip onto the damper tube. The damper's lower
spherical joint is an integral part of the lateral lower control-arm, and the damper takes the form of a clevis-end, which
straddles the spherical joint.
The damper piston is connected to a damper rod which is sealed at its exit point from the damper body. The threaded
outer end of the damper rod locates through a hole in the top mount. A self locking nut secures the top mount to the
damper rod. The damper rod on the adaptive damper has an electrical connector on the outer end of the damper rod.
Supercharged 4.2L vehicles up to 2010MY: The adaptive damper functions by restricting the flow of hydraulic fluid through
internal galleries in the damper's piston. The adaptive damper has a solenoid operated valve, which when switched allows
a greater flow of hydraulic fluid through the damper's piston. This provides a softer damping characteristic from the
damper. The adaptive damper defaults to a firmer setting when not activated. The solenoid is computer controlled and can
switch between soft and hard damping settings depending on road wheel inputs and vehicle speed.
Supercharged 5.0L vehicles from 2010MY: The variable damper functions by adjustment of a solenoid operated variable
orifice, which opens up an alternative path for oil flow within the damper. W hen de-energized the bypass is closed and all
the oil flows through the main (firm) piston. When energized the solenoid moves an armature and control blade, which
work against a spring. The control blade incorporates an orifice which slides inside a sintered housing to open up the
bypass as required. In compression, oil flows from the lower portion of the damper through a hollow piston rod, a separate
soft (comfort) valve, the slider housing and orifice and into the upper portion of the damper, thereby bypassing the main
(firm) valve. In rebound the oil flows in the opposite direction
The damper rod is fitted with a spring aid which prevents the top mount making contact with the top of the damper body
during full suspension compression and also assists with the suspension tune.
The spring rate of the coil springs can differ between models and are color coded for identification. The coil spring locates
on a spring packer and a lower spring seat which is located on the damper body. The spring locates in an upper spring seat
which is located on the underside of the top mount. The majority of the roll stiffness is provided by the springs rather than
the stabilizer bar as this arrangement allows for a natural frequency of roll and consequently a consistent suspension ride.
Front Suspension - Front Suspension
For Diagnosis and Testing information.

REFER to: Suspension System (204-00 Suspension System - General Information, Diagnosis and Testing).
Front Suspension - Front Shock Absorber
Removal
NOTE: Fuse box release only required on removal of the RH front shock absorber.
NOTE: Expansion tank release only required for supercharged variant removal of the LH front shock absorber.
All vehicles
1. W ARNING: 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.

2. Remove the front wheel and tire.
For additional information, refer to: Wheel and Tire (204-04
W heels and Tires, Removal and Installation).
3. Remove the front stabilizer bar link.
For additional information, refer to: Front Stabilizer Bar Link
(204-01 Front Suspension, Removal and Installation).
4. Release the front shock absorber from the lower arm.
5. CAUTIONS:
Make sure the wheel knuckle is supported. Failure to follow

these instructions may result in damage to the vehicle.
Use an Allen key to prevent the ball joint rotating whilst

removing the nut.
Disconnect the upper arm from the wheel knuckle.
6. Lower the vehicle.

7. Release the fuse box.
Remove the 2 bolts and 1 nut.
Position the fuse box aside for access to the inboard

retaining nut.
Vehicles with supercharger

8. Release the coolant expansion tank for access.
All vehicles
9. Disconnect the front shock absorber electrical connector.
10. NOTE: Some variation in the illustrations may occur, but the
essential information is always correct.
Remove the front shock absorber and spring assembly.
11. NOTE: Do not disassemble further if the component is

removed for access only.
Install the front shock absorber and spring assembly in the

spring compressor.
12. W ARNING: The spring is under extreme tension, care

must be taken at all times. Failure to follow these instruction
may result in personal injury.
Compress the spring.
13. Remove the front shock absorber retaining nut
14. Carefully release the spring tension.

15. Remove the front shock absorber.
Installation
All vehicles
1. Vehicles without adaptive damping: Tighten the nut to 50 Nm.
2. Vehicles with adaptive damping: Tighten the nut to 27 Nm.

Install the front shock absorber and spring assembly.
Tighten the nuts to 27 Nm.

4. Connect the front shock absorber electrical connector.
5. Secure the fuse box.

6. Secure the coolant expansion tank.
Tighten to 10 Nm.
All vehicles
7. Raise the vehicle.
8. CAUTIONS:
Use an Allen key to prevent the ball joint rotating whilst

installing the nut.
Make sure the wheel knuckle is supported. Failure to follow

Secure the upper arm to the wheel knuckle.
Tighten the nut to 90 Nm.
9. Connect the front shock absorber and spring assembly to the

lower arm.
Tighten the bolt to 175 Nm.
10. Install the front stabilizer bar link.

11. Install the front wheel and tire.
Front Suspension - Front Lower Arm
Removal


2. Remove the air deflector.
For additional information, refer to: Air Deflector (501-02 Front
End Body Panels, Removal and Installation).
4. NOTE: Note the fitted position.
NOTE: RH illustration shown, LH is similar
Release the front lower arm.
Remove the 2 bolts and discard the nuts.
Installation
1. NOTE: RH illustration shown, LH is similar
Install the front lower arm.
Install the bolt and tighten the new nut to 60 Nm + 135

degrees.
Install the front lower arm inner retaining nut and bolt,
but do not fully tighten at this stage.
2. Install the front wheel and tire.

4. CAUTION: The final tightening of the front lower arm

inner retaining nut and bolt must be carried out with the vehicle
on its wheels
Tighten the 14mm bolt to 175 Nm.

5. Install the air deflector.
Jaguar, check the wheel alignment, and adjust if required.
Front Suspension - Rear Lower Arm
Special Tool(s)
Ball joint splitter
204-327
Removal

Raise the vehicle on a 4 post lift.

2. Remove the engine undertray.

Raise and support the body.

4. Remove the wheel and tire.
5. Remove the stabilizer bar link.
6. Release the tie rod.
7. Release the steering gear.

8. Secure the steering gear.
9. Release the shock absorber and spring assembly.
10. Remove the rear lower arm inner bolt.
11. Release the front lower arm.
Remove and discard the nut and bolt.

12. CAUTION: Prevent the rear lower arm ball joint ball pin
hexagon from rotating. Failure to follow this instruction may
result in damage to the lower ball joint boot.
Loosen the rear lower arm ball joint retaining nut.
Adjust the rear lower arm ball joint retaining nut until the ball
joint thread cannot be seen.
14. W ARNING: Make sure the special tool is supported

while carrying out the operation. Failure to follow this instruction
CAUTIONS:
Make sure the special tool is supported while carrying out

the operation. Failure to follow this instruction may result in
damage to the special tool.
Make sure the special tool is correctly located and the

lower ball joint boot is not damaged while carrying out the
operation. Failure to follow this instruction may result in damage
to the component.
Using the special tool, release the rear lower arm ball joint
from the wheel knuckle lower pivot.
Tighten the special tool adjusting bolt to a maximum of

60 Nm.
If the rear lower arm ball joint releases from the wheel
knuckle lower pivot, using no more than 60 Nm on the
special tool adjusting bolt, proceed to step 13.
If the rear lower arm ball joint does not release from the
wheel knuckle lower pivot, using no more than 60 Nm on
the special tool adjusting bolt, proceed to step 12.
15. W ARNING: Make sure the special tool is supported
while carrying out the operation. Failure to follow this instruction
CAUTIONS:
Make sure the special tool is supported while carrying out

the operation. Failure to follow this instruction may result in
damage to the special tool.
Make sure the special tool is correctly located and the

lower ball joint boot is not damaged while carrying out the
operation. Failure to follow this instruction may result in damage
to the component.
NOTE: Do not carry out this step if the rear lower arm ball joint
released from the wheel knuckle lower pivot in step 12.
Using the special tool, release the rear lower arm ball joint
from the wheel knuckle lower pivot.
Tighten the special tool adjusting bolt to a maximum of

60 Nm.
Strike the top surface of the special tool directly above

the rear lower arm ball joint at the point indicated using a
copper mallet.
Remove the rear lower arm.
Remove and discard the retaining nut.
Installation
1. W ARNING: Make sure that a new lower arm ball joint nut
is installed.
CAUTION: Prevent the rear lower arm ball joint ball pin
Install the rear lower arm.

2. NOTE: Install a new retaining nut and bolt.
Secure the front lower arm.
Stage 1: Tighten to 60 Nm.
Stage 2: Tighten to a further 135 degrees.
3. Secure the rear lower arm.
Install the rear lower arm inner retaining nut, but do not
tighten fully at this stage.
4. Install the shock absorber and spring assembly.
5. Remove and discard the retaining straps.

6. Install the steering gear.
Tighten the bolts to 100 Nm.
7. Secure the tie rod end.
8. Install the stabilizer bar link.

9. Install the wheel and tire.
10. Lower the body.
11. CAUTION: The final tightening of the upper arm must

be carried out with the vehicle on it's wheels.
Tighten to 175 Nm.
12. Install the engine undertray.

Jaguar, check and adjust the wheel alignment.
For additional information, refer to: Camber and Caster
Adjustment (204-00 Suspension System - General Information,
General Procedures).
Front Suspension - Rear Lower Arm Bushing
Special Tool(s)
Rear lower arm bushing remover and
installer
204-464
Rear lower arm bushing remover
204-333
Rear lower arm bushing installer
204-332
204-465
204-334
Removal
CAUTION: Nuts and bolts must be tightened with the weight of the vehicle on the suspension.


2. Remove the rear lower arm.
For additional information, refer to: Rear Lower Arm (204-01
Front Suspension, Removal and Installation).
Using the special tools, remove and discard the lower arm rear
bushings.
Installation
1. Install the special tools to the rear lower arm.
Tighten the bolts.
2. NOTE: Align to the position noted on removal.
Position the bushing in the special tool.
3. Using the special tools, partially install the lower arm bushing.
4. Change the special tools, then complete installation of the
bushing.
5. Install the rear lower arm.

Front Suspension - Shock Absorber Bushing
Special Tool(s)
Replacer support-bush
204-337
Replacer-bush
204-338
Remover-bush
204-336
Remover support-bush
204-335
Removal
CAUTION: Nuts and bolts must be tightened with the weight of the vehicle on the suspension.


3. NOTE: Take note of the fitted position of the bush.
Using the special tools, remove the shock absorber bushing.
Installation
1. NOTE: Make sure the shock absorber bushing boot is correctly
located into the special tool.
Install the bushing into the special tool.
Using the special tools, install the shock absorber bushing.

Front Suspension - Front Stabilizer BarTDV6 2.7L Diesel
Special Tool(s)
Powertrain Assembly Jack
HTJ1200-2
Engine Lifting Brackets
303-1129
Engine Support Bracket
303-021
Subframe Alignment Bolt
502-005
Removal
1. Disconnect the battery ground cable.
For additional information, refer to: Battery Disconnect and Connect
(414-01, General Procedures).
2. Using suitable tie straps, secure the radiator.
3. Remove the intake air shutoff throttle.

For additional information, refer to: Intake Air Shutoff Throttle
(303-04A, Removal and Installation).
4. CAUTION: Protect the paintwork during this operation.
Install the special tool.

5. Install the special tool.
6. W ARNING: Do not work on or under a vehicle supported only by a

jack. Always support the vehicle on safety stands.

7. Remove both the front wheel and tires.
For additional information, refer to: Wheel and Tire (204-04, Removal
and Installation).
For additional information, refer to: Air Deflector (501-02, Removal and
Installation).
9. Remove the radiator splash shield.
For additional information, refer to: Radiator Splash Shield (501-02,
Removal and Installation).
10. Detach the transmission fluid cooler.
Tie aside.
11. Remove the right-hand splash shield.
12. Detach the engine coolant inlet pipe from the front subframe.
13. Detach the power steering hose retaining clip from the front subframe.
Remove the front stabilizer bar link upper retaining nut.
Remove the front stabilizer bar link lower retaining bolt and nut and
remove the front stabilizer bar link.
16. Detach the steering gear.
Secure the steering gear.
Release the front lower arm and position it to one side.

Release the rear lower arm and position it to one side.
Remove the engine mount retaining nut.
20. Install the special tool to the front subframe.
Remove the front subframe front retaining bolt.
Remove the front subframe rear retaining bolt.

23. CAUTION: When lowering the special tool care must be taken to
manoeuvre the special tool so that the front subframe does not touch the
air conditioning (A/C) pipes. Failure to follow this instruction may result in
damage to the A/C pipes.
Lower the special tool by approximately 200 mm (7.9 in).

Remove the front stabilizer bar clamp.
25. Remove the front stabilizer bar.
Installation
1. Install the front stabilizer bar.
Install the front stabilizer bar clamp.
Tighten to 55 Nm.
3. CAUTION: When raising the special tool care must be taken to
Install the front subframe.
Install the front subframe rear retaining bolt.
Tighten to 150 Nm + 240.
6. Remove the special tool.
7. Install the front subframe front retaining bolt.

Install the engine mount retaining nut.
Tighten to 63 Nm.
12. CAUTION: The final tightening of the rear lower arm inner
retaining nut and bolt must be carried out with the vehicle on its wheels.

13. CAUTION: The final tightening of the front lower arm inner
Install the steering gear.
Tighten to 100 Nm.
Install the front stabilizer bar link.
Attach the front stabilizer bar link and install the front stabilizer bar link
retaining nut.
Tighten to 43 Nm.
17. Attach the power steering hose retaining clip to the front subframe.
18. Attach the engine coolant inlet pipe to the front subframe.
19. Install the right-hand splash shield.
20. Attach the transmission fluid cooler.
21. Install the radiator splash shield.

For additional information, refer to: Radiator Splash Shield (501-02,
Installation).
23. Install both the front wheel and tires.
For additional information, refer to: Wheel and Tire (204-04, Removal
and Installation).
Tighten to 175 Nm.

Tighten to 175 Nm.
Tighten to 70 Nm.
Remove the special tool.
30. Install the intake air shutoff throttle.

For additional information, refer to: Intake Air Shutoff Throttle
(303-04A, Removal and Installation).
31. Remove the radiator support.
32. Using only four-wheel alignment equipment approved by Jaguar, check

and adjust the wheel alignment.
For additional information, refer to: Four-Wheel Alignment (204-00,
Front Suspension - Front Stabilizer BarV6 3.0L Petrol
Special Tool(s)
Power train assembly jack
HTJ1200-2
Engine lifting bracket
303-661
Engine support bracket
303-021
502-005
Removal
(414-01 Battery, Mounting and Cables, General Procedures).
Loosen the exhaust manifold retaining nut.

4. Install the special tool to the exhaust manifold.
Install the retaining bolt.
6. Install the special tool support bars to the special tool.


For additional information, refer to: Wheel and Tire (204-04 Wheels and
Tires, Removal and Installation).
For additional information, refer to: Air Deflector (501-02 Front End Body
Panels, Removal and Installation).
For additional information, refer to: Radiator Splash Shield (501-02 Front
13. Detach the power steering hose retaining clip from the front subframe.
Remove the front stabilizer bar link lower retaining bolt and nut and
remove the front stabilizer bar link.

Mark the position of the bolt.

23. CAUTION: When lowering the special tool care must be taken to

Installation
Tighten to 55 Nm.
3. CAUTION: When raising the special tool care must be taken to


Tighten to 63 Nm.
Tighten to 100 Nm.
Attach the front stabilizer bar link and install the front stabilizer bar link
retaining nut.
Tighten to 43 Nm.
17. Attach the power steering hose retaining clip to the front subframe.

Tighten to 175 Nm.
Tighten to 175 Nm.

Tighten to 70 Nm.
27. Remove the special tool support bars from the special tool.
Remove the retaining bolt.
29. Remove the special tool from the exhaust manifold.

Tighten the exhaust manifold retaining nut.
32. Connect the battery ground cable.

33. Using only four-wheel alignment equipment approved by Jaguar, check
and adjust the wheel alignment.
For additional information, refer to: Four-Wheel Alignment (204-00
Suspension System - General Information, General Procedures).
Front Suspension - Front Stabilizer Bar4.2L NA V8 - AJV8/4.2L SC V8 - AJV8
Special Tool(s)
Powertrain Assembly Jack, HTJ
1200-2
Engine lifting brackets
303-749
303-021
502-005
Removal
All vehicles
For additional information, refer to: Battery Disconnect and
Connect (414-01 Battery, Mounting and Cables, General
Procedures).
Vehicles without supercharger

3. Remove the throttle body.
For additional information, refer to: Throttle Body (303-04A
Fuel Charging and Controls - 4.2L NA V8 - AJV8, Removal and
Installation).

4. Remove the air cleaner outlet pipe.
For additional information, refer to: Air Cleaner Outlet Pipe
(303-12B Intake Air Distribution and Filtering - 4.2L SC V8 -
AJV8, Removal and Installation).
All vehicles
NOTE: Vehicles without supercharger shown, vehicles with

supercharger similar.
Install the special tools.
6. NOTE: Vehicles with supercharger shown, vehicles without

NOTE: Right-hand shown, left-hand similar.
NOTE: Some variation in the illustrations may occur, but the



For additional information, refer to: Radiator Splash Shield
(501-02 Front End Body Panels, Removal and Installation).
12. Detach the power steering hose retaining clip from the front
subframe.
Remove the front stabilizer bar link lower retaining bolt and
nut and remove the front stabilizer bar link.

22. CAUTION: When lowering the special tool care must be

taken to manoeuvre the special tool so that the front subframe
does not touch the air conditioning (A/C) pipes. Failure to follow
this instruction may result in damage to the A/C pipes.


Installation
All vehicles
Tighten to 55 Nm.
3. CAUTION: When raising the special tool care must be

taken to manoeuvre the special tool so that the front subframe
does not touch the air conditioning (A/C) pipes. Failure to follow
this instruction may result in damage to the A/C pipes.


Tighten to 63 Nm.
www.JagDocs.com
12. CAUTION: The final tightening of the rear lower arm
on its wheels.

on its wheels.
Tighten to 100 Nm.

Attach the front stabilizer bar link and install the front
stabilizer bar link retaining nut.
Tighten to 43 Nm.
17. Attach the power steering hose retaining clip to the front
subframe.

23. CAUTION: The final tightening of the rear lower arm

on its wheels.
Tighten to 175 Nm.

on its wheels.
Tighten to 175 Nm.
Tighten to 70 Nm.
NOTE: Vehicles with supercharger shown, vehicles without

Loosen the special tool adjustment bolts.

27. NOTE: Vehicles without supercharger shown, vehicles with
Remove the special tools.

28. Install the air cleaner outlet pipe.

29. Install the throttle body.
Installation).
All vehicles

Procedures).
For additional information, refer to: Four-Wheel Alignment
Procedures).
Front Suspension - Front Stabilizer Bar Link
Removal


3. NOTE: Use an additional wrench to prevent the ball joint
rotating.
Remove the front stabilizer bar link.
Remove and discard the 2 nuts.
Installation
rotating.
Tighten the upper nut to 47 Nm.
Tighten the lower nut to 70 Nm.

Front Suspension - Stabilizer Bar Link Bushing
Special Tool(s)
Bush installer
204-340
Bush remove
204-342
Support
204-341
Support
204-339
Removal
CAUTION: The final tightening of the suspension components must be carried out with the vehicle on its wheels.


3. Using the special tools, remove and discard the stabilizer bar
link bushing.
Installation
1. NOTE: Apply water to lubricate the bushing.
Using the special tools, install the stabilizer bar link bushing.

Front Suspension - Upper Arm LH
Removal


For additional information, refer to: Front Shock Absorber
3. Remove the secondary bulkhead panel LH.
For additional information, refer to: Secondary Bulkhead Panel
LH - 2.7L V6 - TdV6/3.0L NA V6 - AJ27/4.2L NA V8 - AJV8/4.2L
SC V8 - AJV8 (501-02 Front End Body Panels, Removal and
Installation).
4. Remove the air cleaner.
For additional information, refer to: Air Cleaner (303-12A,
Removal and Installation) /
Air Cleaner (303-12B, Removal and Installation) /
Air Cleaner (303-12A Intake Air Distribution and Filtering - 4.2L
NA V8 - AJV8, Removal and Installation) /
Air Cleaner LH (303-12D, Removal and Installation).
Remove the upper arm retaining nut.

7. Remove the upper arm.

Installation
1. Install the upper arm.

Install the upper arm retaining nut, but do not tighten fully at
this stage.

this stage.
4. Install the front shock absorber.

5. CAUTION: The final tightening of the suspension

components must be carried out with the vehicle on its wheels.

Tighten to 47 Nm.

Tighten to 47 Nm.
7. Install the air cleaner.

For additional information, refer to: Air Cleaner (303-12A,
Removal and Installation) /
Air Cleaner (303-12B, Removal and Installation) /
Air Cleaner (303-12A Intake Air Distribution and Filtering - 4.2L
NA V8 - AJV8, Removal and Installation) /
Air Cleaner LH (303-12D, Removal and Installation).
8. Install the secondary bulkhead panel LH.
Installation).
Front Suspension - Upper Arm RH
Removal


3. Remove the secondary bulkhead panel RH.
RH - 2.7L V6 - TdV6/3.0L NA V6 - AJ27/4.2L NA V8 - AJV8/4.2L
Installation).

Installation
1. Install the upper arm.

this stage.

this stage.
4. Install the front shock absorber.



Tighten to 47 Nm.

Tighten to 47 Nm.
7. Install the secondary bulkhead panel RH.

Installation).
Front Suspension - Front Wheel Bearing and Wheel Hub
Removal

Raise and support the body.

2. Remove the brake disc.
For additional information, refer to: Brake Disc - Vehicles With:
Standard Brakes (206-03 Front Disc Brake - 2.7L V6 -
TdV6/3.0L NA V6 - AJ27/4.2L NA V8 - AJV8/4.2L SC V8 - AJV8,
Release the wheel speed sensor.
Release the clip.
Tie aside.
4. CAUTION: Do not attempt to release the wheel hub by

hitting it with a hammer directly, loosen the wheel hub
retaining bolts partially before applying an even amount of
force to the head of each bolts to release the wheel hub from
the wheel knuckle. Failure to follow this instruction may cause
damage to the component.
NOTE: Note the fitted position.

Remove the hub assembly.
Remove and discard the 4 bolts.
Installation
NOTE: Make sure that all the component mating faces are
clean.
Install the hub assembly.
Clean the component mating faces.
Tighten the bolts to 90 Nm (66 lb.ft).
2. Install the wheel speed sensor.
Secure the clip.
3. Install the brake disc.

Front Suspension - Wheel Knuckle
Special Tool(s)
Ball joint splitter
204-327
Removal


2. Remove the hub assembly.
For additional information, refer to: Front Wheel Bearing and
W heel Hub (204-01 Front Suspension, Removal and
Installation).
Remove the brake disc shield.
Remove the 3 rivets.
NOTE: Use an additional wrench to prevent the ball joint

rotating.
Disconnect the steering gear tie rod end ball joint.
Remove and discard the tie rod end retaining nut.

rotating.
Disconnect the upper arm from the wheel knuckle.
Remove and discard the nut.
6. CAUTION: Make sure the ball joint seal is not

damaged. A damaged seal will lead to the premature failure of
the joint.
NOTE: Use an additional wrench to prevent the ball joint

rotating.
Remove the wheel knuckle.
Using the special tool, release the ball joint from the
lower suspension arm.
Installation
rotating.
Install the wheel knuckle.

rotating.
Connect the upper arm and wheel knuckle.

3. NOTE: Use an additional wrench to prevent the component
from rotating.
Connect the tie-rod end ball joint.
4. Install the brake disc shield.
Install the rivets.
5. Install the hub assembly.

For additional information, refer to: Front Wheel Bearing and
W heel Hub (204-01 Front Suspension, Removal and
Installation).
Rear Suspension -
Halfshaft outer constant velocity joint retaining nut 300 221 -
Lower arm to wheel knuckle retaining nut and bolt 190 140 -
Lower arm to subframe retaining nut and bolt 192 142 -
Lower arm to subframe retaining bolt 192 142 -
Upper arm ball joint to wheel knuckle retaining nut 96 71 -
Upper arm to subframe retaining nut and bolt 115 85 -
Toe link to subframe ball joint retaining nut 90 66 -
Toe link to wheel knuckle retaining nut and bolt 63 46 -
Toe link setting nut 55 41 -
Shock absorber and spring assembly upper mounting to body retaining nuts 28 21 -
Shock absorber and spring assembly upper mounting retaining nut (without adaptive damping) 50 37 -
Shock absorber and spring assembly upper mounting retaining nut (with adaptive damping) 27 20 -
Shock absorber to lower arm retaining bolt 133 98 -
Stabilizer bar link to stabilizer bar retaining nut 48 35 -
Stabilizer bar clamp to subframe retaining bolt 55 41 -
Stabilizer bar link to lower arm retaining nut 48 35 -
W heel and tire to wheel hub retaining nuts 125 92 -
Rear Suspension - Rear Suspension - Component Location
COMPONENT LOCATION
ItemDescription
1 Subframe
2 Upper control arm
5 Toe link
7 W heel knuckle
8 Lower control arm
9 Shear bracket
10 Cross brace
11 Single brace
12 Stabilizer bar
Rear Suspension - Rear Suspension - Overview
OVERVIEW
The double wishbone type rear-suspension is a fully independent design assembled on a steel subframe; large diameter
bushes isolate the subframe from the vehicle's body.
A toe-link located between the wheel knuckle and the subframe is used to adjust the toe angle of the rear wheels.
The wheel knuckle attaches to the upper and lower control arms, and the coil spring and damper assembly is located
between the lower control arm and the vehicle body.
Dependant on vehicle model there are three types of coil spring and damper available:

Rear Suspension - Rear Suspension - System Operation and Component
Description
System Operation
The double wishbone type rear-suspension is assembled on a fabricated high-grade steel subframe. Large diameter
mounting bushes are used to isolate the subframe from the vehicle's body; the front bushes are hydrabushes, the rear are
voided rubber.
To achieve optimum suspension refinement a cross-brace is used to increase the torsional stiffness of the subframe. The
single brace attached to the shear brackets helps to reduce the transmission of road noise.
An adaptive damping system is available on specified models. For additional information refer to Vehicle Dynamic
Suspension 4.2L or 5.0L.
COMPONENTS
ItemDescription
1 Subframe
2 Stabilizer bar
3 Upper control arm
5 Toe link
6 W heel knuckle
9 Lower control arm
Upper Control Arm

The cast aluminum upper control arm locates to the subframe via one cross-axis joint and one plain rubber bush, and links
to the aluminum wheel knuckle via an integral ball-joint.
Lower Control Arm

The aluminum lower arm locates to the subframe via one cross-axis joint and one plain rubber bush, and to the wheel
knuckle via a second plain rubber bush.
The rear of the control arm has mounting points for the damper and the stabilizer link.
Toe-Link
The toe-link is located between the wheel knuckle and brackets on the subframe.
The toe-link comprises an inner rod with integral axial ball joint. The inner ball joint has a threaded spigot which locates in
a bracket on the subframe and is secured with a locknut. The rod has an internal thread which accepts the outer rod.
The outer rod has a cross-axis joint at its outer end which is located in a clevis on the wheel knuckle, and is secured with
a bolt and locknut.
The length of the toe-link can be adjusted by rotating the inner rod. This allows for adjustment of the toe angle for the
rear wheel. Once set the inner rod can be locked in position by tightening a locknut on the outer rod against the inner rod.
Wheel Knuckle
The cast aluminum wheel knuckle attaches to:
the upper control arm via a ball-joint located in the arm,

the lower control arm via a plain rubber bush located in the arm,
the toe-link via a cross-axis joint located in the toe link.
The wheel knuckle also provides the mounting locations for the:
wheel hub assembly,

wheel bearing,
wheel speed sensor,
brake caliper,
and disc shield.
Stabilizer Bar
The solid construction stabilizer bar and bushes have been designed to provide particular characteristics in maintaining roll
rates, specifically in primary ride comfort. There are four derivatives of rear stabilizer bar, with different diameters, to
support the various powertrains:
V6 gasoline - 12.7 mm solid bar

V8 4.2L and 5.0L gasoline - 13.6 mm solid bar
V6 2.7L diesel -14.5 mm solid bar
V6 3.0L diesel - 14.5 mm solid bar
V8 4.2L gasoline supercharged 16mm tubular
V8 5.0L gasoline supercharged - 18 mm tubular
The stabilizer bar is attached to the top of the subframe with two bushes and mounting brackets. The stabilizer bar has
crimped, 'anti-shuffle' collars pressed in position on the inside edges of the bushes. The collars prevent sideways
movement of the stabilizer bar.
Each end of the stabilizer bar curves rearward to attach to a ball joint on each stabilizer link. Each link is attached via a
second ball joint to a cast bracket on the lower control arm. The links allow the stabilizer bar to move with the wheel
travel providing maximum effectiveness.
Spring and Damper Assembly

The spring and damper assembly are attached to cast brackets on the lower control arms and to the vehicle body by four
studs secured by locking nuts. Dependant on vehicle model there are three types of coil spring and damper available:

The dampers are a monotube design with a spring located by a circlip onto the damper tube. The lower end of the damper
has a spherical joint which locates in the lower control arm and is secured with a bolt.
The damper piston is connected to a damper rod which is sealed at its exit point from the damper body. The threaded
outer end of the damper rod locates through a hole in the top mount. A self locking nut secures the top mount to the
damper rod. The damper rod on the adaptive damper has an electrical connector on the outer end of the damper rod.
Supercharged 4.2L vehicles up to 2010MY: The damper functions by restricting the flow of hydraulic fluid through internal
galleries in the damper's piston. The adaptive damper has a solenoid operated valve, which when switched allows a
greater flow of hydraulic fluid through the damper's piston. This provides a softer damping characteristic from the damper.
The adaptive damper defaults to a firmer setting when not activated. The solenoid is computer controlled and can switch
between soft and hard damping settings depending on road wheel inputs and vehicle speed.
Supercharged 5.0L vehicles from 2010MY: The variable damper functions by adjustment of a solenoid operated variable
orifice, which opens up an alternative path for oil flow within the damper. W hen de-energized the bypass is closed and all
the oil flows through the main (firm) piston. When energized the solenoid moves an armature and control blade, which
work against a spring. The control blade incorporates an orifice which slides inside a sintered housing to open up the
bypass as required. In compression, oil flows from the lower portion of the damper through a hollow piston rod, a separate
soft (comfort) valve, the slider housing and orifice and into the upper portion of the damper, thereby bypassing the main
(firm) valve. In rebound the oil flows in the opposite direction
The damper rod is fitted with a spring aid which prevents the top mount making contact with the top of the damper body
during full suspension compression and also assists with the suspension tune.
The spring rate of the coil springs can differ between models and are color coded for identification. The coil spring locates
on a spring packer and a lower spring seat which is located on the damper body. The spring locates in an upper spring seat
which is located on the underside of the top mount. The majority of the roll stiffness is provided by the springs rather than
the stabilizer bar as this arrangement allows for a natural frequency of roll, providing a consistent suspension ride.
Rear Suspension - Rear Suspension
For Diagnosis and Testing information.

Rear Suspension - Upper Arm
Removal

Raise the vehicle.

3. Release the high intensity discharge (HID) sensor link rod.
4. Release the anti-lock brake system (ABS) sensor wiring

harness.
5. Release the upper arm from the wheel knuckle.

Installation
1. To install, reverse the removal procedure.
2. Tighten to 98 Nm.
Rear Suspension - Lower Arm
Removal
NOTE: Before commencing work on the vehicle ensure the park brake is in the off position.
NOTE: LH shown RH similar.
1. W ARNING: Make sure to support the vehicle with axle

stands.
Raise the vehicle.

3. Release the shock absorber and spring assembly from the
lower arm.
4. Release the rear stabilizer bar link.
5. CAUTION: Do not allow the brake caliper to hang on the

brake hose.
NOTE: Make sure that new bolts are installed.
Release the rear brake caliper and tie aside.

6. Release the lower arm from the wheel hub assembly.
7. Remove the lower arm.
Installation
1. CAUTION: Nuts and bolts must be tightened with the

weight of the vehicle on the suspension.
Install the lower arm.

Secure the lower arm to the wheel hub assembly.

3. CAUTION: Do not allow the brake caliper to hang on the
brake hose.
Secure the rear brake caliper.
4. Secure the rear stabilizer bar link.

Secure the shock absorber and spring assembly to the lower

arm.


Rear Suspension - Shock Absorber and Spring Assembly
Removal
All vehicles
1. Remove the luggage compartment side trim panel.
For additional information, refer to: Loadspace Trim Panel LH
(501-05 Interior Trim and Ornamentation, Removal and
Installation).
Vehicles with active damping

2. Disconnect the active suspension damper electrical connector.
All vehicles
3. Remove the shock absorber and spring assembly top mount
nuts. TORQUE: 28 Nm

stands.
Raise the vehicle.

Remove the shock absorber and spring assembly. TORQUE: 133

Nm
7. WARNINGS:
Make sure the shock absorber is secured by fully

inserting the locking pin in to the special tool. Failure to follow
these instructions may result in personal injury.
As the spring is under extreme tension care must be

taken at all times. Failure to follow these instructions may
result in personal injury.
Make sure that a new nut is installed.
Using the special tool, compress the suspension spring to

remove the shock absorber.
Remove the nut. TORQUE: 27 Nm
Vehicles without active damping

8. WARNINGS:



remove the shock absorber.
Remove the nut. TORQUE: 50 Nm
All vehicles
9. Remove the shock absorber rod components.
Installation
All vehicles
1. Install the shock absorber rod components.

2. WARNINGS:



install the shock absorber.
Vehicles without active damping

3. WARNINGS:



install the shock absorber.
Tighten to 133 Nm.

All vehicles
6. Install the shock absorber and spring assembly top mount
nuts.
Tighten to 28 Nm.

7. Connect the active suspension damper electrical connector.
All vehicles
8. Install the luggage compartment side trim panel.
Installation).
Rear Suspension - Shock Absorber Lower Bushing
Special Tool(s)
Bushing Remover / Installer
204-335
Bushing remover
204-533
Bushing installer
204-534
Removal
1. W ARNING: Failure to follow this instruction may cause

damage to the vehicle.
Mark the orientation of the shock absorber in relation to the

lower suspension arm.
2. Remove the shock absorber and spring assembly.
For additional information, refer to: Shock Absorber and Spring
Assembly (204-02 Rear Suspension, Removal and Installation).
3. NOTE: Place the shock absorber with the recessed side facing
upwards.
NOTE: With assistance make sure the special tool is aligned.
Using the special tool, support the shock absorber.
4.
5. NOTE: Position
Using the the
special special
tools, tool onto
carefully the recessed
remove sidefrom
the bushing of the
the
bush.
shock absorber.
Installation
NOTE: With assistance make sure the special tool is aligned.
Position and align the special tool to the shock absorber

bushing.
1. NOTE: Make sure the bush is clean and free from oil or grease.
NOTE: Use a suitable lubricant to allow the bush to locate into

the special tool.
Locate the new bushing in the special tool.
2. W ARNING: Failure to follow this instruction may cause

NOTE: Make sure the shock absorber is clean and free from oil
or grease and is not damaged prior to pushing in the new bush.
NOTE: Make sure the bush is installed following the same

direction as removal.
NOTE: Make sure correct alignment is maintained.
Using the special tools, align the bushing to the shock

absorber.
3. NOTE: Make sure correct alignment is maintained.
Slowly push the bush into the shock absorber until the tool
reaches the stop.

For additional information, refer to: Shock Absorber and Spring
Assembly (204-02 Rear Suspension, Removal and Installation).
Rear Suspension - Rear Stabilizer Bar
Special Tool(s)
1200-2
Removal
Procedures).

stands.

3. Remove both rear wheels and tires.
4. Drain the fuel tank.
For additional information, refer to: Fuel Tank Draining (310-00
Fuel System - General Information, General Procedures).
5. Remove the exhaust system.
For additional information, refer to: Front Muffler (309-00
Exhaust System - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8,
6. CAUTION: Always plug any open connections to

prevent contamination.
NOTE: To prevent the loss of brake fluid, using the special

tool apply the brake pedal and set to 40mm ( 1.6 in ) below
the rest position.
NOTE: RH illustration shown, LH is similar.
Disconnect the brake hose from the brake caliper.
Using the special tool, press and hold the brake pedal.
Remove and discard the two sealing washers.
Release the brake caliper.
Tie the brake caliper aside.

Disconnect the rear wheel speed sensor.
9. Disconnect the electronic parking brake actuator electrical

connector.
Disconnect both parking brake cables from the rear brake

calipers.
Detach the shock absorber.

12. Detach the fuel filler hose.
13. CAUTION: Under no circumstances must the flexible

coupling (or its fixings) be loosened or removed from the
driveshaft.
Detach the driveshaft from the rear drive axle flange.
Mark the position of the driveshaft in relation to the rear

drive axle flange.
Mark the position of the balance nut in relation to the rear

drive axle flange. (if fitted).
Mark the position of each nut and bolt in relation to the

driveshaft flexible joint.
Remove the rear subframe reinforcement plate retaining bolts.
15. Install the special tool to support the rear subframe.
www.JagDocs.com
Remove the rear subframe rear retaining bolt.
Remove the rear subframe front retaining bolt.
18. Remove the rear subframe.
19. Remove the stabilizer bar link nuts.

20. Remove the rear stabilizer bar.
Remove the stabilizer bar bushings.
Installation
1. Install the stabilizer bar.
Install the stabilizer bar bushings.
Tighten to 55 Nm.
2. Install new nuts to the stabilizer bar links.
Tighten to 48 Nm.
3. Install the rear subframe.

Loosely install the rear subframe front bolt.
5. Loosely install the rear subframe rear bolt.
Loosely install the rear subframe reinforcement plate bolts.
7. Tighten the subframe bolts.
9. Tighten the rear subframe reinforcement plate retaining bolts.
Tighten to 47 Nm.
Install the shock absorber.
Tighten to 133 Nm.
11. NOTE: Install the components to their original fitted

positions.
Attach the driveshaft to the rear drive axle flange.

12. Attach the fuel filler hose to the fuel tank.
13. Connect both park brake cables to the rear brake calipers.
14. Connect the parking brake actuator electrical connector.
15. Connect the wheel speed sensor electrical connector.

16. Install the brake caliper.
17. Connect the brake hose to the brake caliper.
Install new sealing washers.
Tighten the union to 38 Nm.
18. Install the exhaust system.

For additional information, refer to: Front Muffler (309-00
Exhaust System - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8,
19. Refill the fuel tank.
20. Bleed the brake system.
For additional information, refer to: Brake System Bleeding
(206-00 Brake System - General Information, General
Procedures).
21. Install the rear wheels and tires.
Procedures).
For additional information, refer to: Camber and Caster
Adjustment (204-00 Suspension System - General Information,
Rear Suspension - Rear Wheel Bearing
Special Tool(s)
204-250
W heel bearing install and removal tool
204-269
Flange remover forcing screw
204-305
Remover, W heel Bearing
204-725
W heel hub support tool
204-726
W heel bearing install and removal tool
204-727A
Installer, Wheel Bearing
204-791
Installer, Wheel Bearing
205-491
Hub puller
205-491-1
Adapter nuts
Removal
1. 1. WARNING: Make sure to support the vehicle with axle

stands.
2. Refer to: Wheel and Tire (204-04 W heels and Tires, Removal and
Installation).
3.
4.
5.
6.
7.
8.
9. Special Tool(s): 205-491, 205-491-1, 204-269
10. 10. NOTE: Use an additional wrench to prevent the

component from rotating.
11. Special Tool(s): 204-726, 204-725

12. Special Tool(s): 204-305, 204-726, 204-725
13.
14. Special Tool(s): 204-726
Installation
1. 1. NOTE: Make sure correct alignment of the bearing is
maintained when installing into the hub carrier.
Special Tool(s): 204-727A, 204-791
2.
3. 3. NOTE: Make sure the correct alignment of the drive

flange is maintained when installing into the hub carrier
and bearing assembly.
Special Tool(s): 204-726, 204-250

4. 4. CAUTION: The final tightening of the
suspension components must be carried out with the
vehicle on its wheels.
Torque: 90 Nm
5. 5. NOTE: The wheel hub nut is not tightened at this

stage.

Torque: 150 Nm

Torque: 55 Nm
8. Torque: 6 Nm
9.
10. Torque: 103 Nm

11. Torque: 300 Nm
Installation).
Rear Suspension - Shock Absorber and Spring Assembly
Disassembly and Assembly
Special Tool(s)
Compressor, Coil Spring
204-476
Disassembly
1. Remove the shock absorber and spring assembly.
For additional information, refer to Shock Absorber and Spring
Assembly in this section.
2. W ARNING: Make sure the shock absorber is secured by

fully inserting the locking pin in to the special tool. Failure to
follow these instructions may result in personal injury.
Install the shock absorber and spring assembly to the special

tool as shown.
3. W ARNING: AS THE SPRING IS UNDER EXTREME TENSION

CARE MUST BE TAKEN AT ALL TIMES. FAILURE TO FOLLOW THESE
INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
Clamp the road spring.
4. Remove the shock absorber retaining nut.
Remove and discard the retaining nut.
5. Release the road spring.

6. Remove the shock absorber.
Assembly
1. CAUTION: Make sure the spring ends butt correctly

against the spring seats.
Install the shock absorber and spring assembly to the special

tool.
2. W ARNING: AS THE SPRING IS UNDER EXTREME TENSION

CARE MUST BE TAKEN AT ALL TIMES. FAILURE TO FOLLOW THESE
INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
Clamp the road spring.
3. Vehicles without adaptive damping.
Install a new retaining nut.
Tighten to 50 Nm.
4.
5. Vehicles withroad
Release the adaptive damping.
spring.
Install a new retaining nut.
Tighten to 27 Nm.
6. Remove the shock absorber and spring assembly from the
special tool.
Wheels and Tires - Wheels and Tires - Component Location
ItemDescription
1 7.5J x 17 inch
2 8.5J x 18 inch (optional)
3 8.5J x 18 inch
4 8.5J x 19 inch (optional)
5 Front - 8.5J x 20 inch Rear 9.5J x 20 inch
Tire Pressure Monitoring System
ItemDescription
1 Tire pressure sensor
2 Tire pressure monitoring system module
3 Tire pressure receiver
4 Tire pressure monitoring system initiator
Wheels and Tires - Wheels and Tires - Overview
OVERVIEW
A number of alloy wheel designs are available ranging from 17 to 20 inch in diameter. A Tire Pressure Monitoring System
(TPMS) is used to monitor the air pressure in each tire and inform the driver if the pressure falls below predetermined
thresholds.
Refer to: Wheels and Tires (204-04 Wheels and Tires, Description and Operation).
All wheels are of cast construction in aluminum alloy with the choice of wheel design dependant on the vehicle trim level:
The 17 inch wheel, not available in North America, is available on Luxury vehicles.
The two variants of the 18 inch wheel are offered on the High Luxury vehicle.
The 19 inch wheel is an optional fit for both Luxury and High Luxury models; it will also be available with run-flat
tires.
The 20 inch wheel is available on Super Charged vehicles only.
A 4J X 18 inch temporary spare wheel is supplied as standard, although in some major European markets an Instant
Mobility System is offered as an alternative to the spare wheel. The Instant Mobility System is capable of providing a
temporary repair and tire inflation to a puncture of up to 6mm in diameter in the tread area of the tire. A puncture in the
tire wall cannot be repaired using the system.
The vehicle jack and accessories are stored in the spare wheel-well in the luggage compartment.
Tire Changing
W ARNINGS:
Tires must be inflated to the recommended pressures when the tires are cold (ambient temperature) only. Refer to
label on the 'B' pillar for recommended tire pressures. If the tires have been subjected to use or exposed to direct
sunlight, move the vehicle into a shaded position and allow the tires to cool before checking or adjusting the pressures.
Valve stem seal, washer nut, valve core and cap should be replaced at every tire change. Valve stem seal, washer
and nut must be replaced if the valve retention nut is loosened. Sensor units and nuts must be fitted using correct torque
figures and associated profile. Damage to the vehicle and consequently injury to the vehicle's occupants may result if
these instructions are not adhered to.
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.
ItemDescription
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 degrees 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.
Run-Flat Tires
Run-flat tires can be handled, fitted and removed using the same principles as used for normal low profile and
high-performance tires, with two exceptions:
They are always fitted with tire pressure sensors.

They have thicker bead cores and more rigid sidewalls which require special care when being mounted on the rims.
It is recommended that the tire fitting machine is fitted with plastic rollers for the upper and lower bead. This will ensure
that the bead is removed gently, protecting the rims and the tire pressure sensors.
Adequate amounts of special fitting lubricant must be used to ensure that the sidewalls move with the minimum exertion
and locate on the rim flange correctly.
Run-flat tires can be identified by the marking 'RSC' on the tire sidewall.
NOTE: Vehicles fitted with run-flat tires are not supplied with a spare wheel, vehicle jack or wheel brace.
TREAD Act - NAS Only

Vehicles supplied to the North American markets must comply with the legislation of the Transport Recall Enhancement,
Accountability and Documentation (TREAD) act. Part of the requirement of the TREAD act is for the vehicle to display a
label which defines the recommended tire inflation pressure, load limits and maximum load of passengers and luggage
weight the vehicle can safely carry. This label will be specific to each individual vehicle and will be installed on the
production line. The label is positioned on the driver's side 'B' pillar on NAS vehicles and the inside rear face of the LH door
on Canadian specification vehicles.
This label must not be removed from the vehicle. The label information will only define the specification of the vehicle as
it came off the production line. It will not include dealer or owner fitted accessory wheels and tires of differing size from
the original fitment.
If the label is damaged or removed for body repair, it must be replaced with a new label specific to that vehicle. A new
label is requested from Jaguar parts and will be printed specifically for the supplied VIN of the vehicle.

The Tire Pressure Monitoring System (TPMS) is a driver assistance system which assists the driver to maintain the tire
pressures at the optimum level. TPMS is standard fitment on NAS vehicles and an optional fitment in other markets. TPMS
provides the following benefits:
Maintain optimal 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: 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 vehicle's tires and issues warnings to the driver if any of the pressures
deviate from defined tolerances. The space saver spare wheel is not monitored.
NOTE: TPMS is not designed to warn the driver of a tire 'blow-out', as due to the short duration of a 'blow-out', it is not
possible to give the driver sufficient warning that such an event is occurring. The design of the TPMS is to assist the driver
in keeping the tires at the correct pressure, which will assist to reduce the likelihood of a tire 'blow-out' occurring.
Wheels and Tires - Wheels and Tires - System Operation and Component
Description
Control Diagram
NOTE: A = Hardwired; F = RF Transmission; N = Medium speed CAN bus; W = LF Transmission
Tire Pressure Monitoring System (TPMS)
ItemDescription
1 Battery
2 Megafuse (250A)
3 CJB (central junction box)
4 RJB (rear junction box)
5 TPMS receiver
6 Tire pressure sensors
7 Initiators
8 TPMS module
9 Instrument cluster
System Operation
The controlling software for the Tire Pressure Monitoring System (TPMS) is located within a Tire Pressure Monitoring
System Module. The software detects the following:
When the tire pressure is below the recommended low pressure value - under inflated tire.
The location of the tire on the vehicle that is below the recommended pressure.
Malfunction warning.
The TPMS system comprises:
Tire pressure monitoring system module located below the right-hand front seat.
Tire pressure receiver located near the gear shifter within the floor console.
Two front initiators positioned forward of the wheels and behind the fender splash shields.
Two rear initiators positioned rearward of the wheels and assembled on dedicated brackets located behind the
fender splash shields.
Four sensors, each sensor is integral with a tire valve and located within the tire; the space saver spare wheel is
not fitted with a sensor.
The four initiators are hard wired 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 Radio Frequency (RF) transmission. The 315
or 433 MHz RF signals are detected by the tire pressure receiver 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 medium speed 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 front left, front right, rear left and rear right. This feature is required
because of the different pressure targets and threshold that could exist 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
TPMS module can 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 through the tire learn and location process.
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 12 mph (20 km/h) for 15 minutes. If the vehicle speed reduces to below 12 mph (20 km/h), the
learn process timer is suspended until the vehicle speed increases to more than 12 mph (20 km/h), after which time the
timer is resumed. If the vehicle speed remains below 12 mph (20 km/h) for more than 15 minutes, the timer is set to zero
and process starts again.
Low Pressure Monitoring
The tire low pressure sensor transmits by RF (315 MHz or 433 MHz depending on market) signal. These signals contain
data which corresponds to tire low pressure sensor identification, tire pressure, tire temperature, acceleration and tire low
pressure sensor mode.
Each time the vehicle is driven, the tire pressure monitoring system module activates each LF antenna in turn. The
corresponding tire low pressure sensor detects the LF signal and responds by modifying the mode status within the RF
transmission.
The system enters 'parking mode' after the vehicle speed has been less than 20 km/h (12.5 miles/h) for 12 minutes. In
parking mode the tire low pressure sensors transmit a coded signal to the tire pressure monitoring system module once
every 13 hours. If the tire pressure decreases by more than 0.06 bar (1 lbf/in) the tire low pressure sensor will transmit
more often as pressure is lost.
As each wheel responds to the LF signal from the tire pressure monitoring system module, it is assigned a position on the
vehicle and is monitored for the remainder of that drive cycle in that position.
When the vehicle has been parked for more than 15 minutes and then driven at a speed of more than 20 km/h (12.5
miles/h), the antennas fire in turn for 6 seconds on all except North American specification vehicles or for 18 seconds on
North American specification only vehicles in the following order:
Front left
Six second pause (for the tire pressure monitoring system module to detect a response from the tire low pressure
sensor)
Front right
Six second pause
Rear right
Six second pause
Rear left
Six second pause
Each tire low pressure sensor responds in turn so the tire pressure monitoring system module can establish the tire low
pressure sensor positions at the start of the drive cycle. This process is repeated up to three times but less if the tire low
pressure sensor positions are already known in the tire pressure monitoring system module.
This process is known as 'Auto Location' and takes:
three to five minutes on all except North American specification vehicles to complete, and
seven to eight minutes on North American specification vehicles to complete.
During this period the tire low pressure sensors transmit at regular intervals:
once every 5 seconds on all except North American specification vehicles, and
once every 15 seconds on North American specification vehicles.
For the remainder of the drive cycle the tire low pressure sensors transmit once every 60 seconds or if a change in tire
pressure is sensed until the vehicle stops and the tire pressure monitoring system returns to parking mode.
Once the wheel position is established, the antennas stop firing and do not fire again until the vehicle has been parked for
more than 15 minutes. The signal transmissions from each tire low pressure sensor continue at one minute intervals whilst
the vehicle is being driven. This transmission is to monitor the tire pressure. The warning occurs at 25% deflation and
comprises the low tire pressure warning indicator and an appropriate message displayed in the instrument cluster message
center. The message center will also display additional information about the position of the affected wheel(s).
Spare Tire Monitoring
Tire pressure sensors are not fitted to the space saver spare wheel and therefore the spare wheel is not monitored.
Initiator
Each initiator has a connector which connects to the vehicle body harness. The initiator is a passive, LF transmitter. The
initiators transmit their 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
which houses a PTC (positive temperature coefficient)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 either 315 MHz or 433 MHz dependant on market
requirements.
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 wheel, the new sensor identification will be learnt
through the learn and location process.
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.
NOTE: For important information regarding the removal and fitting of tire pressure sensors and associated valves, see
the Tire Changing section.
Refer to: Wheels and Tires (204-04 Wheels and Tires, Description and Operation).
Instrument Cluster Indications
ItemDescription
1 Low tire pressure warning indicator
2 Message center
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 centre.
The TPMS module passes system status information to the instrument cluster on the medium speed CAN bus. The
instrument cluster converts this data into illumination of the warning indicator and the 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.
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.
The following table shows the warning indicator functionality for given events:
Event Instrument Cluster Indications

Low pressure warning limit reached in one W arning indicator illuminated. 'CHECK TYRE PRESSURE' message
wheel displayed and applicable tire highlighted on display.
Low pressure warning limit reached in one or W arning indicator illuminated. 'CHECK ALL TYRE PRESSURES' message
more wheels in low speed mode (only if displayed.
programmed or learning)
TPMS fault W arning indicator flashes for 72 seconds and is then permanently
illuminated. The flash sequence repeats after ignition on cycle. 'TYRE
PRESSURE SYSTEM FAULT' message displayed.
No transmission from a specific tire pressure W arning indicator flashes for 72 seconds and is then permanently
sensor or Specific tire pressure sensor fault illuminated. The flash sequence repeats after ignition on cycle. 'TYRE NOT
MONITORED' message displayed.
No transmission from more than one tire W arning indicator flashes for 72 seconds and is then permanently
pressure sensor or more than one tire pressure illuminated. The flash sequence repeats after ignition on cycle. 'TYRE
sensor fault PRESSURE SYSTEM FAULT' message displayed.
CAN signals missing W arning indicator flashes for 72 seconds and is then permanently
illuminated. The flash sequence repeats after ignition on cycle. 'TYRE
PRESSURE SYSTEM FAULT' message displayed.
Vehicle enters high speed mode (only available W arning indicator illuminated. 'TYRE PRESSURE LOW FOR SPEED' message
in certain markets) displayed.
Wheels and Tires - Wheels and Tires
For a detailed description of the wheels and tires, refer to the relevant Description and Operation section in the workshop
manual. REFER to: (204-04 Wheels and Tires)
Wheels and Tires (Description and Operation),

Wheels and Tires (Description and Operation),
Wheels and Tires (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.
1. 1. Verify the customer complaint. As much information as possible should be gathered from the driver to assist in
diagnosing the cause(s). Confirm which of the following two warning types exist for the TPMS
Check tyre pressure warnings. A low tire pressure warning will continuously illuminate the low tire
pressure warning lamp. This warning will generate a text message CHECK TYRE PRESSURE. No Diagnostic
Trouble Codes (DTCs) are generated with this type of warning.
NOTE: Tire pressure adjustments are part of routine owner maintenance. Tire pressure adjustments that
are required due to a lack of owner maintenance are not to be claimed under vehicle warranty. To extinguish
this warning it is essential that, with the ignition 'ON', all vehicle tires are to be set to the correct pressure
as stated in the vehicle handbook or as indicated on the placard label in the passenger/driver door aperture
System fault warnings. W hen a system fault is detected, the low tire pressure warning lamp will flash for
approximately 75 seconds prior to being continuously illuminated. This indicates the presence of a system
fault.
Visual Inspection
Mechanical Electrical
Tire pressures Fuses
Tire/W heel damage. Refer to component tests in this section
Tire low pressure sensor installation/damage (metal valve stems as opposed to rubber)
3. 3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before
4. 4. If the cause is not visually evident check for Diagnostic Trouble Codes (DTCs) and refer to the DTC Index.
5. 5. If the tester fails to communicate with the TPMS module, it is recommended that the TPMS power supply fuse is
removed from the Rear Junction Box (RJB) for approximately 10 seconds and re-installed.
Drive Cycle
The vehicle must remain stationary for 15 minutes. Carry out a road test, for a minimum of 15 minutes at a speed greater
than 12.5 mph (20 kph) for at least 75% of the road test.
DTC Index
CAUTION: W hen 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 or a 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 programme is in operation, prior
to the installation of a new module/component.
NOTE: Generic scan tools may not read the codes listed, or may read only five digit codes. If this is the case, 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 extra information read by the manufacturer-approved diagnostic system).
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. W hen 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: 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

C1A5631 Left Front Tire No signal GO to Pinpoint Test F.
Pressure Sensor and Missing, incompatible or
Transmitter Assembly defective tire pressure
monitoring system low
pressure sensor or
receiver
C1A5668 Left Front Tire Event information No action required, event information only DTC
Pressure Sensor and Vehicle exposed to
Transmitter Assembly extreme temperature
environment
Tire low pressure sensor
low battery event
C1A5691 Left Front Tire Data out of range Suspect the left front tire low pressure sensor, check
Pressure Sensor and Tire low pressure sensor and install a new sensor as required.
Transmitter Assembly has reported out of range REFER to: Tire Low Pressure Sensor (204-04 W heels and
information for pressure, Tires, Removal and Installation).
temperature or
acceleration
C1A5693 Left Front Tire No sensor can be found at GO to Pinpoint Test G.

Pressure Sensor and this location
Transmitter Assembly Tire pressure monitoring
system initiator failure
failure
C1A5711 Left Front Initiator Left front initiator or Carry out any pinpoint tests associated with this DTC
circuit - short to ground using the manufacturer approved diagnostic system,
alternatively GO to Pinpoint Test B. . Refer to the
electrical circuit diagrams and check front left initiator
and circuits for short to ground. Carry out On Demand
Self Test (ODST) using manufacturer approved
diagnostic system to confirm rectification
circuit - short to power using the manufacturer approved diagnostic system,
and circuits for short to power. Carry out On Demand
circuit - open circuit using the manufacturer approved diagnostic system,
and circuits for open circuit. Carry out On Demand Self
Test (ODST) using manufacturer approved diagnostic
system to confirm rectification
C1A5831 Right Front Tire No signal GO to Pinpoint Test F.
pressure sensor or
receiver
C1A5868 Right Front Tire Event information No action required, event information only DTC
environment
low battery event
C1A5891 Right Front Tire Data out of range Suspect the right front tire low pressure sensor, check
temperature or
acceleration
C1A5893 Right Front Tire No sensor can be found at GO to Pinpoint Test G.

Pressure Sensor and this location
failure
C1A5911 Right Front Initiator Right front initiator or Carry out any pinpoint tests associated with this DTC
circuit - short to ground using the manufacturer approved diagnostic system,
alternatively GO to Pinpoint Test C. . Refer to the
electrical circuit diagrams and check front right initiator
circuit - short to power using the manufacturer approved diagnostic system,
circuit - open circuit using the manufacturer approved diagnostic system,
C1A6031 Left Rear Tire Pressure No signal GO to Pinpoint Test F.
Sensor and Missing, incompatible or
pressure sensor or
receiver
C1A6068 Left Rear Tire Pressure Event information No action required, event information only DTC
Sensor and Vehicle exposed to
environment
low battery event
C1A6091 Left Rear Tire Pressure Data out of range Suspect the left rear tire low pressure sensor, check and
Sensor and Tire low pressure sensor install a new sensor as required.
temperature or
acceleration
C1A6093 Left Rear Tire Pressure No sensor can be found at GO to Pinpoint Test G.
Sensor and this location
failure
C1A6111 Left Rear Initiator Left rear initiator or circuit Carry out any pinpoint tests associated with this DTC
- short to ground using the manufacturer approved diagnostic system,
alternatively GO to Pinpoint Test D. . Refer to the
electrical circuit diagrams and check left rear initiator
- short to power using the manufacturer approved diagnostic system,
- open circuit using the manufacturer approved diagnostic system,
C1A6231 Right Rear Tire No signal GO to Pinpoint Test F.
pressure sensor or
receiver
C1A6268 Right Rear Tire Event information No action required, event information only DTC
environment
low battery event
C1A6291 Right Rear Tire Data out of range Suspect the right rear tire low pressure sensor, check
Component Tests
Wheels and Tires information for pressure, Tires, Removal and Installation).
temperature or
acceleration
For wheel and tire specification information (pressures, torques, etc), refer to the specification section in 204-04.
When replacing wheels or tires, local legislation regarding health and safety must be complied with.
If the vehicle has TPMS installed, only Jaguar approved wheels and tires should be used. If the wheel and tire size is
changed (for example from R18 to R20) the TPMS module should be updated with the correct pressure information
appropriate to the new wheel and tire set. Update the Car Configuration File using the manufacturer approved diagnostic
system.
As a general guideline, only replace tires in pairs or as a set, and only with tires of equivalent size and specification.
Confirm the symptoms of the customer complaint.
As much information as possible should be gathered from the driver to assist in diagnosing the cause(s).
1. 1. Before a road test, carry out a basic inspection to make sure the vehicle is safe and legal to drive.
Basic inspection
Correct tire inflation

Legal tire tread depth
Cuts/Bulges in tire sidewall(s)
Tire ply separation
Embedded objects
Wheel rim damage
Correct tire installation (specification, direction of rotation, etc)
Any obvious distortion of the tire (flat/high spots)
Worn/Damaged steering or suspension components.
Road test
If the results of the basic inspection are acceptable, carry out a road test to confirm the symptoms.
To reproduce the symptoms, test the vehicle on similar roads to those on which the fault occurs and at similar speeds
(provided it is legal to do so).
If the vibration or noise can be reproduced, note the speed at which it occurs and see if it is possible to drive through the
symptom, meaning, is it possible to alter the fault by driving faster or slower than the speed at which it occurs?
If it is possible, it is likely that the fault is caused by an imbalance in the wheel or tire.
If the vibration or noise gets worse as the vehicle speed increases, it is likely that the fault is caused by distortion in the
wheel or tire, or worn or damaged components.
Distortion checks
Check for distortion by raising the vehicle so that the wheels are free and placing an axle stand or similar fixed object next
to each wheel in turn.
If the stand is placed at the tread of the tire, the tire can be checked for ovality by turning the wheel by hand and
checking for high or low spots where the gap between the tread and the stand increases or reduces.
If the stand is placed next to the wheel rim or tire sidewall, the wheel and tire can be checked for run-out in a similar way.
Pinpoint Tests
PINPOINT TEST A : TPMS EXTERNAL RECEIVER DATA LINE CIRCUIT

CONDITIONS
A1: CHECK THE EXTERNAL RECEIVER DATA LINE CIRCUIT FOR SHORT CIRCUIT TO GROUND
1 Key off.
2 Disconnect the TPMS external receiver electrical connector, C3MC45.
3 Measure the resistance between:
C3MC45, harness side Battery
Pin 1 Negative terminal
Is the resistance less than 10,000 ohms?
Yes
GO to A3.
No
GO to A2.
A2: CHECK THE EXTERNAL RECEIVER DATA LINE CIRCUIT FOR SHORT CIRCUIT TO POWER
Pin 1 Positive terminal
Yes
GO to A4.
No
GO to A5.
A3: CHECK WHETHER THE SHORT CIRCUIT IS IN THE HARNESS OR THE MODULE
1 Disconnect the TPMS module connector, C3MC39B.
Yes
REPAIR the short circuit. For additional information, refer to the wiring diagram. Clear the DTC and
test the system for normal operation.
No
INSTALL a new TPMS module.
REFER to: Tire Pressure Monitoring System (TPMS) Module (204-04 W heels and Tires, Removal and
Installation).
A4: CHECK WHETHER THE SHORT CIRCUIT IS IN THE HARNESS OR THE MODULE
1 Disconnect the TPMS module connector, C3MC39B.
Yes
REPAIR the short circuit. For additional information, refer to the wiring diagram. Clear the DTC and
test the system for normal operation.
No
REFER to: Tire Pressure Monitoring System (TPMS) Module (204-04 W heels and Tires, Removal and
Installation).
A5: CHECK THE EXTERNAL RECEIVER DATA LINE CIRCUIT FOR HIGH RESISTANCE
C3MC39B, harness side C3MC45, harness side
Pin 4 Pin 1
Is the resistance greater than 5 ohms?
Yes
REPAIR the high resistance. For additional information, refer to the wiring diagram. Clear the DTC
and test the system for normal operation.
No
INSTALL a new external receiver.
REFER to: Tire Pressure Monitoring System (TPMS) Receiver (204-04 Wheels and Tires, Removal
and Installation).
PINPOINT TEST B : FRONT LEFT LOW-FREQUENCY INITIATOR CIRCUIT

B1: CHECK THE INITIATOR RETURN CIRCUIT FOR SHORT CIRCUIT TO GROUND
1 Key off.
2 Disconnect the left hand front low-frequency initiator electrical
connector, C1MC40.
Measure the resistance between:

3
Yes
GO to B5.
No
GO to B2.
B2: CHECK THE INITIATOR NEGATIVE CIRCUIT FOR SHORT CIRCUIT TO POWER
Yes
GO to B6.
No
GO to B3.
B3: CHECK THE INITIATOR POWER CIRCUIT FOR SHORT CIRCUIT TO GROUND
Yes
GO to B7.
No
GO to B4.
B4: CHECK THE INITIATOR POWER CIRCUIT FOR SHORT CIRCUIT TO POWER
Yes
GO to B8.
No
GO to B9.
B5: CHECK WHETHER THE SHORT CIRCUIT IS IN THE HARNESS OR THE MODULE
1 Disconnect the TPMS module connector, C3MC39A.

2
Yes
REPAIR the short circuit. This circuit contains intermediate
connector, C13-B. For additional information, refer to the
wiring diagram. Clear the DTC and test the system for normal
operation.
No
REFER to: Tire Pressure Monitoring System (TPMS) Module
(204-04 W heels and Tires, Removal and Installation).

2
Yes
operation.
No
2
Yes
operation.
No

2
Yes
operation.
No
B9: CHECK THE INITIATOR RETURN CIRCUIT FOR HIGH RESISTANCE
C3MC39A, harness side C1MC40, harness side
Pin 14 Pin 2
Yes
REPAIR the high resistance circuit. This circuit contains
intermediate connector, C13-B. For additional information,
refer to the wiring diagram. Clear the DTC and test the system
for normal operation.
No
GO to B10.
B10: CHECK THE INITIATOR POWER CIRCUIT FOR HIGH RESISTANCE
Pin 13 Pin 1
Yes
No
INSTALL a new left hand front low-frequency initiator.
REFER to: Tire Pressure Monitoring System Front Antenna
PINPOINT TEST C : FRONT RIGHT LOW FREQUENCY INITIATOR CIRCUIT

C1: CHECK THE INITIATOR RETURN CIRCUIT FOR SHORT CIRCUIT TO GROUND
1 Key off.
2 Disconnect the right hand front low-frequency initiator
electrical connector, C1MC41.

Yes
GO to C5.
No
GO to C2.
C2: CHECK THE INITIATOR RETURN CIRCUIT FOR SHORT CIRCUIT TO POWER
Yes
GO to C6.
No
GO to C3.
C3: CHECK THE INITIATOR POWER CIRCUIT FOR SHORT CIRCUIT TO GROUND
Yes
GO to C7.
No
GO to C4.
C4: CHECK THE INITIATOR POWER CIRCUIT FOR SHORT CIRCUIT TO POWER
Yes
GO to C8.
No
GO to C9.
C5: CHECK WHETHER THE SHORT CIRCUIT IS IN THE HARNESS OR THE MODULE

Yes
operation.
No

Yes
operation.
No

Yes
operation.
No

Yes
operation.
No
C9: CHECK THE INITIATOR RETURN CIRCUIT FOR HIGH RESISTANCE
Pin 16 Pin 2
Yes
No
GO to C10.
C10: CHECK THE INITIATOR POWER CIRCUIT FOR HIGH RESISTANCE
Pin 15 Pin 1
Yes
No
INSTALL a new right hand front low-frequency initiator.
REFER to: Tire Pressure Monitoring System Front Antenna
PINPOINT TEST D : REAR LEFT LOW-FREQUENCY INITIATOR CIRCUIT

D1: CHECK THE INITIATOR RETURN CIRCUIT FOR SHORT CIRCUIT TO GROUND
1 Key off.
2 Disconnect the left hand rear low-frequency initiator electrical
connector, C4MC42.

Yes
GO to D5.
No
GO to D2.
D2: CHECK THE INITIATOR RETURN CIRCUIT FOR SHORT CIRCUIT TO POWER
Yes
GO to D6.
No
GO to D3.
D3: CHECK THE INITIATOR POWER CIRCUIT FOR SHORT CIRCUIT TO GROUND
Yes
GO to D7.
No
GO to D4.
D4: CHECK THE INITIATOR POWER CIRCUIT FOR SHORT CIRCUIT TO POWER
Yes
GO to D8.
No
GO to D9.
D5: CHECK WHETHER THE SHORT CIRCUIT IS IN THE HARNESS OR THE MODULE

Yes
connector, C44-K. For additional information, refer to the
operation.
No

Yes
operation.
No

Yes
operation.
No

Yes
operation.
No
D9: CHECK THE INITIATOR RETURN CIRCUIT FOR HIGH RESISTANCE
Pin 6 Pin 2
Yes
intermediate connector, C44-K. For additional information,
No
GO to D10.
D10: CHECK THE INITIATOR POWER CIRCUIT FOR HIGH RESISTANCE
Pin 5 Pin 1
Yes
intermediate connector, C44-K. For additional information,
No
INSTALL a new rear left hand low-frequency initiator.
REFER to: Tire Pressure Monitoring System Rear Antenna
PINPOINT TEST E : REAR RIGHT LOW-FREQUENCY INITIATOR CIRCUIT

E1: CHECK THE INITIATOR RETURN CIRCUIT FOR SHORT CIRCUIT TO GROUND
1 Key off.
2 Disconnect the right hand rear low-frequency initiator electrical
connector, C4MC43.

Yes
GO to E5.
No
GO to E2.
E2: CHECK THE INITIATOR RETURN CIRCUIT FOR SHORT CIRCUIT TO POWER
Yes
GO to E6.
No
GO to E3.
E3: CHECK THE INITIATOR POWER CIRCUIT FOR SHORT CIRCUIT TO GROUND
Yes
GO to E7.
No
GO to E4.
E4: CHECK THE INITIATOR POWER CIRCUIT FOR SHORT CIRCUIT TO POWER
1
Yes
GO to E8.
No
GO to E9.
E5: CHECK WHETHER THE SHORT CIRCUIT IS IN THE HARNESS OR THE MODULE

Yes
connector, C44-L. For additional information, refer to the
operation.
No

Yes
operation.
No

Yes
operation.
No

Yes
operation.
No
E9: CHECK THE INITIATOR RETURN CIRCUIT FOR HIGH RESISTANCE
Pin 8 Pin 2
Yes
intermediate connector, C44-L. For additional information,
No
GO to E10.
E10: CHECK THE INITIATOR POWER CIRCUIT FOR HIGH RESISTANCE
Pin 7 Pin 1
Yes
intermediate connector, C44-L. For additional information,
No
INSTALL a new rear right hand low-frequency initiator.
REFER to: Tire Pressure Monitoring System Rear Antenna
PINPOINT TEST F : MISSING, INCOMPATIBLE OR DEFECTIVE RUNNING TIRE LOW PRESSURE

SENSOR OR RECEIVER
CONDITIONS
F1: CHECK FOR CORRECT WHEEL AND TIRE ASSEMBLY AND TIRE LOW PRESSURE SENSOR
NOTE: One way of identifying if a tire low pressure sensor is installed to a wheel and tire assembly is
by a metal valve stem rather than rubber. A tire low pressure sensor cannot be installed to a space saver
spare wheel.
1 Check that the wheel and tire assembly installed to the applicable position on the vehicle is a full
size wheel and tire with a tire low pressure sensor installed.
Is a full size wheel and tire assembly with tire low pressure sensor installed?
Yes
GO to F2.
No
Install the correct wheel and tire assembly or tire low pressure sensor, of correct frequency, in
accordance with that defined in the manufacturer approved diagnostic system new tire low pressure
sensor application.
F2: CHECK FOR ADDITIONAL DTCS
1 Check for additional DTCs C1A5631, C1A5831, C1A6031, C1A6231.
Have all four DTCs logged in the tire pressure monitoring system module?
Yes
Suspect the tire pressure monitoring system receiver. Check and install a new receiver as required.
REFER to: Tire Pressure Monitoring System (TPMS) Receiver (204-04 Wheels and Tires, Removal and
Installation).
No
GO to F3.
F3: VERIFY THE POSITION OF THE DEFECTIVE TIRE LOW PRESSURE SENSOR
1 Clear DTCs and carry out Drive Cycle as outlined in Inspection and Verification section above.
2 Check tire pressure monitoring system DTCs.
Are any C1AXX31 DTCs logged?
Yes
Install the correct tire low pressure sensor, of correct frequency, in accordance with that defined in
the manufacturer approved diagnostic system new tire low pressure sensor application, to the
position identified by the logged DTC.
REFER to: Tire Low Pressure Sensor (204-04 W heels and Tires, Removal and Installation).
No
No further action is required.
PINPOINT TEST G : LOCALIZATION FAILURE

CONDITIONS
G1: CHECK FOR ADDITIONAL DTCS
1 Check for additional DTCs: Left Front - C1A5711, C1A5712, C1A5713. Right Front - C1A5911,
C1A5912, C1A5913. Left Rear - C1A6111, C1A6112, C1A6113. Right Rear - C1A6311, C1A6312,
C1A6313.
Are any of the DTCs listed above also logged?
Yes
Refer to the DTC Index and remedial actions. If a fault has been rectified, run On Demand Self Test
routine to confirm.
No
GO to G2.
G2: CHECK FOR ADDITIONAL DTCS
1 Check for additional DTCs: C1AXX31.
Is a C1AXX31 DTC also logged?
Yes
Refer to the DTC Index and remedial actions.
No
GO to G3.
G3: CHECK INITIATOR INSTALLATION
1 Check for correct installation of Initiator. REFER to: (204-04 W heels and Tires)
Tire Pressure Monitoring System Front Antenna (Removal and Installation),
Tire Pressure Monitoring System Rear Antenna (Removal and Installation).
Is the Initiator correctly installed?
Yes
GO to G4.
No
Rectify as required. REFER to: (204-04 Wheels and Tires)
Tire Pressure Monitoring System Front Antenna (Removal and Installation),
Tire Pressure Monitoring System Rear Antenna (Removal and Installation).
G4: CHECK FOR SHORT CIRCUIT IN INITIATOR HARNESS
1 Check for short circuit between Initiator power and return circuits.
Has a short circuit been identified?
Yes
Rectify the short circuit as required.
No
Install the correct tire low pressure sensor, of correct frequency, in accordance with that defined in
the manufacturer approved diagnostic system new tire low pressure sensor application, to the
position identified by the logged DTC.
REFER to: Tire Low Pressure Sensor (204-04 W heels and Tires, Removal and Installation).
PINPOINT TEST H : MISSING MESSAGE FROM RECEIVER

CONDITIONS
H1: CHECK TIRE PRESSURE MONITORING SYSTEM RECEIVER OR DATALINE CIRCUITS FOR OPEN CIRCUIT
1 Check tire pressure monitoring system receiver or dataline circuits for open circuit.
Has an open circuit fault been identified?
Yes
Rectify the open circuit as required, run On Demand Self Test routine to confirm.
No
GO to H2.
H2: CHECK FOR CORRECT WHEEL AND TIRE ASSEMBLY AND TIRE LOW PRESSURE SENSOR
NOTE: One way of identifying if a tire low pressure sensor is installed to a wheel and tire assembly is
by a metal valve stem rather than rubber. A tire low pressure sensor cannot be installed to a space saver
spare wheel.
1 Check that the wheel and tire assemblies installed to all four running wheel positions are full size
wheel and tires with tire low pressure sensors installed.
Are full size wheel and tire assemblies with tire low pressure sensors installed?
Yes
Drive the vehicle for an accumulative period of at least 19 minutes at a speed greater than 28 mph
(45kph), then check for DTCs. If DTC remains install a new tire pressure monitoring system receiver.
REFER to: Tire Pressure Monitoring System (TPMS) Receiver (204-04 W heels and Tires, Removal and
Installation).
If no DTC, suspect RF blocking event, no further action is required.
No
Install the correct wheel and tire assembly or tire low pressure sensor, of correct frequency, in
accordance with that defined in the manufacturer approved diagnostic system new tire low pressure
sensor application.
Wheels and Tires - Tire Low Pressure Sensor
Removal

stands.
Installation).
3. Remove the tire from the wheel, release the tire bead from the rim
180 degrees from the valve.
4.
5.
Discard the tire valve and retaining nut.
Installation
1. 1. CAUTIONS:
Make sure that the seal is correctly located.
Make sure that new components are installed.
Install the washer and seal, making sure the valve

remains pressed fully onto its seat.
2. 2. WARNINGS:
Make sure that any corrosion or dirt is removed from

the mating surfaces.
Make sure that a new tire valve, valve core, seal,

washer, cap and retaining nut is installed.
CAUTIONS:
Use lint free cloth.
Only use moderate force when installing the sensor.
NOTE: Only tighten the nut finger tight at this stage.
Install the tire low pressure sensor and support the

sensor body in position.
Support the back of the valve stem in order to
prevent rotation to the tire low pressure sensor
body.
Gently push the nut towards the center of the
wheel. Tighten the nut.
Torque: 8 Nm
3. Install the tire and balance the wheel.
Installation).

stands.
Lower the vehicle.

Wheels and Tires - Tire Pressure Monitoring System (TPMS) Front Antenna
Removal
1. 1. WARNING: Make sure to support the vehicle with axle stands.
2. 2. NOTE:
This step
requires
the aid of
another
technician.
NOTE:
Lower the
radiator
splash
shield
enough to
access the
tire
pressure
monitoring
system
front
antenna.
NOTE:
Note the
position of
the
component
before
removal.
Installation
1. 1. CAUTION: Make sure that the component is secured in the retainer.
NOTE: Make sure that the component is installed to the noted removal position.
To install, reverse the removal procedure.

Wheels and Tires - Tire Pressure Monitoring System (TPMS) Rear Antenna
Removal

stands.
Installation).
3.
4. 4. NOTE: Note the position of the component before

removal.
Installation 1. 1. CAUTION: Make sure that the component is secured in the

retainer.
NOTE: Make sure that the component is installed to the noted
removal position.

Wheels and Tires - Tire Pressure Monitoring System (TPMS) Module
Removal
1. Switch the igntion off.
2. Remove the right-hand front seat.
Refer to: Front Seat (501-10 Seating, Removal and Installation).
3. Refer to: B-Pillar Lower Trim Panel (501-05 Interior Trim and
Ornamentation, Removal and Installation).
4. Detach and reposition the floor covering.
5.
6.
Installation

Wheels and Tires - Tire Pressure Monitoring System (TPMS) Receiver
Removal
NOTE: The tire pressure monitoring system receiver is installed in the same location on both LHD and RHD vehicles.
1. Switch the ignition off.
2. Remove the left-hand floor console side trim panel.
Refer to: Floor Console Side Trim Panel (501-12 Instrument Panel
and Console, Removal and Installation).
3.
4.
Installation
2. Configure the tire pressure monitoring system using the diagnostic

tool.
Wheels and Tires - Wheel and Tire
Removal

stands.
2. Torque: 125 Nm
Installation
1. 1. CAUTION: Apply a small amount of grease to the hub and

wheel mating surfaces before installation. Make sure the grease
does not come into contact with the vehicles braking components
and the wheel stud threads. Failure to follow these instructions may

Vehicle Dynamic Suspension - Vehicle Dynamic Suspension4.2L NA V8 -
AJV8/4.2L SC V8 - AJV8 - Component Location
Adaptive Damping System Components
ItemDescription
1 Right-hand front-spring and damper assembly
2 Right-hand rear-spring and damper assembly
3 Rear vertical accelerometer
4 Left-hand rear-spring and damper assembly
5 Adaptive damping module
6 Left-hand front-spring and damper assembly
7 Front vertical accelerometer
AJV8/4.2L SC V8 - AJV8 - Overview
Adaptive Damping System

The adaptive damping system, also known as Computer Active Technology Suspension (CATS), is an electronically
controlled suspension system which constantly adjusts the damping characteristics of the suspension dampers in reaction
to the existing driving conditions. The adaptive damping system is available on specified models.
The system is controlled by an adaptive damping module, located beneath the right-hand front seat; the module receives
signals from two dedicated vertical accelerometers; one at the front of the vehicle and one at the rear.
In addition to these inputs, further signals from other vehicle electronic system components are monitored by the adaptive
damping module to determine vehicle body motion and driver inputs. These combined signals are used by the adaptive
damping module to control the damping characteristics of each damper and switch them to either 'soft' or 'firm' to give the
optimum vehicle ride for the prevailing driving conditions.
AJV8/4.2L SC V8 - AJV8 - System Operation and Component Description
Control Diagram
NOTE: A = Hardwired D = High speed CAN bus
ItemDescription
1 Battery
2 Megafuse (250 A)
4 High Speed CAN (controller area network) connection to other vehicle systems
5 Adaptive damping module
6 Right-hand rear active damper
7 Left-hand rear active damper
8 Rear vertical accelerometer
9 Left-hand front active damper
10 Right-hand front active damper
11 Front vertical accelerometer
System Operation
The adaptive damping module uses a combination of information from other system modules and data from the
accelerometer to measure the vehicle motion and driver inputs. Using this information, the module applies algorithms to
control the dampers for the existing driving conditions.
The adaptive damping module receives signals on the high speed CAN bus from the following system components:
Vehicle speed - ABS (anti-lock brake system) module

Brake switch status - ECM (engine control module)
Brake pressure - ABS module
Gear position - TCM (transmission control module)
Lateral acceleration - ABS module
Throttle pedal position - ECM
Power mode - CJB via the instrument cluster gateway
Steering wheel angle - Steering angle sensor via ABS module
Steering wheel speed - Steering angle sensor via ABS module
Engine speed - ECM
Engine running status - ECM
Car Configuration File Data - auxiliary junction box via instrument cluster gateway
Master configuration identification - auxiliary junction box via instrument cluster gateway
Vehicle information parameters - auxiliary junction box via instrument cluster gateway.
The adaptive damping module also outputs information for use by other systems as follows:
Computer Active Technology Suspension (CATS) fault - instrument cluster

Front left damper status - ECM
Front right damper status - ECM
Rear left damper status - ECM
Rear right damper status - ECM.
When the vehicle is stationary with the engine running, the dampers are set to the soft setting. With the vehicle in motion
the adaptive damping module monitors the input signals and operates the damper solenoids appropriately. The input
signals are compared against algorithms within the adaptive damping module and preset speed thresholds. The gear
position signal is also used to determine longitudinal detection and, along with the speed signal, is compared against
algorithms to select the appropriate 'soft' or 'firm' damper setting.
The adaptive damping module receives its power supply via a relay in the CJB. The relay remains energized for a period of
time after the ignition is off. This allows the adaptive damping module to record and store any fault codes relating to the
adaptive damping system faults.
Adaptive Damping System Fault Message
The adaptive damping has a CAN connection to the instrument cluster. If a fault is detected by the adaptive damping
module, a message is sent to the instrument cluster and a message 'CATS SYSTEM FAULT' is displayed.
When this message is displayed a fault has been detected and an appropriate DTC (diagnostic trouble code) will be logged
in the module. The faults can be interrogated using the recommended Jaguar Diagnostic System.
When a fault is detected, the module stops outputs to the active dampers and the dampers operate continually on their
default 'hard' setting until the fault is corrected.
Dampers
The adaptive dampers are nitrogen-gas and oil-filled monotube units. The dampers have a two-stage adjustment which
allows the damping force to be electrically adjusted when the vehicle is being driven. The two-stage dampers provide the
optimum compromise between performance handling and ride comfort.
The adaptive dampers can be easily identified by an electrical connector on the end of the piston rod, in the center of the
top mount.
The two-stage adjustment is achieved by a solenoid controlled valve. W hen the solenoid valve is de-energized, the
damper is on its firm setting and oil flow is restricted to a controlled rate through orifices in the damper piston. The
restricted oil flow stiffens the damper action improving the handling when braking, accelerating and cornering.
ItemDescription
A Firm setting
B Soft setting
The solenoid is connected to a by-pass valve which allows additional oil flow through the damper. When the solenoid is
energized, the valve is lifted from its seat, allowing oil to flow through a hollow piston rod in the center of the damper
piston and out through additional orifices. The increased oil flow softens the damper action providing a more comfortable
ride quality.
The solenoid is operated by a 400 Hz PWM (pulse width modulation) signal from the adaptive damping module. W hen
energized, the module applies a 1.3 ampere push current for 75 milliseconds to move the valve and then applies a 0.5
ampere hold current to operate the damper in the 'soft' setting.
Vertical Accelerometer
Two accelerometers are used by the adaptive damping system:
a front accelerometer attached to the bracket of the right-hand engine oil cooler,
a rear accelerometer mounted in the luggage compartment, in the rear left-hand corner next to the rear lamp
assembly.
The accelerometers measure acceleration in the vertical plane and output a corresponding analogue signal to the adaptive
damping module. Each accelerometer is connected to the adaptive damping module via three wires which supply: ground, 5
volt supply and signal return.
The accelerometers are of the capacitive type. The sensing element comprises two parallel plate capacitors. The capacitors
alter the peak voltage which is generated by an internal oscillator when the accelerometer is subjected to acceleration.
Detection circuits within the accelerometer measure the peak voltage and pass an analogue output signal to the adaptive
damping module. The accelerometers output a signal voltage of approximately 1 V/g 0.05 V/g.
Vehicle Dynamic Suspension - Vehicle Dynamic Suspension
For a detailed description of the adaptive damping system operation, refer to the relevant Description and Operation
section of the workshop manual. REFER to: (204-05 Vehicle Dynamic Suspension)
Vehicle Dynamic Suspension - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8 (Description and Operation),

Vehicle Dynamic Suspension - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8 (Description and Operation),
Vehicle Dynamic Suspension - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8 (Description and Operation).

1. 1. Verify the customer concern.
Visual Inspection
Coil spring(s) Fuse(s)
Shock absorber(s) W iring harness/electrical connectors
Accelerometer(s) installation Accelerometer(s)
Height sensor(s) installation Adaptive Damping Control Module
Height sensor(s)
4. 4. If the cause is not visually evident, check the system for any logged Diagnostic Trouble Codes (DTCs) and refer
to the DTC index.
DTC Index
part number 3548-1358-00.
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: Inspect connectors for signs of water ingress, and pins for damage and/or corrosion.
NOTE: If DTCs are logged and, after carrying out the pinpoint tests, a fault is not identified, an intermittent concern may

C101D-12 Left Front Left Front vertical Refer to the electrical circuit diagrams and check left front
vertical acceleration sensor vertical acceleration sensor circuit for short to power or another
acceleration circuit short to power circuit. Repair circuit, clear the DTC and retest the system
sensor - short to
power
C101D-14 Left Front Left Front vertical Refer to the electrical circuit diagrams and check front vertical
vertical acceleration sensor acceleration sensor circuit for short to ground, open circuit. If no
acceleration circuit short to ground, fault found on wiring suspect sensor. Replace sensor, clear DTC
sensor - short to open circuit and retest the system
ground, open Vertical acceleration
circuit sensor fault
C101D-22 Left Front Left front vertical W ith vehicle parked on a level surface, read Left Front Vertical
vertical acceleration sensor Accelerometer voltage and check it lies in range 1.9 to 2.1 volts.
acceleration insecurely mounted If not OK then check electrical wiring for shorts, loose
sensor - signal Left front vertical connections and repair as required. If wiring OK then suspect
amplitude > acceleration sensor faulty sensor/incorrectly fitted sensor. Check the sensor is
maximum signal circuit short to correctly mounted, secure or replace sensor as required. Refer to
another circuit the new module/component installation note at the top of the
Left front vertical DTC Index, clear DTC and retest system
acceleration sensor
internal fault
C101D-26 Left Front Left front vertical Refer to the electrical circuit diagrams and check Left Front
vertical acceleration sensor Vertical Accelerometer signal circuit for faults, if circuit is correct
acceleration signal circuit short to suspect faulty sensor, refer to the new module/component
sensor - signal another circuit installation note at the top of the DTC Index. Replace the
rate of change Left front vertical sensor, clear the DTC and retest the system
below threshold acceleration sensor
internal fault
C101D-78 Left Front Left front vertical Check Left Front Vertical Accelerometer for location and security,
vertical acceleration sensor if correct suspect faulty Accelerometer, refer to the new module
acceleration bracket bent installation note at the top of the DTC Index. Replace the
sensor - Left front vertical sensor/bracket as required, clear the DTC and retest the system
alignment or acceleration sensor
adjustment damaged
incorrect
C101E-12 Right Front Right Front vertical Refer to the electrical circuit diagrams and check right front
sensor - short to
power
C101E-14 Right Front Right Front vertical Refer to the electrical circuit diagrams and check right front
vertical acceleration sensor vertical acceleration sensor circuit for short to ground, open
acceleration circuit short to ground, circuit. If no fault found on wiring suspect sensor. Replace
sensor - short to open circuit sensor, clear DTC and retest the system
C101E-22 Right Front Right front vertical W ith vehicle parked on a level surface, read Right Front Vertical
sensor - signal Right front vertical connections and repair as required. If wiring OK then suspect
Right front vertical DTC Index, clear DTC and retest system
acceleration sensor
internal fault
C101E-26 Right Front Right front vertical Refer to the electrical circuit diagrams and check Right Front
vertical acceleration sensor Vertical Accelerometer signal circuit for faults, if circuit is correct
acceleration signal circuit short to suspect faulty sensor, refer to the new module/component
sensor - signal another circuit installation note at the top of the DTC Index. Replace the
rate of change Right front vertical sensor, clear the DTC and retest the system
below threshold acceleration sensor
internal fault
C101E-78 Right Front Right front vertical Check Right Front Vertical Accelerometer for location and
vertical acceleration sensor security, if correct suspect faulty Accelerometer, refer to the new
acceleration bracket bent module installation note at the top of the DTC Index. Replace
sensor - Right front vertical the sensor/bracket as required, clear the DTC and retest the
alignment or acceleration sensor system
adjustment damaged
incorrect
C1024-00 System Loss of power to Refer to the electrical circuit diagrams and check power and
Temporarily control module whilst ground circuits to Adaptive Damping Control Module for
Disabled Due To driving intermittent or poor connection. Repair wiring circuits as
Power required, clear DTC and retest the system
Interruption
During Driving -
no sub type
information
C1030-12 Left Rear Left Rear vertical Refer to the electrical circuit diagrams and check left Rear
sensor - short to
power
C1030-14 Left Rear Left rear vertical Refer to the electrical circuit diagrams and check left Rear
vertical acceleration sensor vertical acceleration sensor circuit for short to ground, open
acceleration circuit short to ground, circuit. If no fault found on wiring suspect sensor. Replace
sensor - short to open circuit sensor, clear DTC and retest the system
C1030-22 Left Rear Left Rear vertical W ith vehicle parked on a level surface, read Left Rear Vertical
sensor - signal Left Rear vertical connections and repair as required. If wiring OK then suspect
Left Rear vertical DTC Index, clear DTC and retest system
acceleration sensor
internal fault
Vehicle Dynamic Suspension - Adaptive Damping Module
Removal
1. Refer to: Front Seat (501-10 Seating, Removal and Installation).
4.
5.
6.
Torque: 5 Nm
Installation

Vehicle Dynamic Suspension - Front Suspension Vertical Accelerometer
Removal
1. 1. WARNING: Do not work on or under a vehicle supported only

by a jack. Always support the vehicle on safety stands.
2. Refer to: Fender Splash Shield (501-02 Front End Body Panels,
3. 3. CAUTION: The accelerometer is an extremely

delicate component and can easily be rendered
unserviceable. Never use an accelerometer which has
been dropped or subjected to mistreatment of any
type.
Torque: 5 Nm
Installation
1. 1. CAUTION: The accelerometer is an extremely delicate

component and can easily be rendered unserviceable. Never use an
accelerometer which has been dropped or subjected to mistreatment
of any type.

Vehicle Dynamic Suspension - Rear Suspension Vertical Accelerometer
Removal
1. Refer to: Loadspace Trim Panel LH (501-05 Interior Trim and

2. 2. CAUTION: The accelerometer is an extremely

delicate component and can easily be rendered
unserviceable. Never use an accelerometer which has
been dropped or subjected to mistreatment of any
type.
Torque: 5 Nm
Installation
1. 1. CAUTION: The accelerometer is an extremely delicate

component and can easily be rendered unserviceable. Never use an
accelerometer which has been dropped or subjected to mistreatment
of any type.

Ride and Handling Optimization - Ride and Handling Optimization -
Component Location
COMPONENT LOCATION
ItemDescription
1 ABS (anti-lock brake system) module
2 ECM (engine control module)
3 JaguarDrive Control selection buttons
5 TCM (transmission control module)
Ride and Handling Optimization - Ride and Handling Optimization -
Overview
OVERVIEW
JaguarDrive Control is a selectable vehicle optimisation system, designed to fine-tune the driving characteristics of the
vehicle by accommodating different driving conditions or driving styles. The system allows the performance envelope of the
vehicle to be stretched and prevents the necessity for a single, compromised configuration for all conditions. JaguarDrive
Control increases the vehicle's abilities by changing the characteristics of engine mapping, transmission shifts and stability
and traction interventions. The software for the JaguarDrive control is incorporated in the JaguarDrive selector module.
NOTE: The JaguarDrive Control system is a co-ordinating system only. It CANNOT generate a fault in one of the
participating sub-systems. All participating subsystems should be FULLY diagnosed before assuming a fault with
JaguarDrive Control. Replacing the JaguarDrive selector module should not be done until all other options have been
exhausted.
Ride and Handling Optimization - Ride and Handling Optimization - System
Operation and Component Description
System Operation
JAGUARDRIVE CONTROL OPERATION
Engine Management System
The Engine Management System (EMS) varies the accelerator pedal maps to change the amount of torque per percentage
of pedal travel. The EMS can also change the accelerator pedal response to control the allowed torque change relative to
the speed of pedal travel.
Each driving mode uses a combination of operating parameters for each sub-system. Changing between driving modes
initiates a different set of operating characteristics, which will be noticeable to the driver. The driver will notice differences
in engine response when, for example, the accelerator pedal is held in a constant position and the driving mode is changed
from Winter to Dynamic, the driver will notice the torque and engine speed increase. Similarly, if the mode is changed from
Normal or Dynamic to W inter the driver will notice a reduction in torque and engine speed.
NOTE: The change in torque and engine speed can take approximately 30 seconds and care must be taken not to confuse
the JaguarDrive Control system operation with an EMS fault.
Transmission Control
The TCM (transmission control module) changes the shift maps for the JaguarDrive Control mode selected. This changes
the shift points providing early or late upshifts and downshifts. For example, on slippery surfaces in W inter mode the
transmission will select 2nd gear for starting from a standstill on a flat surface to minimize wheel slip.
Anti-lock Braking System Control
The ABS (anti-lock brake system) module controls several vehicle functions and adjusts the operating parameters of these
functions to optimize the selected JaguarDrive Control mode. Traction control uses different slip/acceleration thresholds to
improve traction and vehicle composure. For example, the system sensitivity is increased on slippery surfaces to reduce
wheel spin.
If TracDSC is selected or DSC is switched off, then subsequently the JaguarDrive Control mode is changed, DSC is
automatically switched back on (or to TracDSC for Dynamic mode).
The stability control uses different threshold values for the selected mode, reducing the requirement for the driver to
change the DSC system mode for optimum performance in various driving scenarios.
Incorrect Mode Usage
Selection of an inappropriate mode is discouraged in the following ways:
The active mode icon is continually displayed in the instrument cluster message center
In any special mode, when the ignition has been in the off position continuously for more than 6 hours, the
JaguarDrive Control system defaults to the special modes off (DSC on).
Selection of an inappropriate mode for the conditions will not endanger the driver or immediately cause damage to the
vehicle. Continued use of an inappropriate mode may reduce the life of some components. The driver may notice a
different vehicle response, with the engine and transmission responses being different than in the special modes off.
Driver Information
The instrument cluster contains a message center, which displays vehicle information to the driver. The message center
contains the JaguarDrive Control mode icons, which display the currently selected mode. If no symbol is displayed, no
special mode is selected and the system is in special modes off.
Any required changes to the subsystems are also passed to the driver in the form of warning illumination in the instrument
cluster or appropriate messages in the message center, DSC off for example.
In Dynamic mode when the transmission is in manual mode, the gear information is displayed in amber when the
appropriate engine speed is reached for optimum sporty change point.
DIAGNOSTICS
JaguarDrive Control relies on the correct functionality of the sub-systems. If one of the sub-systems develops a fault, the
JaguarDrive Control system will not function, even though the fault is not in the JaguarDrive Control system.
The JaguarDrive Selector module and rotary control should only be investigated if there are no apparent faults in any of the
sub-systems. If a fault in a sub-system is subsequently corrected, the JaguarDrive Control system will function normally
after an ignition on and off cycle.
JaguarDrive Control Sub-System Faults
If a fault occurs in a sub-system, the driver is alerted by the illumination of a warning indicator and/or an appropriate
message for that sub-system in the instrument cluster message center. No JaguarDrive Control message will be shown
when a failed sub-system displays its own message.
When a sub-system fault is present and the driver attempts to select a different JaguarDrive Control mode or at the next
ignition on cycle, a message 'W INTER MODE FAULT' or 'DYNAMIC MODE FAULT' will appear in the message center. This
generally implies that the JaguarDrive Control system has a fault, but only because a sub-system fault is preventing its
operation. This message will be displayed once per ignition cycle, but is repeated if a further selection is made by the
driver using the JaguarDrive Control buttons or at the next ignition on cycle.
NOTE: The message 'WINTER MODE FAULT' or 'DYNAMIC MODE FAULT' can also in very rare circumstances be generated
by a fault in the JaguarDrive Control module.
It is not possible for the JaguarDrive Control module to cause any fault behavior (warning indicator illumination or
message generation) in any of the sub-systems. Illumination of a sub-system warning indicator and/or a sub-system
related message will never be associated with a JaguarDrive Control module or JaguarDrive Control system fault.
The sub-system control modules can detect a fault with the CAN (controller area network) bus signal from the transmission
selector module. If a fault in the JaguarDrive Control system is detected, the sub-system control modules will operate in
the 'special modes off' setting. The sub-system control modules will record a fault code for a failure of the JaguarDrive
Control CAN signal. These faults can be retrieved using the Jaguar approved diagnostic tool and will provide useful
information to indicate investigation of the JaguarDrive Selector module or the CAN bus network.
JaguarDrive Control System or Control Module Fault
If a fault occurs in the JaguarDrive Control system, all button icon LED (light emitting diode)'s will be turned off
(background illumination will remain on) and pressing of the JaguarDrive Control buttons is ignored. The instrument cluster
message center will display a message 'WINTER MODE FAULT' or 'DYNAMIC MODE FAULT' when the fault occurs, if the fault
is present and the driver attempts to select a special mode (if the control module is able to do this) or at the next ignition
on cycle.
The JaguarDrive Control buttons and control module (JaguarDrive Selector module) are an integral unit. If a fault occurs in
either component, the whole unit will require replacement, however, this is extremely unlikely.
CAN Bus Faults
If a CAN bus fault exists and prevents JaguarDrive Control system operation, all of the JaguarDrive Control button icon
LED's will be illuminated and rotation pressing of the JaguarDrive Control buttons is ignored.
If the instrument cluster does not receive a JaguarDrive Control system CAN bus message from the JaguarDrive Control
module, the message 'SPECIAL MODE UNAVAILABLE' will be displayed when the fault occurs and will be repeated at every
ignition on cycle.
User Error
A special mode change while DSC or ABS is active (this includes ABS cycling) may be misinterpreted as a system fault.
JAGUARDRIVE CONTROL DESCRIPTION
JAGUARDRIVE CONTROLS
ItemDescription
1 W inter mode button
2 DSC/TracDSC mode button
3 ASL (automatic speed limiter) - Reference only, not part of JaguarDrive system
4 Dynamic mode (Supercharged models only)
The system is controlled by buttons adjacent to the JaguarDrive Selector located on the floor console. The buttons allow
the selection of one of the following 3 modes:
Special modes off

Winter mode
Dynamic mode (Supercharged models only).
The instrument cluster will display the selected JaguarDrive Control mode in the message center.
The JaguarDrive Control system uses a combination of a number of vehicle sub-systems to achieve the required vehicle
characteristics for the mode selected. The following sub-systems make up the JaguarDrive Control system:
The Engine Management System (EMS)

Automatic transmission
Brake system.
The JaguarDrive Control software is stored in the JaguarDrive Selector module located below the JaguarDrive selector. The
module detects the selection made using the buttons and transmits a signal on the high speed CAN bus, which is received
by each of the sub-system control modules.
Each of the affected sub-system control modules contain software, which applies the correct operating parameters to their
controlled system for the JaguarDrive Control mode selection made.
Each sub-system control module also provides a feedback for the selected mode so that the JaguarDrive Control software
can check that all systems have changed to the correct operating parameters.
NOTE: The JaguarDrive Control system is a co-ordinating system only. It CANNOT generate a fault in one of the
participating sub-systems. All participating sub-systems should be FULLY diagnosed before assuming a fault with
JaguarDrive Control. Replacing the JaguarDrive Selector module should not be done until all other options have been
exhausted.
Winter Mode
To activate winter mode, press the winter mode button briefly (not less than 300 ms) to activate or de-activate the mode.
NOTE: Winter mode cannot be active at the same time as dynamic mode (Supercharged models only).
When active the winter mode icon and message appear in the instrument cluster message center to confirm the activation.
Dynamic Stability Control (DSC)
Press the DSC mode button briefly (not less than 300 ms) to switch between DSC and TracDSC. The instrument cluster
message center will display either 'DSC ON' or 'TRAC DSC' depending on which selection is made. W hen TracDSC is
selected, the DSC warning lamp in the instrument cluster is illuminated and the DSC button is illuminated.
DSC can be manually switched off by pressing the DSC mode button for more than 10 seconds. Confirmation is given by a
chime from the instrument cluster, 'DSC OFF' is displayed in the instrument cluster message center and the DSC warning
lamp in the instrument cluster is illuminated.
NOTE: DSC is operational at all times when the engine is running unless manually switched off.
Dynamic Mode (Supercharged models only)
To activate Dynamic mode, press the button briefly. The dynamic mode and DSC buttons are illuminated. 'Dynamic Mode
Confirmed' message is displayed in the instrument cluster message center and the DSC off warning lamp in the instrument
cluster is illuminated (due to automatic selection of TracDSC in Dynamic mode).
NOTE: Dynamic mode cannot be active at the same time as winter mode.
Once activated, TracDSC is automatically selected. In gearbox Sport mode, the driver has full control over the transmission
shift points and the TCM will not intervene to prevent engine overspeed (for example; upshifts are inhibited in gearbox
sport mode when Dynamic mode is selected). In this setting, the gear indicator in the instrument cluster will turn amber at
high rev's to indicate an appropriate manual upshift point.
Driveline System - General Information - Driveline System
For a detailed description of driveline operation, refer to the relevant Description and Operation section in the workshop
manual. REFER to:
Driveshaft (205-01 Driveshaft, Description and Operation),

Rear Drive Axle and Differential - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8 (205-02 Rear Drive Axle/Differential,
Description and Operation),
Rear Drive Halfshafts (205-05 Rear Drive Halfshafts, Description and Operation),
Rear Drive Halfshafts (205-05 Rear Drive Halfshafts, Description and Operation),
Rear Drive Halfshafts (205-05 Rear Drive Halfshafts, Description and Operation).
CAUTION: Only serviceable items can be renewed or adjusted. Failure to follow this instruction may result in the
warranty of the component being rejected.
Certain driveline trouble symptoms are also common to the engine, transmission, wheel bearings, tires, and other parts of
the vehicle. For this reason, make sure that the cause of the trouble is in the driveline before adjusting, repairing, or
installing any new components. For additional information, refer to Workshop Manual section 100-04 Noise, Vibration and
Harshness.
1. 1. Verify the customer concern by carrying out a road test of the vehicle.
2. 2. Visually inspect for obvious signs of mechanical damage and system integrity.
4. 4. If the concern is not visually evident, verify the symptom and refer to the Symptom Chart.
Identify the Condition
Gear Howl and Whine
Howling or whining of the ring gear and pinion is 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, which
are operating at driveshaft speed. 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.
Chuckle
Chuckle that occurs on the coast driving phase is usually caused by excessive clearance between the differential gear hub
and the differential case bore.
Damage to a gear tooth on the coast side can cause a noise identical to a chuckle. A very small tooth nick or ridge on the
edge of a tooth can cause the 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 transmission is engaged in REVERSE or DRIVE. The noise may also
occur when the throttle is applied or released. Clunk is caused by transmission calibration, backlash in the driveline or
loose suspension components and is felt or heard in the vicinity of the rear drive axle.
Bearing Rumble
Bearing rumble sounds like marbles being tumbled. This condition 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
also may be high-pitched, similar to gear noise, but will be evident in all four driving modes.
Symptom Chart

Noise is at constant tone Rear drive axle For additional information, GO to Pinpoint Test
over a narrow vehicle A.
speed range. Usually
heard on light drive and
coast conditions
Noise is the same on Road No action required for road noise
drive or coast W orn or damaged driveshaft Install new components as required
joint
Driveshaft center bearing
W heel bearing
Noise is produced with Engine For additional information, REFER to:

the vehicle standing and Transmission Engine - 3.0L NA V6 - AJ27/4.2L NA V8 -
driving AJV8/4.2L SC V8 - AJV8 (303-00 Engine
System - General Information, Diagnosis
and Testing),
Engine - 2.7L Diesel (303-00, Diagnosis and
Testing),
Diagnostic Strategy (307-01 Automatic
Transmission/Transaxle - 2.7L V6 -
TdV6/3.0L NA V6 - AJ27/4.2L NA V8 -
AJV8/4.2L SC V8 - AJV8, Diagnosis and
Testing).
Loud clunk in the driveline Transmission calibration Using the Manufacturer approved diagnostic
when shifting from Transmission Mount system, re-configure the Transmission Control
reverse to forward Transmission Module (TCM) with the latest available
Suspension components calibration
Backlash in the driveline Inspect and install new transmission mounts as
Engine idle speed set too high required
Engine mount For additional transmission information,
REFER to: Diagnostic Strategy (307-01 Automatic
Transmission/Transaxle - 2.7L V6 - TdV6/3.0L NA
V6 - AJ27/4.2L NA V8 - AJV8/4.2L SC V8 - AJV8,
Inspect and install new suspension components
as required
Inspect and install new driveline components as
required
Check and adjust the idle speed as required
Inspect and install new engine mounts as
required
Clicking, popping, or Inadequate or contaminated Inspect, clean and lubricate with new grease as
grinding noises lubrication in the rear drive required
halfshaft constant velocity (CV) Inspect and repair as required
joint Inspect and install new components as required
Another component contacting
the rear drive halfshaft
W heel bearings, brakes or
suspension components
Vibration at highway Out-of-balance wheel(s) or Balance and install new wheel(s) and tire(s) as
speeds tire(s) required
Driveline out of REFER to: Wheel and Tire (204-04 Wheels and
balance/misalignment Tires, Removal and Installation).
Driveshaft center bearing For additional information,
touching body mounting point REFER to: Driveline Angle Inspection (205-00
Driveline System - General Information, General
Procedures).
Refer to the Manufacturer approved diagnostic
system for driveshaft balancing application
Check for correct spacer washer thickness.
Inspect and install new washers as required
Shudder, Vibration DuringPowertrain/driveline Check for misalignment. Install new components

Pinpoint
AccelerationTests misalignment as required. For driveshaft alignment,
High constant velocity (CV) REFER to: Driveline Angle Inspection (205-00
jointDRIVELINE
PINPOINT TEST A : EXCESSIVE operating angles caused
NOISE Driveline System - General Information, General
by incorrect ride height Procedures).
Check the ride height and verify the correct
CONDITIONS spring rate. Install new components as required
A1: CHECK NOISE FROM VEHICLE ON ROAD TEST
1 Road test vehicle to determine load and speed conditions when noise occurs.
2 Assess the noise with different gears selected.
Does the noise occur in different gears at the same vehicle speed?
Yes
Install a new rear drive axle/differential assembly.
REFER to: Axle Assembly - 2.7L V6 - TdV6/3.0L NA V6 - AJ27/4.2L NA V8 - AJV8/4.2L SC V8 - AJV8,
Vehicles W ithout: Differential Drain Plug (205-02 Rear Drive Axle/Differential, Removal and
Installation).
Re-test the system for normal operation.
No
Suspect the engine or transmission. For additional information, REFER to:
Engine - 3.0L NA V6 - AJ27/4.2L NA V8 - AJV8/4.2L SC V8 - AJV8 (303-00 Engine System -
General Information, Diagnosis and Testing),
Engine - 2.7L Diesel (303-00, Diagnosis and Testing),
Diagnostic Strategy (307-01 Automatic Transmission/Transaxle - 2.7L V6 - TdV6/3.0L NA V6 -
AJ27/4.2L NA V8 - AJV8/4.2L SC V8 - AJV8, Diagnosis and Testing).
Driveline System - General Information - Driveline Angle Inspection
General Procedures
Special Tool(s)
Alignment Tool
205-535
All vehicles

All vehicles
3. Remove the engine rear undershield.
4. Remove the rear subframe crossbrace.
All except vehicles with diesel engine

5. Remove the support bracket.
6. Loosen the retaining nuts.
Vehicles with diesel engine

Remove the bolts.
Detach the intermediate muffler exhaust hanger

insulators.
8. Loosen the catalytic converter to diesel particulate filter
(DPF) retaining clamps.
All vehicles
9. CAUTION: Make sure that the exhaust system is

supported with a suitable transmission stand.
Lower the exhaust assembly sufficiently to gain access to

the driveshaft heat shield.
Release the 6 exhaust hangers.
10. Remove the driveshaft heat shield.
All vehicles
11. CAUTION: Make sure that the special tool is correctly
located.
Using the special tool, align the driveshaft center bearing.
Tighten to 40 Nm.
12. Install the driveshaft heat shield.
Tighten to 10 Nm.
13. CAUTION: Make sure that the exhaust system is
supported with a suitable transmission stand.
Attach the exhaust hangers.

14. Tighten the catalytic converter to DPF retaining clamps.
Tighten to 11 Nm.
15. Install the support bracket.
Attach the intermediate muffler exhaust hanger

insulators.
Tighten to 10 Nm.

16. Tighten the retaining nuts.
Tighten to 45 Nm.
17. Install the support bracket.
Tighten to 10 Nm.
All vehicles
18. Install the rear subframe cross brace.
Tighten to 62 Nm.
19. Install the engine rear undershield.

Driveshaft -
Centre bearing retaining bolts 48 36 -
Transmission flexible joint retaining bolts 127 94 -
Rear drive axle CV joint retaining bolts 73 54 -
Driveshaft heat shield retaining bolts 7 - 62
Driveshaft - Driveshaft - Component Location
ItemDescription
1 Transmission flexible joint
2 Collapsible front driveshaft tube
3 Splined slip joint
4 Center bearing
5 Universal joint
6 Rear driveshaft tube
7 Differential flexible joint
Driveshaft - Driveshaft - Overview
Driveshaft Overview
The two-piece driveshaft, manufactured from lightweight tubular steel, transmits drive from the engine, via the
transmission, to the differential. The driveshaft aligns with the centerline of the vehicles body and is supported by a
center bearing.
Driveshaft - Driveshaft - System Operation and Component Description
System Operation
Driveshaft
The two-piece driveshaft, manufactured from lightweight tubular steel, transmits drive from the engine, via the
transmission, to the differential. The driveshaft aligns with the centerline of the vehicles body and is supported by a
center bearing.
The driveshaft's front tube is of swaged construction, which is a crash energy management feature, designed to collapse
progressively and predictably in the event of a severe frontal impact. A low-friction splined slip-joint at the center of the
driveshaft provide the driveshaft's plunge capability.
Flexible couplings connecting the driveshaft to both the transmission and the differential counteract the angular movement
of the driveshaft caused by the driveline's acceleration and braking forces.
The center universal joint is positioned at a specified angle using shims between the center bearing and the vehicle's
body. The driveline angles have been carefully configured to balance minimum power losses with excellent vibration and
wear characteristics. The universal joint is lubricated during manufacture and sealed for life.
Driveshaft - Universal Joints - Component Location
ItemDescription
1 Transmission flexible joint
2 Collapsible front driveshaft tube
3 Splined slip joint
4 Center bearing
5 Universal joint
6 Rear driveshaft tube
7 Differential flexible joint
Driveshaft - Universal Joints - Overview
Refer to: Driveshaft (205-01 Driveshaft, Description and Operation).

Driveshaft - Universal Joints - System Operation and Component
Description
System Operation
Refer to: Driveshaft (205-01 Driveshaft, Description and Operation).
Driveshaft - Driveshaft
For additional information.

REFER to: Driveline System (205-00 Driveline System - General Information, Diagnosis and Testing).
Driveshaft - Driveshaft Runout and Balancing
General Procedures
1. For additional information, refer to the Jaguar Approved

Diagnostic System.
Driveshaft - Driveshaft
Removal

2. Refer to: Exhaust System (309-00A, Removal and Installation).
3.
Torque: 9 Nm
4. 4. CAUTIONS:
Under no circumstances must the flexible

coupling (or its fixings) be loosened or removed from
the driveshaft.
Make sure that the driveshaft is supported with

suitable retaining straps.
Mark the position of the driveshaft flange in

relation to the output flange.
Torque: 127 Nm
5. 5. CAUTIONS:
Under no circumstances must the flexible

coupling (or its fixings) be loosened or removed from
the driveshaft.
Make sure that the driveshaft is supported with

suitable retaining straps.
Mark the position of the driveshaft in relation to

the rear drive axle flange.
Mark the position of the balance nut (if fitted) in
relation to the flexible coupling.
Torque: 108 Nm
6. 6. WARNING: This step requires the aid of

another technician.
NOTE: Note the fitted position of the spacers.
Torque: 88 Nm
Installation
1. 1. NOTE: Make sure that these components are installed to the

noted removal position.

Rear Drive Axle/Differential -
Item Specification
Differential fluid type M2C192A synthetic
Differential fluid capacity 1.25 liters
Axle assembly front retaining bolt 90 66 -
Axle assembly rear retaining bolts 200 148 -
Driveshaft flexible joint 88 65 -
Rear Drive Axle/Differential - Rear Drive Axle and Differential4.2L NA V8 -
AJV8/4.2L SC V8 - AJV8 - Component Location
Component Location
ItemDescription
1 Differential
AJV8/4.2L SC V8 - AJV8 - Overview
Differential
The differential's purpose is to compensate for discrepancies in the rotation rates of the vehicle's drive wheels during
cornering.
AJV8/4.2L SC V8 - AJV8 - System Operation and Component Description
System Operation
Differential
The differential's pinion shaft aligns with the centerline of the vehicles body and is supported by two taper-roller bearings.
The pinion shaft receives power from the engine through the transmission and driveshaft. The pinion shaft gear rotates the
differential ring gear, which is bolted to the differential housing outer flange. Inside the differential housing, two
differential pinion gears are mounted on a differential shaft, which is pinned to the differential housing. These pinion gears
are engaged with the differential side gears to which the halfshafts are splined. As the differential side gears turn, they
rotate the halfshafts and rear wheels.
When it is necessary for one wheel and halfshaft 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 halfshafts.
Differential
The differential is supported at three mounting points, one at the front of the unit, and two at the rear, through rubber
bushes to the vehicles rear subframe. This mounting arrangement plus the subframe to vehicle-body mounting
arrangement provides the rear driveline with double isolation from the vehicles body.
The main casing of the differential is constructed of lightweight cast-iron with an aluminum rear cover. The rear cover
incorporates fins to aid air cooling of the differential unit.
ItemDescription
1 Pinion nut
2 Pinion flange
3 Dust shield
4 Pinion oil seal
5 Pinion shaft oil slinger
6 Pinion bearing
7 Collapsible spacer
8 Pinion bearing cup
9 Differential housing
10 Halfshaft oil seal
11 Differential pinion bearing cup
12 Pinion bearing
13 Drive pinion bearing adjustment shim
14 Pinion
15 Circlip
16 Differential bearing cup
17 Differential pilot bearing
18 Differential ring gear
19 Differential rear cover
20 Rear cover bolt (10 off)
21 Differential bearing cap
22 Differential bearing adjustment shim
23 Ring gear bolt (10 off)
24 Differential
25 Dished plate
26 Differential side gear
27 Shaft
28 Differential pinion gear
29 Thrust washer
Rear Drive Axle/Differential - Rear Drive Axle and Differential

Rear Drive Axle/Differential - Axle Assembly2.7L V6 - TdV6/3.0L NA V6 -
AJ27/4.2L NA V8 - AJV8/4.2L SC V8 - AJV8, Vehicles Without: Differential
Drain Plug
Removal

stands.
Raise the vehicle.

2. Remove both halfshafts.
For additional information, refer to: Rear Halfshaft (205-05
Rear Drive Halfshafts, Removal and Installation).
3. Remove the rear crossmember.
Remove the rear subframe crossbrace.

driveshaft.
Mark the position of the driveshaft in relation to the

rear drive axle flange.
Mark the position of the balance nut in relation to the

rear drive axle flange. (if fitted).

6. Using the special tool, support the axle assembly.

7. Remove the axle assembly.
Installation
Tighten to 190 Nm.

Rear Drive Axle/Differential - Axle Housing Bushing2.7L V6 - TdV6/3.0L NA
V6 - AJ27/4.2L NA V8 - AJV8/4.2L SC V8 - AJV8
Special Tool(s)
Forcing screw
204-275
Forcing screw nut
204-274
Bearing kit
JAG-061
Receiving cup and mount plate
205-534
Remover front mount bush
205-533
Installer front mount bush
204-245
Installer front mount bush
204-243
Removal


2. Remove the axle assembly.
For additional information, refer to: Axle Assembly - 2.7L V6 -
Vehicles W ithout: Differential Drain Plug (205-02 Rear Drive
Axle/Differential, Removal and Installation).
3. Using the special tools, remove the differential bushing.
Installation
1. The raised mouldings on the bushing, should be set at 45
degrees to the center line of the pinion shaft.
2. Using the special tools, install the bushing.
3. Install the axle assembly.

For additional information, refer to: Axle Assembly - 2.7L V6 -
Vehicles W ithout: Differential Drain Plug (205-02 Rear Drive
Axle/Differential, Removal and Installation).
Rear Drive Halfshafts -
Lubricants, Fluids, Sealers and Adhesives
Item Specification
Constant velocity (CV) grease Optimal LN 584 LO
Fill Capacities
Description Grams
Grease for inner CV joint - all vehicles 140
Grease for outer CV joint - all vehicles 125
Torque Specifcations
NOTE: Make sure that a new nut is installed.
Item Nm lb-ft lb-in

Halfshaft outer constant velocity joint retaining nut 300 221 -
Rear Drive Halfshafts - Rear Drive Halfshafts - Component Location
Component Location
ItemDescription
1 Outer constant velocity joint
2 Outer constant velocity joint gaiter
3 Left hand halfshaft
4 Inner constant velocity joint gaiter
5 Inner constant velocity joint
6 Right hand halfshaft
Rear Drive Halfshafts - Rear Drive Halfshafts - Overview
Overview
The CV (constant velocity) joint at each end of the halfshafts meets the angle change requirements due to suspension
deflection. The plunge capability of the CV joint accommodates the length change.
Rear Drive Halfshafts - Rear Drive Halfshafts - System Operation and
System Operation
Rear Drive Halfshafts
The solid-steel halfshafts are of unequal length, with each halfshaft comprising inner and outer CV (constant velocity)
joints. The CV joints are the 'ball and socket' type packed with grease and protected by gaiters.
The outer CV joint is an interference fit into the wheel hub and secured by a locking nut. The inner CV joint is a slide fit
and is retained in the differential with a spring clip.
Rear Drive Halfshafts - Rear Drive Halfshafts

Rear Drive Halfshafts - Rear Halfshaft
Special Tool(s)
Halfshaft splitter handle
307-443
Halfshaft splitter
307-442
Halfshaft oil seal installer
205-532
Halfshaft seal protector
205-461
Hub puller
205-491
Adaptor nuts
205-491-01
Flange remover forcing screw
204-269
Removal

stands.

2. Loosen the wheel hub nut.

For additional information, refer to: Brake Disc (206-04 Rear
Disc Brake - 2.7L V6 - TdV6/3.0L NA V6 - AJ27/4.2L NA V8 -
AJV8/4.2L SC V8 - AJV8, Removal and Installation).
4. CAUTION: Note the fitted position of the component

prior to removal.
Detach the anti-lock brake system (ABS) sensor.
5. Detach the outer tie rod.

6. Detach the lower arm from the wheel knuckle.
7. Remove the wheel hub nut.

8. Using the special tools, detach the rear halfshaft.

Remove the wheel knuckle assembly.
10. CAUTION: To avoid damage to the halfshaft constant

velocity (CV) joints and boots, do not allow the CV joints to
exceed 18 degrees of travel.
NOTE: The halfshaft is retained in the axle assembly by a

retaining clip.
Using the special tools, remove the rear halfshaft.
Remove and discard the retaining clip.

11. Remove the halfshaft seal.
Installation

Using the special tool, install the halfshaft seal.
2. Install a new retaining clip.
3. CAUTION: The next four steps must be carried out within

5 minutes of applying the sealant.
Apply a 3mm diameter bead of Loctite 648 or equivalent

meeting Jaguar specification to the halfshaft.
4. CAUTIONS:
To avoid damage to the halfshaft constant velocity (CV)

joints and boots, do not allow the CV joints to exceed 18
degrees of travel.
Make sure no damage occurs to the halfshaft seal when

installing the halfshaft.
NOTE: Do not fully engage the halfshaft into the axle

assembly.
Install the halfshaft.
Install the special tool to the rear halfshaft seal.
Install the halfshaft.
6. CAUTIONS:
To avoid damage to the halfshaft constant velocity (CV)

joints and boots, do not allow the CV joints to exceed 18
degrees of travel.
Make sure no damage occurs to the halfshaft seal when

installing the halfshaft.
NOTE: Make sure the retaining clip is correctly seated.
Attach the rear halfshaft.
7. CAUTION: Axle fluid should flow from the filler plug

threaded hole when full. Failure to follow this instruction may
result in damage to the axle.
NOTE: Install a new fluid level filler plug.
Check and top up the axle assembly fluid level as required.
Tighten to 34 Nm.
Install the wheel knuckle assembly.
9. NOTE: Using the old wheel hub nut, tighten to 150 Nm.

Attach the wheel knuckle to the rear halfshaft.
10. Install the lower arm to the wheel knuckle.
11. Install the outer tie rod retaining nut.

12. Install the ABS sensor.
Tighten to 6 Nm.
13. Install the brake disc.

14. Remove and discard the old wheel hub nut, install a new
wheel hub nut.
Tighten to 300 Nm.

Tighten to 150 Nm.

Tighten to 55 Nm.
Rear Drive Halfshafts - Inner Constant Velocity (CV) Joint Boot
Removal


2. Remove the rear halfshaft.
For additional information, refer to: Rear Halfshaft - 5.0L/3.0L
Diesel (205-05, Removal and Installation).
3. CAUTION: Use suitable protective covers to protect the

halfshaft.
Using a suitable clamp, secure the rear halfshaft.
4. CAUTION: Make sure the inner constant velocity (CV)

joint is not separated from the halfshaft.
Remove and discard the inner CV joint boot retaining clip.
5. CAUTION: Make sure the CV joint ball bearings do not

drop out of the CV joint.
Using a suitable tool, remove the inner CV joint.

6. Remove the inner CV joint boot.
Installation
1. NOTE: Make sure that the protective sleeve is correctly
installed, prior to installing the CV joint boot.
2. NOTE: Install a new retaining clip.

3. CAUTIONS:
Only use lubricants meeting the Jaguar specification.
Make sure the CV joint ball bearings do not drop out of

the CV joint.
NOTE: Clean the constant velocity (CV) joint, removing as

much of the old grease as possible.
Install the inner CV joint.
Fill the CV joint with 40 grams of grease.
Fill the CV joint boot with 100 grams of grease.
4. CAUTIONS:
Make sure the CV joint is not separated from the

halfshaft.
Make sure enough air is present in the CV boot.
Install a new retaining clip.
5. Install a new retaining clip.
6. Remove the rear halfshaft from the clamp.

7. Install the rear halfshaft.
For additional information, refer to: Rear Halfshaft - 5.0L/3.0L
Diesel (205-05, Removal and Installation).
Rear Drive Halfshafts - Outer Constant Velocity (CV) Joint Boot
Removal


2.
3. For additional information, refer to: Inner Constant Velocity
(CV) Joint Boot (205-05 Rear Drive Halfshafts, Removal and
Installation).
4.
5.
6. CAUTION: Make sure the CV joint ball bearings do not

drop out of the CV joint.
NOTE: Clean the constant velocity (CV) joint, removing as

much of the old grease as possible.
Installation
1. CAUTION: Only use lubricants meeting the Jaguar
specification.
NOTE: Make sure that the protective sleeve is correctly

installed, prior to installing the CV joint boot.
Fill the CV joint with 50 grams of grease.
Fill the CV joint boot with 85 grams of grease.
2. CAUTION: Make sure enough air is present in the CV

boot.
NOTE: Install new retaining clips.

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 Shell ESL Dot 4
Brake Lining and Disc Specifications
Item Specification
Brake pad material nominal thickness - front - Vehicles with 2.7L Diesel, 3.0L or 4.2L engine 13 mm (0.51 in)
Brake pad material minimum thickness - front - Vehicles with 2.7L Diesel, 3.0L or 4.2L engine 2 mm (0.08 in)
Brake pad material nominal thickness - front - Vehicles with high performance brakes 13 mm (0.51 in)
Brake pad material minimum thickness - front - Vehicles with high performance brakes 2 mm (0.08 in)
Brake pad material nominal thickness - rear - Vehicles with 2.7L Diesel, 3.0L or 4.2L engine 11 mm (0.43 in)
Brake pad material minimum thickness - rear - Vehicles with 2.7L Diesel, 3.0L or 4.2L engine 2 mm (0.08 in)
Brake pad material nominal thickness - rear - Vehicles with high performance brakes 11 mm (0.43 in)
Brake pad material minimum thickness - rear - Vehicles with high performance brakes 2 mm (0.08 in)
Front brake disc diameter - Vehicles with 2.7L Diesel, 3.0L, 4.2L engine 326 mm (12 in)
Front brake disc diameter - Vehicles with high performance brakes 355 mm (14 in)
New front Brake disc nominal thickness - Vehicles with 2.7L Diesel, 3.0L or 4.2L engine 30 mm (1.2 in)
New front brake disc nominal thickness - Vehicles with high performance brakes 32 mm (1.28 in)
W orn brake disc discard thickness - Vehicles with 2.7L Diesel, 3.0L, 4.2L engine 28 mm (1.10 in)
W orn front brake disc discard thickness - Vehicles with high performance brakes 30 mm (1.2 in)
Rear brake disc diameter - Vehicles with 2.5L, 2.7L Diesel, 3.0L or 4.2L engine 288 mm (11.52 in)
Rear brake disc diameter - All Vehicles 326 mm (13 in)
New rear brake disc nominal thickness - All Vehicles 20 mm (0.8 in)
W orn rear brake disc minimum thickness - All Vehicles 18 mm (0.71 in)
Maximum front brake disc runout (installed) - All Vehicles 0.09 mm ( 0.003 in)
Maximum rear brake disc runout (installed) - All Vehicles 0.075 mm ( 0.003 in)
Maximum front hub face runout (installed) 0.015 mm ( 0.006 in)
Maximum rear hub face runout (installed) 0.05 mm ( 0.02 in)
Front brake caliper piston diameter - All Vehicles 60 mm (2.36 in)
Rear brake caliper piston diameter - All Vehicles 45 mm (1.77 in)
Brake System - General Information - Brake System
For a detailed description of the brake system, refer to the relevant Description and Operation sections in the workshop
manual. REFER to:
Front Disc Brake (206-03 Front Disc Brake - 2.7L V6 - TdV6/3.0L NA V6 - AJ27/4.2L NA V8 - AJV8/4.2L SC V8 - AJV8,
Front Disc Brake (206-03 Front Disc Brake - 2.7L V6 - TdV6/3.0L NA V6 - AJ27/4.2L NA V8 - AJV8/4.2L SC V8 - AJV8,
Front Disc Brake (206-03, Description and Operation),
Rear Disc Brake (206-04 Rear Disc Brake - 2.7L V6 - TdV6/3.0L NA V6 - AJ27/4.2L NA V8 - AJV8/4.2L SC V8 - AJV8,
Rear Disc Brake (206-04 Rear Disc Brake - 2.7L V6 - TdV6/3.0L NA V6 - AJ27/4.2L NA V8 - AJV8/4.2L SC V8 - AJV8,
Rear Disc Brake (206-04, Description and Operation),
Parking Brake (206-05 Parking Brake and Actuation, Description and Operation),
Hydraulic Brake Actuation (206-06 Hydraulic Brake Actuation, Description and Operation),
Brake Booster (206-07 Power Brake Actuation, Description and Operation),
Brake Booster (206-07 Power Brake Actuation, Description and Operation),
Brake Booster (206-07, Description and Operation).

Visually examine the front and rear wheel and tire 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 manufacturer. Replace the damaged
wheel or excessively worn tire.
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 and, if necessary, check and adjust front wheel alignment. REFER to: (204-00 Suspension
System - General Information)
Specifications (Specifications),
Front Toe Adjustment (General Procedures).
Visual Inspection
Brake master cylinder Parking brake actuator
Brake caliper piston(s) Parking brake module
Brake discs Parking brake switch
W heel bearings Damaged or corroded wiring harness
Brake pads Brake master cylinder fluid level switch
Power brake booster
Brake pedal linkage
Brake booster vacuum hose
Tires
Debris
Road Test
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 GO to Pinpoint Test A.
Brake discs
Vibration when brakes are W heels/tires out of balance GO to Pinpoint Test B.

applied W heel hub nuts loose
Brake caliper mounting bolts loose
Brake pads
Foreign material/scratches/corrosion
on brake disc contact surfaces
Excessive brake disc thickness
variation
Excessive brake disc runout
W heel bearing wear or failure
Suspension bushing wear or failure
Steering bushing wear or failure
The brakes pull or drift Tire pressures/wear GO to Pinpoint Test C.

Brake calipers
Brake pads
Brake discs
W heel alignment adjustment
W heel bearing
Suspension bushings and ball joints
The pedal feels spongy Air in brake hydraulic system GO to Pinpoint Test D.
Leak in hydraulic system
Brake booster/master cylinder
Brake pads
The pedal goes down fast Air in brake hydraulic system GO to Pinpoint Test E.
Leak in hydraulic system
Brake booster/master cylinder
Brake pads
The pedal goes down Air in brake hydraulic system GO to Pinpoint Test F.
slowly Brake booster/master cylinder
Excessive brake pedal Brake pads GO to Pinpoint Test G.

effort required Brake booster
Brake lockup during light Brake pads GO to Pinpoint Test H.

brake pedal force Brake calipers
Brakes drag Parking brake control GO to Pinpoint Test I.

applied/malfunction
Seized parking brake cables
Seized brake caliper slide pins
Seized brake caliper
Brake booster
Pedal gear
Excessive/Erratic brake Hydraulic system GO to Pinpoint Test J.

pedal travel Brake pads
Brake discs
Hub and bearing assembly
The red brake warning Fluid level Fill the system to specification. Check for leaks.
indicator is always on Brake master cylinder fluid level Install a new brake master cylinder fluid reservoir
sensor as required.
Parking brake control REFER to: Brake Fluid Reservoir (206-06 Hydraulic
Electrical circuit Brake Actuation, Removal and Installation).
For parking brake control and circuit tests.
REFER to: Parking Brake (206-05 Parking Brake
and Actuation, Diagnosis and Testing).
Slow or incomplete brake Brake pedal binding GO to Pinpoint Test K.
pedal return Brake booster/master cylinder
Pinpoint Tests
PINPOINT TEST A : BRAKES NOISY

CONDITIONS
A1: INSPECT BRAKE PADS
1 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/install new front and rear brake pads as required. REFER to:
Brake Pads - Vehicles With: Standard Brakes (206-03 Front Disc Brake - 2.7L V6 - TdV6/3.0L
NA V6 - AJ27/4.2L NA V8 - AJV8/4.2L SC V8 - AJV8, Removal and Installation),
Brake Pads - Vehicles With: High Performance Brakes (206-03 Front Disc Brake - 2.7L V6 -
TdV6/3.0L NA V6 - AJ27/4.2L NA V8 - AJV8/4.2L SC V8 - AJV8, Removal and Installation),
Brake Pads (206-04 Rear Disc Brake - 2.7L V6 - TdV6/3.0L NA V6 - AJ27/4.2L NA V8 - AJV8/4.2L
SC V8 - AJV8, Removal and Installation),
Brake Pads - Vehicles With: High Performance Brakes (206-04, Removal and Installation).
Re-test vehicle for brake noise.
A2: INSPECT BRAKE DISCS
1 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 and rear brake discs and brake pads as required. REFER to:
Brake Pads - Vehicles With: High Performance Brakes (206-04, Removal and Installation),
Brake Disc - Vehicles W ith: Standard Brakes (206-03 Front Disc Brake - 2.7L V6 - TdV6/3.0L NA
V6 - AJ27/4.2L NA V8 - AJV8/4.2L SC V8 - AJV8, Removal and Installation),
Brake Disc - Vehicles W ith: High Performance Brakes (206-03 Front Disc Brake - 2.7L V6 -
Brake Disc (206-04 Rear Disc Brake - 2.7L V6 - TdV6/3.0L NA V6 - AJ27/4.2L NA V8 - AJV8/4.2L
Brake Disc - Vehicles W ith: High Performance Brakes (206-04, Removal and Installation).
Re-test vehicle for brake noise.
No
No action required, vehicle is OK.
PINPOINT TEST B : VIBRATION WHEN BRAKES ARE APPLIED

CONDITIONS
B1: ROAD TEST VEHICLE
1 Road test the vehicle between 40-80 km/h (25-50 mph) without applying brakes.
Is the vibration present?
Yes
For noise vibration and harshness tests.
REFER to: Noise, Vibration and Harshness (NVH) (100-04 Noise, Vibration and Harshness, Diagnosis
and Testing).
No
GO to B2.
B2: CHECK FOR BRAKE VIBRATION
1 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 the brake caliper mounting bolts and wheel hub nuts and tighten to specification as required.
Check the balance of all road wheels and tires and repair as required. Check the brake discs for
excessive wear, runout, thickness variation or cracks. Install new brake discs and brake pads as
required. GO to B3.
No
B3: IS VIBRATION STILL PRESENT UNDER BRAKE APPLICATION?
1 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 gear bushings. Check for wear or failure of steering gear ball
joints. Check for wear or failure of front wheel bearings, suspension bushings and ball joints. Check
for wear or failure of rear wheel bearings, suspension bushings and ball joints. Refer to relevant
section in workshop manual and install new components as required.
No
PINPOINT TEST C : THE BRAKES PULL OR DRIFT

CONDITIONS
C1: ROAD TEST VEHICLE
1 Road test the vehicle and apply the brake pedal.
Does the vehicle pull or drift?
Yes
GO to C2.
No
C2: INSPECT TIRE CONDITION/PRESSURE
1 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. Re-test the system for normal
operation.
C3: CHECK CALIPERS
1 Check the disc brake caliper pistons and pins for binding, leaking or sticking.
Do the disc brake caliper pistons and pins bind, leak or stick?
Yes
Rectify sticking pins and install new brake calipers as required. REFER to:
Brake Caliper - Vehicles With: Standard Brakes (206-03 Front Disc Brake - 2.7L V6 - TdV6/3.0L
Brake Caliper - Vehicles With: High Performance Brakes (206-03 Front Disc Brake - 2.7L V6 -
Brake Caliper (206-04 Rear Disc Brake - 2.7L V6 - TdV6/3.0L NA V6 - AJ27/4.2L NA V8 -
AJV8/4.2L SC V8 - AJV8, Removal and Installation),
Brake Caliper - Vehicles With: High Performance Brakes (206-04, Removal and Installation).
No
GO to C4.
C4: INSPECT BRAKE DISCS
1 Check the brake discs for excessive damage, thickness variation or runout.
REFER to: Brake Disc Runout Check (206-00 Brake System - General Information, General
Procedures).
Does excessive damage or runout exist?
Yes
Install new brake discs and brake pads as required. Re-test the system for normal operation.
No
GO to C5.
C5: INSPECT THE FRONT HUB AND WHEEL BEARING ASSEMBLY
1 Check the front hub and wheel bearing assembly.
Are the wheel bearings OK?
Yes
GO to C6.
No
Install new wheel bearings as required.
REFER to: Front W heel Bearing and Wheel Hub (204-01 Front Suspension, Removal and Installation).
C6: CHECK SUSPENSION BUSHINGS AND BALL JOINTS.
1 Check all suspension bushings and ball joints.
Are the suspension bushings and ball joints OK?
Yes
GO to C7.
No
Install new front suspension bushings and ball joints as required. Install new rear suspension
bushings and ball joints as required. Refer to the relevant section in the workshop manual.
C7: CHECK VEHICLE ALIGNMENT
1 Check the vehicle alignment. REFER to:
Front Subframe - 2.7L Diesel (502-00, Removal and Installation),
Front Subframe - 3.0L (502-00, Removal and Installation),
Front Subframe - 4.2L SC V8 - AJV8 (502-00 Uni-Body, Subframe and Mounting System,
Is the alignment within specification?
Yes
No action is required, vehicle is OK.
No
Adjust the alignment as required. REFER to:
Front Subframe - 2.7L Diesel (502-00, Removal and Installation),
Front Subframe - 3.0L (502-00, Removal and Installation),
Front Subframe - 4.2L SC V8 - AJV8 (502-00 Uni-Body, Subframe and Mounting System,
PINPOINT TEST D : THE PEDAL FEELS SPONGY

CONDITIONS
D1: CHECK FOR SPONGY PEDAL (ENGINE OFF)
1 Check for a firm brake pedal.
Is the brake pedal effort and brake pedal travel normal?
Yes
No action is required, vehicle is OK.
No
GO to D2.
D2: CHECK BRAKE PEDAL RESERVE (ENGINE OFF)
1 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.
REFER to: Brake System Bleeding (206-00 Brake System - General Information, General
Procedures).
D3: CHECK BRAKE PEDAL RESERVE (ENGINE ON)
1 With engine running at idle speed.
2 Apply the brake pedal lightly three or four times.
3 Wait 15 seconds for the vacuum to recover.
4 Push down on the brake pedal until it stops moving downward or an increased resistance to the
brake pedal travel occurs.
5 Hold the brake pedal in the applied position while increasing the engine speed to 2000 revs/min.
6 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.
D4: CHECK BRAKE FLUID LEVEL
1 Check the brake master cylinder reservoir fluid level.
Is the fluid level OK?
Yes
Procedures).
No
Check for leaking brake system and rectify as required. Add fluid and bleed the brake system.
Procedures).
PINPOINT TEST E : THE PEDAL GOES DOWN FAST

CONDITIONS
E1: ROAD TEST VEHICLE
1 Road test the vehicle and apply the brake pedal.
Yes
No
GO to E2.
E2: CHECK BRAKE PEDAL TRAVEL-PRESSURIZE SYSTEM
1 Pump the brake pedal rapidly (five times).
Does the brake pedal travel build up and then hold?
Yes
Procedures).
No
GO to E3.
E3: CHECK FOR BRAKE SYSTEM LEAKS
1 Check for external brake system leaks. For additional information, refer to brake master cylinder
component test in this section.
Is there a leak present?
Yes
Repair as necessary, add fluid and bleed brake system.
Procedures).
No
No action required, system is OK.
PINPOINT TEST F : THE PEDAL GOES DOWN SLOWLY

CONDITIONS
F1: ROAD TEST VEHICLE - CHECK BRAKE PEDAL OPERATION
1 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
1 Check for external brake system leaks. For additional information, refer to brake master cylinder
component test in this section.
Are there any external brake system leaks?
Yes
Rectify as necessary. Add fluid and bleed the brake system.
Procedures).
No
GO to F3.
F3: CARRY OUT A BRAKE MASTER CYLINDER BYPASS TEST
1 Test for brake master cylinder bypass condition. Refer to Brake master cylinder component test in
this section.
Has a concern been identified?
Yes
Install a new brake master cylinder, add fluid and bleed the brake system.
Procedures).
No
No action required, system is OK.
PINPOINT TEST G : EXCESSIVE BRAKE PEDAL EFFORT

CONDITIONS
G1: CHECK BRAKE PADS
1 Check the brake pads for wear, contamination, correct installation, damage and type.
Yes
Correctly install or install new brake pads as required. REFER to:
Brake Pads - Vehicles With: High Performance Brakes (206-04, Removal and Installation).
No
GO to G2.
G2: CHECK VACUUM
1 Disconnect the vacuum hose from the brake booster.
2 Connect a vacuum/pressure tester to the vacuum hose.
3 Run the engine at normal operating temperature.
4 Record the vacuum reading.
Is the reading 40.5 kPa (12 in-Hg) or greater?
Yes
GO to G3.
No
Locate and rectify the source of low vacuum. Re-test the system for normal operation.
G3: INSPECT SYSTEM
1 Switch the engine off.
2 Reconnect the vacuum hose.
3 Inspect the brake booster, rubber grommet, and all vacuum plumbing for cracks, holes, damaged
connections, or missing clamps.
4 Pump the brake pedal several times to exhaust 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
1 Check the brake booster valve. For additional information, refer to Brake Booster component test in
this section.
Is the power brake booster valve OK?
Yes
Check the brake booster. For additional information, refer to Brake Booster component test in this
section. Install a new brake booster as required. REFER to:
Brake Booster (206-07 Power Brake Actuation, Removal and Installation),
Brake Booster - RHD (206-07, Removal and Installation).
No
Install a new brake booster valve. Re-test the system for normal operation.
PINPOINT TEST H : BRAKE LOCKUP DURING LIGHT BRAKE PEDAL FORCE

CONDITIONS
H1: TEST BRAKE LOCKUP
1 Road test the vehicle and apply the brake pedal lightly.
Do the brakes lockup?
Yes
GO to H2.
No
H2: INSPECT BRAKE PADS
1 Inspect brake pads for contamination, correct installation, damage and type.
Yes
Correctly install or install new brake pads as required. REFER to:
Brake Pads - Vehicles W ith: Standard Brakes (206-03 Front Disc Brake - 2.7L V6 - TdV6/3.0L
Brake Pads - Vehicles W ith: High Performance Brakes (206-03 Front Disc Brake - 2.7L V6 -
Brake Pads - Vehicles W ith: High Performance Brakes (206-04, Removal and Installation).
No
GO to H3.
H3: INSPECT BRAKE CALIPERS
1 Inspect brake calipers for binding, leaking or sticking.
Yes
Correctly install or install new brake calipers as required. REFER to:
Brake Caliper - Vehicles With: Standard Brakes (206-03 Front Disc Brake - 2.7L V6 - TdV6/3.0L
Brake Caliper - Vehicles With: High Performance Brakes (206-03 Front Disc Brake - 2.7L V6 -
Brake Caliper (206-04 Rear Disc Brake - 2.7L V6 - TdV6/3.0L NA V6 - AJ27/4.2L NA V8 -
AJV8/4.2L SC V8 - AJV8, Removal and Installation),
Brake Caliper - Vehicles With: High Performance Brakes (206-04, Removal and Installation).
No
PINPOINT TEST I : BRAKES DRAG

CONDITIONS
I1: ROAD TEST VEHICLE
1 Road test the vehicle and apply the brakes.
Are the brakes functioning correctly?
Yes
No
GO to I2.
I2: CHECK BRAKE CALIPERS
1 Check the front and rear calipers pistons and pins for binding, leaking or sticking.
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 required. Re-test
the system for normal operation.
No
GO to I3.
I3: CHECK BRAKE BOOSTER
1 Check the brake booster connecting rod alignment and travel.
Is the connecting rod OK?
Yes
Vehicle is OK.
No
Install a new brake booster as required. REFER to:
PINPOINT TEST J : EXCESSIVE/ERRATIC BRAKE PEDAL TRAVEL

CONDITIONS
J1: TEST ON ROUGH ROAD
1 Road test the vehicle on rough road conditions.
2 Apply the brakes slowly.
Yes
No
GO to J2.
J2: CHECK BRAKE FLUID LEVEL
1 Check the brake master cylinder reservoir 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 component test in this section. Add brake fluid and bleed the brake system.
REFER to: Brake System Bleeding (206-00 Brake System - General Information, General Procedures).
J3: CHECK BRAKE PEDAL RESERVE
1 Run engine at idle speed.
2 Apply the brake pedal lightly three or four times.
3 W ait 15 seconds for the vacuum to replenish.
4 Push down on the brake pedal until it stops moving downward or an increased resistance to the
brake pedal travel occurs.
5 Hold the brake pedal in the applied position while increasing the engine speed to 2000 revs/min.
6 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.
J4: CHECK THE FRONT WHEEL BEARING ASSEMBLY
1 Check the front wheel bearing assembly.
Are the front wheel bearings loose/damaged?
Yes
Tighten to specification or install a new front wheel bearing as required.
REFER to: Front W heel Bearing and Wheel Hub (204-01 Front Suspension, Removal and
Installation).
No
Check the front brake discs for thickness variances.
PINPOINT TEST K : SLOW OR INCOMPLETE BRAKE PEDAL RETURN

CONDITIONS
K1: CHECK FOR BRAKE PEDAL RETURN
1 Run the engine at idle while making several brake applications.
2 Pull the brake pedal rearward with approximately 44.5 N (10lb) force.
3 Release the brake pedal and measure the distance to the toe board.
4 Make a hard brake application.
5 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
No
GO to K2.
K2: CHECK FOR BRAKE PEDAL BINDING
1 Disconnect the brake booster from the brake pedal. Check the brake pedal to ensure free
operation.
Is the brake pedal operating freely?
Yes
Install a new brake booster as required. REFER to:
No
Repair or install new brake pedal. Re-test the system for normal operation.
Component Tests
Brake Booster
1. 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.
2. 2. Check the hydraulic brake system for leaks or low fluid.
3. 3. With the automatic transmission in PARK, stop the engine and apply the parking brake. Pump the brake pedal
several times to exhaust all vacuum in the system. W ith 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. 4. 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 automatic transmission in PARK. 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. 5. 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 (20lb) 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.
REFER to: Brake System Bleeding (206-00 Brake System - General Information, General Procedures).
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
The following conditions are considered normal and are not indications that the brake master cylinder is in need of repair.
Modern 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
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:
NOTE: Prior to carrying out any diagnosis, make sure the brake system warning indicator is functional.
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, 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 may be caused by two types of none pressure external
leaks.
Type 1: An external leak may occur at the brake master cylinder reservoir cap because of incorrect positioning of the
gasket and cap. Reposition cap and gasket.
Type 2: An external leak may occur at the brake master cylinder reservoir mounting seals. Repair such a leak by installing
new seals and make sure that the brake master cylinder reservoir retaining bolt is correctly installed.
Brake System - General Information - Brake Disc Runout Check
General Procedures
Check
2. Install all wheel nuts and tighten equally to 20 Nm (15 lb.ft).
Make sure that the brake disc is fully seated against the
hub face.
3. Install a dial test indicator gauge and holding fixture to a

suitable mounting point.
4. NOTE: If the runout is outside specification, check the hub
face runout.
Using the dial test indicator, measure the inner and outer faces
of the brake disc.
For additional information, refer to: Specifications (206-03,
Specifications) /
Specifications (206-04, Specifications).
1. Position the gauge so that it contacts the disc 10

mm (0.4 in) from the outer edge.
2. Slowly rotate the hub/disc assembly. Note the

reading.
5. If a front hub runout check is required, remove the front brake

disc.
Standard Brakes (206-03 Front Disc Brake, Removal and
Installation).
6. If a rear hub runout check is required, remove the rear brake
disc.
Standard Brakes (206-04 Rear Disc Brake, Removal and
Installation).
7. 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: 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: Rear W heel Bearing
(204-02 Rear Suspension, Removal and Installation).
8. If the front hub face is within specification, install a new brake

disc.
Standard Brakes (206-03 Front Disc Brake, Removal and
Installation).
If the rear hub face is within specification, install a new disc.
Standard Brakes (206-04 Rear Disc Brake, Removal and
Installation).
Brake System - General Information - Brake System Bleeding
General Procedures
CAUTIONS:
The brake fluid reservoir must remain full with new, clean brake fluid at all times during bleeding.
Brake fluid will damage paint finished surfaces. If spilled, immediately remove the fluid and clean the area with
water.
NOTE:
All vehicles


2. Check that the brake fluid lines are secure and that there are
no signs of a brake fluid leak. If a brake fluid leak is detected,
investigate and rectify the cause of the leak before bleeding
the brakes.
3. Remove the brake master cylinder cover.
Carefully release the clip.
4. WARNING: Do not allow dirt or foreign liquids to enter

the reservoir. Use only new brake fluid of the correct
specification from airtight containers. Do not mix brands of
brake fluid as they may not be compatible.
CAUTION: Brake fluid will damage paint finished

surfaces. If spilled, immediately remove the fluid and clean
the area with water.
Remove the brake fluid reservoir cap.

5. Fill the brake fluid reservoir to the MAX mark.
All vehicles
6. Install the bleed tube to the right hand rear brake caliper
bleed screw and immerse the free end of the bleed tube in a
bleed jar, containing a small quantity of approved brake fluid.
Remove the bleed screw caps.
7. Loosen the bleed screw by one-half to three-quarters of a

turn.
8. CAUTION: The brake fluid reservoir must remain full with

new, clean brake fluid at all times during bleeding.
NOTE: If the bleed tube used, does not have a one way valve
the bleed screw will need to be closed before the brake pedal is
returned to the rest position. Then opened again and the
procedure repeated for each pedal application.
W ith assistance, depress the brake pedal steadily through its

full stroke and allow it to return to the rest position. Repeat
the procedure until brake fluid, clean and air-free flows into the
bleed jar.
9. CAUTION: Make sure the bleed screw cap is installed

after bleeding. This will prevent corrosion to the bleed screw.
W ith the brake pedal fully depressed, tighten the bleed screw.
Vehicles with standard brakes: Tighten the front caliper

bleed screw to 8 Nm.
Vehicles with high performance brakes: Tighten the front

caliper bleed screw to 14 Nm.
Tighten the rear bleed screw to 14 Nm.
Left-hand drive vehicles

11. WARNING: Braking efficiency may be seriously
impaired if an incorrect bleed sequence is used.
Repeat the brake bleeding procedure for each brake

caliper, following the above sequence.
Right-hand drive vehicles
12. WARNING: Braking efficiency may be seriously

impaired if an incorrect bleed sequence is used.
Repeat the brake bleeding procedure for each brake

caliper, following the above sequence.
All vehicles
14. Apply the brakes and check for leaks.
15. Install the brake fluid reservoir cap.
16. Install the brake master cylinder cover.
Carefully secure the clip.

Front Disc Brake - 2.7L V6 - TdV6/3.0L NA V6 - AJ27/4.2L NA V8 -
AJV8/4.2L SC V8 - AJV8 -
Item Specification
Brake caliper anchor plate retaining bolts 115 85 -
Brake caliper retaining bolts - Vehicles with high performance brakes 58 43 -
Brake caliper retaining bolts - Vehicles with standard brakes 28 21 -
Brake hose retaining bolt 38 28 -
AJV8/4.2L SC V8 - AJV8 - Front Disc Brake - Component Location
Component Location - Standard Brakes
ItemDescription
1 Guide pin dust cover (2 off)
2 Guide pin (2 off)
3 Guide pin bush (2 off)
4 Bleed screw dust cap
5 Bleed screw
6 Brake hose
7 Bolt - brake hose to caliper
8 Anti-rattle spring
9 Brake caliper housing
10 Piston dust cover
11 Piston
12 Caliper carrier
13 Inboard brake pad
14 Outboard brake pad
15 Retaining washers (2 off)
16 Brake disc
17 Rivets (3 off)
18 Brake dust shield
19 Caliper carrier bolts (2 off)
Component Location - Performance Brakes
ItemDescription
2 Bleed screw
5 Piston
6 Piston dust cover
7 Inboard brake pad
9 Brake disc
11 Rivets (2 off)
12 Brake heat shield
13 ABS (anti-lock brake system) sensor cable
15 Caliper carrier
17 Guide pin (2 off)
19 Brake hose
20 Bolt - brake hose to caliper
AJV8/4.2L SC V8 - AJV8 - Front Disc Brake - Overview
Overview
Standard Brakes
The standard front braking system used on naturally aspirated vehicles features 326 mm (12.83 in.) diameter x 30 mm
(1.18 in.) thick ventilated brake discs and cast iron, single piston, sliding calipers. The brake disc is also manufactured
from cast iron. The brake disc is retained on the wheel hub by two washers and the wheel nuts.
The caliper is mounted within a fixed carrier that is secured to the front wheel knuckle with two bolts. When hydraulic
pressure is supplied to the caliper, the piston extends to force the inner pad against the brake disc. The caliper reacts and
slides along two guide pins to bring the outer pad into contact with the brake disc.
Each inboard brake pad is installed with a pressed steel anti-rattle spring. There is no wear indicator installed in the brake
pads.
Performance Brakes
The performance front braking system used on vehicles with supercharger features 355 mm (13.98 in.) diameter x 32 mm
(1.26 in.) thick ventilated brake discs and composite aluminum and cast iron, single piston and sliding calipers. The brake
disc is manufactured from cast iron. The brake disc is retained on the wheel hub by two washers and the wheel nuts.
The caliper is mounted within a fixed carrier that is secured to the front wheel knuckle with two bolts. When hydraulic
slides along two guide pins to bring the outer pad into contact with the brake disc.
Each inboard brake pad is installed with a pressed steel anti-rattle spring. There is no wear indicator installed in the brake
pads.
AJV8/4.2L SC V8 - AJV8 - Front Disc Brake

REFER to: Brake System (206-00 Brake System - General Information, Diagnosis and Testing).
AJV8/4.2L SC V8 - AJV8 - Brake CaliperVehicles With: Standard Brakes
Special Tool(s)
Brake pedal hold down tool
JDS9013
Removal
CAUTION: Brake fluid will damage paint finished surfaces. If spilled, immediately remove the fluid and clean the area
with water.


2. Remove the LH front wheel and tire.
3. CAUTION: Always plug any open connections to prevent

contamination.
NOTE: To prevent the loss of brake fluid, using the special tool
apply the brake pedal and set to 40mm ( 1.6 in ) below the rest
position.
Remove the LH anti-rattle spring.
Release the 2 clips.

5. CAUTION: Do not allow the brake caliper to hang on
the brake hose.
Remove the LH brake caliper.
Remove the 2 access plugs.
Release the 2 brake caliper guide pins.
Release the inboard brake pad from the caliper.
Release the clip.
Remove the outboard brake pad.
Installation
Install the outboard brake pad.
Using a suitable tool, fully retract the brake caliper

piston.

Install the inboard brake pad.
Install the brake caliper.
Tighten the guide pins to 28 Nm.
Install the access plugs.
Install the anti-rattle spring.
Carefully secure the clips.
Connect the brake hose to the brake caliper.

Procedures).
7. Install the front wheels and tires.
AJV8/4.2L SC V8 - AJV8 - Brake CaliperVehicles With: High Performance
Brakes
Special Tool(s)
JDS9013
Removal
with water.



contamination.
NOTE: To prevent the loss of brake fluid, using the special tool
apply the brake pedal and set to 40mm ( 1.6 in ) below the rest
position.
Apply protective tape to the caliper.

5. Apply heatshrink or protective tape to the end of the screw-
driver.
6. CAUTION: Removal of the clips is a delicate procedure,

damage will occur if any force is used.
Remove the anti-rattle spring.
Lever the anti-rattle spring in the center of the spring

until either side is released.

the brake hose.
Remove the brake caliper.
Remove the 2 caliper guide pins.

Release the clip.
Installation
Install the outboard brake pad.
Using a suitable tool, fully retract the brake caliper

pistons.
Install the inboard brake pad.

Tighten the guide pins to 58 Nm (43 lb.ft).
Secure the bottom arm of the anti-rattle spring under

the bottom anchor bracket of the caliper.
Compress the upper spring arm into the correct

position, under the upper anchor bracket, whilst
retaining the logo plate.
Using the screw-driver, tap the central locating tag into

the locked position.
Connect the brake hose to the brake caliper.
Tighten the union to 38 Nm (28 lb.ft).

Procedures).
AJV8/4.2L SC V8 - AJV8 - Brake DiscVehicles With: Standard Brakes
Removal
CAUTION: Brake discs must be renewed in pairs, unless one disc requires changing before 1000 miles (1600
kilometers) from new.


2. Remove the front brake pads.
For additional information, refer to: Brake Pads - Vehicles
W ith: Standard Brakes (206-03 Front Disc Brake - 2.7L V6 -
Remove the brake caliper anchor bracket.
Remove the brake disc.
Remove the 2 clips.
Installation
3. Install the brake pads.

1.
2. WARNING:
CAUTION: Do not
Make usethat
sure compressed
new boltsair
aretoinstalled.
clean brake
components. Dust from friction materials can be harmful if
W ith: Standard Brakes (206-03 Front Disc Brake - 2.7L V6 -
inhaled.
Install the
TdV6/3.0L NAbrake caliper anchor
V6 - AJ27/4.2L NA V8bracket.
- AJV8/4.2L SC V8 - AJV8,
Removal
Install and Installation).
the brake disc.
Clean the
Tighten component
the mating
bolts to 115 Nm. faces.
Secure the clips.
AJV8/4.2L SC V8 - AJV8 - Brake DiscVehicles With: High Performance
Brakes
Removal


2. Remove the front brake pads.
W ith: High Performance Brakes (206-03 Front Disc Brake - 2.7L
V6 - TdV6/3.0L NA V6 - AJ27/4.2L NA V8 - AJV8/4.2L SC V8 -
3. Remove the brake caliper anchor bracket.
Remove the 2 clips.
Installation
1. WARNING: Do not use compressed air to clean brake
inhaled.
Install the brake disc.
Secure the clips.
2. CAUTION: Make sure that new bolts are installed.
Install the brake caliper anchor bracket.

W ith: High Performance Brakes (206-03 Front Disc Brake - 2.7L
V6 - TdV6/3.0L NA V6 - AJ27/4.2L NA V8 - AJV8/4.2L SC V8 -
AJV8/4.2L SC V8 - AJV8 - Brake Disc ShieldVehicles With: Standard Brakes
Removal

stands.

3. Remove the brake disc shield.
Installation
Install the rivets.

AJV8/4.2L SC V8 - AJV8 - Brake Disc ShieldVehicles With: High
Performance Brakes
Removal

stands.

2. Remove the front brake disc.
High Performance Brakes (206-03 Front Disc Brake - 2.7L V6 -
Installation
Install the rivets.

AJV8/4.2L SC V8 - AJV8 - Brake PadsVehicles With: Standard Brakes
Removal
W ARNINGS:
Brake pads must be renewed in axle sets only. Failure to follow this instruction may result in braking efficiency being
impaired.
Do not allow dirt or foreign liquids to enter the reservoir. Use only new brake fluid of the correct specification from
airtight containers. Do not mix brands of brake fluid as they may not be compatible.
CAUTION: Replacement of nuts and bolts: Various thread-locking devices are used on nuts and bolts throughout the
vehicle. These devices restrict the number of times a nut or bolt can be used.


2. Remove the front wheels and tires.

the brake hose.

Release the clip.
Repeat the above procedure for the RH brake pads.
Installation
1. W ARNING: Do not use compressed air to clean brake

inhaled.
Clean the brake caliper housings and anchor plates, using

brake cleaning fluid.
2. CAUTIONS:
As the piston is pushed back into the caliper housing, the

brake fluid level in the reservoir will rise. Do not allow the
reservoir to overflow.
Brake fluid will damage paint finished surfaces. If spilled,

immediately remove the fluid and clean the area with water.
Press the pistons into the caliper housing.

Secure the inboard brake pad in the clip.
Position the outboard brake pad.

6. Repeat the above procedure for the RH brake pads.

AJV8/4.2L SC V8 - AJV8 - Brake PadsVehicles With: High Performance
Brakes
Removal
W ARNINGS:
Do not use compressed air to clean brake components. Dust from friction materials can be harmful if inhaled.
Brake pads must be renewed in axle sets only. Failure to follow this instruction may result in braking efficiency being
impaired.
CAUTIONS:
Replacement of nuts and bolts: Various thread-locking devices are used on nuts and bolts throughout the vehicle.
These devices restrict the number of times a nut or bolt can be used.
The High performance brake caliper is aligned to the brake disc when it is first installed to the vehicle, therefore,
care must be taken not to disturb this alignment. When removing the caliper; remove the bolts that secure the anchor
bracket to the vertical link and/or the guide pin bolts only. DO NOT loosen any other caliper bolts.
NOTE: Open engine compartment and fit paint work protection covers to fenders.


2. Remove the front road wheels and tires.
Apply protective tape to the caliper.

Apply heatshrink or protective tape to the end of the screw-

driver.

Lever the anti-rattle spring in the center of the spring

until either side is released.

the brake hose.

Release the clip.
9. Repeat the above procedure on the opposite side.
Installation

inhaled.

2. CAUTIONS:
As the piston is pushed back into the caliper housing, the

brake fluid level in the reservoir will rise. Do not allow the
Brake fluid will damage paint finished surfaces. If spilled,

immediately remove the fluid and clean the area with water.
Press the piston into the caliper housing.

Secure the inboard brake pad in the clip.

Secure the bottom arm of the anti-rattle spring under

the bottom anchor bracket of the caliper.
Compress the upper spring arm into the correct

position, under the upper anchor bracket, whilst
retaining the logo plate.
Using the screw-driver, tap the central locating tag into

the locked position.

7. Install both wheels and tires.
Rear Disc Brake - 2.7L V6 - TdV6/3.0L NA V6 - AJ27/4.2L NA V8 -
AJV8/4.2L SC V8 - AJV8 -
Item Specification
Brake hose to brake caliper 38 28 -
Brake caliper anchor plate 103 76 -
Brake caliper retaining bolts 28 21 -
Brake caliper logo badge retaining screws - Vehicles with high performance brakes 5 4 -
AJV8/4.2L SC V8 - AJV8 - Rear Disc Brake - Component Location
Component Location
ItemDescription
2 Brake dust shield
3 Rivets (3 off)
4 Brake disc
7 Inboard brake pad
8 Piston dust cover
9 Piston
10 Parking brake return spring
11 Parking brake lever
12 Parking brake lever stop
13 Brake hose
15 Guide pins (2 off)
19 Caliper carrier
22 Brake hose to caliper bolt
AJV8/4.2L SC V8 - AJV8 - Rear Disc Brake - Overview
Overview
The rear braking system on all vehicles features 326 mm (12.83 in.) diameter x 20 mm (0.79 in.) thick ventilated brake
discs with aluminum, single acting piston, sliding calipers. The brake disc is manufactured from cast iron. The disc is
retained on the wheel hub by two washers and the wheel nuts.
The caliper is mounted within a fixed carrier that is secured to the rear wheel knuckle with two bolts. W hen hydraulic
slides along two guide pins to bring the outer pad into contact with the brake disc. The brake calipers on the supercharged
vehicle are painted and also include a logo badge, which must be removed in order to renew the brake pads.
Each inboard brake pad is installed with a wire type anti-rattle spring. There is no wear indicator installed in the brake
pads.
Also incorporated into each rear brake caliper carrier is the parking brake mechanism.
Refer to: Parking Brake (206-05 Parking Brake and Actuation, Description and Operation).
After any work on the rear brakes, the parking brake must be re-calibrated.
Refer to: Parking Brake (206-05 Parking Brake and Actuation, Diagnosis and Testing).
AJV8/4.2L SC V8 - AJV8 - Rear Disc Brake

AJV8/4.2L SC V8 - AJV8 - Brake Caliper
Special Tool(s)
JDS9013
Removal
WARNING: Failure to release the tension and calibrate the electric parking brake during rear parking brake related
service procedures, could cause the parking brake to function incorrectly or become inoperative.
with water.
All vehicles


2. Remove the rear wheel and tire.
3. Release the parking brake cable tension.
For additional information, refer to: Parking Brake Cable
Tension Release (206-05 Parking Brake and Actuation, General
Procedures).
Vehicles with high performance brakes

Remove the logo badge.
Remove the two retaining screws.
All vehicles

NOTE: To prevent the loss of brake fluid, using the special

tool apply the brake pedal and set to 40mm ( 1.6 in ) below
the rest position.

6. NOTE: RH illustration shown, LH is similar.
7. Disconnect and release the parking brake cable from the

caliper.
Release the clip.
Remove the brake pads.
Installation
All vehicles
2. Install the brake caliper.
3. Install the anti-rattle spring.
4. Connect the brake hose to the brake caliper.
5. Connect the parking brake cable.

Install the logo badge.
Install the two retaining screws.

All vehicles
Procedures).
9. Re-calibrate the electric park brake.
Procedures).
AJV8/4.2L SC V8 - AJV8 - Brake Disc
Removal


2. Remove the rear brake pads.
For additional information, refer to: Brake Pads (206-04 Rear
3. Remove the brake caliper anchor bracket.
Remove the 2 clips.
Installation
1. WARNING: Do not use compressed air to clean brake

inhaled.
Install the brake disc.
Secure the clips.

Install the brake caliper anchor bracket.

For additional information, refer to: Brake Pads (206-04 Rear
AJV8/4.2L SC V8 - AJV8 - Brake Pads
Special Tool(s)
Crankshaft pulley/damper
remover
303-588
Brake caliper piston

retractor tool
206-080
Brake caliper piston

retractor tool
206-081
Removal
W ARNINGS:
Brake pads must be renewed in axle sets only, otherwise braking efficiency may be impaired.
Failure to release the tension and calibrate the electric parking brake during rear parking brake related service
procedures, could cause the parking brake to function incorrectly or become inoperative.
NOTE: Only extraction bolt from special tool 303-588 is used.
All vehicles


Procedures).
3. Remove the rear wheels and tires.

Remove the logo badge.
Remove the two retaining screws.
All vehicles
5. NOTE: Right-hand shown, left-hand similar.

the brake hose.
Remove the brake pads.
8. Repeat the above procedure for the other side.
Installation
All vehicles

inhaled.

Repeat the above procedure for the other side.
2. CAUTIONS:
As the piston is pushed back into the caliper housing,

the brake fluid level in the reservoir will rise. Do not allow the
Brake fluid will damage paint finished surfaces. If

spilled, immediately remove the fluid and clean the area with
water.
Using the special tools, fully retract the brake caliper piston.
Install the brake pads.
Position the inboard brake pad.


Install the logo badge.
Install the two retaining screws.
All vehicles
7. Repeat the above procedure for the other side.
8. Install the wheels and tires.
9. W ARNING: Calibrate the electric park brake using Jaguar

approved diagnostic equipment. If Jaguar approved diagnostic
equipment is not available disconnect the battery for
approximatly 30 seconds , the vehicle will then prompt the driver
to carry out the calibration procedure as per the vehicle hand
book on re-connection.
Re-calibrate the electric park brake.

Procedures).
AJV8/4.2L SC V8 - AJV8 - Brake Disc Shield
Removal
WARNING: Make sure to support the vehicle with axle stands.
1. Raise and support the body.

Drill out the 3 rivets
Installation
Parking Brake and Actuation - Parking Brake - Component Location
Component Location
ItemDescription
1 Parking brake switch
2 EPB (electronic parking brake) module
3 Parking brake actuator
4 Caliper and disc assemblies (2 off)
5 Stoplamp switch
6 Brake warning indicator - NAS vehicles
7 Brake warning indicator (all except NAS (North American Specification) vehicles)
Parking Brake and Actuation - Parking Brake - Overview
Overview
The parking brake is an electrically actuated system that operates on the rear brake calipers. Two cables are connected to
the rear brake calipers, and act directly on the same pistons used for normal, hydraulic rear brake actuation.
Refer to: Rear Disc Brake (206-04, Description and Operation).
The parking brake is controlled by the EPB (electronic parking brake) module. In response to commands from the driver
through the parking brake switch, the EPB module controls operation of the parking brake actuator. The actuator adjusts
the tension of the brake cables to apply and release the rear brake calipers. Features of the parking brake include:
Manual apply.
Manual release.
Automatic release.
A service mode is also available and must be activated using the Jaguar approved diagnostic system. This allows the
decoupling of the components and prevention of damage to the actuator. When in service mode all switch functions will be
inhibited.
Parking Brake and Actuation - Parking Brake - System Operation and
Control Diagram
NOTE: A = Hardwired; D = High speed CAN (controller area network) bus.
ItemDescription
1 Battery
2 BJB (battery junction box)
5 EPB module
6 Stoplamp switch
9 Parking brake actuator
System Operation
Static Apply
The EPB module receives a vehicle speed signal from the ABS (anti-lock brake system) module on the high speed CAN bus.
If the parking brake switch is pulled to the 'Apply' position and vehicle speed is less than 2 mph (3 km/h), the EPB module
will instigate its 'Static Apply' mode and drive the actuator to apply full parking brake force to the rear wheels.
The EPB module monitors the current drawn by the actuator and compares this to information held within its configuration
software to determine when full braking force has been applied.
Dynamic Apply
There are two 'Dynamic Apply' modes; low speed dynamic and high speed dynamic. The low speed dynamic mode operates
at speeds between 2 mph (3 km/h) and 20 mph (32 km/h). The high speed dynamic mode operates at speeds above 20
mph (32 km/h).
If the parking brake switch is pulled up to the 'Apply' position and vehicle speed is within the low speed dynamic range,
the EPB module drives the actuator to apply full parking brake force to the rear wheels.
If the parking brake switch is pulled up to the 'Apply' position and vehicle speed is within the high speed dynamic range,
the EPB module will apply braking force to the rear wheels at a slower rate until full braking load is reached or the switch
is released. The rate with which braking force is applied is controlled by the EPB module, which monitors both current
drawn by the actuator and positional information from the actuator hall sensor and compares this to information held
within its configuration software.
Drive Away Release

The EPB module will initiate its 'Drive Away Release' function and automatically release the parking brake if the following
conditions are detected:
The engine is running.

Drive , or reverse is selected.
Positive throttle movement is detected.
The EPB module receives messages of gear selector position and throttle angle over the high speed CAN bus from the TCM
(transmission control module) and the ECM (engine control module) respectively.
Release from Park

The EPB module will initiate its 'Release from Park' function and automatically release the parking brake if the gear
selector is moved from Park to any position except Neutral.
Repairs
Before carrying out any work on the parking brake system, the Jaguar approved diagnostic system must be connected and
the 'parking brake unjam' routine run. The routine can be found in the 'Vehicle Configuration' area, under the 'Set-up and
Configuration' menu. After any work has been carried out on the parking brake, the system will require resetting.
CAUTION: Do not use the 'Emergency Release' tool to allow work to be carried out on the parking brake. W ork can
only be carried out on the parking brake system after the 'parking brake unjam' routine has been run.
Resetting
If the electrical supply is disconnected from the EPB module, the actuator will loose its position memory. On battery
re-connection and ignition on, 'APPLY FOOT AND PARK BRAKE' will be displayed in the instrument cluster message center
indicating the parking brake requires resetting.
Refer to: Parking Brake (206-05 Parking Brake and Actuation, Diagnosis and Testing).
Operating Voltages
The EPB module will only operate the actuator if the power supply from the battery is between 9 V and 16 V. At any
voltage within this range, the actuator is able to fully tighten and release the brake cables. If the power supply falls
outside of the range, a fault code is stored in the EPB module and can be retrieved using the Jaguar approved diagnostic
system.
Parking Brake Switch
The parking brake switch is mounted in the floor console, rearward of the rotary gear selector. The switch has 3 states:
Apply: When the switch is pulled up to apply the parking brake.

Release: W hen the switch is pushed down to release the parking brake.
Neutral: The central default position. The switch returns to this position regardless of parking brake status.
The parking brake switch contains a pair of micro-switches for both the apply and release actions. The EPB module
provides an individual hardwired electrical feed to each of the four micro-switches plus a single ground connection,
allowing it to constantly monitor switch status.
EPB Module
The EPB module is mounted in the luggage compartment on the RH (right-hand) side quarter panel and is connected to the
vehicles electrical wiring by two multiplugs. The EPB module is also connected to the high speed CAN bus, allowing it to
communicate with other vehicle systems.
The EPB module monitors the condition of the parking brake switch through a series of hardwired electrical connections and
controls operation of the parking brake actuator accordingly.
Parking Brake Actuator

The parking brake actuator is mounted on the rear cross beam, underneath the vehicle. Operation of the actuator is
controlled by the EPB module in response to parking brake switch requests from the driver.
A Hall sensor is located within the actuator and provides positional information back to the EPB module. The principle
function of the Hall sensor is to ensure the actuator fully releases the parking brake when a static release request is
made. The signal provided by the Hall sensor is compared to configuration information contained within the EPB module
software to determine when a full release has been carried out.
Stoplamp Switch
The stoplamp switch is mounted on the brake pedal box. One of the prerequisites for releasing the parking brake is that
the foot brake is applied. The EPB module is able to determine the position of the footbrake by monitoring the status of
the stoplamp switch via a hardwired electrical connection.
The stoplamp switch also forms part of:
The ABS.
Refer to: Anti-Lock Control - Stability Assist (206-09 Anti-Lock Control - Stability Assist, Description and
Operation).
The speed control system. For additional information, refer to:
Speed Control (310-03A, Description and Operation),
Speed Control (310-03B, Description and Operation),
Speed Control (310-03 Speed Control - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8, Description and Operation).
Instrument Cluster
Depending on market specification, the instrument cluster may contain a red and an amber brake warning indicator, or only
a red brake warning indicator. The functionality of the warning indicators is shown in the table below.
Indicator Status Details

Red Illuminated Parking brake applied
Red Flashing Parking brake electrical failure
Amber Illuminated Parking brake electrical failure
If a parking brake failure warning indicator is active, the message 'CANNOT APPLY PARK BRAKE' or 'PARK BRAKE FAULT'
will also appear in the instrument cluster message center. If the vehicle is moving with the parking brake applied, the
message 'PARK BRAKE ON' will appear in the message center accompanied by a chime from the instrument cluster.
Refer to: Information and Message Center (413-08 Information and Message Center, Description and Operation).
Parking Brake and Actuation - Parking Brake
For a detailed description of the Parking Brake system, refer to the relevant Description and Operation sections of the
workshop manual. REFER to: (206-05 Parking Brake and Actuation)
Parking Brake (Description and Operation),

Parking Brake (Description and Operation),
Parking Brake (Description and Operation).
Parking Brake Calibration

The parking brake system must be calibrated whenever the battery has been disconnected or has been in a state of
discharge, or repairs have been carried out to the rear service or parking brake system.
NOTE: If new rear brake pads have been installed, pressure must be applied to the brake pedal a minimum of five times
prior to calibration of the parking brake system.
To calibrate the parking brake system:
1. 1. Place gear selector lever in 'P' Park position.
2. 2. Release parking brake cable tension to service position.

REFER to: Parking Brake Cable Tension Release (206-05 Parking Brake and Actuation, General Procedures).
3. 3. Set the ignition status to 'ON'.
4. 4. Apply and hold the footbrake then pull up the parking brake switch.
5. 5. To release the parking brake, apply and hold the footbrake then press down the parking brake switch.

Visual Inspection
Parking brake cable Fuse(s)
Parking brake actuator Wiring harness/electrical connectors
Brake caliper Check for bent/corroded pins
Brake pads Parking brake switch
Stabilizer bar drop link rubber cable deflector block Parking brake module
4. 4. If the cause is not visually evident check the system for any logged Diagnostic Trouble Codes (DTCs) and
proceed to the DTC Index , alternatively, verify the customer concern and refer to the Symptom Chart.
DTC Index
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
places, and with an up-to-date calibration certificate. W hen testing resistance always take the resistance of the DMM
leads into account.

B114264 Ignition Status 1 Signal plausibility failure - Refer to electrical circuit diagrams and check parking
Ignition power supply is brake module ignition power supply for short to
detected open circuit when ground, open circuit
ignition status is set to 'ON'
B131700 Parking Brake Module Battery voltage is high Check for charging system failure, refer to section
Voltage High (above 18 volts) 303-04
B131800 Parking Brake Module Battery voltage is low Carry out the pinpoint test associated with this DTC
Voltage Low (below 8 volts) (not logged using the manufacturer approved diagnostic system.
on battery disconnect) Check vehicle battery is in fully charged and
serviceable condition. Check for charging system
failure, refer to section 303-04. Refer to the
electrical circuit diagrams and check parking brake
module logic power circuit for high resistance
B134200 Parking Brake Module Is Internal module fault Install new Parking Brake module as required, refer
Defective to the new module installation note at the top of
the DTC Index
C109400 Primary Parking Brake Connector fault - bent, Carry out the pinpoint test associated with this DTC
Apply Switch Circuit loose or corroded pin(s) using the manufacturer approved diagnostic system.
Failure Harness fault - high Refer to the electrical circuit diagrams and check
resistance, open circuit primary parking brake apply switch circuit for high
Switch fault resistance, open circuit. Check and install a new
switch as required
Release Switch Circuit loose or corroded pin(s) using the manufacturer approved diagnostic system.
Voltage Out Of Range Harness fault - low Refer to the electrical circuit diagrams and check
resistance to ground primary parking brake release switch circuit for low
Switch fault resistance to ground. Check and install a new switch
as required
Voltage Out Of Range Harness fault - low Refer to the electrical circuit diagrams and check
resistance to ground primary parking brake apply switch circuit for low
Switch fault resistance to ground. Check and install a new switch
as required
Short To Ground Harness fault - short to Refer to the electrical circuit diagrams and check
ground primary parking brake apply switch circuit for short
Switch fault to ground. Check and install a new switch as
required
Failure Harness fault - high Refer to the electrical circuit diagrams and check
resistance, open circuit primary parking brake release switch circuit for high
switch as required
Short To Ground Harness fault - short to Refer to the electrical circuit diagrams and check
ground primary parking brake release switch circuit for short
Switch fault to ground. Check and install a new switch as
required
C178400 Parking Brake Motor Connector fault - bent, Carry out the pinpoint test associated with this DTC
Output Circuit Short To loose or corroded pin(s) using the manufacturer approved diagnostic system.
Ground Harness fault - short to Refer to the electrical circuit diagrams and check
ground parking brake motor output circuit for short to
Actuator fault ground. Check and install a new actuator as required
Output Circuit Open loose or corroded pin(s) using the manufacturer approved diagnostic system.
Circuit Harness fault - open circuit Refer to the electrical circuit diagrams and check
Actuator fault parking brake motor output circuit for open circuit.
Check and install a new actuator as required
Output Circuit Short To loose or corroded pin(s) using the manufacturer approved diagnostic system.
Power Harness fault - short to Refer to the electrical circuit diagrams and check
power parking brake motor output circuit for short to
Actuator fault power. Check and install a new actuator as required
C179900 Hall Effect Circuit Connector fault - bent, Carry out the pinpoint test associated with this DTC
Failure loose or corroded pin(s) using the manufacturer approved diagnostic system.
Parking brake motor Hall Refer to the electrical circuit diagrams and check
effect position sensor power parking brake motor hall effect position sensor
circuit fault circuits for short, open circuit. Check and install a
Parking brake motor Hall new sensor/actuator as required
effect position sensor
ground circuit fault
Parking brake motor Hall
effect position sensor signal
circuit fault
Mechanical fault with
sensor/actuator
C180100 Motor Engage Current Service brake not correctly Carry out parking brake calibration procedure. Check
Reached Before Full adjusted following lining for mechanical failure of parking brake system
Apply Travel Distance replacement
Parking brake not calibrated
after lining replacement
Cables fouled, trapped or
damaged
Cables incorrectly routed or
fixed
Caliper malfunction
Actuator malfunction
C180200 Motor Engage Current Service brake not correctly Carry out parking brake calibration procedure. Check
Not Reached or adjusted following lining for mechanical failure of parking brake system
Travelled Too Far Upon replacement
Apply Parking brake not calibrated
after lining replacement
Cables broken
Cables incorrectly routed or
fixed
Caliper malfunction
Actuator malfunction
C180300 Motor Disengage Full Intermittent motor or circuit Check for additional motor and circuit DTCs and refer
Travel Distance Not - open circuit to DTC Index. Check for mechanical failure of
Reached Upon Release Actuator malfunction parking brake system
(excessive noise may be
heard during release)
C198900 Parking Brake Apply And Connector fault - bent, Carry out the pinpoint test associated with this DTC
Release Switches Are loose or corroded pin(s) using the manufacturer approved diagnostic system.
Active At The Same Harness fault - apply and Refer to the electrical circuit diagrams and check
Time release circuits - short to parking brake apply/release switch circuits for short
each other to each other. Check and install a new switch as
Switch fault required
C1D0062 Apply Switch Active Connector fault - bent, Refer to electrical circuit diagrams and check
Then Release Switch loose or corroded pin(s) apply/release switch circuits. Check and install a
Active Switch fault new switch as required
C1D0064 Erroneous Apply Switch Connector fault - bent, Carry out the pinpoint test associated with this DTC
Active loose or corroded pin(s) using the manufacturer approved diagnostic system.
Harness fault - primary or Refer to electrical circuit diagrams and check
secondary apply circuit apply/release switch circuits. Check and install a
Switch fault new switch as required
C1D0066 Parking Brake High amount of Clear DTC and cycle ignition to re-enable switch
Apply/Release Switch apply/release applications functionality
Signal Has Too Many in short space of time
Transitions/Events (switch locked out due to
abuse)
C1D0711 Secondary Parking Brake Connector fault - bent, Refer to electrical circuit diagrams and check
Apply Switch Circuit loose or corroded pin(s) secondary parking brake apply switch circuit for short
Short To Ground Harness fault - short to to ground. Check and install a new switch as
ground required
Switch fault
C1D0715 Secondary Parking Brake Connector fault - bent, Carry out the pinpoint test associated with this DTC
Failure Harness fault - high Refer to electrical circuit diagrams and check
resistance, open circuit secondary parking brake apply switch circuit for high
switch as required
C1D071C Secondary Parking Brake Connector fault - bent, Refer to electrical circuit diagrams and check
Apply Switch Circuit loose or corroded pin(s) secondary parking brake apply switch circuit for low
Voltage Out Of Range Harness fault - low resistance to ground. Check and install a new switch
resistance to ground as required
Switch fault
C1D0811 Secondary Parking Brake Connector fault - bent, Refer to electrical circuit diagrams and check
Release Switch Circuit loose or corroded pin(s) secondary parking brake release switch circuit for
Short To Ground Harness fault - short to short to ground. Check and install a new switch as
ground required
Switch fault
C1D0815 Secondary Parking Brake Connector fault - bent, Carry out the pinpoint test associated with this DTC
Failure Harness fault - high Refer to electrical circuit diagrams and check
resistance, open circuit secondary parking brake release switch circuit for
Switch fault high resistance, open circuit. Check and install a
new switch as required
C1D081C Secondary Parking Brake Connector fault - bent, Refer to electrical circuit diagrams and check
Release Switch Circuit loose or corroded pin(s) secondary parking brake release switch circuit for
Voltage Out Of Range Harness fault - low low resistance to ground. Check and install a new
resistance to ground switch as required
Switch fault
C1D1000 Field Effect Transistor Internal module fault Install a new parking brake module, refer to the new
Circuit Over module/component installation note at the top of
Current/Over the DTC Index
Temperature
C1D1162 Release Switch Active Connector fault - bent, Refer to electrical circuit diagrams and check release
Then Apply Switch loose or corroded pin(s) switch circuit for short, open circuit. Check and
Active Switch fault install a new switch as required
C1D1164 Erroneous Release Connector fault - bent, Carry out the pinpoint test associated with this DTC
Switch Active loose or corroded pin(s) using the manufacturer approved diagnostic system.
Harness fault - primary or Refer to electrical circuit diagrams and check release
secondary apply circuit switch circuit for short, open circuit. Check and
Switch fault install a new switch as required
C1D1564 Brake Switch Status ECM off Bus (ECM off Bus Carry out the pinpoint test associated with this DTC
DTC may also be logged) using the manufacturer approved diagnostic system.
Harness fault - brake switch Refer to the electrical circuit diagrams and check
circuit open circuit to brake switch circuits for open circuit
parking brake module
Harness fault - brake switch
circuit open circuit to ECM
C1D1614 High Power Battery Feed Fuse Carry out the pinpoint test associated with this DTC
Circuit Failure Harness fault - high using the manufacturer approved diagnostic system.
resistance, open circuit Refer to the electrical circuit diagrams and check
Connector fault - bent, battery power supply circuits to parking brake
loose or corroded pin(s) module for high resistance and open circuit
C1D2092 Vehicle Deceleration, Implausible vehicle speed Cycle the ignition. Check ABS for DTCs and refer to
Performance Or message sent from ABS DTC Index
Incorrect Operation
U000187 High Speed CAN All CAN messages are Carry out the pinpoint test associated with this DTC
Communication Bus detected missing at Ignition using the manufacturer approved diagnostic system
ON
U000188 High Speed CAN CAN Bus circuit fault Carry out the pinpoint test associated with this DTC
Communication Bus - using the manufacturer approved diagnostic system
Bus Off
U010000 Lost Communication ECM off Bus Carry out the pinpoint test associated with this DTC
W ith ECM using the manufacturer approved diagnostic system.
Check ECM for related DTCs and refer to the relevant
DTC Index
U010300 Lost Communication Transmission Shift Module Carry out the pinpoint test associated with this DTC
W ith The Gear Shift off Bus using the manufacturer approved diagnostic system.
Control Module A Check the transmission shift module for related
DTCs and refer to the relevant DTC Index
U010400 Lost Communication Speed control module off Carry out the pinpoint test associated with this DTC
W ith Speed Control Bus using the manufacturer approved diagnostic system.
Front Distance Range Check the speed control module for related DTCs
Sensor and refer to the relevant DTC Index
U012100 Lost Communication ABS module off Bus Carry out the pinpoint test associated with this DTC
W ith Anti-Lock Brake using the manufacturer approved diagnostic system.
System Check the ABS module for related DTCs and refer to
the relevant DTC Index
U015500 Lost Communication Instrument cluster off Bus Carry out the pinpoint test associated with this DTC
W ith Instrument Cluster using the manufacturer approved diagnostic system.
Check the instrument cluster for related DTCs and
refer to the relevant DTC Index
U030000 Internal Control Module Invalid configuration Re-configure the RJB using the manufacturer
Software Incompatibility message is received approved diagnostic system. Clear the DTC and
retest. If the DTC is still logged suspect the Parking
Brake module, refer to the new module installation
note at the top of the DTC Index
U040100 Invalid Data Received Invalid message from the No fault with parking brake system if this DTC is
From ECM ECM logged. Check ECM for DTCs and refer to the
relevant DTC Index
From Gear Shift Control transmission shift module logged. Check transmission shift module for related
Module A DTCs and refer to the relevant DTC Index
From Anti-Lock Brake anti-lock brake system logged. Check anti-lock control - stability assist
System (ABS) Control module module for DTCs and refer to the relevant DTC Index
Module
From Body Control CJB logged. Check CJB for DTCs and refer to the relevant
Module DTC Index
From Instrument Panel instrument cluster logged. Check the instrument cluster for DTCs and
Control Module refer to relevant DTC Index
U043364 Invalid Data Received Incorrect parking brake No fault with parking brake system if this DTC is
From Cruise Control apply request from the logged. Check the speed control module for DTCs
Front Distance Range speed control when the and refer to relevant DTC Index
Sensor conditions were not correct
U200168 Reduced System Invalid or missing message No fault with parking brake system if this DTC is
Function from ABS with ignition OFF logged. Check the anti-lock control - stability assist
and vehicle speed > 3Kph module for DTCs and refer to the relevant DTC Index
U300281 Vehicle Identification Vehicle/component VIN Install original module, check for parking brake
Number (VIN) mis-match between RJB and related DTCs and refer to DTC Index. If DTC remains
parking brake module, suspect parking brake module, refer to new
module installed from donor module/component installation note at top of DTC
vehicle Index
U300362 Battery Voltage Mis-match in battery Carry out the pinpoint test associated with this DTC
voltage, of 2 volts or more, using the manufacturer approved diagnostic system
between parking brake
module and RJB
Symptom Chart

The parking brake will Cables fouled, trapped or damaged Check parking brake system for DTCs and
not engage or release Cables incorrectly routed or installed refer to DTC Index
(with no parking brake Rear lining wear Check the rear and primary cables for correct
warning message) Service brake incorrectly adjusted installation and damage.
following lining change Inspect the rear brake linings for wear
Caliper malfunction Carry out parking brake calibration procedure
Check the rear service brake for correct
installation and operation
The parking brake will Cables fouled, trapped or damaged Check parking brake system for DTCs and
not engage or release Cables incorrectly routed or installed refer to DTC Index
(with parking brake Rear lining wear Check the rear and primary cables for correct
warning message) Actuator malfunction installation and damage.
Caliper malfunction Inspect the rear brake linings for wear
Carry out parking brake calibration procedure
Check the rear service brake for correct
installation and operation
No communication with Fuse Check fuses

the parking brake module Module off Bus Ensure battery is fully charged and in
CAN network error serviceable condition. Check battery voltage
Parking brake module fault at parking brake module
Check CAN network using manufacturer
approved diagnostic system
'Park brake Fault' Parking brake system fault Check the parking brake module for DTCs
displayed on message and refer to DTC Index
center with associated
warning lamps
Brakes drag Parking brake not re-calibrated after Check parking brake levers are fully returned
battery has been disconnected or has to the hard stops when the parking brake is
been in a state of discharge, or released. If the levers are fully returned,
repairs have been carried out to the check service brake for correct operation. If
rear service or parking brake system not, carry out the parking brake calibration
Service brake system fault procedure
Parking Brake and Actuation - Parking Brake Cable Tension Release
General Procedures
Special Tool(s)
Electric parking brake release tool
206-082. Only to be used for
EMERGENCY brake
release
Electric parking brake release tool link

lead 206-082-01. Only to be used for
EMERGENCY brake
release
1. W ARNING: Always use Jaguar approved diagnostic

equipment to release the cable tension, when carrying out repair
operations on the electric park brake which require cable tension
release.
Connect the Jaguar approved diagnostic equipment to release

the electric parking brake cable tension.
Follow the on-screen instructions.
2. W ARNING: The procedure below should only be used in

emergency situations, to release the electric park brake. All
calibration of the parking brake system will be lost, and the
parking brake will need to be re-calibrated to function correctly.
NOTE: The tools shown must only be used in the event of an

emergency.
Remove the RH loadspace trim panel.

For additional information, refer to: Loadspace Trim Panel RH
Installation).
3. WARNING: Failure to follow this instruction may result

in a diagnostic trouble code (DTC) being generated.
Disconnect the 2 electrical connectors from the parking brake

module, in the sequence illustrated.
Connect the special tool to the parking brake module.
An audible 'click', signals complete parking brake cable

tension release.
6. Remove the special tool and carry out any necessary repairs
on the system.
7. Connect the electrical connectors in the sequence shown.
8. Install the RH loadspace trim panel.

Installation).
9. W ARNING: Calibrate the electric park brake using Jaguar

approved diagnostic equipment. If Jaguar approved diagnostic
equipment is not available disconnect the battery for
approximatly 30 seconds , the vehicle will then prompt the driver
to carry out the calibration procedure as per the vehicle hand
book on re-connection.
Calibrate the electric park brake.

Parking Brake and Actuation - Parking Brake Cable LH2.7L V6 - TdV6/3.0L
NA V6 - AJ27/4.2L NA V8 - AJV8/4.2L SC V8 - AJV8
Removal


2. Remove the LH rear wheel and tire.
Procedures).
4. Detach the LH parking brake cable.
1. Detach the LH parking brake cable from the

retaining tang.
2. Release the 2 clips.
Detach and remove the LH parking brake cable from the

caliper.
1. Detach the LH parking brake cable.
Installation
Install the LH parking brake cable.
Attach the LH parking brake cable.
2.
3. NOTE:
Install Make sure and
the wheel that tire.
the RH parking brake cable is correctly
seated in the retaining
For additional tang. refer to: Wheel and Tire (204-04
information,
Attach the LH parking brake cable.
Attach the LH parking brake cable to the retaining tang.

Parking Brake and Actuation - Parking Brake Cable RH2.7L V6 - TdV6/3.0L
Removal


2. Remove the RH rear wheel and tire.
Procedures).
4. Detach the RH parking brake cable.
1. Detach the RH parking brake cable from the

retaining tang.
Detach and remove the RH parking brake cable from the

caliper.
1. Detach the RH parking brake cable.
Installation
Install the RH parking brake cable.
Attach the RH parking brake cable.
2.
3. NOTE:
Install Make sure and
the wheel that tire.
the RH parking brake cable is correctly
seated in the retaining
For additional tang. refer to: Wheel and Tire (204-04
information,
Attach the RH parking brake cable.
Attach the RH parking brake cable to the retaining tang.

Parking Brake and Actuation - Parking Brake Module
Removal
1. Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting

and Cables, General Procedures).
2. Refer to: Loadspace Trim Panel RH (501-05 Interior Trim and

3. Torque: 4 Nm
Installation
1. To install, reverse the removal position
2. Configure the electronic parking brake (EPB) using the diagnostic

tool.
Parking Brake and Actuation - Parking Brake Switch
Removal
NOTE: The parking brake switch is part of the transmission control switch (TCS) assembly and therefore can not be
serviced separately.

2. Refer to: Transmission Control Switch (TCS) (307-05 Automatic

Transmission/Transaxle External Controls, Removal and
Installation).
Installation
1. 1. CAUTION: Make sure that all diagnostic trouble codes

(DTCs) have been removed after the road test.

Parking Brake and Actuation - Parking Brake Release Actuator4.2L NA V8 -
Removal
1. Carry out the parking brake cable tension release.
Procedures).

stands.

3. Disconnect the parking brake release actuator electrical
connector.
4. Remove the parking brake release actuator retaining bolts.
5. Detach the parking brake release actuator cable.
1. For right-hand side connector bracket:

1. Reposition the retaining tang.
2. Detach the parking brake cable.
2. For left-hand side reaction bracket, detach the

parking brake cable.
Detach the parking brake release actuator cable.

For additional information, refer to: Engine Rear Undershield

driveshaft.

rear drive axle flange.
Mark the position of the balance nut in relation to the

rear drive axle flange. (if fitted).

11. Using the special tool, support the axle assembly.

12. Remove the axle assembly retaining bolts.
13. CAUTION: Make sure the halfshafts remain clear of the

rear suspension/subframe.
Lower the rear axle assembly.

14. Remove the parking brake actuator.
Installation
1. NOTE: Make sure the parking brake cable is correctly routed.
NOTE: Make sure that the parking brake cables are correctly
seated in the retaining tangs.
Tighten to 20 Nm.

8. CAUTION: Calibrate the electric park brake using Jaguar

approved diagnostic system. If the Jaguar approved diagnostic
system is not available disconnect the battery for approximately
30 seconds, the vehicle will then prompt the driver to carry out
the calibration procedure as per the vehicle hand book on
re-connection.
Calibrate the electric parking brake (EPB) using the diagnostic

tool.
Hydraulic Brake Actuation - Hydraulic Brake Actuation - Component
Location
NOTE: RHD (right-hand drive) installation shown, LHD (left-hand drive) installation similar.
Component Location
ItemDescription
1 Brake master cylinder and fluid reservoir
2 Brake pedal
3 Brake pipes
4 Stoplamp switch
5 ABS (anti-lock brake system) module/ HCU (hydraulic control unit)
6 Brake booster
Hydraulic Brake Actuation - Hydraulic Brake Actuation - Overview
Overview
The hydraulic brake system is a diagonally split dual line system. The system consists of a brake pedal, vacuum brake
booster, brake master cylinder assembly, HCU (hydraulic control unit), hydraulic pipes and brake hoses.
Brake pipes from the master cylinder supply pressure to the brake calipers at the four corners of the vehicle via the HCU.
Braided steel hoses are used to connect the brake pipes to the front and rear brake calipers.
Hydraulic Brake Actuation - Hydraulic Brake Actuation - System Operation
and Component Description
System Operation
When the brake pedal is pressed, the front push rod in the brake booster pushes the master cylinder primary piston along
the bore of the housing. This produces pressure in the primary pressure chamber which, in conjunction with the primary
spring, overcomes the secondary spring and simultaneously moves the secondary piston along the bore. The initial
movement of the pistons away from the piston stops closes the primary and secondary center valves in the master
cylinder. Further movement of the pistons then pressurizes the fluid in the primary and secondary chambers and thus the
brake circuits. The fluid in the chambers behind the pistons is unaffected by the movement of the pistons and can flow
unrestricted through the inlet ports between the chambers and the reservoir.
Pressurized fluid enters the HCU (hydraulic control unit), which is mounted on the front of the ABS (anti-lock brake system)
module. The HCU modulates the supply of pressurized fluid to the brakes under control of the ABS module.
Refer to: Anti-Lock Control - Stability Assist (206-09 Anti-Lock Control - Stability Assist, Description and Operation).
Brake Pedal
The brake pedal is mounted to a bracket attached to the rear side of the engine bulkhead. The bracket also contains the
accelerator pedal. A clevis pin connects the brake pedal to the input push rod of the brake booster and master cylinder
assembly.
The stoplamp switch is mounted in the brake pedal bracket and is operated by the brake pedal.
Brake Master Cylinder and Fluid Reservoir
ItemDescription
1 Brake fluid level switch electrical connector
2 Brake fluid reservoir cap
3 Brake fluid reservoir
4 Primary circuit inlet port
5 Brake master cylinder
6 Torx bolt
7 Primary circuit outlet
8 Secondary circuit outlet
9 Secondary circuit inlet port
10 Reservoir to master cylinder seal (2 off)
The brake booster and master cylinder assembly is fitted in the engine compartment. The brake master cylinder housing
consists of two hydraulic chambers containing two pistons in tandem. The primary piston (adjacent to the brake booster)
produces pressure for the primary braking circuit and this pressure acts on the secondary piston and hence creates
pressure in the secondary circuit. A brake fluid reservoir is mounted on top of the master cylinder to provide a supply of
brake fluid to the brake system. The reservoir cap is fitted with a brake fluid level switch.
Brake Fluid Level Switch

The brake fluid level switch is located in the fluid reservoir and is hardwired to the instrument cluster. When the level of
fluid in the reservoir reaches a predetermined low level, the switch contacts close and provide a signal feed back to the
instrument cluster. On receipt of the signal, the brake fluid red warning indicator will illuminate and 'BRAKE FLUID LOW'
will be displayed in the message center.
ABS Module
ItemDescription
1 LH (left-hand) front brake
2 RH (right-hand) rear brake
3 LH rear brake
4 RH front brake
5 Primary circuit inlet port
6 Secondary circuit inlet port
The ABS module is located in the passenger side, rear engine bay and incorporates the HCU. The HCU is a four channel
unit that modulates the supply of hydraulic pressure to the brakes under control of the ABS module.
The primary and secondary outlets of the master cylinder are connected to the primary and secondary circuits within the
HCU. The primary circuit in the HCU has separate outlet ports to the RH front and LH rear brakes. The secondary circuit in
the HCU has separate outlet ports to the LH front and RH rear brakes.
CAUTION: The ABS module and the HCU are a single unit and must not be separated.
HCU Schematic Diagram

ItemDescription
1 Brake booster
2 Primary circuit
3 Secondary circuit
4 HCU
5 Pulsation damper
6 Pulsation damper
7 Separation valve
8 Damping chambers
9 Separation valve
10 Shuttle valve
11 Hydraulic pumps
12 Motor
13 Shuttle valve
14 Pressure sensor - all vehicles
15 Low pressure accumulator
16 Check valve
17 Low pressure accumulator
18 Inlet valve
19 Inlet valve
20 Inlet valve
21 Inlet valve
22 Outlet valve
23 Outlet valve
24 Outlet valve
25 Outlet valve
26 Pressure sensors - vehicles fitted with adaptive speed control only
27 RH front brake
28 LH rear brake
29 RH rear brake
30 LH front brake
Hydraulic Brake Actuation - Hydraulic Brake Actuation

Hydraulic Brake Actuation - Brake Fluid Reservoir
Removal
CAUTION: If brake fluid is spilt on the paintwork, the affected area must be immediately washed down with cold
water.
1. Remove the brake fluid reservoir cap.
2. Disconnect the brake fluid level electrical connector.
3. Using a suitable suction device drain the brake fluid resrvoir.
4.5.Remove
Removethe
andbrake fluid
discard reservoir.
the O-ring seals.
Installation
Remove and discard the O-ring seals.
Tighten to 8 Nm.
Fill the brake fluid reservoir to the MAX mark.

Hydraulic Brake Actuation - Brake Master Cylinder
Removal

stands.

2. Remove the cowl vent screen.
For additional information, refer to: Cowl Vent Screen (501-02
Front End Body Panels, Removal and Installation).
3. CAUTION: Brake fluid will damage paint finished

surfaces. If spilled, immediately remove the fluid and clean the
area with water.
Remove the brake fluid reservoir.

For additional information, refer to: Brake Fluid Reservoir
(206-06 Hydraulic Brake Actuation, Removal and Installation).
4. Remove the brake booster vacuum line from the brake vacuum
pump.
5. CAUTION: Make sure that all openings are sealed. Use

new blanking caps.
Disconnect the master cylinder brake pipes.

6. Release the fuse box.
7. Remove the brake master cylinder.
Installation
Install new O-ring seals.


Procedures).
Power Brake Actuation -
Brake booster retaining nuts - all vehicles 25 18 -
Exhaust gas recirculation valve coolant pipe - vehicles with 3.0L Diesel 9 - 80
Brake vacuum pump nut - vehicles with 3.0L Diesel 23 17 -
Brake vacuum pump threaded stud - vehicles with 3.0L Diesel 13 10 -
Brake vacuum pump bolts - vehicles with 3.0L Diesel 23 17 -
Brake vacuum pump bolts - vehicles with 5.0L 12 9 -
Power Brake Actuation - Brake Booster - Component Location
Component Location
ItemDescription
1 Output pushrod
2 Brake booster
3 Input pushrod
4 Vacuum pipe
5 Non return valve
Power Brake Actuation - Brake Booster - Overview
Overview
Power assistance for the braking system is provided by a vacuum brake booster. The unit increases the input load by a
ratio of 6.2 : 1 and is secured to the driver's side of the engine compartment bulkhead by four studs and nuts.
The booster and master cylinder assembly is fitted in the engine compartment. A two piece plastic vacuum pipe connects
the brake booster to the inlet manifold to provide the necessary vacuum to the booster. The connection into the brake
booster has a non return valve to maintain the vacuum level in the booster and also prevent fuel vapor from entering the
brake booster.
The input push rod within the brake booster is connected to the brake pedal lever. Initially, any effort applied by the driver
is increased by pedal ratio which is transferred to the input push rod. This load is further increased by the booster. The
increased load is applied to the primary piston of the master cylinder via the output pushrod of the booster. Hydraulic
pressure in the master cylinder is then applied to the brakes.
Refer to: Hydraulic Brake Actuation (206-06 Hydraulic Brake Actuation, Description and Operation).
Power Brake Actuation - Power Brake System

Power Brake Actuation - Brake Booster
Removal
1. Remove the brake master cylinder.
2. Disconnect the brake booster vacuum electrical connector.
3. Remove the lower trim panel.
4. Remove the retaining nut.
5. Remove the brake booster retaining nuts.

6. Remove the brake booster.
Installation
1. NOTE: Replace the brake booster/pedal box gasket.
Tighten to 25 Nm.
2. Tighten to 3 Nm.
Power Brake Actuation - Brake Vacuum Pump2.7L V6 - TdV6
Removal
Procedures).
2. Remove the engine cover.
For additional information, refer to: Engine Cover - 2.7L Diesel
(501-05, Removal and Installation).
3. Remove the secondary bulkhead center panel.
For additional information, refer to: Secondary Bulkhead Center
Panel (501-02 Front End Body Panels, Removal and
Installation).
4. Remove the engine compartment brace.
5. Disconnect both vacuum lines from the brake vacuum pump.
6. Remove the crankcase breather pipe bracket retaining nut.

7. Remove the brake vacuum pump retaining stud.
8. Remove the high pressure fuel pipe bracket retaining bolt.
9. NOTE: Remove and discard the O-ring seal.
Remove the brake vacuum pump.
Remove the gasket.
Installation
1. NOTE: Install a new O-ring seal.
Install a new gasket.
Apply silicone gasket sealant or equivalent meeting

Jaguar specification.
The application of sealant must be 10 mm square in two

places. Install the brake vacuum pump immediately after
applying the sealant.
The brake vacuum pump should be fitted directly to the

engine without smearing the sealant.
Make sure that the drive coupling is aligned with camshaft

coupling.
Anti-Lock Control - Stability Assist -
Item Specification
Brake master cylinder primary pressure transducer 30 22
Brake tubes to hydraulic control unit (HCU) 17 13
Rear wheel speed sensor retaining bolt 6 53
Yaw rate sensor and accelerometer retaining nuts 7 62
Hydraulic control unit (HCU) retaining bolts 8 71
Steering wheel rotation sensor retaining screws 4 35
Steering column to lower shroud retaining screws 3 27
Anti-Lock Control - Stability Assist - Anti-Lock Control - Stability Assist -
Component Location
Component Location
ItemDescription
2 RH (right-hand) front wheel speed sensor
4 Steering angle sensor
5 Yaw rate and lateral acceleration sensor
6 RH rear wheel speed sensor
7 LH (left-hand) rear wheel speed sensor
8 LH front wheel speed sensor
Overview
Overview
The ABS (anti-lock brake system) and DSC (dynamic stability control) system features a Bosch modulator, which is an
integrated four-channel HCU (hydraulic control unit) and ABS module. The unit is located in the rear of the engine
compartment on the passenger side, and is installed in the brake hydraulic circuit between the brake master cylinder and
the four brake calipers.
The ABS module is connected to the high speed CAN (controller area network) bus, and actively interacts with other vehicle
system control modules and associated sensors to receive and transmit current vehicle operating information.
When required, the ABS module will actively intervene and operate the HCU during braking or vehicle maneuvers to correct
the vehicle attitude, stability, traction or speed. During incidents of vehicle correction, the ABS module may also request
the ECM (engine control module) to control engine power in order to further stabilize and correct the vehicle.
To provide full system functionality, the ABS and DSC system comprise the following components:
DSC switch.
Four wheel speed sensors.
Steering angle sensor.
Yaw rate and lateral acceleration sensor.
Stoplamp switch.
Instrument cluster indicator lamps.
Integrated ABS module and HCU.
Brake booster vacuum sensor (3.0L vehicles only).
Two variants of ABS module are available, Bosch ESP8.1 and Bosch ESPplus8.1. The Bosch ESPplus8.1 system is
fitted to vehicles with ACC (adaptive cruise control) and incorporates a new feature to Jaguar known as 'electronic brake
prefill'.
Electronic brake prefill, senses any rapid throttle lift off, activating a small brake hydraulic pressure build-up of
approximately 3 to 5 bar (43.5 to 72.5 lbf/in) in anticipation of the brakes being applied. This application produces a
quicker brake pedal response and consequently slightly shorter stopping distances. When the ECM detects rapid throttle
lift off it signals the ABS module which controls the HCU to apply a low brake pressure to assist in a quicker brake
application.
NOTE: All vehicles with ACC are supported by the Bosch ESPplus8.1 system.
The ABS provides the following brake functions that are designed to assist the vehicle or aid the driver:
ABS.
DSC, including Trac DSC.
CBC (corner brake control).
EBD (electronic brake force distribution).
ETC (electronic traction control).
EBA (emergency brake assist).
EDC (engine drag-torque control).
Understeer control.
Electronic brake prefill (vehicles with ACC only).
Brake vacuum assist (3.0L vehicles only).
All the brake functions listed are automatically active when the ignition is in power mode and the engine is running. The
DSC system can be selected to off using the DSC switch.
WARNING: Although the vehicle is fitted with DSC, it remains the drivers responsibility to drive safely according to
the prevailing conditions.
Control Diagram
NOTE: A = Hardwired; D = High speed CAN (controller area network) bus; N = Medium speed CANCAN bus; V = Private
CAN bus.
ItemDescription
1 Battery
2 BJB (battery junction box) (250 A megafuse)
4 EJB (engine junction box)
5 LH (left-hand) front wheel speed sensor
6 RH (right-hand) front wheel speed sensor
7 Brake fluid level switch
8 LH rear wheel speed sensor
9 RH rear wheel speed sensor
11 High mounted stop lamp
12 LH stop lamp
13 RH stop lamp
14 Diagnostic socket
16 Electronic parking brake module
20 JaguarDrive selector module
21 Adaptive damping control module
22 Adaptive speed control module
23 Yaw rate and lateral acceleration sensor
24 Roof opening panel motor/module
25 Brake booster vacuum sensor (3.0L vehicles only)
26 Steering angle sensor
System Operation
Anti-Lock Brake System
ABS controls the speed of all road wheels to ensure optimum wheel slip when braking at the adhesion limit. The wheels
are prevented from locking to retain effective steering control of the vehicle.
The brake pressures are modulated separately for each wheel. Rear brake pressures are controlled to maintain rear
stability on split friction surfaces.
Dynamic Stability Control

DSC (dynamic stability control) uses brakes and powertrain torque control to assist in maintaining the yaw stability of the
vehicle. While the ignition is energized the DSC function is permanently enabled, unless selected off using the DSC switch.
DSC enhances driving safety in abrupt maneuvers and in under-steer or over-steer situations that may occur in a bend. The
ABS module monitors the yaw rate and lateral acceleration of the vehicle, steering input and individual wheel speeds, then
selectively applies individual brakes and signals for powertrain torque adjustments to reduce under-steer or over-steer
conditions.
In general:
In an under-steer situation the inner wheels are braked to counteract the yaw movement towards the outer edge of
the bend.
In an over-steer situation the outer wheels are braked to prevent the rear end of the vehicle from pushing towards
the outer edge of the bend.
The ABS module monitors the tracking stability of the vehicle using inputs from the wheel speed sensors, the steering
angle sensor, and the yaw rate and lateral acceleration sensor. The tracking stability is compared with stored target data.
Whenever the tracking stability deviates from the target data, the ABS module intervenes by applying the appropriate
control strategy.
The following interactions occur in an intervention situation:
High speed CAN signal to the ECM, to reduce engine torque.

Application of braking to the appropriate corner of the vehicle.
Trac DSC
TracDSC is an alternative setting of DSC with reduced system interventions. With TracDSC engaged, traction may be
somewhat increased, although stability may be reduced compared to normal DSC. TracDSC is intended for use only on dry
tarmac, by suitably experienced drivers and should not be selected for other surfaces or by drivers with insufficient skill
and training to operate the vehicle safely with the TracDSC function engaged.
The less restrictive TracDSC setting may be preferred, for example, by expert drivers engaged in high performance driving
on dry Tarmac surfaces such as tracks and circuits.
Switching between DSC and Trac DSC:
Press and hold the DSC switch for less than 10 seconds.
The message center will temporarily display either Trac DSC or DSC ON.
The warning indicator in the instrument panel will illuminate while Trac DSC is selected.
The warning indicator will flash when DSC or Trac DSC is active.
NOTE: If cruise control is engaged, it will automatically disengage if DSC activates.
Refer to: Speed Control (310-03 Speed Control - 2.7L V6 - TdV6, Description and Operation).
Corner Brake Control

CBC (corner brake control) influences the brake pressures, below and within DSC and ABS thresholds, to counteract the
yawing moment produced when braking in a corner. CBC produces a correction torque by limiting the brake pressure on one
side of the vehicle.
Electronic Brake Force Distribution

EBD (electronic brake force distribution) limits the brake pressure applied to the rear wheels. When the brakes are applied,
the weight of the vehicle transfers forwards, reducing the ability of the rear wheels to transfer braking effort to the road
surface. This may cause the rear wheels to slip and make the vehicle unstable.
EBD uses the ABS braking hardware to automatically optimize the pressure to the rear brakes, below the point where ABS
is normally invoked.
NOTE: Only the rear brakes are controlled by the EBD function.
Electronic Traction Control

ETC (electronic traction control) attempts to optimize forward traction by reducing engine torque, or by applying the brake
of a spinning wheel until traction is regained.
ETC is activated if an individual wheel speed is above that of the vehicle reference speed (positive slip) and the brake
pedal is not pressed. The brake is applied to the spinning wheel, allowing the excess torque to be transmitted to the
non-spinning wheel through the drive line. If necessary, the ABS module also sends a high speed CAN bus message to the
ECM to request a reduction in engine torque.
When the DSC function is selected off using the DSC switch, the braking and engine torque reduction features are both
disabled, except when the JaguarDrive control is in winter mode. When the JaguarDrive control is in winter mode, selecting
the DSC function off retains the braking and engine torque reduction features, but reduces intervention levels compared to
DSC and Trac DSC modes.
Emergency Brake Assist

EBA (emergency brake assist) assists the driver in emergency braking situations by automatically increasing the applied
braking effort. The ABS module invokes EBA when:
The brake pedal is rapidly pressed.

The brake pedal is pressed hard enough to bring the front brakes into ABS operation.
When the brake pedal is rapidly pressed, the ABS module increases the hydraulic pressure to all of the brakes until the
threshold for ABS operation is reached. This action applies the maximum braking effort for the available traction. The ABS
module monitors for the sudden application of the brakes, using inputs from the brake pedal switch and from the pressure
sensor within the HCU (hydraulic control unit). W ith the brake pedal pressed, if the rate of increase of hydraulic pressure
exceeds the predetermined limit, the ABS module invokes emergency braking.
When the brake pedal is pressed hard enough to bring the front brakes into ABS operation, the ABS module increases the
hydraulic pressure to the rear brakes up to the ABS threshold.
EBA operation continues until the driver releases the brake pedal, sufficiently for the hydraulic pressure in the HCU to drop
below a threshold value stored in the ABS module.
Engine Drag-Torque Control

EDC (engine drag-torque control) prevents wheel slip caused by any of the following:
A sudden decrease in engine torque when the accelerator is suddenly released.

A downshift using the Jaguar sequential shift function on automatic transmission vehicles.
When the ABS module detects the onset of wheel slip without the brakes being applied, the ABS module signals the ECM
via the high speed CAN bus to request a momentary increase in engine torque.
Understeer Control
Understeer Logic Control is a proactive system which monitors the vehicle for understeer by comparing signals from the
yaw rate and lateral acceleration sensor with signals from the steering angle sensor and wheel speed sensors.
When the ABS module detects the onset of understeer, the ABS module signals the ECM via the high speed CAN bus to
request a decrease in engine torque. At the same time the ABS module will control the HCU to apply brake pressure to the
relevant wheels to correct the understeer.
Electronic Brake Prefill (Vehicles With ACC Only)

Electronic brake prefill (Bosch ESPplus8.1), senses any rapid throttle lift off, activating a small brake hydraulic pressure
build-up of approximately 3 to 5 bar (43.5 to 72.5 lbf/in) in anticipation of the brakes being applied.
This application produces a quicker brake pedal response and consequently slightly shorter stopping distances. The system
supports vehicles with ACC (adaptive cruise control).
When the ABS module detects rapid throttle lift off (from the signals received from the ECM over the high speed CAN bus),
it controls the HCU to apply a low brake pressure to assist in a quicker brake application.
Brake Vacuum Assist (3.0L Vehicles Only)

Operation of Brake Vacuum Assist generally occurs at the beginning of an ignition cycle when brake booster vacuum levels
are low; refer to Brake Booster Vacuum sensor, below.
Brake vacuum assist operation will be recognized by the driver experiencing a vibrating brake pedal and slight modulator
noise. This will be similar to that experienced when ABS system is operating.
As the engine warms up, Brake Vacuum Assist operation will become less frequent. However, it can be become more active
when vacuum levels are low due to driving at high-altitudes, or during frequent heavy-braking.
Noise levels during Brake Vacuum Assist may vary with initial system activity being the loudest observed. In some
circumstances initial activity may be interpreted as a 'thump' noise, particularly if there is no immediate and significant
Brake Vacuum Assist functionality.
In this circumstance system behavior is normal and should not be a cause for fault investigation.
Dynamic Stability Control Switch
ItemDescription
1 DSC switch
The DSC switch is mounted in the floor console adjacent to the JaguarDrive selector.
DSC becomes active whenever the engine is running. A momentary press of the switch allows the driver to toggle between
the standard DSC settings and the optimized 'Trac DSC' settings. The message 'Trac DSC' or 'DSC on' will temporarily be
displayed in the instrument cluster message center. The amber DSC warning indicator in the instrument cluster remains
illuminated while 'Trac DSC' is selected.
The DSC can be switched off by pressing and holding the switch for more than 10 seconds.
In each case the message 'DSC OFF' will be displayed in the instrument cluster message center to confirm DSC has been
switched off. The amber DSC warning indicator in the instrument cluster will remain illuminated. The system can be
switched back on again by simply pressing and releasing the switch. The message 'DSC ON' will then temporarily appear in
the instrument cluster message center to confirm the system is on.
NOTE: Switch requests may be delayed if the switch is pressed while a DSC operation is taking place. The switch request
will be displayed in the instrument cluster but the ABS module will not initiate any stability changes until it is safe to do
so.
If a fault is detected with the DSC switch, the ABS module defaults to the 'DSC ON' setting and any switch requests are
ignored.
WARNING: It is recommended that when using snow chains, Trac DSC is switched off and JaguarDrive control winter
mode is selected.
Wheel Speed Sensors

ItemDescription
1 Front wheel speed sensor
2 Rear wheel speed sensor
An active wheel speed sensor is installed in each wheel hub to provide the ABS module with a rotational speed signal from
each road wheel. The head of each front wheel speed sensor is positioned close to a magnetic encoder ring incorporated
into the inboard seal of the wheel bearing. The head of each rear wheel speed sensor is positioned close to a magnetic
encoder ring incorporated into the rear wheel bearing assembly. Each encoder ring contains 46 north and south poles. A fly
lead connects each sensor to the vehicle harness.
The wheel speed sensors each have a signal and a return connection with the ABS module. W hen the ignition is ON the
ABS module supplies a signal feed to the wheel speed sensors and monitors the return signals. Any rotation of the road
wheels induces current fluctuations in the return signals, which are converted into individual wheel speeds and overall
vehicle speed by the ABS module.
The ABS module broadcasts the individual wheel speeds and the vehicle speed on the high speed CAN bus for use by other
systems, although vehicle speed information to the roof opening panel motor/module is a hardwired connection.
If a wheel speed sensor fault is detected by the ABS module, 'ABS FAULT' will be displayed in the instrument cluster
message center and an amber warning indicator will illuminate.
As the wheel speed sensors are active devices, a return signal is available when the road wheels are not rotating. This
enables the ABS module to check the condition of the speed sensors while the vehicle is stationary.
Steering Angle Sensor

The steering angle sensor measures the steering wheel angle and the rate of change of the steering wheel angle. These
measurements are received by the ABS module and broadcast on the high speed CAN bus for use by other systems.
The steering angle sensor is mounted on the steering column upper shroud mounting bracket, immediately behind the
multifunction switches, and is secured by 2 screws. A fly lead connects the sensor to the passenger compartment wiring
harness via a 4 pin multiplug.
The sensor is housed in a 'U' shaped plastic casing and contains two offset LED (light emitting diode)s facing two
detectors.
An encoder ring is mounted on the inner steering column shaft and intersects the LEDs and detectors. The encoder ring
contains 60 slots which break and restore the light beams between the LEDs and the detectors as the steering wheel is
rotated. The ABS module is able to determine the direction of rotation of the steering wheel by monitoring when the light
beams change state. The LEDs and detectors are mounted in such a way that only one beam will change state, either to
broken or restored, at any one time.
The center (straight ahead) position of the steering wheel has to be learned by the ABS module every time the ignition is
switched ON. The steering angle sensor is unable to determine the center position so inputs from the yaw rate and lateral
acceleration sensor and wheel speed signals are also used by the ABS module to help it perform this process. If extreme
weather conditions are present, for example ice causing extreme wheel spin or understeer/oversteer, the ABS module may
not be able to determine the center position of the steering wheel. In this situation 'DSC NOT AVAILABLE' will be
displayed in the instrument cluster message center and the amber warning indicator will illuminate.
'DSC NOT AVAILABLE' will also be displayed if the ABS module detects a steering angle sensor fault. The amber warning
indicator will illuminate until the fault is rectified.
Yaw Rate and Lateral Acceleration Sensor

The yaw rate and lateral acceleration sensor is mounted on the rear parcel shelf. The sensor is secured by two screws and
connects to the vehicle wiring via a four pin multiplug.
When the ignition is ON, the sensor receives a power feed from the CJB. The ground path for the sensor is located behind
the left hand rear seat back. The sensor measures the yaw rate and lateral acceleration of the vehicle, providing values to
the ABS module via a dedicated, private high speed CAN bus connection. The ABS module broadcasts these values on the
high speed CAN bus for use by other systems.
If a sensor fault is detected by the ABS module, 'DSC NOT AVAILABLE' will be displayed in the instrument cluster message
center and the amber warning indicator will illuminate.
Stoplamp Switch
The stoplamp switch is mounted on the brake pedal box and is connected to the vehicle harness via a four pin multiplug.
When the brake pedal is pressed, the switch contacts close. This allows a hard wired signal feed to be sent to the ECM. A
stoplamp switch status message is then sent from the ECM to the ABS module on the high speed CAN bus. The ABS
module is then able to control braking force accordingly in conjunction with the HCU.
NOTE: The stoplamp switch also forms part of the speed control system.
For additional information, refer to:
Speed Control (310-03 Speed Control - 2.7L V6 - TdV6, Description and Operation),
Speed Control (310-03 Speed Control - 3.0L NA V6 - AJ27, Description and Operation),
Instrument Cluster Warning Indicators

ItemDescription
1 ABS warning indicator (USA only)
2 ABS warning indicator (Canada and Mexico only)
3 ABS warning indicator (all except USA, Canada and Mexico)
4 DSC warning indicator
5 Brake warning indicator (USA only)
6 Brake warning indicator (all except USA)
The instrument cluster and message center contains warning indicators and warning messages to display the operating
status of the anti-lock control - stability assist functions. The warning indicators and messages provide a visual
notification of either a system warning or information indication to the driver. There are three warning indicators on the
instrument cluster, which vary dependant on market, and several types of message relating to the anti-lock control -
stability assist functions. The DSC OFF message is accompanied by an audible warning.
The following anti-lock control - stability assist warning indicators are installed in the instrument cluster:
An amber ABS warning indicator.

A red brake warning indicator.
An amber DSC warning indicator.
Refer to: Instrument Cluster (413-01 Instrument Cluster, Description and Operation) / Information and Message Center
(413-08 Information and Message Center, Description and Operation).
ABS Module
ItemDescription
1 LH front brake
2 RH rear brake
3 LH rear brake
4 RH front brake
5 Primary inlet
6 Secondary inlet
The ABS module is located in the passenger side, rear engine bay and incorporates the HCU. The module is mounted on
the rear face of the HCU, which it uses to control all braking and stability functions by modulating hydraulic pressure to the
individual wheel brakes.
Two types of ABS modules are available; one for vehicles with standard Speed Control, one for vehicles fitted with
Adaptive Speed Control.
If an ABS modulator fault is detected, 'ABS FAULT' will be displayed in the instrument cluster message center and the
amber warning indicator will illuminate.
CAUTION: The ABS module and the HCU comprise a single unit and must not be separated.
Hydraulic Control Unit

The HCU is a four channel unit, secured to a mounting bracket located in the passenger side, rear engine bay. The HCU
modulates the supply of hydraulic pressure to the brakes under the control of the ABS module.
Refer to: Hydraulic Brake Actuation (206-06 Hydraulic Brake Actuation, Description and Operation).
Brake Booster Vacuum Sensor (3.0L Vehicles Only)

ItemDescription
1 Brake booster vacuum sensor
When the brake booster vacuum is low the ABS control module will raise the braking systems hydraulic pressure to
compensate for the brake boosters vacuum deficiency. This function will operate until the brake boosters vacuum has
been replenished. See Brake Vacuum Assist above.
The brake booster vacuum sensor, mounted on the brake booster, provides vacuum pressure information to the ABS
module. The sensor monitors the vacuum pressure in both chambers of the brake booster, providing vacuum pressure
values to the ABS module via hard wired connections.
The brake booster vacuum sensor receives a power feed from the ABS module, which also provides a ground path for the
sensor.
Anti-Lock Control - Stability Assist - Anti-Lock Control - Stability Assist
For a detailed description of the Anti-Lock Control - Stability Assist system, refer to the relevant Description and Operation
sections in the workshop manual. REFER to: (206-09 Anti-Lock Control - Stability Assist)
Anti-Lock Control - Stability Assist (Description and Operation),

Anti-Lock Control - Stability Assist (Description and Operation),
Anti-Lock Control - Stability Assist (Description and Operation).
vehicle.
2. 2. Confirm if the Anti-Lock Brake System (ABS) warning light was illuminated, or still is.
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 status is set to ON, the warning will not re-flag until the routine does run.
Visual Inspection
Brake fluid level Warning light operation
Vacuum system Fuses
W heel speed sensor installation Wheel speed sensors
W heel speed sensor air gap Connectors/Pins
Magnetic pulse wheel(s) (damaged/contaminated) Harnesses
Steering angle sensor Steering wheel rotation sensor
Yaw rate sensor and accelerometer cluster installation Yaw rate sensor and accelerometer cluster
Incorrect wheel or tire size Booster pressure sensor
Hydraulic Control Unit (HCU)
DTC Index
NOTE: If the Hydraulic Control Unit (HCU) is suspect and the vehicle remains under manufacturer warranty, refer to the
to the installation of a new HCU.
information read by the manufacturer-approved diagnostic system).
places and with a current calibration certificate. W hen testing resistance, always take the resistance of the DMM leads into
account.

C0021-09 Brake Booster No vacuum available from Check integrity of brake booster vacuum hose.
Performance engine due to split/leaking Check and install a new brake booster as
hose etc required
Brake booster servo has
failed due to lack of vacuum
C0030-38 Left Front Tone Left front magnetic pulse Check the left front magnetic pulse ring for
Wheel - signal ring damaged/contaminated damage or contamination. Clean or replace as
frequency incorrect Incorrect component required. If no damage/contamination found,
installed suspect wheel speed sensor. Refer to the
* Sensor internal fault Warranty Policy and Procedures manual if a
module/component is suspect. To validate the
repair and extinguish the lamps, the vehicle
needs to be driven above 9mph/15kph for more
than 10 seconds
C0031-12 Left Front W heel Electrical wiring harness Refer to the electrical circuit diagrams and check
Speed Sensor - fault the wheel speed sensor circuit for short to
short to battery Sensor internal fault power. Repair harness as required. If no harness
fault found, suspect wheel speed sensor. Refer
to the W arranty Policy and Procedures manual if
a module/component is suspect
circuit short to Sensor internal fault ground or open circuit. Repair harness as
ground or open required. If no harness fault found, suspect
wheel speed sensor. Refer to the Warranty Policy
and Procedures manual if a module/component is
suspect
Speed Sensor - fault the wheel speed sensor circuit for partial or
signal Sensor internal fault intermittently grounded signal circuit. Repair
shape/waveform harness as required. If no harness fault found,
failure suspect wheel speed sensor. Refer to the
Warranty Policy and Procedures manual if a
needs to be driven above 9mph/15kph
C0031-2F Left Front W heel Electrical wiring harness Refer to the electrical circuit diagrams and check
Speed Sensor fault the wheel speed sensor circuit for intermittent
-signal erratic Sensor internal fault short to power, ground or open circuit. Repair
harness as required. If no harness fault found,
suspect wheel speed sensor. Refer to the
Speed Sensor - no fault the wheel speed sensor circuit for open circuit or
signal Magnetic pulse ring high resistance. Check connectors for damage or
de-magnetised or damaged corrosion. Check the wheel speed sensor for
Sensor internal fault correct location and contamination. Check the
magnetic pulse wheel for contamination, damage
or de-magnetisation. Clean or replace the sensor
or wheel bearing as required. Refer to the
Speed Sensor - fault the wheel speed sensor circuit for intermittent
signal compare Sensor internal fault short to power, ground or open circuit. Repair
failure harness as required. If no harness fault found,
C0031-64 Left Front W heel Incorrect wheels/tyres Check the correct wheels and tyres are installed.
Speed Sensor - installed Refer to the electrical circuit diagrams and check
signal plausibility Electrical wiring harness the wheel speed sensor circuit for intermittent
failure fault short to power, or ground. Check for EMC
EMC influences on left front influences on the speed sensor and circuits.
wheel speed sensor and Check magnetic pulse wheel for
supply line damage/contamination and de-magnetisation.
Magnetic pulse wheel Repair Wiring harness, install a new sensor or
damaged/contaminated, wheel bearing as required. Refer to the W arranty
de-magnetised Policy and Procedures manual if a
Sensor internal fault module/component is suspect
C0032-11 Left Front wheel Electrical wiring harness Refer to the electrical circuit diagrams and check
Speed Sensor fault the wheel speed sensor circuit for short to
Supply - circuit Sensor internal fault ground. Repair harness as required. If no
short to ground harness fault found, suspect wheel speed
sensor. Refer to the Warranty Policy and
Procedures manual if a module/component is
suspect
C0033-38 Right Front Tone Right front magnetic pulse Check the right front magnetic pulse ring for
than 10 seconds
C0034-12 Right Front W heel Electrical wiring harness Refer to the electrical circuit diagrams and check
suspect
C0034-2F Right Front W heel Electrical wiring harness Refer to the electrical circuit diagrams and check
C0034-64 Right Front W heel Incorrect wheels/tyres Check the correct wheels and tyres are installed.
EMC influences on right influences on the speed sensor and circuits.
front wheel speed sensor Check magnetic pulse wheel for
and supply line damage/contamination and de-magnetisation.
Magnetic pulse wheel Repair wiring harness, install a new sensor or
suspect
C0036-38 Left Rear Tone Left rear magnetic pulse Check the left rear magnetic pulse ring for
than 10 seconds
C0037-12 Left Rear Wheel Electrical wiring harness Refer to the electrical circuit diagrams and check
suspect
C0037-2F Left Rear Wheel Electrical wiring harness Refer to the electrical circuit diagrams and check
C0037-64 Left Rear Wheel Incorrect wheels/tyres Check the correct wheels and tyres are installed.
EMC influences on left rear influences on the speed sensor and circuits.
suspect
C0039-38 Right Rear Tone Right rear magnetic pulse Check the right rear magnetic pulse ring for
frequency incorrect Incorrect component required. . If no damage/contamination found,
Sensor internal fault Warranty Policy and Procedures manual if a
than 10 seconds
C003A-12 Right Rear Wheel Electrical wiring harness Refer to the electrical circuit diagrams and check
suspect
C003A-2F Right Rear Wheel Electrical wiring harness Refer to the electrical circuit diagrams and check
C003A-64 Right Rear Wheel Incorrect wheels/tyres Check the correct wheels and tyres are installed.
EMC influences on left rear influences on the speed sensor and circuits.
C003B-11 Right Rear Wheel Electrical wiring harness Refer to the electrical circuit diagrams and check
suspect
C0047-16 Brake Booster Brake booster pressure Carry out any pinpoint test associated with this
Pressure Sensor - sensor supply circuit - DTC using the manufacturer approved diagnostic
circuit voltage voltage below threshold system. Refer to the electrical circuit diagrams
below threshold HCU failure and check brake booster pressure sensor power
supply for short to ground. Check and install a
new HCU as required, refer to the new
module/component installation note at the top
of the DTC Index
C0047-1C Brake Booster Brake booster pressure Carry out any pinpoint test associated with this
Pressure Sensor - sensor supply circuit - DTC using the manufacturer approved diagnostic
circuit voltage out voltage out of range system. Refer to the electrical circuit diagrams
of range 4.5v-5.3v and check brake booster pressure sensor power
Brake booster pressure supply for short, high resistance. Establish if
sensor failure sensor or HCU is at fault. Check and install a
HCU failure new brake booster pressure sensor or HCU as
required, refer to the new module/component
installation note at the top of the DTC Index
C0047-29 Brake Booster Brake booster pressure Carry out any pinpoint test associated with this
Pressure Sensor - sensor signal 1 circuit - DTC using the manufacturer approved diagnostic
signal invalid short to ground, power, system. Refer to the electrical circuit diagrams
open circuit and check brake booster signal 1 and 2 circuits
Brake booster pressure for short to ground, power, open circuit. Clear
sensor signal 2 circuit - DTC and re-test. If DTC remains, suspect the
short to ground, power, brake booster pressure sensor, check and install
open circuit a new sensor as required, refer to the new
Brake booster pressure module/component installation note at the top
sensor failure of the DTC Index. To validate the repair and
extinguish the lamps, start the engine and apply
the foot brake
C0047-62 Brake Booster NOTE: Fault detected during Carry out any pinpoint test associated with this
Pressure Sensor - braking event DTC using the manufacturer approved diagnostic
signal compare system. Refer to the electrical circuit diagrams
failure Brake booster pressure and check brake booster pressure sensor signal
sensor signal circuits 1 and circuits 1 and 2 for shorting together. Repair any
2 - shorted together harness faults found and retest. To validate the
repair and extinguish the lamps, start the engine
and apply the foot brake
C0047-64 Brake Booster NOTE: Fault detected during Carry out any pinpoint test associated with this
Pressure Sensor - non-braking event DTC using the manufacturer approved diagnostic
signal plausibility system. Refer to the electrical circuit diagrams
failure Signal plausibility failure and check brake booster signal 1 and 2 circuits
Electrical wiring harness for short to ground, power, open circuit or high
fault resistance. Check connectors for damage or
Brake booster pressure corrosion. Repair any harness faults found and
sensor failure retest. If DTC remains, suspect the brake
booster pressure sensor, check and install a new
sensor as required, refer to the new
of the DTC Index. To validate the repair and
extinguish the lamps, start the engine and apply
and release the foot brake
C0062-28 Longitudinal Yaw sensor insecurely Check the yaw sensor is securely mounted. If the
Acceleration Sensor mounted mounting is secure suspect the yaw sensor,
- signal bias level Yaw sensor fault Refer to the W arranty Policy and Procedures
out of range/zero manual if a module/component is suspect
adjustment failure
C0062-54 Longitudinal The longitudinal Check the longitudinal acceleration sensor has
Acceleration Sensor acceleration sensor has not been calibrated
- missing been calibrated If it has been calibrated check that the sensor is
calibration Mounting bracket aligned correctly, check for bent mounting
bent/misaligned bracket
To validate the calibration/repair, ignition on and
wait 10 seconds. Check lamps remain
extinguished
C0063-08 Yaw Rate Sensor - W iring harness fault Refer to the electrical wiring diagrams and check
bus signal Yaw sensor fault the integrity of the power and ground supplies to
/message failures the yaw sensor. Check the integrity of the bus
connections. Repair any harness faults found and
retest. If no harness faults are found suspect
the yaw sensor, Refer to the Warranty Policy and
suspect. To validate the repair, ignition on and
wait 10 seconds. Check lamps remain
extinguished.
C0063-14 Yaw Rate Sensor - W iring harness fault Refer to the electrical wiring diagrams and check
circuit short to Sensor fault the high speed CAN circuit between the yaw
ground or open sensor and the Anti-Lock Braking System
Hydraulic Control Unit for short to ground or
open circuit. Repair any harness faults found and
suspect
C0063-1C Yaw Rate Sensor - Yaw rate sensor power Refer to the electrical wiring diagrams and check
circuit voltage out distribution fault the power and ground supplies to the yaw
of range W iring harness fault sensor. Check power circuit for short to ground or
Yaw sensor internal fault open circuit. Check ground circuit for short to
power or open circuit. Repair any harness faults
found and retest. If no harness faults are found
suspect the yaw sensor, Refer to the Warranty
Policy and Procedures manual if a
module/component is suspect
To confirm the repair and extinguish the warning
lamps, clear the DTC, cycle the ignition state to
off, then return the ignition state to on and wait
up to 10 seconds
C0063-27 Yaw Rate Sensor - Yaw sensor insecurely Check the yaw sensor is securely mounted.
signal rate of mounted Check the yaw sensor harness connector is
change Yaw sensor connector securely located. Refer to the electrical wiring
insecure diagrams and check the power and ground
W iring harness fault supplies to the yaw sensor. Check circuits for
Yaw sensor fault intermittent open circuit or high resistance.
Anti-Lock Braking System Repair any harness faults found and retest. If no
Hydraulic Control Unit fault harness faults are found suspect the yaw sensor
or Anti-Lock Braking System Hydraulic Control
Unit, Refer to the W arranty Policy and
suspect
C0063-28 Yaw Rate Sensor - Yaw sensor insecurely Check the yaw sensor is securely mounted. If the
signal bias level out mounted mounting is secure suspect the yaw sensor,
of range/zero Yaw sensor fault Refer to the W arranty Policy and Procedures
adjustment failure manual if a module/component is suspect
C0063-41 Yaw Rate Sensor - Yaw sensor fault Replace the yaw sensor, clear the DTC and
checksum error Anti-Lock Braking System retest the system. If the DTC remains install a
Hydraulic Control Unit fault new Anti-Lock Braking System Hydraulic Control
Unit. Refer to the W arranty Policy and
suspect
up to 10 seconds
C0063-49 Yaw Rate Sensor - Yaw rate sensor internal Refer to the electrical wiring diagrams and check
internal electronic electronic failure the power and ground supplies to the yaw
failure W iring harness fault sensor. Repair any harness faults found and
suspect
up to 10 seconds
Anti-Lock Control - Stability Assist - Anti-Lock Brake System (ABS) Module
Removal
1. NOTE: The anti-lock braking system (ABS) module mounted to
the hydraulic control unit (HCU) cannot be serviced separately. If
the ABS module requires replacement, the unit must be replaced
as a complete assembly.
Remove the HCU.

For additional information, refer to: Hydraulic Control Unit
(HCU) (206-09, Removal and Installation).
Installation
1. Install the HCU.
For additional information, refer to: Hydraulic Control Unit
(HCU) (206-09, Removal and Installation).
Anti-Lock Control - Stability Assist - Front Wheel Speed Sensor
Removal

stands.
3. 3. NOTE: LH illustration shown, RH is similar.

5. 5. CAUTION: Note the fitted position of the
component prior to removal.
Installation

Anti-Lock Control - Stability Assist - Rear Wheel Speed Sensor
Removal
NOTE: The ignition must be switched off.
NOTE: Some variation in the illustrations may occur, but the essential information is always correct.


2. Disconnect the wheel speed sensor electrical connector.
3. CAUTION: Make sure that the harness retaining

bracket is not removed. Failure to follow this instruction may
result in damage to the harness.
NOTE: Note the orientation of the clip.
Release the wiring harness grommet.

4. CAUTION: Note the fitted position of the component
prior to removal.
Remove the wheel speed sensor.
Release the wheel speed sensor.
Installation
1. NOTE: Make sure that the component is installed to the
position noted on removal.
Tighten to 6 Nm.
Anti-Lock Control - Stability Assist - Steering Wheel Rotation Sensor
Removal

2. Refer to: Clockspring (501-20B Supplemental Restraint System,

3.
4.
Installation

Anti-Lock Control - Stability Assist - Yaw Rate Sensor and Accelerometer
Removal

2. Refer to: Parcel Shelf (501-05 Interior Trim and Ornamentation,

3. Torque: 6 Nm
4. 4. CAUTION: Make sure that all diagnostic trouble

codes (DTCs) have been removed after the road test.
NOTE: Make sure that this component is installed to

the noted removal position.
Installation

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 Dextron 3
Steering System - General Information - Steering System
For a detailed description of the steering system operation, refer to the relevant Description and Operation sections of the
Power Steering (211-02 Power Steering, Description and Operation),

Steering Linkage (211-03 Steering Linkage, Description and Operation),
Steering Column (211-04 Steering Column, Description and Operation),
Steering Column Switches (211-05 Steering Column Switches, Description and Operation),
Steering Column Switches (211-05 Steering Column Switches, Description and Operation),
Steering Column Switches (211-05 Steering Column Switches, Description and Operation).

Visual Inspection
Tire condition/pressure Fuses
Fluid level Harnesses for damage/corrosion
Leaks Electrical connector(s)
Security, condition and correct installation of suspension components Damaged/corroded pins
Security, condition and correct installation of steering system components
CAUTION: If a steering gear assembly is returned under warranty with leaking output shaft 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 output
shaft seals being damaged due to foreign materials entering the steering gear boot and damaging the steering gear
output shaft seals thereafter.
4. 4. If the concern is not visually evident, verify the symptom and refer to the symptom chart.
Symptom Charts
WARNING: It is not possible to CHECK the torque of a patchlock bolt, if the torque is suspected to be low, the bolt
must be REMOVED/DISCARDED and a new bolt MUST be INSTALLED and torque to the correct value.
NOTE: If the module or a component is suspect and the vehicle remains under manufacturer warranty, refer to the
Fluid Leakage
NOTE: Confirm the location of the fluid leak. CLEAN the area of the leak, inspect the area and confirm the exact position.
Ensure the fluid is not from another system on the vehicle.
Symptom Possible Causes Action

Overfilled system Correct the fluid level as required
Check and install new steering gear as required, refer to the

Steering gear new module/component installation note at the top of the
Symptom Charts
Damaged fluid
Power steering Check and install a new fluid cap/reservoir as required
cap/reservoir
fluid leakage
Tighten the hose connection or latch plate fixing to the
Loose or damaged recommended torque.
hoses and fittings REFER to: Specifications (211-00 Steering System - General
O-ring or Dowty Information, Specifications).
seals Check and install new components as required
Install new O-ring or Dowty seals as required
Check and install a new fluid cooler as required, refer to the
Fluid cooler new module/component installation note at the top of the
Symptom Charts
Check and install a new power steering pump as required, refer

Power steering pump to the new module/component installation note at the top of
the Symptom Charts
Functional

Check the steering alignment.
Steering wheel REFER to: Specifications (204-00
Steering not correctly centred
misalignment Suspension System - General
Check and tighten the steering

wheel retaining bolt as required.
Steering wheel loose REFER to: Specifications (211-00
Steering System - General
Check and install new

Excess play in the steering linkage
components as required
CAUTION: DO NOT attempt to

adjust the steering gear yoke. Failure to
follow this instruction will invalidate the
Steering gear not correctly adjusted steering gear warranty
(causing excessive backlash)
Check and install a new steering
gear as required, refer to the new
module/component installation
note at the top of the Symptom
Charts
Check and tighten the lower

steering column pinch bolts as
Lower steering column universal joint required.
pinch bolts loose REFER to: Specifications (211-00
Excessive free play at Check and install a new steering

steering wheel (refer to column or steering column lower
the Steering Linkage Excessive wear in steering column shaft as required, refer to the
Inspection and universal joints new module/component
Backlash (Free play) installation note at the top of
Check in this section) the Symptom Charts
Check/tighten and install new

steering gear mounting bolts as
Steering gear mounting bolts loose or required.
damaged REFER to: Specifications (211-00
Check and install new tie-rod

ends as required, refer to the
Wear in steering gear tie-rod end ball
new module/component
joints
installation note at the top of
the Symptom Charts
NOTE: Inner ball joint wear is rare. The steering

gear installed to all Jaguar vehicles has a spring
loaded pinion to ensure the correct level of
engagement between the rack and pinion. This Check and install new steering
play is optimized with the steering gear in the gear as required, refer to the new
central position and should not be confused with module/component installation
inner ball joint wear. Check for vertical motion in note at the top of the Symptom
the inner ball joint with the steering gear in the Charts
central position.
Wear in steering gear inner ball joints
Check and install new

W ear in suspension ball joints/bushings
components as required
Veer under braking Steering gear not correctly adjusted CAUTION: DO NOT attempt to
steering gear warranty

Charts
Check and rectify the source of

the contamination and install
new brake pads and discs as
Contamination of brake pads and discs required, refer to the new
Charts
Check and rectify sticking slide

pins and install new calipers as
required, refer to the new
Seized front brake caliper slide pins or note at the top of the Symptom
piston Charts
Damaged brake discs Check and install new brake discs
as required, refer to the new
Charts
For information on diagnosis of

uneven tire wear.
REFER to: Suspension System
(204-00 Suspension System -
General Information, Diagnosis
Uneven tire wear
and Testing).
Incorrect tire pressure
Check and adjust tire pressures
as required.
REFER to: Specifications (204-04
Wheels and Tires,
Specifications).
NOTE: Dealerships must keep a copy

of the BEFORE and AFTER geometry
figures with job card for future reference
Check and adjust geometry as

required. REFER to: (204-00
Suspension System - General
Incorrect geometry settings Information)
Camber and Caster
Adjustment (General
Procedures),
Front Toe Adjustment
(General Procedures),
Rear Toe Adjustment
Vehicle pulls to one (General Procedures).
side when driving on a
level surface Notify the customer of incorrect
Vehicle is unevenly loaded or overloaded
vehicle loading
CAUTION: DO NOT attempt to

steering gear warranty
Steering gear is not correctly adjusted
Charts

front suspension components as
Loose, damaged or worn front suspension required.
components REFER to: Specifications (204-00

rear suspension components as
Loose, damaged or worn rear suspension required.
components REFER to: Specifications (204-00
Noise

Check for leaks and rectify as required. For
further information refer to the symptom charts
Low power steering fluid level
for leakage in this section. Fill power steering
fluid reservoir to correct level
NOTE: Look for small air bubbles

Bleed the power steering system.
visible in the fluid, air may also get
REFER to: Power Steering System Bleeding
trapped in the hydraulic system
(211-00 Steering System - General Information,
Air in hydraulic system
Continuous noise Power steering pipe/hose in Check and reposition, or install new IF
contact with the vehicle body damaged/deformed, power steering pipe/hose
Check and clear restriction to pipe/hose

Power steering pipe/hose Reposition power steering pipe/hose. Install
restricted or twisted new pipe/hose IF permanently
damaged/deformed
Tighten the power steering pump mounting

Power steering pump bolts to the correct torque.
mounting bolts loose REFER to: Specifications (211-00 Steering
System - General Information, Specifications).
Check and fill power steering fluid reservoir to

NOTE: Refer to the power steering correct level
pressure check in this section Bleed the power steering system.
Noise gets worse REFER to: Power Steering System Bleeding
when system is Low power steering fluid level (211-00 Steering System - General Information,
loaded Aerated fluid General Procedures).
Low power steering pump Check power steering pump pressure. If the
pressure pump pressure is low, install a new power
steering pump
Front End Accessory Check FEAD belt tension

FEAD belt incorrectly
Drive (FEAD) belt Check FEAD belt condition and install a new
tensioned or glazed
squeal belt as required
Chirp noise from the Check FEAD belt tension

steering pump when Loose or worn FEAD belt Check FEAD belt condition and install a new
a load is applied belt as required
Scrape/grind noise Steering column shroud foul Correctly install the steering column shroud to
from behind steering condition or clockspring eliminate the foul condition
wheel while steering Install a new clockspring as required
Foreign objects Remove foreign objects from between steering

column shroud and steering wheel/steering
column rotating components
Click Clockspring or steering column Correctly install and install new components as
multifunction switch LH required
Loose universal joint pinch Install a new universal joint pinch bolt and
bolt tighten to correct specification.
REFER to: Specifications (211-00 Steering
Squeak Steering column shroud joints Apply Krytox spray to steering column shroud
joints
Clockspring Install new clockspring as required
Loose fixings (universal joint Tighten fixings to correct specification.

Knock pinch bolt and steering REFER to: Specifications (211-00 Steering
column fixings) System - General Information, Specifications).
Foreign objects Remove foreign objects from between steering

column shroud and steering wheel/steering
column rotating components
Rattle
Loose fixings Tighten steering column fixings to correct
specification.
REFER to: Specifications (211-00 Steering
Electric motor/solenoid NOTE: Before carrying out repairs/replacement,

Noise while adjusting assess column adjustment noise levels against other
vehicles of the same model
column
Install new components as required
Motor spindle/lead screw Lubricate lead screw
Vibration
CAUTION: DO NOT attempt to adjust the

steering gear yoke. Failure to follow this
W heel Fight (Kick Back) - Loose or worn steering instruction will invalidate the steering gear
condition where roughness is felt components/bushings warranty.
in the steering wheel by the driver
when the vehicle is driven over Tighten and install new steering
rough surfaces components/bushings as required
Loose or worn suspension Tighten and install new suspension

components/bushings components/bushings as required
Check for wheel and tire damage.

Nibble (Shimmy) - condition where Road wheel and tire Install new components as required
oscillation of the steering wheel condition Check for tire uniformity. Install new
occurs (not vertical which is tire(s) as required
Shake). This is driven by road
wheel imbalance Check and adjust road wheel balance
Road wheel imbalance
as required
NOTE: Vibration smooths out Ensure tires installed are to Jaguar

Shake - condition where vertical
after several miles of driving specification. Install new tires as
vibration of the steering
required
wheel/column occurs (not
Road wheel imbalance due Check and adjust tire pressures to
oscillation which is Nibble) to tire flat-spotting correct specification
Component Tests
Steering Linkage Inspection and Backlash (Free play) 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 required.
NOTE: The following steps must be carried out with assistance.
1. 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.
2. 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.
CAUTION: DO NOT attempt to adjust the steering gear yoke. Failure to follow this instruction will invalidate the
steering gear warranty.
3. 3. The backlash of the steering gear cannot be adjusted, install a new steering gear if excessive backlash is
diagnosed.
4. 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.
Power Steering Fluid Condition Check
1. 1. Run the engine for 2 minutes.
2. 2. Check the power steering fluid system level.
3. 3. Observe the color and the odor. The color under normal circumstances should be dark reddish, not brown or
black.
4. 4. Using a suitable clean syringe extract a suitable amount of fluid from the reservoir.
5. 5. Allow the fluid to drip onto a facial tissue and examine the stain.
6. 6. If evidence of solid material is found, the power steering fluid system should be drained for further inspection.
7. 7. 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.
Power Steering Pressure Test
Test Equipment
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 to check the system pressure.
With the control valve (7) OPEN and the engine idling, the following system pressures may be checked:
During turning when static (dry parking pressure).

When the steering is held on full lock (maximum system pressure or pressure relief).
With the steering at rest (idle pressure or back pressure).
CAUTIONS:
To avoid excessive heating of the power steering pump when checking the pressure, do not close the valve for more
than 5 seconds maximum.
W hen checking the pump pressure 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.
REFER to: Power Steering System Bleeding (211-00 Steering System - General Information, General Procedures).
Description of Terms
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
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 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.
Whirr/Whine
High-pitched buzzing sound, like an electric motor or drill.

Whistle
Sharp, shrill sound, like wind passing a small opening.
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 full 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 tests 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. It is generally caused by interference
between moving components such as the steering wheel to steering column shroud.
Grunt (Squawk/Whoop)
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 loud 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.
Steering Gear Knock (Steering Gear Slap)
CAUTION: DO NOT attempt to adjust the steering gear yoke. Failure to follow this instruction will invalidate the
steering gear warranty.
Steering gear knock is a rattle sound and steering wheel vibration caused by separation of the steering gear and pinion
while driving over bumps. It is a structure-borne noise transmitted through the intermediate shaft and column. Steering
gear 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 of 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 components,
movable and flexible components, 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.
Weep
Weep is an air-borne noise, occasionally generated when turning the steering across lock at a constant rate. W hen 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 when steering inputs are slow. 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 (PW M) 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/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 suspension 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 System - General Information - Power Steering System Bleeding
General Procedures
1. Clean power steering fluid reservoir around the filler cap and
fluid indicator.
Check the power steering fluid, if aerated, wait until fluid

is free from bubbles then top-up reservoir to UPPER level
mark with recommended fluid.
2. CAUTION: Fluid must always be present in the reservoir

during bleeding.
Remove the filler cap and fill to the MAX level mark.
Install the reservoir filler cap.
3. Start the engine and allow to run for 10 seconds, stop the
engine.
Check the power steering fluid, if aerated, wait until fluid

is free from bubbles then top-up reservoir to UPPER level
mark with recommended fluid.
4. CAUTION: Do not hold steering on full lock for longer

than 10 seconds.
Start the engine and turn steering fully lock to lock, stop the
engine.
Check and top-up power steering fluid level.
5. Start and run the engine for 2 minutes, turn the steering fully
lock to lock.
Check and top-up power steering fluid level.

Power Steering - Power Steering - Component Location
POWER STEERING - COMPONENT LOCATION 2.7L TdV6
ItemDescription
1 Tie-rod end (2 off)
2 Power steering pump
3 Power steering fluid reservoir
4 Feed pipe to pump
5 Low pressure fluid return hose
6 Servotronic transducer valve
7 High pressure feed pipe to steering gear
8 Valve unit
9 Tie-rod (2 off)
10 Mounting bolt (3 off)
11 Steering gear
POWER STEERING - COMPONENT LOCATION 3.0L V6
ItemDescription
1 Power steering fluid cooler
3 Tie-rod (2 off)
7 Feed pipe to pump
10 Valve unit
12 Steering gear
POWER STEERING - COMPONENT LOCATION 4.2L V8
ItemDescription
NOTE: Naturally aspirated 4.2L V8 shown, Supercharged 4.2L V8 similar
1 Power steering fluid cooler
3 Tie-rod (2 off)
7 Feed pipe to pump
10 Valve unit
12 Steering gear
Power Steering - Power Steering - Overview
OVERVIEW
The steering system comprises a ZF manufactured rack and pinion Servotronic 2 steering gear, a power steering pump, a
fluid reservoir, a fluid cooler (if fitted) and fluid hoses. The steering gear is an end take-off rack and pinion power assisted
unit with the addition of road speed proportional ZF Servotronic 2 assistance.
The steering rack is connected to the front wheel knuckles by adjustable tie-rods. The tie-rods allow for adjustment to
centralize the steering wheel and also adjust the toe setting of the front wheel geometry.
The steering gear has a variable ratio rack. This provides conventional response when the steering is in the centre,
straight ahead position, but provides more direct and faster steering as the turning angle increases. The variable ratio
provides precise and rapid steering response at high speeds and provides optimized steering of the vehicle when
manoeuvring into parking spaces, turning in tight areas and when cornering in extreme conditions.
Fluid is supplied to the steering gear by a fixed displacement vane pump on petrol models and a variable displacement
pump on diesel models. The pump is driven by a belt from the crankshaft pulley. The pump is mounted on the LH
(left-hand) side of the engine, above the A/C (air conditioning) compressor. A fluid reservoir is positioned at the front LH
side of the engine compartment, forward of the front suspension housing.
On petrol engine vehicles, a fluid cooler is located in front of the engine cooling radiator. Diesel models do not have a fluid
cooler.
Servotronic 2 adds electronic control and speed sensitive steering to the steering gear. The Servotronic 2 feature provides
easy and comfortable steering operation when parking, improved 'road feel' at increased road speeds and adds an
integrated, positive center feel feature which optimises steering wheel torque during high speed driving. The Servotronic 2
system is controlled by software which is incorporated into the instrument cluster. The software responds to road speed
signals and controls the power assistance via a transducer valve located on the steering gear valve housing.
Power Steering - Power Steering - System Operation and Component
Description
System Operation
The following hydraulic circuits show power steering operation and fluid flow for the steering in a straight ahead, neutral
position and when turning right. The circuit diagram for turning left is similar to that shown for turning right.
Power Steering in Neutral Position
ItemDescription
1 Return fluid control groove
2 Radial groove
3 Feed fluid control groove
4 Radial groove
5 Axial groove
6 Feed fluid control edge
7 Feed fluid radial groove
8 Return fluid control edge
9 Return fluid chamber
10 Cut-off valve
11 Radial groove
14 Radial groove
15 Orifice
16 Balls
17 Compression spring
18 Torsion bar
20 Valve rotor
21 Reaction piston
22 Reaction chamber
23 Centering piece
24 Pressure relief/flow limiting valve
26 Inner tie-rod
27 Pinion
28 Valve sleeve
29 Steering gear rack
30 Steering gear housing
31 Power assist cylinder - right
32 Piston
33 Power assist cylinder - left
When the engine is started, the power steering pump draws fluid from the reservoir down the low pressure suction line.
The fluid passes through the pump and is delivered at pressure, via a hose, to the steering rack valve unit.
The pressurized fluid flows through a connecting bore in the valve and, via the feed fluid radial groove and the transverse
bores in the valve sleeve, passes to the feed fluid control groove of the valve rotor.
In the neutral (straight ahead) position , the fluid passes over the open feed fluid control edges to all valve sleeve axial
grooves. The fluid then passes through return fluid control edges and the return fluid grooves of the valve rotor, back to
the reservoir passes via the fluid cooler.
Simultaneously, the radial grooves of the valve and their associated pipes provide a connection the left and right power
assist cylinders.
Power Steering in Right Turn Position
ItemDescription
1 Return fluid control groove
2 Radial groove
3 Feed fluid control groove
4 Radial groove
5 Axial groove
6 Feed fluid control edge
8 Return fluid control edge
10 Cut-off valve
11 Radial groove
14 Radial groove
15 Orifice
16 Balls
18 Torsion bar
20 Valve rotor
21 Reaction piston
22 Reaction chamber
23 Centering piece
24 Pressure relief/flow limiting valve
26 Inner tie-rod
27 Pinion
28 Valve sleeve
29 Steering gear rack
30 Steering gear housing
31 Power assist cylinder - right
32 Piston
33 Power assist cylinder - left
When the steering wheel is turned to the right, the steering rack and piston moves to the left in the piston bore. The
valve rotor is rotated to the right (clockwise) and pressurized fluid is directed over the further opened feed fluid control
edges and to the associated axial grooves, the radial groove and via an external pipe to the left power assist cylinder
chamber. The pressure applied to the piston from the left power assist cylinder chamber provides the hydraulic assistance.
An adaptable pressure build-up is achieved by the partially or fully closed feed fluid control edges restricting or preventing
a connection between the fluid pressure inlet and the other axial grooves connected to the radial groove.
Simultaneously, the fluid pressure outlet to the pressurized axial grooves are restricted or partially restricted by the
closing return fluid control edges. The fluid displaced by the piston from the right power assist cylinder chamber, flows
through an external pipe to the radial grooves. From there the fluid passes to the associated axial grooves and on to the
return fluid control grooves, via the further opened return fluid control edges.
The return flow of fluid to the reservoir passes via interconnecting bores which lead to the return fluid chamber. When the
steering wheel is turned to the left the operating sequence is as above but the pressure is applied to the opposite side of
the piston.
Servotronic Operation
The Servotronic software contains a number of steering maps which are selected via the car configuration file depending on
the vehicle mode and tire fitment.
If a failure of the Servotronic valve or software occurs, the system will suspend Servotronic assistance and only normal
power steering wheel be available. Fault codes relating to the fault are stored, but no warning lamps are illuminated and
the driver may be aware of the steering being 'heavier' than usual.
When the vehicle is manoeuvred into and out of a parking space (or other similar manoeuvre), the Servotronic software
uses road speed data from the ABS module to determine the vehicle speed, which in this case will be slow or stationary.
The Servotronic software analyses the signals and outputs an appropriate control current to the Servotronic transducer
valve. The Servotronic valve closes and prevents fluid flowing from the feed fluid radial groove to the reaction chamber. An
orifice also ensures that there is return pressure in the reaction chamber. This condition eliminates any 'reaction' ensuring
that the steering is very light to operate, reducing the effort required to turn the steering wheel.
As the vehicle is driven and the road speed increases, the Servotronic software analyses the road speed signals from the
ABS (anti-lock brake system) module and reduces the amount of control current supplied to the Servotronic valve which
increases the reaction pressure. This modifies the input torque applied through the steering wheel and provides the driver
with an improved 'road feel' allowing precise steering and directional stability.
Steering Gear
ItemDescription
1 Locknut ( 2 off)
2 RH (right-hand) tie-rod
3 Steering gear boot (2 off)
4 Steering gear
5 Bolt and washer (3 off)
6 Servotronic valve
7 Valve unit
8 Input shaft
9 LH (left-hand) tie-rod
10 Steering gear mounting bushes
The steering gear is located at the rear of the engine and attached to the front sub-frame. The gear is secured to the
sub-frame with 3 bolts and washers which screw into threaded tubes in bushes which are integral with the sub-frame.
The steering gear comprises an aluminum, cast, valve housing which contains the hydraulic valve unit and Servotronic
valve. The mechanical steering rack and the hydraulic actuator are located in a steel cylinder which is attached to the cast
valve housing.
The steering gear uses a rack with an integrated piston which is guided on plain bearings within the cylinder and the valve
housing. The pinion, which is attached to the valve unit, runs in bearings and meshes with the rack teeth. The rack is
pressed against the pinion by a spring loaded yoke which ensures that the teeth mesh with the minimum of play. The
pinion is connected to the valve unit via a torsion bar. The rotary motion of the steering wheel is converted into linear
movement of the rack by the rack and pinion mechanism and is initiated by the valve unit. This movement is transferred
into movement of the road wheels by adjustable tie-rods.
The rack teeth angles vary from 20 degrees in the centre position to 40 degrees at the end sections of the rack. It is this
variation in teeth angles which provides the variable ratio.
The piston of the hydraulic actuator is located on the rack bar. Each side of the piston is connected to fluid pressure or
fluid return via external metal pipes which are connected to the valve unit.
Each end of the rack bar has a threaded hole which provides for the fitment of the tie-rod. The external ends of the gear
are sealed with boots which prevent the ingress of dirt and moisture. The tie-rod has a long threaded area which allows for
the fitment of the tie-rod end. The thread allows for the adjustment of the steering toe. W hen the correct toe setting is
achieved, a locknut is tightened against the tie-rod end preventing inadvertent movement.
The gear has a central hole machined along most of its length. The hole allows the air in the boots to be balanced when
the steering is turned. The boots are serviceable items and are retained on the gear housing and the tie-rod with clips.
Valve Unit
ItemDescription
1 Pressure/return to/from steering gear
3 Cut-off valve
4 Radial groove
6 Fluid feed radial groove
7 Radial groove
8 Orifice
9 Balls
11 Torsion bar
12 Valve rotor
13 Reaction piston
14 Reaction chamber
15 Centering piece
16 Return to reservoir
17 Pressure supply from pump
18 Pinion
19 Steering gear rack bar
20 Valve sleeve
The valve unit is an integral part of the steering gear. The principle function of the valve unit is to provide power
assistance (i.e. when parking) to optimize the effort required to turn the steering wheel.
The pinion housing of the valve is an integral part of the main steering gear casting. The pinion housing has four machined
ports which provide connections for pressure feed from the power steering pump, return fluid to the reservoir and pressure
feeds to each side of the cylinder piston.
The valve unit comprises an outer sleeve, an input shaft, a torsion bar and a pinion shaft. The valve unit is co-axial with
the pinion shaft which is connected to the steering column via the input shaft. The valve unit components are located in
the steering gear pinion housing which is sealed with a cap.
The outer sleeve is located in the main bore of the pinion housing. Three annular grooves are machined on its outer
diameter. PTFE (polytetrafluoroethylene) rings are located between the grooves and seal against the bore of the pinion
housing. Holes are drilled radially in each annular groove through the wall of the sleeve. The bore of the outer sleeve is
machined to accept the input shaft. Six equally spaced slots are machined in the bore of the sleeve. The ends of the slots
are closed and do not continue to the end of the outer sleeve. The radial holes in the outer sleeve are drilled into each
slot.
The input shaft has two machined flats at its outer end which allow for the attachment of the steering column
intermediate shaft yoke. The flats ensure that the intermediate shaft is fitted in the correct position. The inner end of the
input shaft forms a dog-tooth which mates with a slot in the pinion shaft. The fit of the dog-tooth in the slot allows a
small amount of relative rotation between the input shaft and the pinion shaft before the dog-tooth contacts the wall of
the slot. This ensures that, if the power assistance fails, the steering can be operated manually without over stressing the
torsion bar. The central portion of the input shaft has equally spaced longitudinal slots machined in its circumference. The
slots are arranged alternately around the input shaft.
The torsion bar is fitted inside the input shaft and is an interference fit in the pinion shaft. The torsion bar is connected to
the input shaft by a drive pin. The torsion bar is machined to a smaller diameter in its central section. The smaller
diameter allows the torsion bar to twist in response to torque applied from the steering wheel in relation to the grip of the
tyres on the road surface.
The pinion shaft has machined teeth on its central diameter which mate with teeth on the steering gear rack. A slot,
machined in the upper end of the pinion shaft mates with the dog-tooth on the input shaft. The pinion shaft locates in the
pinion housing and rotates on ball and roller bearings.
Servotronic Valve
The Servotronic transducer valve is located in a port in the side of the steering gear valve housing. The valve is sealed in
the housing with an O-ring seal and is secured with two long screws into threaded holes in the housing. The Servotronic
valve is a transducer controlled valve which responds to control signals supplied from Servotronic software in the
instrument cluster.
The Servotronic valve determines the hydraulic reaction at the steering gear rotary valve and controls the input torque
required to turn the steering wheel. The Servotronic system allows the steering to be turned with the optimum effort when
the vehicle is stationary or manoeuvred at slow speed. The hydraulic reaction changes proportional to the vehicle speed,
with the required steering effort increasing as the vehicle moves faster. At high speeds, the Servotronic system provides
the driver with a good feedback through the steering providing precise steering and improved stability.
The instrument cluster receives road speed signals from the ABS module and calculates the correct controlling signal for
the Servotronic valve. The Servotronic software within the instrument cluster has a diagnostic capability which allows a
Jaguar approved diagnostic system to check the tune of the steering and retrieve fault codes relating to the Servotronic
valve. Two fault codes are stored relating to the valve for positive connection short to ground or battery and negative
connection short to ground or battery.
The Servotronic software within the instrument cluster also contains a number of steering maps which are selected via the
car configuration file depending on the vehicle model and tire fitment.
If a failure of the Servotronic valve or software occurs, the system will suspend Servotronic assistance and only a default
level of assistance will be available. Fault codes relating to the fault are stored in the instrument cluster. No warning
lamps are illuminated and the driver may be aware of the steering being 'heavier' than usual.
Power Steering Pump - V6 and V8 Petrol Models

NOTE: V8 pump shown
The power steering pumps used on the different petrol engine variants are basically the same pump with different flow
control valve mechanisms. The pump is a positive displacement, vane type pump which supplies a constant fluid flow to
the steering gear valve unit. The pump is driven by a Poly Vee belt from the crankshaft pulley. A self-adjusting tensioner is
fitted to maintain the correct tension on the belt.
The pump has an internal pressure relief valve and a flow control valve. The pressure relief valve limits the maximum
pressure supplied to the steering gear to 110 bar (1595 lbf in2) 4 bar (58 lbf in2). The flow control valve limits the
maximum flow to 7.5 l/min (1.64 gal/min) 0.75 l/min (0.16 gal/min) regardless of engine speed. The pump has a
displacement of 10.5 cm3/rev (0.64 in3/rev).
A shaft runs longitudinally through the pump. One end of the shaft is fitted with a pressed-on drive pulley, the opposite
end of the shaft is closed by a cover. The shaft runs in bearings located in the body and oil seals at each end of the shaft
prevent leakage of hydraulic fluid. The pump contains ten vanes which rotate within a cam ring and are driven by the shaft.
As the vanes rotate, the cam ring causes the space between the vanes to increase. This causes a depression between the
vanes and fluid is drawn from the reservoir via the suction hose into the space between the vanes.
As the shaft rotates, the inlet port is closed to the vanes which have drawn in fluid, trapping the fluid between the vanes.
The cam ring causes the space between the vanes to reduce and consequentially compresses and pressurises the hydraulic
fluid trapped between them.
Further rotation of the shaft moves the vanes to the outlet port. As the vanes pass the port plate the pressurized fluid
passes from the pump outlet port into the pressure hose to the steering gear.
The pressurized fluid is subject to control by the flow control and pressure relief valve. The flow control valve maintains a
constant flow of fluid supplied to the steering gear irrespective of engine speed variations. The pressure relief valve limits
the maximum pressure on the output side of the pump. A metering orifice is included in the discharge port of the pump. If
the pressure in the orifice reaches a predetermined level, a spring loaded ball in the centre of the flow control valve is
lifted from its seat and allows pressurized fluid to recirculate within the pump.
The pressure relief valve will operate if the discharge from the pump is restricted, i.e.; steering held on full lock. If the
output from the pump is blocked, all output is recirculated through the pump. In this condition, as no fresh fluid is drawn
into the pump from the reservoir, the fluid temperature inside the pump will increase rapidly. Consequentially, periods of
operation of the steering gear on full lock should be kept to a minimum to prevent overheating of the pump and the fluid
within it.
Power Steering Pump - 2.7L V6 Diesel Models
A variable displacement power steering pump is used on the diesel engine variants. The variable displacement, vane type
pump supplies the required hydraulic pressure to the steering gear valve unit. The pump is located at the front of the
engine and is driven by the FEAD (front end accessory drive) Poly Vee belt which is directly driven from the crankshaft. The
output from the pump increases proportionally with the load applied to the steering valve unit.
ItemDescription
1 Power steering fluid inlet port
2 Flow control valve
3 Power steering fluid outlet port
4 Variable Orifice
5 Pump rotor
6 High pressure
7 Adapter ring
8 Cam Ring
9 Low pressure
The pump consists of a shaft containing a number of slots into which vanes are inserted and these vanes run within a cam
ring in the pump body. The centerline of the shaft is not concentric with that of the bore of the body and this creates the
expanding and contracting cavities that form the pumping action.
The vanes rotate within the cam ring and are driven by the shaft. As the vanes rotate, the cam ring causes the space
between the vanes to increase. This causes a depression between the vanes and fluid is drawn from the reservoir via the
suction hose into the space between the vanes. As the shaft rotates, the inlet port is closed to the vanes which have
drawn in fluid, trapping the fluid between the vanes. The cam ring causes the space between the vanes to reduce and
consequentially compresses and pressurizes the hydraulic fluid trapped between them. Further rotation of the shaft moves
the vanes to the outlet port. As the vanes pass the port plate the pressurized fluid passes from the pump outlet port into
the pressure hose to the steering gear.
The cam ring in the pump body can move within the valve body. By moving the cam ring it is possible to vary the
eccentricity of the shaft and the vanes in relation to the cam ring. As the eccentricity is decreased, the volume of hydraulic
fluid trapped between the vanes decreases, maintaining the flow in response to pump speed. This reduces the load
required to turn the pump and therefore improves engine output and economy. This allows the flow rate to be matched to
the system demands and increased flow rate is only required when the steering wheel is turned.
The pump has an internal regulating valve which controls the eccentricity of the cam ring and therefore varies the flow rate
according to demand. The regulating relief valve limits the maximum pressure supplied to the steering gear to 110 bar
(1595 lbf in2) 4 bar (58 lbf in2) and also limits the maximum flow to 8.5 l/min (1.86 gal/min) 0.5 l/min (0.1 gal/min)
regardless of engine speed.
Fluid Reservoir
ItemDescription
1 Bolt and washer (2 off)
2 Rubber mounting (2 off)
3 Cap
4 Reservoir body
5 Return connection
6 Suction hose connection
7 Max/Min level
8 Lanyard
The reservoir is located in the engine compartment, on the LH suspension housing. The reservoir is attached to a bracket
via 2 rubber mounts, and the bracket is attached to the suspension housing.
The reservoir is a plastic moulding with an integral 80 micron, non-serviceable filter. Two moulded ports at the base of the
reservoir provide for attachment of the fluid supply hose to the power steering pump and fluid return hose from the fluid
cooler. The reservoir is fitted with a removable cap which is screwed 1/4 turn to lock into the reservoir body.
The reservoir has upper and minimum marks moulded on its outside of the body.
Fluid Cooler
ItemDescription
A V8 naturally aspirated and 3.0 V6
B V8 supercharged
1 Fluid cooler
2 Hose - return to fluid reservoir
3 Hose - Return from steering gear valve unit
The fluid cooler is located in the return circuit from the steering gear to the reservoir. The cooler is an aluminum fin and
tube design. Cool air entering the front of the vehicle passes over the cooler and flows through the fins. The fins act as
heat exchangers, conducting heat from the fluid as it passes through the tube.
Power Steering - Power Steering

REFER to: Specifications (211-00 Steering System - General Information, Specifications).
Power Steering - Steering Gear
Removal
CAUTIONS:
Do not turn the steering wheel with the steering column lower shaft disconnected as damage to the clockspring and
steering wheel switches may occur.
NOTE: Make sure the steering is in the straight ahead position.

stands.

2. Center the steering wheel.
Lock in position and remove the ignition key.
3. Remove the front wheels and tires.

5. Make sure the alignment mark, on the steering gear pinion
seal protection cover, is central to the steering gear pinion
casting.
6. Release both track rods from tie rod ends, note the number
of turns for installation.
7. Disconnect the power steering control valve actuator

electrical connector.
8. CAUTION: Air tools MUST NOT be used on steering

column bolts.
Disconnect the lower steering column from the steering gear.
Remove and discard the bolt.
9. Release the power steering line support bracket.
10. CAUTIONS:
Before disconnecting or removing the components,

ensure the area around the joint faces and connections are
clean and dry. Plug open connections to prevent
contamination.
Cap the power steering line to prevent loses of fluid and

dirt ingress.
If power steering fluid is spilt on the paintwork, the

effected area must be immediately washed down with cold
water. Failure to follow this instruction may result in damage
to the vehicle.
NOTE: Some fluid spillage is inevitable during this operation.
Disconnect the power steering feed and return fluid lines

from the steering gear.
Remove the bolt.

Position a container to collect spillage.
Remove and discard both O-ring seals.
11. Remove the steering gear.
Remove the 3 bolts.
NOTE: Do not disassemble further if the component is

Remove the outer tie-rod end, note the number of turns for
installation.
Loosen the tie-rod end lock nut.
Installation
2. Install the tie rod end, note the number of turns until
adjacent to the locknut.
3. Tighten the bolts to 100 Nm.

4. NOTE: Make sure that all the component mating faces are
clean.
Tighten to 24 Nm.
Install the new O-ring seals.
Install a new retaining bolt.
6. Fill and bleed the power steering system.

For additional information, refer to: Power Steering System
Bleeding (211-00 Steering System - General Information,
Procedures).
Power Steering - Power Steering Fluid Cooler3.0L NA V6 - AJ27/4.2L NA V8
- AJV8/4.2L SC V8 - AJV8
Removal
1. For additional information, refer to: Power Steering System

2. For additional information, refer to: Radiator Splash Shield

stands.

4.
5.
6. TORQUE: 10 Nm
7.
Installation
Power Steering - Power Steering Fluid Reservoir
Removal
1. For additional information, refer to: Battery Disconnect and

Procedures).
2. For additional information, refer to: Air Cleaner (303-12 Intake
Air Distribution and Filtering - 2.7L Diesel, Removal and
Installation).
3. For additional information, refer to: Power Steering System
4. Torque: 8 Nm
5.
Installation
Power Steering - Power Steering PumpTDV6 2.7L Diesel
Special Tool(s)
303-703
W rench, Accessory Belt Tensioner
Removal
1. Refer to: Battery Disconnect and Connect (414-01, General Procedures).
2. Raise and support the vehicle.
3. Refer to: Engine Cover - 2.7L Diesel (501-05, Removal and Installation).
4. Refer to: Air Cleaner (303-12, Removal and Installation).
5. Refer to: Air Deflector (501-02, Removal and Installation).
6.
Using the special tool , rotate the accessory drive belt tensioner
counter-clockwise.
Special Tool(s): 303-703

Detach the accessory drive belt.
7.
8. 8. CAUTIONS:
Ensure any open connections are plugged to prevent

contamination.
If power steering fluid comes into contact with the paintwork, the
affected area must be immediately washed down with cold water.
NOTE: Remove and discard the O-ring seal.
Torque: 22 Nm
9. Torque: 25 Nm
10.
11. 11. CAUTIONS:
Ensure any open connections are plugged to prevent

contamination.
Installation
1. 1. CAUTION: A new O-ring seal is to be installed.
NOTE: Lubricate the O-ring seal.
2. Refer to: Power Steering System Bleeding (211-00, General Procedures).

Power Steering - Power Steering PumpV6 3.0L Petrol
Special Tool(s)
303-703
Removal
1. Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables,
2. Refer to: Air Cleaner (303-12B Intake Air Distribution and Filtering - V6 3.0L Petrol,
4. 4. WARNING: Do not work on or under a vehicle supported only by a jack.

Always support the vehicle on safety stands.
5.
6. 6. CAUTION: Always plug any open connections to prevent
contamination.
7. 7. WARNING: Fluid loss is unavoidable, use absorbent cloth or a

container to collect the fluid.
CAUTION: Always plug any open connections to prevent

contamination.
Torque: 25 Nm
8. Torque: 25 Nm
Installation
2. Refer to: Power Steering System Bleeding (211-00 Steering System - General
Information, General Procedures).
Power Steering - Power Steering Pump4.2L NA V8 - AJV8
Special Tool(s)
Accessory belt tensioner
303-703
Removal
Procedures).
2. Remove the air cleaner assembly.
For additional information, refer to: Air Cleaner (303-12A
Intake Air Distribution and Filtering - 4.2L NA V8 - AJV8,
3. Release the accessory drive belt.
Using the special tool 303-703, rotate the accessory

drive belt tensioner counter-clockwise.


5. Remove the splash shield.
Disconnect the high pressure line from the power steering

pump.
Remove and discard the O-ring seal.
7. WARNING: Fluid loss is unavoidable, use absorbent

cloth or a container to collect the fluid.

contamination.
Disconnect the low pressure line from the power steering

pump.
Release the clip.
8. Remove the power steering pump.
Remove the 4 bolts.
Installation
1. Install the power steering pump.
Tighten to 25 Nm.
2. Connect the high pressure line.
Install a new O-ring seal.
3. Connect the low pressure line.
Secure with the clip.

4. Install the accessory drive belt.
Using the special tool 303-703, rotate the accessory

drive belt tensioner counter-clockwise.
5. Install the splash shield.
6. Install the air cleaner assembly.

For additional information, refer to: Air Cleaner (303-12A
7. Check and top-up power steering fluid level.
For additional information, refer to: Power Steering System
Procedures).
Steering Linkage -
Tie-rod end retaining nut 133 98 -
Tie-rod end lock nut 55 41 -
Steering Linkage - Steering Linkage - Component Location
STEERING LINKAGE COMPONENT LOCATION
ItemDescription
1 Steering gear boot
2 Inner tie-rod arm
3 Locknut
4 Outer tie-rod arm
5 Taper ball joint
6 Locknut
Steering Linkage - Steering Linkage - Overview
OVERVIEW
The steering linkage comprises the tie rod which provides the connection between the steering gear and the front wheel
knuckle. Each end of the steering gear has a threaded hole which provides for the fitment of the inner tie rods. The
external ends of the inner tie rods are sealed with boots to prevent the ingress of dirt and moisture into the steering gear.
Steering Linkage - Steering Linkage - System Operation and Component
Description
System Operation
TIE-ROD
The threads on the tie rods allow the position of the outer tie rod to be adjusted in order to set the correct toe angle for
each front wheel.
TIE-ROD
Each tie rod comprises two parts; an inner and outer tie rod. The inner and outer tie rods are screwed into each other and
locked with a locknut to prevent inadvertent movement.
The outer tie rod incorporates a non-serviceable tapered ball joint which locates in a tapered hole in the front wheel
knuckle and is secured with a self-locking nut. The ball joint has an internal hexagonal drive which enables the joint to be
held stationary when the self-locking nut is tightened.
Steering Linkage - Steering Linkage

REFER to: Steering System (211-00 Steering System - General Information, Diagnosis and Testing).
Steering Linkage - Tie Rod End
Removal


3. Loosen the tie-rod end lock nut.
4. CAUTION: Make sure that the ball joint ball does not
rotate.
Remove and discard the tie rod end retaining nut.
5. Remove the tie-rod end, note the number of turns for

installation.
Installation
1. Install the tie rod end, note the number of turns until adjacent
to the locknut.
2. CAUTION: Make sure that the ball joint ball does not
rotate.
Connect the tie-rod end ball joint.

Install a new nut and tighten to 133 Nm.
3. Tighten the tie-rod locking nut.
4. Install the front wheel.

Procedures).
Steering Column -
Steering wheel retaining bolt 65 48 -
Steering column pinch bolt 35 26 -
Steering column retaining nuts 30* 22 -
Tilt solenoid retaining bolts 1 - 9
Telescopic solenoid retaining bolts 1 - 9
Telescopic housing retaining bolts 8 - 71
If you are re-using this fixing on a vehicle built prior to VIN N83337, then tighten to 25 Nm. If you are replacing a fixing,
then you must tighten to 30 Nm.
Steering Column - Steering Column - Component Location
ItemDescription
1 Steering wheel
2 Gear change paddle switch
3 Column adjust switch
4 Lower shroud
5 Rake adjustment housing
6 Reach adjustment housing
7 Column adjustment motor
8 Lower column - Upper collapse shaft
9 Bulkhead bearing and seal assembly
10 Lower column - Lower collapse shaft
11 Electric steering lock mechanism
12 Column mounting plate
13 Upper shroud
Steering Column - Steering Column - Overview
OVERVIEW
The steering column comprises the upper column assembly, the lower column assembly and the steering wheel. The 3
components are positively connected together to pass driver rotary input from the steering wheel to a linear output of the
steering rack.
The upper column assembly contains electrical adjustment for steering wheel reach and rake, the electric steering lock
mechanism and the steering angle sensor. Steering adjustment memory positions are stored in the driver's seat module.
The electric steering column is a standard fitment on all models. The upper column assembly contains electrical
adjustment for steering wheel reach and rake, the electric column lock mechanism and the steering angle sensor. Steering
adjustment memory positions are stored in the driver's seat module. The column also features a 'tilt away' function which
moves the steering column away from the driver allowing easier exit and entry to the vehicle.
Column adjustment is provided by a single motor for both reach and rake adjustment. Operation of the column adjustment
is controlled by a four way joystick type switch located in the column lower shroud. Column adjustment is an integral part
of the driver position memory system.
Steering Column - Steering Column - System Operation and Component
Description
Control Diagram
NOTE: A = Hardwired; D = High speed CAN bus; N = Medium speed CAN bus
ItemDescription
1 Battery
2 BJB (battery junction box) - Megafuse (175A)
4 Electric steering column lock
5 High Speed CAN (controller area network) bus to other vehicle systems
7 Rake adjustment solenoid and potentiometer
8 Reach adjustment solenoid and potentiometer
11 Steering column adjust switch
12 Driver's seat module (position memory)
System Operation
STEERING COLUMN ADJUSTMENT
Power for the column adjustment motor is supplied via a megafuse in the BJB to the CJB. A fused supply from the CJB is
passed to the instrument cluster which controls the power application to the motor.
The column adjust switch is hardwired to the instrument cluster. Up/down and in/out selections on the switch are each
passed through a resistor of differing values to the instrument cluster. The cluster monitors the output value from the
switch and operates the motor in the required direction and simultaneously energizes the required solenoid for rake or
reach adjustment. When the applicable solenoid is energized, a clutch is engaged and locates on a lead screw. The motor
rotates the lead screw and the rotational drive of the screw is transferred into linear movement of the applicable clutch to
move either the rake or reach adjustment. For reach adjustment, the lead screw drives the outer housing in or out as
required. For rake adjustment the lead screw drives a rake lever which moves the column up or down as required.
The position of the column is monitored by potentiometers which are connected to the instrument cluster. The cluster
monitors the output signal from the potentiometers to precisely control the positioning of the column in each plane.
The instrument cluster controls the memory positioning of the column via a medium speed CAN bus connection to the
driver's seat module. The driver's seat module receives information regarding the particular remote handset used to enter
the vehicle and outputs positional information relative to that stored for the handset. This information is passed to the
instrument cluster via the medium speed CAN bus which moves the column to the memorized positions.
The column logic in the instrument cluster also incorporates an entry/exit mode. When the vehicle is unlocked or the
ignition is switched off, the instrument cluster lifts the column upwards to its maximum rake position to allow the driver
more room below the steering wheel and improve access/egress of the vehicle. When the ignition is next switched on the
column will adjust to its previous position.
The electric steering column lock is controlled by the CJB and is an integral function of the passive start system.
Refer to: Anti-Theft - Passive (419-01B Anti-Theft - Passive, Description and Operation).
STEERING COLUMN
ItemDescription
1 Rake housing
3 Mounting plate
4 Rake lever
5 Crash tube
6 Distance keeper
7 Steering wheel mounting splines
8 Steering angle sensor ring
9 Crash adaptor
10 Rake lever pivot bearing (2 off)
11 Flanged locknut (4 off) - mounting to cross-beam
12 Rake solenoid
13 Rake clutch
14 Spindle
15 Reach solenoid
16 Reach clutch
18 Outer clamping yoke
19 Clamp bolt
20 Inner tube yoke
WARNING: Do not attempt to dismantle the steering column. The crash safety of the unit will be compromised.
The steering column is attached to the in-vehicle cross-beam and secured with 4 flanged lock nuts onto 4 studs integral
with the cross-beam.
Steering Column - Sectional View

ItemDescription
1 Tube and clamping yoke pivot bearing
2 Tube yoke
3 Tolerance ring
4 Locking ring
5 Axial housing
6 Rake housing
7 Tube
8 Splined shaft
9 Crash adaptor
10 Steering angle sensor ring
11 Steering wheel mounting splines
12 Upper bearing
14 Lower bearing
15 Outer clamping yoke
16 Ball (12 off)
17 Distance keeper
18 Crash tube
The column comprises a cast magnesium mounting bracket which provides the attachment to the cross-beam. Attached to
the mounting bracket is a rake lever which is attached to the mounting bracket at the lower end with two pivot bearings.
The bearings allow the rake lever to rotate upwards or downward to adjust the column rake.
The rake lever also provides for the attachment of the rake housing which can slide within the lever to provide the reach
adjustment. Within the rake housing is the axial housing which is supported on each side with 6 ball bearings which allow
the rake housing to move forward or backwards. The bearings on each side are arranged in groups of 3 bearings and are
separated by a distance keeper which allows the housing to supported on bearings along its length. W ithin the axial
housing is a tube which is supported at the upper end of the column on the upper bearing. The tube has a central splined
hole which provides for the fitment of the splined shaft. The splined shaft can slide within the tube on the splines when
the column reach is adjusted or the column collapses in a crash condition. The splined shaft also passes rotary motion
from the steering wheel through the length of the column to the outer clamping yoke which is supported on the lower
bearing.
The electric steering column lock is attached to the top of the rake lever. A lock bolt within the steering column lock
engages in one of 8 slots in the locking sleeve located at the lower end of the column preventing rotation of the steering
wheel. The locking sleeve is retained by a tolerance ring which in turn is located on the outer diameter of the tube yoke.
The tolerance ring allows a specified amount of torque to be applied to the splined shaft before it slips, preventing
damage to the column lock due to excessive force being applied to the steering wheel when the lock is engaged. The
tolerance ring is designed to slip on the splined shaft when the applied torque exceeds the fitted slip load of 200 Nm
minimum. Repeated rotation of the lock collar will reduce its slipping torque to 100 Nm minimum. The lock is controlled by
the CJB and is an integral function of the passive start system.
A steering angle sensor is located at the upper end of the steering column and is attached to the crash adaptor. The
sensor measures steering rotation via a toothed wheel located on the splined tube at the upper end of the column. The
sensor receives a power supply from the CJB and supplies 2 signals (A and B) relating to the steering rotation to the ABS
(anti-lock brake system) module. The module transmits this data on the high speed CAN bus for use by other vehicle
systems.
The steering column is adjustable electrically, for reach and rake. The adjustment mechanism comprises an electric
adjustment motor, a lead screw, a rake solenoid, a reach solenoid, a reach clutch and a rake clutch. The column
adjustment is controlled manually using a joystick switch located on the LH (left-hand) side of the column lower cowl. The
joystick can be moved forward and backward to adjust the column reach in and out and moved up and down to adjust the
rake. The switch selection energizes the adjustment motor in the applicable direction and also engages the applicable
solenoid and clutch.
When the joystick switch is rotated to the 'auto' position, the steering column will adjust to the uppermost rake position
when the ignition is switched off. It will re-adjust to the position corresponding to the memory position for the remote
handset when the ignition is switched on.
The memory function of the electric column is linked to and controlled by the driver's seat module. The module provides for
the storage of three separate memory positions which are stored against 3 individual remote handsets.
Refer to: Seats (501-10 Seating, Description and Operation).
The steering wheel locates on a splined shaft in the upper column assembly and is secured with a bolt. The steering wheel
houses the driver's airbag and switches for the audio system, gear change and speed control. A clockspring is used to
connect the steering wheel electrical components to the vehicle harness.
Two plastic shrouds are fitted to the upper column assembly. The lower shroud is fitted with an energy absorbing foam pad
to minimize leg injury in the event of an accident.
LOWER SHAFT ASSEMBLY

ItemDescription
1 Yoke
2 Upper collapse shaft
3 Flexible coupling
4 Shaft plate
5 Rivet (4 off)
6 Upper tube
7 Plastic sleeve
8 Boot
9 Bearing (4 off)
10 Teeth tube
11 Lower shaft
12 Yoke clamp bolt (2 off)
13 Bearing (4 off)
14 Lower yoke
15 Spider
16 Upper yoke
The lower shaft assembly comprises 2 splined shafts connected by a universal joint in the center.
The upper collapse shaft has a flexible couple at its upper end. The flexible coupling controls axial and torsional
movements and also assists with noise and vibration damping. The flexible coupling is fitted with a shaft plate which has
a boss with machined flats on it. The flats provide positive location on the upper column outer clamping yoke. A cut-out in
the boss allows for the fitment of a clamping bolt to secure the upper column outer clamping yoke. The cut-out ensures
that the lower shaft assembly can only be fitted in one orientation.
The upper collapse shaft is connected to the stopper plate of the flexible coupling with splines. The stopper plate is
connected to the shaft plate via the flexible coupling and is secured with rivets. The upper collapse shaft has a series of
splines which engage with the upper tube. The splines allow the upper collapse shaft to slide into the upper tube in the
event of an accident.
The upper tube is positively connected to the upper half of the yoke of the universal joint. A plastic tube is located around
the upper tube and provides for the attachment of a boot which seals the lower shaft assembly where it passes through
the vehicle bulkhead.
The yoke is attached to the teeth tube which in turn is located over the lower shaft on splines. The teeth tube is fitted
with a tolerance ring which provides resistance to movement of the splines on the lower shaft. The splines of the lower
shaft allow it to slide into the teeth tube with the tolerance ring controlling the collapse.
The lower shaft is fitted with a yoke which provides the attachment to the torsion bar of the steering valve unit.
Steering Column - Steering Column

REFER to: Steering System (211-00 Steering System - General Information, Diagnosis and Testing).
Steering Column - Steering Column
Removal

2. Refer to: Instrument Panel Lower Trim Panel (501-12 Instrument

Panel and Console, Removal and Installation).
3. Refer to: Steering Wheel Rotation Sensor (206-09 Anti-Lock Control -

Stability Assist, Removal and Installation).
4.
5.
6.
7.
8.
9. Torque: 30 Nm
10. Torque: 25 Nm
Installation

Steering Column - Steering Column Flexible Coupling
Removal


stands.
3. Refer to: Air Deflector (501-02 Front End Body Panels, Removal and
Installation).

5. 5. WARNING: Make sure that a new steering

column flexible coupling bolt is installed.
Torque: 30 Nm
6. Torque: 10 Nm
7. 7. WARNING: Make sure that a new steering
column flexible coupling bolt is installed.
Torque: 30 Nm
8.
Installation

Steering Column - Steering Wheel
Special Tool(s)
Clockspring locking tool
211-326
Removal
1. Make the SRS system safe.
For additional information, refer to: Standard Workshop
Practices (100-00 General Information, Description and
Operation).
Procedures).
3. Remove the driver air bag module.
For additional information, refer to: Driver Air Bag Module
(501-20B Supplemental Restraint System, Removal and
Installation).
Remove the steering wheel.
Disconnect the electrical connector.
Loosen, but do not fully remove the bolt.
Release the steering wheel from the spline.
Remove the bolt.
Release the electrical harness.
5. CAUTIONS:
Failing to install the clockspring special tool, may result in

damage to vehicle.
Do not dismantle the clockspring, it has no serviceable

parts and must be replaced as a complete assembly.
Do not allow the clockspring to unwind.
Install the special tool to the clockspring.

Remove the upshift and downshift paddle switches.
Remove the Torx bolt.
Release the assembly.
Repeat the procedure and remove the opposite hand.
7. NOTE: The steering wheel is shown removed for clarity.
Release the steering wheel switch assembly.
Repeat the procedure and remove the opposite hand.
8. Remove the air bag housing.
Remove the 4 Torx bolts.
Release the electrical harness.
9. Remove the air bag ground cable.
Remove the Torx screw.
Installation
1. Install the air bag ground cable.
Install the Torx screw.
2. Install the air bag housing.
Secure the electrical harness.
Tighten to 6 Nm.
3. Secure the steering wheel switch assembly.
Connect and secure the electrical connectors.
Tighten to 3 Nm.
Repeat the above procedure on the opposite hand.
4. Install the upshift and downshift paddle switches.
Connect and secure the electrical connector.
Tighten to 3 Nm.
Repeat the above procedure on the opposite hand.

5. CAUTION: Make sure that the arrow on the cassette is
centered and pointing vertically prior to the steering wheel
installation. On removal of the special tool keep the
clockspring cables taught to prevent the cassette moving from
the set position. Do not allow the clockspring to unwind.
Failure to follow this instruction may result in damage to the
component.
6. CAUTION: Check the alignment arrow is still in the

vertical position with the wheels straight ahead to make sure
that the directional indicator cancellation is central.
Install the steering wheel.
Check the clockspring is aligned.
Position the electrical harness.
Connect the electrical connector.
Tighten to 40 Nm.
7. Install the driver air bag module.

For additional information, refer to: Driver Air Bag Module
Installation).
Procedures).
Steering Column Switches - Steering Column Switches - Component
Location
STEERING COLUMN SW ITCHES COMPONENT LOCATION
ItemDescription
1 Audio and telephone switches
2 Steering column adjustment switch
3 LH (left-hand) (-) gear change paddle switch
4 Steering column multifunction switches and clockspring
5 RH (right-hand) (+) gear change paddle switch
6 Speed control switches (Adaptive Speed Control switch pack shown, non adaptive speed control switch pack similar)
Steering Column Switches - Steering Column Switches - Overview
OVERVIEW
The steering column multifunction switch is situated on the steering column and consists of the wiper switch, the turn
signal indicator/lighting switch and the trip computer switch.
The RH (right-hand) multifunction switch controls the following windshield wiper functions:
Flick wipe
Intermittent wipe
Slow speed wipe
High speed wipe
Wash/W ipe
Headlamp powerwash
Rain sensing / variable wipe selection.
The LH (left-hand) multifunction switch controls the following functions:
Turn signal indicators

Side lamps
Headlamps
Auto lamps
High/low beam
Headlamp flash
Headlamp timer
Trip computer.
The steering column adjustment switch is located in the steering column lower shroud on the LH side. The switch is a 4
position 'joystick' which controls reach and rake adjustment.
The trip button allows the driver to cycle though an option menu and also reset trip cycle mileage calculations. The trip
computer information is displayed in the instrument cluster message centre.
Steering wheel mounted switches on the LH side of the driver's airbag, control the audio and telephone functions. Switches
on the RH side of the driver's airbag, control the speed control functions.
The steering wheel has an internal heating element. This is controlled by the driver via the Touch Screen Display (TSD).
Steering Column Switches - Steering Column Switches - System Operation
Control Diagram
NOTE: A = Hardwired; N = Medium speed CAN bus; P = Fibre Optic MOST ring
ItemDescription
1 Battery
4 Heated steering wheel slip rings
5 Heated steering wheel control module
6 Steering wheel heater element
8 Steering column LH (left-hand) multifunction switch
9 Steering column RH (right-hand) multifunction switch
11 Speed control switches
12 Audio/telephone switches
13 Clockspring
14 Information and entertainment module
15 Media Oriented System Transport (MOST) ring connection to other vehicle systems
16 Medium speed CAN (controller area network) bus to other vehicle systems
System Operation
LEFT HAND MULTIFUNCTION SWITCH
Turn Signal Indicators
The instrument cluster outputs a reference voltage to the turn signal indicator switch. When the switch is in the central off
position, the voltage flows through 3 resistors which are connected in series and back to the instrument cluster which
monitors the signal and determines the turn signal indicators are off. This information is broadcast on the medium speed
CAN bus to the CJB.
When the switch is operated in the LH turn signal indicator position, the reference voltage from the instrument cluster is
routed via 1 of the resistors. The returned signal voltage is detected by the instrument cluster which outputs a message
on the medium speed CAN bus to the CJB. The CJB activates the applicable turn signal indicators until it receives an off
message from the instrument cluster.
When the switch is operated in the RH turn signal indicator position, the reference voltage from the instrument cluster is
routed via 2 of the resistors. The returned signal voltage is detected by the instrument cluster which outputs a message
on the medium speed CAN bus to the CJB. The CJB activates the applicable turn signal indicators until it receives an off
message from the instrument cluster.
Lighting Control Switch
The instrument cluster outputs 2 reference voltages to the rotary lighting control switch; one feed being supplied to the
light selection function of the switch and the second feed being supplied to the autolamp exit delay function. The switch
position is determined by instrument cluster by the change in returned signal voltage which is routed through up to 4
resistors in series depending on the selection made.
When the lighting control switch is in the off position, the reference voltage flows through 1 of the resistors. The returned
signal voltage is detected by the instrument cluster which outputs a message on the medium speed CAN bus to the CJB
that no lighting selection is made. The reference voltage to the autolamp exit delay switch is routed through 4 resistors
which is detected by the instrument cluster which outputs a message on the medium speed CAN bus to the CJB that
autolamp or exit delay has not been selected.
When the lighting control switch is in the sidelamp position, the reference voltage flows through 2 of the resistors. The
returned signal voltage is detected by the instrument cluster which outputs a message on the medium speed CAN bus to
the CJB to activate the sidelamps. The reference voltage to the autolamp exit delay switch is routed through 4 resistors
When the lighting control switch is in the headlamp position, the reference voltage flows through 3 of the resistors. The
the CJB to activate the headlamps. The reference voltage to the autolamp exit delay switch is routed through 4 resistors
When the lighting control switch is in the autolamp position, the reference voltage flows through 4 of the resistors. The
the CJB to activate the autolamp function. The reference voltage to the autolamp exit delay switch is routed through 4
resistors which is detected by the instrument cluster which outputs a message on the medium speed CAN bus to the CJB
that autolamp has been selected.
Autolamp Exit Delay
When the lighting control switch is in any of the autolamp exit delay position, the lighting control switch reference voltage
flows through 4 of the resistors. The returned signal voltage is detected by the instrument cluster which outputs a
message on the medium speed CAN bus to the CJB that autolamps has been selected.
Depending on the selected position, the reference voltage to the autolamp exit delay switch is routed through 3, 2 or 1
resistors which is detected by the instrument cluster. The cluster outputs a message on the medium speed CAN bus to the
CJB that autolamp exit delay period has been selected at 30, 60 or 120 seconds respectively.
Trip Function Button
The instrument cluster outputs a reference voltage to the trip function button. W hen the function button is pressed a
ground path is completed and a signal voltage is returned to the instrument cluster via a resistor. The returned reference
voltage is detected by the instrument cluster and performs the requested trip function.
RIGHT HAND MULTIFUNCTION SWITCH

The instrument cluster outputs 4 separate reference voltages to the following switch functions:
Wash/wipe switch
Intermittent wipe switch
Master wiper switch
Flick wipe switch.
Wash/Wipe Switch
The reference voltage is supplied to one of two resistors connected in parallel. When the switch is not being operated the
current flows through one resistor and the returned signal voltage is monitored by the instrument cluster. W hen the
wash/wipe switch is operated, a connection is made and the current flows through the second resistor. The change in
signal voltage is detected by the instrument cluster which outputs a message on the medium speed CAN bus to the CJB to
activate the wash/wipe function.
Intermittent Delay/Auto Wipe Switch
The reference voltage is supplied to the switch and can pass through up to 7 resistors, connected in series, for
intermittent delay selections and the auto wipe function.
When the rotary switch is in the auto position the reference voltage flows through 1 resistor. The returned signal voltage
is detected by the instrument cluster which determines auto wipe is selected. The instrument cluster outputs a message
on the medium speed CAN bus to the CJB to activate the auto wipe function.
With the rotary switch in one of the intermittent positions, the reference voltage is routed through up to 7 of the resistors
depending on the delay period selected. The returned signal voltage is detected by the instrument cluster which
determines selected delay period. The instrument cluster outputs a message on the medium speed CAN bus to the CJB to
activate the selected intermittent wipe function.
NOTE: The delay period for the intermittent selections can vary according to vehicle speed.
Master Wiper Switch
The reference voltage supplied from the instrument cluster to the master wiper switch. The voltage can pass through up to
4 resistors connected in series.
When the switch is in the off position, the reference voltage passes through 4 resistors and the returned voltage is
monitored by the instrument cluster. The instrument cluster outputs a message on the medium speed CAN bus to the CJB
that no wiper selections have been requested.
With the switch in the intermittent, slow wipe or fast wipe position, the reference voltage passes through 3, 2 or 1
resistors respectively. The returned signal voltage is detected by the instrument cluster which determines selected delay
period. The instrument cluster outputs a message on the medium speed CAN bus to the CJB to activate the selected wipe
function.
Flick Wipe Switch
The reference voltage is supplied to one of two resistors connected in parallel. When the switch is not being operated the
current flows through one resistor and the returned signal voltage is monitored by the instrument cluster. W hen the flick
wipe switch is operated, a connection is made and the current flows through the second resistor. The change in signal
voltage is detected by the instrument cluster which outputs a message on the medium speed CAN bus to the CJB to
activate the flick wipe function.
STEERING COLUMN ADJUSTMENT SWITCH

The instrument cluster supplies 2 reference voltages to the column adjustment switch.
The first reference voltage is supplied to the joystick switch. W hen the switch is moved to one of its 4 positions, the
switch contact is completed and the reference voltage is passed through one of 4 different resistors with different values.
The returned signal voltage is measured by the instrument cluster which determines the selected column adjust request.
The instrument cluster outputs a supply to the steering column adjustment motor and energizes the applicable clutch
solenoid to move the column to the desired position.
The second reference voltage is supplied to the auto/manual selection of the switch. When the switch is in the auto
position, the reference voltage passes directly through the switch contacts and is measured by the instrument cluster. The
instrument cluster outputs a message on the medium speed CAN bus to the driver seat module which responds with the
recorded memory position setting. The instrument cluster then activates the column adjustment motor and clutch
solenoids to move the column to the memorized position. W hen the switch is in the manual position the reference circuit
is broken. The instrument cluster detects the broken circuit and allows manual operation of the column adjustment switch
to move the column.
HEATED STEERING WHEEL

The heated steering wheel receives a battery power supply via the CJB. The heated steering wheel is controlled by the
driver using a selection on the TSD. When the driver selects the heated steering wheel to be active, the request is passed
from the TSD on the MOST ring to the information and entertainment module. The information and entertainment module
converts the message into a medium speed CAN bus message which is passed to the CJB. The CJB processes the request
and allows the battery power supply to be passed via the slip ring assembly in the steering wheel to the heated steering
wheel control module. The steering wheel module supplies power to the steering wheel heater element and also monitors
the temperature via a NTC (negative temperature coefficient) temperature sensor incorporated into the heater element.
The control module varies the power supply to the element to maintain the steering wheel rim at the optimum
temperature.
STEERING COLUMN MULTIFUNCTION SWITCHES
The steering column multifunction switches are situated on the steering column and consists of the wiper switch, the turn
signal indicator/lighting switch and the trip computer switch.
The steering column adjustment switch is located in the steering column lower shroud on the LH side. The switch is a 4
position 'joystick' which controls reach and rake adjustment.
Steering wheel mounted switches on the LH side of the driver's airbag, control the audio and telephone functions. Switches
on the RH side of the driver's airbag, control the speed control functions. For additional information, refer to:
Audio System (415-01 Information and Entertainment System, Description and Operation),
Speed Control (310-03A, Description and Operation),
Speed Control (310-03B, Description and Operation),
Two transmission paddle switches are located at the rear of the steering wheel.
Refer to: External Controls - Vehicles With: ZF 6HP26 (307-05 Automatic Transmission/Transaxle External Controls,
LH Multifunction Switch
ItemDescription
1 High beam
2 Lighting control rotary switch
3 RH turn signal indicator
4 Headlamp flash
5 LH turn signal indicator
6 Trip computer function button
The LH multifunction switch controls the following windshield wiper functions:

Side lamps
Headlamps
Auto lamps
High/low beam
Headlamp flash
Headlamp timer
Trip computer.
The switch is located in a slot in the clockspring and secured with 2 plastic clips.
RH Multifunction Switch
ItemDescription
1 Auto/intermittent rotary switch
2 Fast wipe
3 Slow wipe
4 Intermittent wipe
5 Off position
6 W ash/wipe
7 Flick wipe
The RH multifunction switch controls the following windshield wiper functions:
Flick wipe
Intermittent wipe
Slow speed wipe
High speed wipe
Wash/W ipe
Headlamp powerwash
Rain sensing / variable wipe selection.
The switch is located in a slot in the clockspring and secured with 2 plastic clips.
STEERING COLUMN ADJUSTMENT SWITCH

The column adjustment switch is located in the steering column lower shroud and held in place with a spring clip. The
switch allows the adjustment of the steering column for both reach and rake angle. The switch has an auto position which
allows the desired position of the column to be set by the driver using the driver's seat memory buttons. The column
position is automatically reset once the applicable remote handset has been detected by the vehicle security systems.
STEERING WHEEL HEATER

On certain models the rim of the steering wheel contains a heater element. Operation of the heater is selected using the
Touch Screen Display (TSD).
The heater temperature is controlled by a heated steering wheel control module located within the steering wheel. Power
for the heater element is supplied to the steering wheel via 2 contacts on the clockspring and a slip ring mounted on the
steering wheel.
Steering Column Switches - Steering Column Switches
For a detailed description of the steering column lock and switches, refer to the relevant Description and Operation section
in the workshop manual. REFER to: (211-05 Steering Column Switches)
Steering Column Switches (Description and Operation),

Steering Column Switches (Description and Operation),
Steering Column Switches (Description and Operation).
vehicle.
Visual Inspection
Switches Fuse(s)
Steering column lock Electrical connector(s)
W iring Harness
4. 4. If the cause is not visually evident, check for DTCs and refer to the DTC Index.
DTC Index
scan tool to the first five digits of the seven digit code listed to identify the fault (the last two digits give extra
account.

B100D51 Column lock Not programmed Check ignition, power and ground supplies to steering
authorisation column lock and instrument cluster. Re-synchronise ID
by re-configuring the steering column lock as a new
module
B100D62 Column lock CAN fault Check CAN network between steering column lock and
authorisation - Steering column lock fault instrument cluster. Check power and ground supplies to
signal compare Instrument cluster fault steering column lock and instrument cluster. Confirm
failure Incorrect module installed the correct modules are installed. Re-synchronize ID by
(Steering column re-configuring the steering column lock as new. Check
lock/Instrument cluster) CAN network for interference/EMC related issues
Target ID synchronisation
error following re-programming
Noise/EMC related error
B100D64 Column lock CAN fault Check CAN network to steering column lock. Check
authorisation - Steering column lock fault power and ground supplies to steering column lock and
signal plausibility Instrument cluster fault instrument cluster
failure
B100D87 Column lock CAN fault Carry out any pinpoint tests associated with this DTC
authorisation - Steering column lock fault using the manufacturer approved diagnostic system.
missing message Instrument cluster fault Check CAN network between steering column lock and
Low voltage at steering instrument cluster. Check power and ground supplies to
column lock < 8V steering column lock and instrument cluster
Steering Column Switches - Hazard Flasher Switch
Removal
1. 1. NOTE: When removing the component, some of the

clips may remain attached. These clips should be
removed and returned to their original positions in the
instrument panel.
2.
Installation

Steering Column Switches - Steering Column Multifunction Switch LH
Removal
1.
2.
3.
4.
Installation

Steering Column Switches - Steering Column Multifunction Switch RH
Removal
1.
2.
3.
4.
Installation

Steering Column Switches - Steering Column Lock Actuator
Removal

2. Refer to: Steering Column (211-04 Steering Column, Removal and

Installation).
3. Torque: 12 Nm
Installation

Engine System - General Information - Engine3.0L NA V6 - AJ27/4.2L NA
V8 - AJV8/4.2L SC V8 - AJV8
For a detailed description of the 4.2L/3.0L engines, refer to the relevant Description and Operation sections in the
Engine (303-01A Engine - 4.2L NA V8 - AJV8, Description and Operation),

Engine (303-01B Engine - 4.2L SC V8 - AJV8, Description and Operation),
Engine (303-01B Engine - 4.2L SC V8 - AJV8, Description and Operation),
Engine (303-01B Engine - 4.2L SC V8 - AJV8, Description and Operation).

Visual Inspection
Coolant leaks Fuses
Oil leaks Loose or corroded electrical connectors
Leaks in the fuel system Harnesses
Visibly damaged or worn parts Sensors
Loose or missing fixings
Symptom Chart
NOTE: If an engine is suspect, and the vehicle remains under the Manufacturers warranty refer to the Warranty Policy
and Procedure manual (section B1.2), or determine if any prior approval programme is in operation, prior to the installation
of a new engine.
NOTE: Due to the possibility of loose carbon, that has become trapped between the valve face and seat, effecting the
pressure readings, when carrying out a compression test and some cylinders are found to have low pressures, install the
spark plugs, road test the vehicle and re-test the suspect cylinders. If the correct pressures are restored, no further action
is required.
Symptom Action
All engine related issues Check ECM for Diagnostic Trouble Codes (DTCs) and refer to DTC Index. REFER to:
Electronic Engine Controls (303-14 Electronic Engine Controls - 4.2L NA V8 - AJV8/4.2L
SC V8 - AJV8, Diagnosis and Testing).
Difficult to start hot and Carry out general engine checks:

cold - Compression test. Refer to component tests in this section.
- Valve clearances
- Spark plug condition and color
Poor idle Ensure the air intake system is free from leaks
Carry out general engine checks:
- Compression test. Refer to component tests in this section.
- Valve clearances
Check for collapsed catalytic converter/blocked exhaust system
Check long and short term fuel trim datalogger signals
- Readings up to 10%: may be considered as acceptable if the readings are equal
bank to bank
- Positive readings of between 10-20%: check for air leaks in air intake system
- Negative readings of between 10-20%: check for over fuelling e.g. leaking
injectors, high fuel pressure
- Readings above 20%: check for DTCs and refer to DTC Index. REFER to: Electronic
Engine Controls (303-14 Electronic Engine Controls - 4.2L NA V8 - AJV8/4.2L SC V8 -
AJV8, Diagnosis and Testing).
Carry out a vacuum gauge check. Refer to component tests in this section
Insufficient Ensure the air intake system is free from leaks

power/Insufficient Carry out general engine checks:
compression - Compression test. Refer to component tests in this section.
- Valve clearances
Check for collapsed catalytic converter/blocked exhaust system
Check long and short term fuel trim datalogger signals
- Readings up to 10%: may be considered as acceptable if the readings are equal
Symptom Action
bank to bank
- Positive readings of between 10-20%: check for air leaks in air intake system
- Negative readings of between 10-20%: check for over fuelling e.g. leaking
injectors, high fuel pressure
- Readings above 20%: check for DTCs and refer to DTC Index. REFER to: Electronic
Engine Controls (303-14 Electronic Engine Controls - 4.2L NA V8 - AJV8/4.2L SC V8 -
Carry out a vacuum gauge check. Refer to component tests in this section
Oil consumption Carry out oil leak check followed by an oil consumption test. Refer to the component
tests in this section
If oil consumption is excessive:
Check the integrity of the engine breather system
Carry out general engine checks:
- Compression test. Refer to component tests in this section.
- Valve clearances
Noise Refer to the Special Service Messages on the Electronic Product Quality Report (EPQR)
system for sound files. If the symptom does NOT compare to any of the sound files,
contact Dealer Technical Support (DTS)
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 Ultraviolet test:
Fluorescent Oil Additive Method
1. 1. Clean the engine with a suitable cleaning fluid (brake cleaner).
2. 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.
3. 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.
4. 4. As necessary, pressurize the main oil gallery system to locate leaks due to incorrectly sealed, loose or cocked
plugs. If the flywheel bolts leak oil, look for sealer on the threads.
5. 5. Repair all leaks as necessary.
Compression Test
General Remarks
NOTE: Removing fuses and disconnecting electrical components may cause the Engine Control Module (ECM) to log
Diagnostic Trouble Codes (DTCs). After the measurements have been carried out, DTCs should be cleared from memory by
connecting to the Manufacturer Approved Diagnostic System.
NOTE: Only check the compression pressure with the valves set to the prescribed clearance (if this can be adjusted).
The compression pressure should be checked with the engine at normal operating temperature.
Check the Compression Pressure
WARNING: Move gear selector lever to 'P' position. Failure to follow this instruction may result in personal injury.
1. 1. Remove the fuel pump relay.
2. 2. Start the engine - the engine will start, run for a few seconds then stall.
3. 3. Remove the spark plugs.
4. 4. Install the compression tester.
5. 5. Install an auxiliary starter switch in the starting circuit. W ith 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.
6. 6. Repeat the test on each cylinder, cranking the engine approximately the same number of compression strokes.
7. 7. Install the removed components in reverse order, observing the specified tightening torques.
8. 8. Clear all DTCs from the ECM.
Interpretation of the Results

NOTE: Due to the possibility of loose carbon that has become trapped between the valve face and seat effecting the
pressure readings, when carrying out a compression test and cylinders are found to have low pressures, install the spark
plugs, road test the vehicle and re-test the suspect cylinders. If the correct pressures are restored, no further action is
required.
The indicated compression pressures are considered within specification if the lowest reading cylinder is within 75% of the
highest reading.
If the cylinder pressures are found to be low, carry out a leakdown test to determine the location of the fault (if any
leakback can be heard through the engine breather system suspect the piston rings, if any leakback can be heard through
the inlet system suspect the inlet valve or seat, if any leakback can be heard through the exhaust manifold suspect the
exhaust valve or seat. 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).
Oil Consumption Test
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 are examples of conditions that can affect oil consumption rates:
Engine size
Operator driving habits
Ambient temperatures
Quality and viscosity of oil
Engine is 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. The oil level should not be above the top of the cross-hatched area and the letter
"F" in FULL).
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). Oil consumption rate is about one liter per 2,400 km (1,500 miles).
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.
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. High speed driving, towing, high ambient temperature and other factors may result in greater oil use.
1. 1. Define excessive consumption, such as the number of miles driven per liter of oil used. Also determine customers
driving habits, such as sustained high speed operation, towing, extended idle and other considerations.
2. 2. Verify that the engine has no external oil leaks as described under Engine Oil Leaks in this section.
3. 3. Carry out an oil consumption test:
Run the engine to normal operating temperature. Switch engine OFF and allow oil to drain back for at least
five minutes .
With vehicle parked on level surface, check the engine oil level.
If required, add engine oil to set level exactly to the FULL mark.
Record the vehicle mileage.
Instruct the customer to return for a level check after driving the vehicle as usual for 1,610 km (1000 miles).
Check the oil level under the same conditions and at the same location as the initial check.
NOTE: If the oil consumption rate is unacceptable go to Step 4.
4. 4. Check the Positive Crankcase Ventilation (PCV) system. Make sure the system is not plugged.
5. 5. Check for plugged oil drain-back holes in the cylinder head and cylinder block.
6. 6. If the condition still exists after carrying out the above tests go to step 9.
7. 7. Carry out a cylinder compression test. Refer to the Compression Test procedure in this section. This can help
determine the source of oil consumption such as valves, piston rings or other areas.
8. 8. Check valve guides for excessive guide clearance. Install new valve stem seals after verifying valve guide
clearance.
9. 9. 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.
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 damper until 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. 1. NORMAL READING: Needle between 51-74 kPa (15-22 in-Hg) and holding steady.
2. 2. NORMAL READING DURING RAPID ACCELERATION: W hen the engine is rapidly accelerated, 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.
3. 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.
4. 4. WORN RINGS OR DILUTED OIL: When the engine is accelerated, the needle drops to 0 kPa (0 in-Hg). Upon
deceleration, the needle runs slightly above 74 kPa (22 in-Hg).
5. 5. STICKING VALVES: W hen the needle 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.
6. 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.
7. 7. POOR VALVE SEATING: A small but regular downscale flicking can mean one or more valves are not seating
correctly.
8. 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.
9. 9. WEAK VALVE SPRINGS: W hen the needle oscillation becomes more violent as engine RPM is increased, weak
valve springs are indicated. The reading at idle could be relatively steady.
10. 10. LATE VALVE TIMING: A steady but low reading could be caused by late valve timing.
11. 11. IGNITION TIMING RETARDED: Retarded ignition timing will produce a steady but somewhat low reading.
12. 12. INSUFFICIENT SPARK PLUG GAP: When spark plugs are gapped too close, a regular, small pulsation of the
needle can occur.
13. 13. INTAKE LEAK: A low, steady reading can be caused by an intake manifold or throttle body gasket leak.
14. 14. BLOW N HEAD GASKET: A regular drop of fair magnitude can be caused by a blown head gasket or warped
cylinder head to cylinder block surface.
15. 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.
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.
Engine System - General Information - EngineTDV6 2.7L Diesel
For a detailed description of the 2.7L Diesel engine, refer to the relevant Description and Operation section in the workshop manual. REFER
to: (303-14A Electronic Engine Controls - TDV6 2.7L Diesel)
Electronic Engine Controls (Description and Operation),

Electronic Engine Controls (Description and Operation).

2. 2. Visually inspect for obvious signs of mechanical or electrical damage.
Visual Inspection
Coolant level W iring harness
Coolant leaks Electrical connector(s)
Oil level Injectors
Oil leaks Glow plugs
Visibly damaged or worn parts 5 volt sensor supply
Loose or missing nuts or bolts Sensor(s)
Cooling fan control module and motor
Engine Control Module (ECM)
2. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next
step.
3. 3. If the concern is not visually evident, verify the symptom and refer to the relevant Symptom Chart. Symptom Charts have been
separated into Leaks and Noise Vibration and Harshness (NVH) for ease of use.
Symptom Charts
Symptom Chart, Leaks
External coolant leaks Damaged hose(s) For cooling system checks,
Damaged expansion REFER to: Engine Cooling (303-03A Engine Cooling - TDV6 2.7L
tank Diesel, Diagnosis and Testing).
Damaged radiator
Leaking
seals/gaskets
Cracked/damaged
casings
Internal coolant leaks Note: This may be Leaking For cooling system checks,
indicated by the production of white seals/gaskets REFER to: Engine Cooling (303-03A Engine Cooling - TDV6 2.7L
smoke from the exhaust Cracked/damaged Diesel, Diagnosis and Testing).
casings
Engine overheats Insufficient coolant For cooling system checks,

Insufficient oil REFER to: Engine Cooling (303-03A Engine Cooling - TDV6 2.7L
Pressure cap fault Diesel, Diagnosis and Testing).
Thermostat not
opening
Coolant pump
failure
Cooling fan failure
Engine takes too long to reach operating Thermostat stuck For cooling system checks,
temperature open REFER to: Engine Cooling (303-03A Engine Cooling - TDV6 2.7L
Diesel, Diagnosis and Testing).
External oil leaks Gaskets Clean and confirm the area of the leak. Check the visual condition of
Seals oil carrying components. Check the crankcase ventilation system,
Oil pipes REFER to: Engine Emission Control (303-08A Engine Emission Control
Oil filter - TDV6 2.7L Diesel, Diagnosis and Testing).
Oil cooler Carry out a compression test, GO to Pinpoint Test A.
Damaged/cracked
casings
Crankcase
ventilation system
Piston ring blow-by
Internal oil leaks (leaks into coolant or Gaskets Check for traces of oil in the coolant. Check for evidence of oil in the
combustion chamber) Note: This may be Seals combustion chambers (deposits on the glow plugs, etc). Confirm oil
indicated by the production of blue smoke Damaged/cracked consumption and vehicle usage with the owner/driver. Carry out an
from the exhaust casings oil consumption test, GO to Pinpoint Test B.
W orn valve guides
W orn cylinder
bores/pistons
Broken piston rings
Symptom Chart, NVH

NOTE: As the checks suggested here are open to interpretation, they should be used as a guide only. Descriptions of noises, etc, are in
general terms, so depend on a degree of experience on the part of the technician.

Rattle/ticking from top of Valve gear noise Check the engine oil pressure, GO to Pinpoint Test C. . Check the function
engine Camshaft bearing noise of the hydraulic tappets and the camshaft condition. Check the camshaft
Camshaft chain noise bearings, chains and tensioners. Check the vacuum pump, and high
Tensioner noise pressure fuel pump
Vacuum pump noise
High pressure fuel pump
noise
Growl from top of engine High pressure fuel pump Check the high pressure fuel pump belt and tensioner
belt noise
High pressure fuel pump
belt tensioner noise
Squeaking/Creaking/Squeal Front End Accessory Check the FEAD belt and driven components,
from front of engine Drive (FEAD) belt REFER to: Accessory Drive (303-05A Accessory Drive - TDV6 2.7L Diesel,
FEAD belt tensioner Diagnosis and Testing).
Driven components on
FEAD belt
W hine/Slap/Growl from front of Front End Accessory Check the FEAD belt and driven components. Check the timing belt and
engine Drive (FEAD) belt tensioners
FEAD belt tensioner
Driven components on
FEAD belt
Timing belt noise
Timing belt tensioner
noise
Knock from lower half of engine Piston slap Check the engine oil pressure, GO to Pinpoint Test C. . Check piston,
(often worse with a cold Piston pin noise cylinder bore, piston pin and connecting rod bearing for excess wear
engine) Connecting rod bearing
noise
Knock/Rumble from lower half Main bearing noise Check the engine oil pressure, GO to Pinpoint Test C. . Check connecting
of engine (often worse on rod bearing for excess wear
overrun)
Misfire/Rough running Engine management For engine management system tests,
system REFER to: Electronic Engine Controls - 2.7L Diesel (303-14A, Diagnosis and
Fuel charging and Testing).
controls For fuel charging and controls systems tests, REFER to:
Exhaust gas Fuel Charging and Controls (303-04A Fuel Charging and Controls -
recirculation (EGR) TDV6 2.7L Diesel, Diagnosis and Testing),
system Turbocharger (303-04B Fuel Charging and Controls - Turbocharger -
Burnt/sticking valves TDV6 2.7L Diesel, Diagnosis and Testing).
W orn valve guides For EGR system tests,
W orn cylinder REFER to: Engine Emission Control (303-08A Engine Emission Control -
bores/pistons TDV6 2.7L Diesel, Diagnosis and Testing).
Broken piston rings Carry out a compression test, GO to Pinpoint Test A. Check for excess wear
Damaged/cracked in engine components
casings
Pinpoint Tests
NOTE: Where reference is made to 'suitable equipment', this refers to standard workshop equipment. Refer to the operating instructions
for your own equipment when performing any tests.
PINPOINT TEST A : CHECK THE CYLINDER COMPRESSIONS
WARNING: Only compression testers able to read the higher compression pressures found in diesel engines should be used. Failure to
follow this instruction may result in personal injury.
NOTE: W here possible, compression testing should be carried out on an engine at operating temperature.
CONDITIONS
A1: CARRY OUT A DRY CYLINDER COMPRESSION TEST
1 Make sure the parking brake is applied and that the selector lever is in park.
2 Set the ignition status to OFF.
3 Remove the starter relay.
4 Disconnect the starter motor solenoid connector.
5 Connect a suitable remote starter device to the starter motor solenoid.
6 Remove the glow plugs,
REFER to: Glow Plugs - 2.7L V6 - TdV6 (303-07C Glow Plug System, Removal and Installation).
7 Install adaptor 303-1131 in place of the glow plug in the first cylinder to be tested.
8 Connect a suitable compression tester to the adaptor. See warning above.
9 Using the remote starter device, crank the engine a minimum of five revolutions.
10 Record the compression figure and the number of revolutions taken to reach it.
11 Repeat steps 7 - 10 above for the remaining cylinders, cranking the engine for a similar number of revolutions each
time.
12 Compare the compression figures across all the cylinders.
Are the compression figures within 10% of each other?
Yes
Unless the compression figures are universally very low (experience will indicate this), check for other causes for the
customer complaint.
No
GO to A2.
A2: CARRY OUT A WET CYLINDER COMPRESSION TEST
CAUTION: If engine oil is introduced into the cylinders, run the engine at 2,000 rpm for a minimum of ten minutes after completing
testing to prevent damage to the catalytic converters. Failure to follow this instruction may result in damage to the vehicle.
NOTE: There is a combustion chamber in the top of each piston. Make sure that the oil is not allowed to run into this chamber.
1 Using a suitable oil can with a flexible spout, introduce a small amount of clean engine oil into the cylinder just
before testing, such that the oil is able to run between the piston and the cylinder bore.
2 Repeat steps 7 - 10 from the test above, introducing oil into each cylinder just before testing.
3 Compare the compression figures across all the cylinders.
Is the compression figure higher than the dry test?
Yes
A higher figure following the introduction of oil may indicate a worn or damaged cylinder bore, piston and/or piston
rings. Disassembly would be required to confirm this.
No
If the compression figure is unaffected by the introduction of oil, but the figure is still less than 90% of the other
cylinders, this may indicate a burnt and/or sticking valve, leaking head gasket, etc. Disassembly would be required to
confirm this.
Clear any DTCs which may have been induced by the test.
PINPOINT TEST B : OIL CONSUMPTION TEST

NOTE: Oil consumption will vary, depending on a number of factors. New engines will normally use more oil than 'run-in' engines,
although a guideline would be to expect 16,000 Km (10,000 miles) per liter.
CONDITIONS
B1: CHECK FOR EXCESSIVE OIL CONSUMPTION
1 Start the engine and allow it to run until it reaches normal operating temperature.
2 Make sure the vehicle is parked on a level surface and set ignition status to OFF.
3 Allow to settle for at least five minutes.
4 Check the oil level.
5 Correct the level, if necessary, and record the reading and mileage in the vehicle history.
6 Make sure that the owner/driver is aware that a test is being carried out, and that they should not top-up their oil
level for the duration of the test, but should check the level every 160-240 Km (100-150 miles).
7 When the oil level reaches the ADD mark, the customer should bring the vehicle in to be checked.
8 Top-up the oil to the level at the beginning of the test and record the amount of oil needed to do so, and the
mileage covered in the course of the test.
9 From this, the consumption can be calculated, and a decision made as to whether or not the consumption is
considered excessive.
Is the consumption excessive for the mileage and/or use?
Yes
Disassembly will be required to check the components indicated in the symptom chart.
No
No further action is required.
PINPOINT TEST C : CHECK THE ENGINE OIL PRESSURE

NOTE: Check and, if necessary, top-up the engine oil level before beginning this test.
NOTE: W here reference is made to 'suitable equipment', this refers to standard workshop equipment. Refer to the operating instructions
for your own equipment when performing any tests.
CONDITIONS
C1: CHECK FOR LOW ENGINE OIL PRESSURE
1 Remove the oil pressure sensor,
REFER to: Engine Oil Pressure (EOP) Sensor (303-14A Electronic Engine Controls - TDV6 2.7L Diesel, Removal and
Installation).
2 Connect a suitable oil pressure gauge in place of the oil pressure sensor.
3 Start the engine and check for leaks at the gauge connection.
4 Allow the engine to idle and monitor the oil pressure.
5 Raise the engine speed to 2,500 rpm and monitor the oil pressure.
Is the oil pressure less than 0.50 bar (7.25 psi) between idle and 2,500 rpm?
Yes
GO to C2.
No
GO to C3.
C2: CHECK FOR LOW ENGINE OIL PRESSURE AT ENGINE SPEEDS GREATER THAN 2,500 RPM
1 Raise the engine speed to above 2,500 rpm and monitor the oil pressure.
Is the oil pressure less than 1.0 bar (14.5 psi) at engine speeds greater than 2,500 rpm?
Yes
Pressure this low may indicate a problem with: oil pump, filtering, clearances within the engine. Check if there are
any other indications of engine faults (noise, etc), refer to the symptom chart above.
No
GO to C3.
C3: CHECK FOR HIGH ENGINE OIL PRESSURE
1 Monitor the engine oil pressure at varying engine speeds.
Does the oil pressure reach 4.0 bar (58 psi)?
Yes
Pressure this high may indicate a blockage in the lubrication system. If this is not resolved, high oil pressure will
lead to engine oil leaks and other failures.
No
If the oil pressure stays in the band between 0.50 bar (7.25 psi) and 1.0 bar (14.5 psi) this would be considered
normal.
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.
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.
Follow the relevant tightening sequence.
3. NOTE: Do not strike the bearing caps.
Remove the camshaft bearing caps.
Follow the relevant loosening sequence.
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.
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.
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.
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.
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.
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.
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.
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.
Engine System - General Information - Crankshaft Main Bearing Journal ClearanceV6
3.0L Petrol
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.
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.

Engine System - General Information - Crankshaft Main Bearing Journal
Clearance3.0L NA V6 - AJ27
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.
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.

Engine System - General Information - Crankshaft Main Bearing Journal
Clearance4.2L NA V8 - AJV8/4.2L SC V8 - AJV8
General Procedures
CAUTION: THESES PROCEDURES SHOULD NOT BE CARRIED OUT DURING THE MANUFACTURERS WARRANTY
PERIOD.
1. NOTE: Example - *PJEAL* - Crankshaft Main Journal

Diameter.
Read the grade letters from LEFT to RIGHT = FRONT to REAR

of engine eg. for this example engine, the crank journal at the
front of the engine is grade P, and at the rear is grade L.
The selection of main bearing shells is described in the

following chart.
2. NOTE: Example - *ABAA* - Crankshaft (Big End Bearing)

Crankpin Diameter
NOTE: For vehicles built up to 2002 MY.
NOTE: If the crankshaft main bearing carrier retaining bolts

have been marked with a center punch dot, they must be
discarded and new bolts installed.

of engine eg. for this example engine, the crankpin at the front
of the engine is grade A and at the rear is also grade A.
Grade A = 56,000 to 55,994 mm (Bearing Shell Color Code

- Blue).
Grade B = 55,994 to 55,988 mm (Bearing Shell Color Code

- Green).
Grade C = 55,988 to 55,982 mm (Bearing Shell Color Code

- Yellow).
3. NOTE: Example - *ABAA* - Crankshaft (Big End Bearing)

Crankpin Diameter
NOTE: For vehicles built from 2002 MY.

NOTE: If the crankshaft main bearing carrier retaining bolts
have been marked with a center punch dot, they must be
discarded and new bolts installed.

of engine eg. for this example engine, the crankpin at the front
of the engine is grade A and at the rear is also grade A.
Grade A = 53,000 to 52,994 mm (Bearing Shell Color Code

- Blue).
Grade B = 52,994 to 52,988 mm (Bearing Shell Color Code

- Green).
Grade C = 52,988 to 52,982 mm (Bearing Shell Color Code

- Yellow).
4. NOTE: Example - *21222122* - Cylinder Bore and Piston
The cylinder bore grades read from LEFT to RIGHT as follows:
Bank 2 - Cylinder 1, Bank 2 - Cylinder 2, Bank 2 - Cylinder

3, Bank 2 - Cylinder 4, Bank 1 - Cylinder 4,
Bank 1 - Cylinder 3, Bank 1 - Cylinder 2, Bank 1 - Cylinder

1.
(Note, in earlier publications Bank 1 was described as

A-Bank and Bank 2 as B-Bank)
Grade 1 Bore = 85,990 to 86,000 mm.
Grade 2 Bore = 86,000 to 86,010 mm.
Grade 3 Bore = 86,010 to 86,020 mm.
5. NOTE: Example - *WPPNN* - Crankshaft Main Bearing Bore

in Cylinder Block

of engine eg. for this example engine, the crank journal bore at
the front of the engine is grade W , and at the rear is grade N.
The selection of main bearing shells is described in the

following JOURNAL DIAMETER AND MAIN BEARING
BORE CHART.
6. JOURNAL DIAMETER AND MAIN BEARING BORE CHART

7. NOTE: THIS PROCEDURE SHOULD ONLY BE CARRIED OUT
WHEN REPLACIING MAIN BEARING SHELLS.
NOTE: Refer to the JOURNAL DIAMETER AND MAIN

BEARING BORE CHART in step 6 for tolerance and bearing
information.
The number in each diagonal band represents a PAIR of color

coded main bearing shells which must be used with a specific
journal, depending on the combination of journal diameter and
crankshaft bore diameter. The color codes for each band are as
follows:
1. Blue / Green and Blue / Green
2. Blue / Green and Blue
3. Blue and Blue
4. Blue and Green
5. Green and Green
6. Green and Yellow
7. Yellow and Yellow
Consider crankshaft journal 5 (from the example grade

markings on the cylinder block) - the cylinder block bore is
Grade N and the crankshaft journal diameter is Grade L.
From the chart, it will be seen that the point of
intersection is in Band 4 which equates to one Blue shell
and one Green shell.
When the appropriate pair of color codes have been

selected for a journal, either color may be installed to the
cylinder block or to the bedplate, but, the shell which is
to be installed to the cylinder block must have an oil
groove and the shell which is to be installed to the
bedplate must be plain.
8. NOTE: THIS PROCEDURE SHOULD ONLY BE CARRIED OUT

WHEN A REPLACMENT CRANKSHAFT OR CYLINDER BLOCK
HAS BEEN FITTED.
NOTE: Refer to the JOURNAL DIAMETER AND MAIN

BEARING BORE CHART in step 6 for tolerance and bearing
information.
The thickness grade of all main bearing shells are to be

selected to give a total running clearance of not less than
0.022 mm or greater than 0.040 mm.
Each bearing bore in the block/bedplate assembly should

be measured at two mutually perpendicular diameters 45
to the vertical in the middle of the bearing.
The minimum diameter of the two is to be used.
Each crankshaft main bearing journal should be measured

dynamically at a point in line with the middle of each
bearing.
When the appropriate pair of color codes have been

selected for a journal, either color may be installed to the
cylinder block or to the bedplate, but, the shell which is
to be installed to the cylinder block must have an oil
groove and the shell which is to be installed to the
bedplate must be plain.
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.
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.

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.
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.
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.
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.
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.
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.

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.
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.
Engine - TDV6 2.7L Diesel -
Description Specification
Engine oil, SAE 5W-30 W SS-M2C-913B A1
Sealant W SE M4G323A4 (Loctite 5910)
Sealant (camshaft caps) ESK M4G269A (Loctite 518)
Hose assembly surfactant W SE N99C45A2
Capacities
Description Liters
Engine oil, initial fill 77
Engine oil, service fill with oil filter change 66
Maximum permissible cylinder head warp
Total flame face 0.1 mm
150 mm x 150 mm square on flame face 0.05 mm
25 mm x 25 mm square on flame face 0.025 mm
Accessory drive belt idler pulley retaining bolt 47 35
Accessory drive belt idler pulley mount bracket retaining bolts 80 59
Accessory drivebelt tensioner retaining bolt 47 35
Air conditioning compressor retaining bolts 25 18
Air conditioning compressor mounting bracket retaining bolts 25 18
A/C manifold retaining bolt 9 - 80
Camshaft bearing caps retaining bolts A
Camshaft position sensor retaining bolt 10 89
Camshaft hub retaining bolts A
Camshaft pulley retaining bolts 23 17
Crankshaft pulley retaining bolt A
Crankshaft position sensor retaining bolt 5 44
Coolant inlet housing 10 89
Cylinder head retaining bolts A
Engine mount retaining nuts to crossmember 63 46
Engine mount bracket to engine mount retaining nut 48 35
Engine mount bracket to engine block retaining bolts 90 66
Engine wiring harness retaining bracket 4 35
Exhaust manifold heat shield retaining bolts 10 89
Exhaust manifold retaining nuts 23 17
Flexplate retaining bolts A
Fuel injection pump 23 17
Fuel injection pump pulley retaining nut 50 37
Fuel injector retaining bolts 10 89
Generator retaining bolts 47 35
Generator mount bracket retaining bolts 23 17
Glow plugs 10 89
Knock sensor retaining nuts 20 15
Oil cooler to cylinder block retaining bolt 10 89
Oil level indicator tube retaining bolt 10 89
Oil pan retaining bolts 10 89
Oil pump to engine block retaining bolts 22 16 -
Oil pan drain plug 25 18
Oil separator pipe retaining bolts 10 89
Oil filter 25 18
Piston cooling jet retaining bolt 10 89
Power steering bracket retaining bolts 23 17
Power steering pump retaining bolts 22 16
Primary timing chain tensioner retaining bolts 10 - 89
Starter motor retaining bolts 48 35
Timing belt tensioner retaining bolt 24 18
Timing belt idler pulley retaining bolt 45 33
W ater pump retaining bolts 10 89
W ater pump pulley retaining bolts 24 18
W ater pump outlet pipe retaining bolts 10 89
Valve cover retaining bolts 10 89
Vacuum pump retaining bolts 23 17
Vacuum pump retaining nuts 13 10
Engine - TDV6 2.7L Diesel - Engine - Component Location
External View
Engine - TDV6 2.7L Diesel - Engine - Overview
Overview
The 2.7 liter diesel engine is a V6 configuration unit with 2 banks of 3 cylinders arranged at 60 degrees to each other. There are 4 valves
per cylinder, which are operated by 2 overhead camshafts per cylinder bank.
The cylinder block is cast in compacted graphite iron, which uses less material to produce compared to a conventional cast iron block. This
provides reduced weight and length with superior structural capabilities. A separate aluminum ladder frame, bolted to the underside of the
cylinder block, provides a lightweight, compact and very stiff bottom end of the engine.
The cylinder heads are cast aluminum with a moulded plastic camshaft cover. The single-piece oil pan is formed from stamped steel. The
cast iron exhaust manifolds are unique for each cylinder bank. A moulded plastic acoustic cover is fitted over the upper engine to absorb
engine-generated noise.
A low, by diesel standards, compression ratio of 17.3:1 contributes to improved emissions quality, quieter combustion and compatibility
with the engines unique forced induction system.
Refer to: Intake Air Distribution and Filtering (303-12A Intake Air Distribution and Filtering - TDV6 2.7L Diesel, Description and Operation).
The low compression ratio also means less heat build-up in the piston bowl and more efficient fuel burn, resulting in the production of lower
levels of pollutants.
Engine - TDV6 2.7L Diesel - Engine - System Operation and Component Description
System Operation
Operation of the engine is controlled by the ECM (engine control module).
Refer to: Electronic Engine Controls (303-14A Electronic Engine Controls - TDV6 2.7L Diesel, Description and Operation).
Engine Structure
ItemDescription
1 Cylinder heads
2 Cylinder block
3 Ladder frame
4 Oil pan
Cylinder Block Components

The cylinder block is of a single cast compacted graphite iron construction with a hollow beam structure. This type of construction provides
outstanding strength and durability and uses less material than a conventional cast iron block, therefore, reducing engine weight and
length.
As the benefits of compacted graphite iron derive from its strength, this enables lightweight and thin-wall designs to be created for
high-compression diesel applications.
NOTE: Arrow indicates front of engine.
Engine Data
ItemDescription
1 Engine data locations
Engine data is marked at 2 locations at the back of the cylinder block. Component diameters are represented by alphabetical and numerical
codes; keys to the codes are in the removal and installation section of this manual.
Piston Cooling Jets
ItemDescription
1 Bolt
2 Piston cooling jet
Jets located in the cylinder block provide piston and piston pin lubrication and cooling. These jets spray oil on to the inside of the piston,
the oil then flows through 2 internal wave shaped channels to help cool each piston crown.
Lubrication oil is distributed through the cylinder block, via the main oil gallery and channels bored in the block, to all critical moving parts.
These channels divert oil to the main and connecting rod bearings via holes machined into the crankshaft.
A tapping at the front of the cylinder block, below the RH (right-hand) cylinder head, connects a pipe to the turbochargers by means of a
banjo connection. Oil is supplied, under pressure via this tapping, from the oil pump to provide lubrication for the turbochargers bearings.
Cylinder cooling is achieved by coolant circulating through chambers in the cylinder block casting.
Two hollow metal dowels are used to locate the cylinder heads to the cylinder block, 1 on each side at the rear of the unit.
A port is included at the RH and LH (left-hand) side of the cylinder block, below each of the turbochargers, to connect the turbochargers oil
return pipe to the oil pan.
Two coolant drain plugs are installed in the cylinder block, 1 is fitted in the rear RH side, and the other is fitted in the middle of the cylinder
block on the LH side.
On vehicles destined for cold climates, a cylinder block heater replaces a core plug in the middle of the cylinder block on the LH side.
Piston and Connecting Rod Assembly
ItemDescription
1 Connecting rod bolts (2 off)
2 Connecting rod
3 Piston
4 Piston pin
5 Circlips
6 Connecting rod identification
The connecting rods are manufactured from sinter-forged steel and have fracture-split bearing caps. The bearing caps are produced by
fracturing the opposing sides of the connecting rod at the bearing horizontal centre-line. As well as being easier to manufacture, when
reassembled the fractured surfaces interlock to form a strong seamless joint. The cylinder position is etched on adjoining sides of the joint
to identify matching connecting rods and bearing caps. The selective connecting rod bearings are aluminum/tin split plain bearings. The
connecting rod bearing is 'sputter coated', which is a manufacturing process that layers the bearing material to produce a higher load
capacity for improved durability.
NOTE: The connecting rods are not selective.
Piston and Connecting Rod Orientation

ItemDescription
1 Piston and connecting rod assembly, cylinders 4-6
2 Piston and connecting rod assembly, cylinders 1-3
3 Bolts (12 off)
4 Connecting rod bearing cap (6 off)
5 Connecting rod lower bearing (6 off)
When installing a connecting rod, ensure the back of the connecting rod faces the center of the 'vee'.
The pistons are made from aluminum alloy and are fitted with 3 rings. The piston crown incorporates a pronounced bowl; this forms the
combustion chamber, which promotes swirl and turbulence necessary for good combustion and improved emissions. In addition, the piston
skirt has a molybdenum-coated surface, which counteracts scoring of the cylinder bore and piston.
The piston also incorporates a double wave gallery within the piston crown to enhance piston cooling. The pistons are supplied oil by means
of spray jets located in the cylinder block oil gallery. These jets ensure optimum piston cooling to counteract the high temperatures
generated by the combustion process.
Each piston is installed on a piston pin located in a aluminum/tin bushing in the connecting rod.
Piston Ring Orientation

ItemDescription
1 Ring gap oil control
2 Ring gap upper compression
3 Spiral joint oil control
4 Ring gap lower compression
5 Upper compression ring
6 Lower compression ring
7 Oil control ring
When installing pistons ensure the arrows on the piston crowns all point to the front of the engine and the pistons are located in the correct
cylinder banks, i.e. cylinders 1, 2, 3 or cylinders 4, 5, 6.
All pistons are common single grade/single part number for all engines.
The piston top ring is a taper type and is fitted with the taper to the top of the piston. All rings marked 'top' are assembled with 'top'
uppermost. All rings must be spaced evenly around the piston before installing. The circumference gap of the double bevelled oil control ring
must be opposite the spiral control joint.
Crankshaft and Oil Pan Components

Crankshaft
ItemDescription
1 Oil pump drive
2 Main bearing journal
3 Connecting rod bearing journal
4 Rear drive flange
5 Rear oil seal location
6 Trigger wheel location
The crankshaft is forged steel and fillet rolled with induction hardened journals, which run in 4 bearings with clamped 2 layer bearing shells.
The upper and lower shells of bearing number 4 are flanged, which limits the end float of the crankshaft. The main bearing caps are double
bolted and cross bolted to increase the strength and rigidity of the engine block.
The main bearings are aluminum/tin split plain selective bearings. An oil groove in the top half of each bearing transfers oil into the
crankshaft for lubrication of the connecting rod bearings. The upper and lower shells of bearing number 4 contain integral thrust washers,
which limits the end float of the crankshaft.
Rear Main Oil Seal and Retainer

ItemDescription
1 Housing
2 Seal
3 Crankshaft
4 Rear oil seal retainer
5 Bolt (10 off)
The rear main oil seal and retainer assembly is a one-piece unit and is supplied with its own plastic fitting sleeve. The seal and retainer
have 2 locating dowels, 10 fixing bolts and a rubber seal. In addition the retainer has a location for the crankshaft position sensor.
A torsional vibration crankshaft damper pulley is bolted to the front of the crankshaft.
Trigger W heel
ItemDescription
1 Special tool
2 Trigger wheel
The crankshaft trigger wheel is located on the rear of the crankshaft. It is pressed onto the crank using a special tool, which also precisely
aligns the trigger wheel for crankshaft position and timing. The trigger wheel consists of 60 magnets minus 2 for ECM crankshaft position
reference and synchronisation. The magnets cannot be seen on the trigger wheel, which therefore can only be positioned using a special
tool.
If the trigger is removed for any reason, then a new trigger wheel must be fitted.
Ladder Frame
ItemDescription
1 Ladder frame
The ladder frame is fitted to the lower cylinder block to stiffen the base structure of the engine thus helping to reduce Noise, vibration and
harshness. The frame is made of high-pressure die cast aluminum and also incorporates an oil baffle plate to reduce oil foaming and splash.
The ladder frame is secured to the cylinder block with 2 dowels, 2 locator pins for the gasket and 18 retaining bolts; 3 different lengths of
bolts are used:
M6 x 20 (6 off).
M8 x 75 (4 off).
M6 x 105 (8 off).
Iron inserts, cast into the main bearing supports of the ladder frame, minimize main bearing clearance changes due to heat expansion.
A gasket seals the joint between the ladder frame and the cylinder block.
A port for the oil level gage tube is included in the casting on the LH side of the ladder frame.
An oil pick-up pipe with integral strainer locates in the front of the ladder frame to provide oil to the crankshaft driven oil pump.
Oil Pan
ItemDescription
1 Gasket
2 Draining bolt seal
3 Draining bolt
4 Sump pan
5 Retaining bolts
The pressed steel oil pan is bolted to the ladder frame with 14 M6 x 16 bolts and is sealed with a reusable gasket. The engine oil drain plug
and the oil temperature sensor are located towards the front of the oil pan.
Camshaft Timing Components

ItemDescription
1 Rear engine accessory drive rear cover
2 Rear engine accessory drive tensioner
3 Bolt
4 Fuel pump pulley
5 Nut
6 Rear engine accessory drive camshaft pulley
7 Rear engine accessory drive belt
8 Bolt
9 Rear engine accessory drive front cover
10 RH chain tensioner
11 RH timing chain
12 RH intake camshaft
13 RH exhaust camshaft
14 LH intake camshaft
15 LH exhaust camshaft
16 LH chain tensioner
17 LH timing chain
18 Timing belt
19 Front cover bridge
20 Primary drive cover
21 Bolt
22 Tensioner
23 Bolt
24 Idler
25 Camshaft hub
26 LH camshaft timing pulley
27 Bolt (3 off)
28 Bolt
29 Idler
30 Bolt
31 Bolt (3 off)
32 Bolt
33 RH camshaft timing pulley
34 Camshaft hub
Primary drive is provided by a single toothed belt from the crankshaft to the exhaust camshaft gears of each cylinder bank via 2 idler pulleys
and a tensioner.
Timing belt adjustment is carried out by an eccentric type tensioner mounted on the RH front face of the cylinder block.
Secondary Drive
ItemDescription
1 Timing chain
2 Bolts
3 Intake camshaft
4 Exhaust camshaft
5 Tensioner firing pin
Secondary drive is provided by 2 short crossover chains, which transfer drive from the exhaust camshaft gears to the intake camshaft gears.
The crossover drives are located at the rear of the RH cylinder bank and the front of the LH cylinder bank. This allows for a much shorter and
simpler run for the main camshaft drive belt at the front of the engine.
Each crossover chain is tensioned via an automatic chain tensioner, which acts directly on the chains via a guide rail. The tensioners are
located between the exhaust and intake camshafts at the front or rear of the cylinder head, depending on the cylinder bank.
The tensioner firing pin holds the automatic chain tensioner in a compressed state to aid installation.
Timing Cover
The plastic timing cover is bolted to the front of the cylinder block and cylinder heads with 16 bolts and sealed with a rubber seal.
Cylinder Head Components

NOTE: LH cylinder head shown; RH cylinder head similar.
ItemDescription
1 Hydraulic lash adjusters (12 off)
2 Valve spring retainers (12 off)
3 Roller rockers (12 off)
4 Valve stem seals (12 off)
5 Valve guides (12 off)
6 Exhaust valves (6 off)
7 Intake valve seats (6 off)
8 Exhaust valve seats (6 off)
9 Intake valves (6 off)
10 Valve springs (12 off)
11 Bolt
12 Bracket
13 Cover
14 Lifting eye
15 W asher
16 Bolt
17 Bracket
18 Bolt
19 Seal
20 Cap
21 Intake manifold cover assembly
22 W asher
23 Bolt
24 Lifting eye
25 Seal
26 Camshaft bearing caps (7 off)
27 Bolts (18 off)
28 Gasket
29 Camshaft bearing cap and seal housing
30 Camshaft bearing cap and seal housing
31 Intake camshaft
32 Exhaust camshaft
33 Cylinder head
34 Cylinder head bolts (8 off)
35 Exhaust manifold studs (6 off)
36 Cylinder head gasket
37 Core plug
38 Plug
39 Seal
40 Oil filler tube
41 Oil filler cap
42 Cover
43 Injectors (3 off)
44 Bolt (2 off)
45 Bolt
46 Vacuum pump
47 W ater outlet assembly
48 Bolt (4 off)
Cylinder Heads
ItemDescription
1 Studs
2 Bolts
3 Blanking plug
The aluminum gravity die cast cylinder heads are unique to each cylinder bank. Eight deep-seated bolts help reduce distortion and secure
each cylinder head to the cylinder block. The cylinder head bolts are located beneath the camshafts, 4 under the intake camshaft and 4
under the exhaust camshaft. Two hollow dowels align each cylinder head with the cylinder block.
NOTE: The cylinder heads cannot be reworked.
The cylinder head gasket is a 3-layer, laminated steel type and is available in 5 different thickness. The choice of gasket thickness is
dependent on the maximum piston protrusion. Gasket thickness is identified by serrations cut into the front end of the gasket.
The cylinder head has 4 ports machined at each cylinder location, 2 exhaust ports and 2 intake ports. One of the intake ports is helical and
functions as a swirl port, the other is arranged laterally as a tangential port and functions as a charge port.
The camshafts are of a hollow steel tube construction, with pressed on sintered lobes. Each camshaft is retained by aluminum alloy caps, 5
for the exhaust camshafts and 4 for the intake camshafts. Location letters, A to I for the intake camshaft and R to Z for the exhaust
camshaft, are marked on the outer faces of the caps for each cylinder head.
The LH cylinder bank exhaust camshaft is machined to accept a rear camshaft gear. The rear camshaft gear provides drive for the
high-pressure fuel pump.
Refer to: Fuel Charging and Controls (303-04A Fuel Charging and Controls - TDV6 2.7L Diesel, Description and Operation).
The exhaust camshaft gear of the LH cylinder head also incorporates a trigger wheel, which is used in conjunction with the camshaft sensor
to measure engine position.
The RH cylinder head exhaust camshaft is machined at the rear end to provide a drive connection for the vacuum pump.
The fuel injection nozzles are centrally mounted above each cylinder.
Refer to: Fuel Charging and Controls (303-04A Fuel Charging and Controls - TDV6 2.7L Diesel, Description and Operation).
The glow plugs are arranged centrally on the intake side of the cylinder heads, between the 2 intake ports of each cylinder.
Refer to: Glow Plug System (303-07C Glow Plug System, Description and Operation).
The engine lifting eyes are bolted to the cylinder head, 1 at the front and 2 at the rear, 1 per cylinder head.
Camshaft Covers
ItemDescription
1 Stud bolt M6 x 40 (6 off)
2 Bolt M6 x 40 (7 off)
3 Oil filler aperture
4 RH camshaft cover assembly
The camshaft covers are manufactured from vinyl ester composite. The RH bank camshaft cover incorporates an outlet for the full load
engine breather and the engine oil filler cap. The LH bank camshaft cover incorporates an outlet for the part load engine breather.
Refer to: Engine Emission Control (303-08A Engine Emission Control - TDV6 2.7L Diesel, Description and Operation).
Silicon rubber in-groove gaskets seal the joints between the camshaft covers and the cylinder heads. Together with spacers and seals on
the camshaft cover fasteners, they also isolate the covers from direct contact with the cylinder heads, to reduce noise.
Camshaft Timing
Valve Position
Intake valve opens 8.5 BTDC (before top dead center)
Intake valve closes 35.5 ABDC (after bottom dead center)
Exhaust valve opens 64 BBDC (before bottom dead center)
Exhaust valve closes 12 ATDC (after top dead center)
Intake and Exhaust Valves
ItemDescription
1 Valve spring collet (24 off, 12 per cylinder head)
2 Valve spring retainer (24 off, 12 per cylinder head)
3 Valve spring (24 off, 12 per cylinder head)
4 Valve stem seal (24 off, 12 per cylinder head)
5 Intake valve (12 off, 6 per cylinder head)
6 Exhaust valve (12 off, 6 per cylinder head)
Each cylinder head incorporates 2 overhead camshafts operating 4 valves per cylinder via steel roller rockers with hydraulic lash adjusters.
Roller Rockers with Hydraulic Lash Adjusters
ItemDescription
1 Roller rocker (24 off, 12 per cylinder head)
2 Hydraulic lash adjuster (24 off, 12 per cylinder head)
The lightweight valve gear provides good economy and noise levels. Valve head diameters are 31 mm (1.220 in) for the exhaust and 35 mm
(1.378 in) for the intake. All valves have 5 mm (0.197 in) diameter stems supported in sintered metal seats and guide inserts. Collets,
valve collars and spring seats locate single valve springs on both intake and exhaust valves. Valve stem seals are integrated into the spring
seats.
Vacuum Pump
ItemDescription
1 Location dowel (2 off)
2 Bracket
3 Vacuum pump
4 Bolt
5 Bolt (2 off)
6 Nut
7 Bracket (transmission breather hose)
8 Stud
The vacuum pump is located at the rear of the RH side cylinder head and is driven from the exhaust camshaft.
NOTE: LH exhaust manifold shown; undefined (undefined) exhaust manifold similar.
Exhaust Manifolds
ItemDescription
1 Cylinder head
2 EGR (exhaust gas recirculation) valve and cooler assembly
3 Gasket
4 EGR coolant inlet tube
5 Bolt (2 off)
6 Exhaust manifold heat shield
7 Bolt
8 Bolt (2 off)
9 Turbocharger assembly
10 Bolt (2 off)
11 Turbocharger heat shield
12 Nut (6 off)
13 Exhaust manifold
14 Stud (6 off)
15 Gasket
The exhaust manifolds are cast from steel alloy and are unique for each cylinder bank. They are sealed to the cylinder head by means of a
steel gasket. Sacrificial plastic sleeves are used to align the manifolds. These sleeves must be changed when refitting the manifolds.
Spacers on the securing bolts allow the manifolds to expand and retract with changes of temperature while maintaining the clamping loads.
Each manifold has a connection for the EGR transfer pipe.
The engine is fitted with twin variable geometry turbochargers, which fix to the exhaust manifolds by a 3-hole flange with a steel gasket.
Lubrication System
Oil is drawn from the reservoir in the oil pan and pressurized by the oil pump. The output from the oil pump is then filtered and distributed
through internal oil passageways.
All moving parts are lubricated by pressure or splash oil. Pressurized oil is also provided for operation of the hydraulic adjusters and the
timing gear chain tensioners.
Oil/Fuel Cooler and Filter Assembly

ItemDescription
1 Filter housing
2 'O' ring seal
3 Paper element
4 Retaining bolt (8 off)
5 Cooler assembly
6 Coolant outlet connection
The engine is lubricated by a force-feed oil circulation system with a full flow oil filter. The oil cooler forms a unit with the oil filter and fuel
cooler, which is mounted centrally in the middle of the cylinder block between the 2 banks of cylinders. The engine oil is cooled using the
engine cooling system. This eliminates the need for an additional engine oil cooler remotely mounted.
The fuel cooler, which forms part of the oil filter body, is also cooled by engine coolant. In addition there is a further fuel cooler in the
return line to the fuel tank.
Oil returns to the oil pan under gravity. Large drain holes through the cylinder heads and cylinder block ensure the quick return of the oil,
reducing the volume of oil required and enabling an accurate check of the contents soon after the engine stops.
System replenishment is through the oil filler cap on the RH camshaft cover.
The moulded composite oil pick-up is immersed in the oil reservoir to provide a supply to the oil pump during all normal vehicle attitudes. A
mesh screen in the inlet prevents debris from entering the oil system.
Oil Pump
ItemDescription
1 Oil pump
2 Bolt (10 off)
The oil pump is a gear type pump and is bolted and dowelled to the front of the cylinder block. It is sealed by means of a rubber gasket,
which is recessed into the oil pump housing. The pump inlet and outlet ports align with oil passages in the ladder frame.
The pumping element is an eccentric rotor, which is directly driven by flats on the crankshaft. An integral pressure relief valve regulates
pump outlet pressure at 4.5 bar (65.25 psi).
The front crankshaft oil seal is housed in the oil pump casing and is fitted such that its front face is 1 mm (0.04 in) under flush with the
machined front face of the oil pump.
NOTE: The seal is not to be pushed all the way into the bore as this will block the seal drains.
The oil pressure switch, located in the 'vee' at the front of the LH cylinder head, connects a ground input to the instrument cluster when oil
pressure is present. The switch operates at a pressure of 0.15 to 0.41 bar (2.2 to 5.9 psi).
The oil level gage locates midway along the LH side of the oil pan, supported in a tube installed in the ladder frame. There is a difference of
approximately 1 liter (1 US quart) between the upper and lower oil levels.
Engine - TDV6 2.7L Diesel - Engine

REFER to: Engine - TDV6 2.7L Diesel (303-00 Engine System - General Information, Diagnosis and Testing).
Engine - TDV6 2.7L Diesel - Engine Oil Draining and Filling
General Procedures
WARNING: The spilling of hot engine oil is unavoidable during this procedure, care must be taken to prevent scalding.


Installation).
3. W ARNING: Observe due care when draining engine oil as the oil
can be very hot.
NOTE: Remove and discard the seal.
Drain the engine oil.
Allow the fluid to drain into a container.
Remove the drain plug and drain the engine oil.

For additional information, refer to: Engine Cover - TDV6 2.7L Diesel
(501-05 Interior Trim and Ornamentation, Removal and Installation).
Remove the oil filter element housing.
Rotate the oil filter element housing five complete turns counter-
clockwise.
Allow the engine oil to drain from the oil filter element housing for
two minutes.
6. Using the special tool, remove and discard the oil filter element.
7. Install a new oil filter element.
Install the oil filter element housing.
Tighten to 25 Nm.
9. NOTE: Install a new seal.
Install the drain plug.
Tighten to 25 Nm.

Installation).
11. Fill the engine with oil.
12. Start engine and run at idle speed until the oil pressure warning light
extinguishes.
Stop the engine.
Check for leaks.
13. Check and top-up the engine oil if required.

14. Install the engine cover.
Published: 06-Jul-2011
Engine - TDV6 2.7L Diesel - Camshaft Front Seal
Special Tool(s)
Holder - Camshaft Pulleys Front
303-1124
Installer - Camshaft Oil Seal
303-1119
Remover - Camshaft Oil Seal
303-1118
Timing Pin - Camshaft Pulleys
303-1126
Removal


3. Remove the timing belt.
For additional information, refer to: Timing Belt (303-01A Engine - TDV6
2.7L Diesel, Removal and Installation).
4. CAUTION: Do not use the special tools to lock the camshafts.

Failure to follow this instruction may result in damage to the engine or the
special tools.
Stage one: Retain the camshaft pulley.
Stage two: Remove the special tool.

5. Remove the camshaft pulley.
Remove the three retaining bolts.
6. Using the special tool, remove the camshaft position (CMP) sensor
timing plate.
Remove and discard the retaining bolt.
7. Install the special tool to the camshaft.
8. CAUTION: Make sure the special tool is correctly seated behind

the camshaft seal. Failure to follow this instruction may result in damage
to the special tool.
Install the special tool into the camshaft front seal.

9. Install the special tool into the camshaft front seal.
10. Install the special tool extracting bolt.
11. Using the special tool, remove the camshaft front seal.
Installation
1. CAUTIONS:
Make sure the seal is installed correctly.
Do not use any lubricant on the camshaft front seal or the camshaft.
Failure to follow this instruction may result in damage to the vehicle.
NOTE: Make sure that the seal is 1mm below the face of the cylinder
head.
Using the special tool, install the camshaft front seal.
Use the discarded camshaft pulley hub retaining bolt with the
special tool.
2. Using the special tool, install the CMP sensor timing plate.
Tighten the retaining bolt in two stages:
Stage one: Tighten to 80 Nm.
Stage two: Tighten a further 80 degrees.
3. Install the camshaft pulley.
Install the bolts, but do not tighten fully at this stage.

special tools.
Stage one: Retain the camshaft pulley.
Stage two: Install the special tool.
5. Install the timing belt.

Engine - TDV6 2.7L Diesel - Camshaft LH
Special Tool(s)
303-1126
Holder - Camshaft Pulleys Front
303-1124
Holder - Camshaft Pulley - Rear
303-1125
303-1119
Removal
1. WARNINGS:
Wait at least 30 seconds after the engine stops before commencing

any repair to the high-pressure fuel injection system. Failure to follow this
Do not smoke or carry lighted tobacco or 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.
This procedure involves fuel handling. Be prepared for fuel spillage

at all times and always observe fuel handling precautions. Failure to follow
Do not carry out any repairs to the fuel system with the engine
running. The fuel pressure within the system can be as high as 1650 bar
(23,931 lb-sq-in). 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.
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. Failure to follow this
instruction may result in foreign matter ingress to the fuel injection
system.
Disconnect the battery ground cable.

For additional information, refer to: Intake Air Shutoff Throttle (303-04A
Fuel Charging and Controls - TDV6 2.7L Diesel, Removal and
Installation).
3. Remove the fuel injector.
For additional information, refer to: Fuel Injector (303-04A Fuel Charging
and Controls - TDV6 2.7L Diesel, Removal and Installation).
4. CAUTION: Make sure 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
system.
Remove the 2 remaining fuel injectors.

5. Remove the fuel injection pump belt.
For additional information, refer to: Fuel Injection Pump Belt (303-05A
Accessory Drive - TDV6 2.7L Diesel, Removal and Installation).
6. Detach the electrical connector from the left-hand valve cover.
7. Disconnect the electrical sensor.
8. Disconnect the electrical sensor.

9. Detach the engine harness.
11. Remove the engine harness retaining bolts.
12. Detach the engine breather tube.
13. Disconnect the vacuum pipe.

14. Remove the fuel injection pump supply line retaining bolt.
15. Clean the fuel pump, high pressure fuel supply line and surrounding
areas.
For additional information, refer to: Fuel Injection Component Cleaning
(303-04A Fuel Charging and Controls - TDV6 2.7L Diesel, General
Procedures).
16. CAUTIONS:
Make sure 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
Make sure that the fuel injector adaptor union does not move when
loosening the high-pressure fuel supply lines. Failure to follow this
instruction may result in damage to the fuel injector or the fuel injector
adaptor union.
Remove and discard the high-pressure fuel supply line.
Loosen the high-pressure fuel supply line from the fuel injector and
the fuel injection supply manifold.
Install blanking caps to the exposed ports.
17. Remove the fuel injection supply manifold.
18. Remove the fuel injection supply manifold securing bracket.

19. Remove the engine cover locating studs.
20. Remove the LH valve cover.
Remove and discard the valve cover gasket.

1. Retain the camshaft sprocket.
special tools.
Remove the camshaft sprocket.
Remove the camshaft sprocket retaining bolts.

24. Using special tool, remove the camshaft sprocket hub.
Remove the camshaft sprocket hub retaining bolt.
25. Remove the camshaft rear pulley retaining bolt.
Using special tool, retain the camshaft rear pulley.
26. Remove the camshaft rear pulley.
27. Detach the EGR coolant inlet tube.

30. Remove the LH catalytic converter.
For additional information, refer to: Catalytic Converter (309-00A
Exhaust System - TDV6 2.7L Diesel, Removal and Installation).
32. Remove the turbocharger heat shield.

34. Remove the fuel injection pump belt rear cover.
35. Retain the secondary timing chain tensioner plunger.
1. Reposition the secondary timing chain tensioner.
2. Retain the secondary timing chain tensioner plunger.

36. Remove the camshaft bearing caps evenly.
37. Remove the secondary timing chain tensioner retaining bolts.
38. Remove the LH bank camshafts and secondary timing chain tensioner
assembly.
Discard the LH exhaust camshaft seals.
39. Remove the secondary timing chain tensioner assembly.
40. Remove the camshafts.
Remove the secondary timing chain from the camshafts.

Installation
1. WARNINGS:



injury.
CAUTIONS:

system.
Make sure that the colored links on the secondary timing chain align
with the dots and scribed line on the sprocket shoulder. Failure to follow
this instruction may result in damage to the engine.
Install the camshafts.
Install the secondary timing chain onto the camshafts.
2. Install the secondary timing chain tensioner assembly.
3. CAUTION: Make sure that the dots on the camshafts are aligned
at the 12 o'clock position. Failure to follow this instruction may result in
damage to the engine.
NOTE: Lubricate the camshafts and the camshaft bearing caps with oil
meeting Jaguar specification prior to installation.
Use Hypoid oil to lubricate the camshafts.

4. Install the secondary timing chain tensioner retaining bolts.
Tighten to 10 Nm.
5. Apply Loctite 518

sealant to the
exhaust camshaft
seal bearing
caps.
Apply
Loctite 518
sealant, 2
mm wide, to
the LH rear
and RH front
camshaft
bearing
caps.
Apply
Loctite 518
sealant, 7
mm
diameter, to
the LH front
and RH rear
camshaft
bearing
caps.
6. Install the camshaft bearing caps in their original positions.
Tighten the retaining bolts in the sequence shown.
Stage 1: Bolts 1 to 14, 1 Nm.
7. Remove the secondary timing chain tensioner retaining pin.
8. Install the LH valve cover.
Install a new valve cover gasket.
Tighten to 10 Nm.
9. CAUTIONS:
A new camshaft front seal is supplied with a transit sleeve that

must not be removed until the camshaft front seal is fully installed.
Do not use any lubricant on the camshaft front seal, transit sleeve
or the camshaft. Failure to follow this instruction may result in damage to
the vehicle.
NOTE: Make sure all components are clean.
Using the special tool, install the camshaft front seal.
Remove and discard the transit sleeve.
10. Using special tool, install the camshaft sprocket hub.
Install the camshaft sprocket hub retaining bolt.
Tighten the bolt in the sequence shown.

11. NOTE: Loosely install all retaining bolts.
Install the camshaft sprocket.
Install the camshaft sprocket retaining bolts.

14. Install the fuel injection pump belt rear cover.
Tighten to 10 Nm.

16. Install the turbocharger heat shield.
Tighten to 9 Nm.
17. Attach the EGR coolant inlet tube.
18. Install the LH catalytic converter.

Tighten to 10 Nm.
22. CAUTIONS:
A new camshaft front seal is supplied with a transit sleeve that

must not be removed until the camshaft front seal is fully installed.
Do not use any lubricant on the camshaft front seal, transit sleeve
or the camshaft. Failure to follow this instruction may result in damage to
the vehicle.
NOTE: Make sure all components are clean.
Using the special tool, install the new camshaft rear seal.
Remove and discard the transit sleeve.

23. Install the camshaft rear pulley.
24. Install the camshaft rear pulley retaining bolt.
Using special tool, retain the camshaft rear pulley.
Tighten the bolt in the sequence shown.
25. Install the fuel injection pump belt.

26. Install the engine cover locating studs.
Tighten to 10 Nm.
27. Install the fuel injection supply manifold securing bracket.
Tighten to 24 Nm.
Install the fuel injection supply manifold.
29. Install the fuel injector.

30. Install the 2 remaining fuel injectors.
31. Install the new high-pressure fuel supply lines.
Remove and discard the blanking caps.
Install the new high pressure fuel supply line, but do not fully
tighten at this stage.
Tighten the fuel injection supply manifold retaining bolts to 23 Nm.
Tighten the high-pressure fuel supply line in the sequence shown in

four stages.
Stage 1: Tighten the high-pressure fuel supply line union 1 to 15

Nm.

Nm.

Nm.

Nm.
32. Install the fuel injection pump supply line retaining bolt.
Tighten to 10 Nm.
33. Connect the vacuum pipe.

34. Attach the engine breather pipe.
35. Install the engine harness retaining bolts.
Tighten to 4 Nm.
36. Attach the engine wiring harness.
38. Connect the electrical connector.

40. Attach the electrical connector onto the valve cover.

Installation).
Engine - TDV6 2.7L Diesel - Camshaft Rear Seal
Special Tool(s)
Holder - Camshaft Pulley - Rear
303-1125
Remover - Camshaft Oil Seal
303-1118
303-1119
Removal
3. Using special tool, retain the camshaft rear pulley.
Remove and discard the retaining bolt.
4. Remove the camshaft rear pulley.

5. Install the special tool to the camshaft.

Install the special tool into the camshaft rear seal.

Install the special tool into the camshaft rear seal.
8. Using the special tool, remove and discard the camshaft rear seal.
Installation
1. CAUTIONS:
Do not use any lubricant on the camshaft rear seal or the camshaft.
NOTE: Make sure that the seal is 1mm below the face of the cylinder
head.
Using the special tool, install the camshaft rear seal.
Use the discarded camshaft pulley hub retaining bolt with the
special tool.
2. Install the camshaft rear pulley.
3. Using the special tool, install the camshaft rear pulley retaining bolt.
1. Stage one: Tighten to 80 Nm.
2. Stage two: Tighten a further 80 degrees.

Engine - TDV6 2.7L Diesel - Crankshaft Front Seal
Special Tool(s)
Locking Tool - Flywheel
303-1123
Timing Pin - Automatic Transmission
303-1117
Crankshaft Front Seal Remover
303-1120
Crankshaft Front Seal Sleeve
303-1122
Crankshaft Front Seal Installer
303-1121
General purpose puller
303-D121
Removal


6. Loosen the crankshaft pulley retaining bolt.
7. Using the special tool, release the crankshaft pulley.

8. Remove the crankshaft pulley.
Remove the crankshaft pulley retaining bolt.
Discard the bolt.
9. Install the special tool to the crankshaft.
10. Using the special tool, remove the crankshaft front seal.
Remove and discard the seal from the special tool.
Installation
1. CAUTION: Do not use any lubricant on the crankshaft front seal,

special tools or the crankshaft. Failure to follow this instruction may result
in damage to the vehicle.
NOTE: Make sure that all the component mating faces are clean.
Install a new crankshaft front seal to the special tool.

2. Reposition the crankshaft front seal along the special tool.
Remove the sleeve from the special tool.
5. CAUTIONS:
Make sure that the seal is seated 1mm under flush.
Using the special tool, install the crankshaft front seal.
Use the discarded crankshaft bolt with the service tool.
Remove and discard the crankshaft pulley retaining bolt.

7. Install the crankshaft pulley.
Install a new crankshaft pulley retaining bolt.


Engine - TDV6 2.7L Diesel - Crankshaft Pulley
Special Tool(s)
303-1123
303-1117
303-D121
Removal


3. Remove and discard the timing belt.
5. Using the special tool, lock the flexplate.

6. Loosen the crankshaft pulley retaining bolt.
7. Using the special tool, release the crankshaft pulley.
Discard the bolt.
Installation
1. CAUTIONS:
Make sure that the pulley washer is correctly seated before

installing the pulley.
Do not lubricate the components.
Install the crankshaft pulley.
Install a new crankshaft pulley retaining bolt.


Engine - TDV6 2.7L Diesel - Crankshaft Rear Seal
Removal


3. Remove the crankshaft position (CKP) sensor ring.
For additional information, refer to: Crankshaft Position (CKP) Sensor
Ring (303-14A Electronic Engine Controls - TDV6 2.7L Diesel, Removal
and Installation).
4. Remove the crankshaft rear seal retaining bolts.
5. Remove the crankshaft rear oil seal carrier.
Remove the retaining bolts.
Remove and discard the rear crankshaft oil seal.
Installation
1. CAUTIONS:
Make sure that the crankshaft rear oil seal is correctly located.
Make sure the crankshaft seal mating faces are clean and dry.
Apply an 8 mm bead of sealant to the cylinder block in the areas shown.
2. Install the crankshaft rear oil seal carrier.
Lubricate the oil seal.
3. Install the retaining bolt.
Tighten to 10 Nm.
4. Install the remaining retaining bolts.
Tighten to 10 Nm.
5. Install the crankshaft rear seal retaining bolts.
Tighten to 10 Nm.
6. Install the CKP sensor ring.

For additional information, refer to: Crankshaft Position (CKP) Sensor
Ring (303-14A Electronic Engine Controls - TDV6 2.7L Diesel, Removal
and Installation).
Engine - TDV6 2.7L Diesel - Crankshaft Vibration Damper
Special Tool(s)
303-703
Removal
Installation).
1. Using the special tool, rotate the accessory drive belt

tensioner counter clockwise.
5. Remove the crankshaft damper.
1. Remove the 6 bolts.
Installation
1. Install the crankshaft damper.
Clean the components.
Tighten to 25 Nm.
2. Attach the accessory drive belt.

Installation).
Engine - TDV6 2.7L Diesel - Cylinder Head LH
Removal
2. Drain the cooling system.
For additional information, refer to: Cooling System Draining, Filling and
Bleeding (303-03A Engine Cooling - TDV6 2.7L Diesel, General
Procedures).
3. Remove the left-hand camshafts.
For additional information, refer to: Camshaft LH (303-01A Engine -
TDV6 2.7L Diesel, Removal and Installation).
4. Remove the LH exhaust manifold.
For additional information, refer to: Exhaust Manifold (303-01A Engine -
5. Detach the coolant expansion tank hose from the cylinder head coolant
outlet assembly.
6. Detach the engine coolant hose from the cylinder head coolant outlet
assembly.
7. Detach the radiator upper hose from the cylinder head coolant outlet
assembly.
8. Remove the cylinder head coolant outlet assembly.
9. Reposition the fuel filter and support bracket.
10. Disconnect the EGR valve electrical connector.
11. Disconnect the coolant hose from the EGR valve.

12. Release the EGR valve.
13. Remove the EGR valve.
Disconnect the coolant hose.
14. Remove the glow plugs.

For additional information, refer to: Glow Plugs - 2.7L V6 - TdV6
(303-07C Glow Plug System, Removal and Installation).
15. Disconnect the camshaft position (CMP) sensor electrical connector.
16. Remove the hydraulic adjuster and rocker assemblies.

17. CAUTION: Only use a plastic scraper to clean off the old gasket.
Remove the LH cylinder head assembly.
Remove and discard the eight cylinder head bolts.
Remove and discard the cylinder head gasket.
Installation
1. CAUTIONS:
Use care when installing the cylinder head. Damage to the cylinder
block, cylinder head or cylinder head gasket may result.
The head gasket must be installed over the cylinder block dowels.
NOTE: Install a new cylinder head gasket.
NOTE: Tighten the retaining bolts in the indicated sequence in four

stages.
NOTE: No additional lubrication to the cylinder head bolts is required.
Install the LH cylinder head assembly and install new cylinder head
retaining bolts.
Stage 4: Tighten a further 180 degrees.
2. Install the hydraulic adjuster and rocker assemblies.
3. Connect the camshaft position (CMP) sensor electrical connector.
4. Install the glow plugs.

For additional information, refer to: Glow Plugs - 2.7L V6 - TdV6
(303-07C Glow Plug System, Removal and Installation).
5. Install the EGR valve.
Connect the coolant hose.
6. Secure the EGR valve.
Tighten to 10 Nm.
7. Connect the coolant hose to the EGR valve.
8. Connect the EGR valve electrical connector.

9. Secure the fuel filter and support bracket.
Tighten to 27 Nm.
10. NOTE: Install new O-ring seals.
Install the cylinder head coolant outlet assembly.
Tighten to 10 Nm.
11. Attach the radiator upper hose onto the cylinder head coolant outlet
assembly.
12. Attach the engine coolant hose onto the cylinder head coolant outlet
assembly.
13. Attach the coolant expansion tank hose onto cylinder head coolant
outlet assembly.
14. Install the exhaust manifold.

For additional information, refer to: Exhaust Manifold (303-01A Engine -
15. Install the LH camshafts.
For additional information, refer to: Camshaft LH (303-01A Engine -
16. Fill and bleed the cooling system.
Procedures).
Engine - TDV6 2.7L Diesel - Engine Mount LH
Special Tool(s)
HTJ1200-2
Removal
All vehicles



4. Make sure the alignment mark, on the steering gear pinion seal
protection cover, is central to the steering gear pinion casting.
5. CAUTION: Do not turn the steering wheel with the steering column
lower shaft disconnected as damage to the clockspring and steering wheel
switches may occur.
Remove the steering gear shaft pinch bolt.

6. Disconnect the power steering control valve actuator electrical
connector.
8. Support the steering gear.
All vehicles
9. Remove the engine mounts lower retaining nuts.
10. Release the LH turbocharger intake tube.

13. Using snap-on tool FRDHM15, remove the nut.

15. Using the special tool, raise and support the engine.
Raise the LH side of the engine.
Remove the LH engine mount.
Installation
All vehicles
Install the LH engine mount.
2. Using the special tools, lower the engine.

4. Using snap-on tool FRDHM15, install the nut.
Tighten to 47 Nm.
Tighten to 27 Nm.

7. Install the engine mount lower retaining nut.
Tighten to 63 Nm.
8. Secure the LH turbocharger inlet tube.

9. Attach the steering gear.
Tighten to 100 Nm.
10. Connect the power steering control valve actuator electrical connector.
11. Install the steering gear shaft pinch bolt.
Tighten to 35 Nm.
All vehicles
Engine - TDV6 2.7L Diesel - Engine Mount RH
Special Tool(s)
303-703
HTJ1200-2
Removal
All vehicles



switches may occur.

connector.
All vehicles
9. Detach the starter motor solenoid harness.
10. Detach the starter motor cable.
11. Remove the right-hand turbocharger outlet pipe.
Remove the bolt.
Release the turbocharger outlet pipe clip.
Detach the wiring harness clip.

13. Disconnect the battery positive cable from the generator.
14. Release and reposition the generator.
15. Disconnect the generator electrical connector.
16. Detach the engine mount.

Raise the RH side of the engine by approximately 15 mm.
18. Release the engine mount bracket.
19. Detach the engine mounting bracket.
20. Remove the RH engine mount.
Installation
All vehicles
1. Install the RH engine mount.
2. Attach the RH engine mount bracket.
Tighten to 47 Nm.
3. Secure the engine mount bracket.
Tighten to 90 Nm.
5. Attach the engine mount.
Tighten to 63 Nm.
6. Connect the generator electrical connector.
7. Secure the generator.
Tighten to 47 Nm.
8. Connect the battery positive cable to the generator.
Tighten to 20 Nm.

10. Install the right-hand turbocharger outlet pipe.
Secure the turbocharger outlet pipe clip.
Attach the wiring harness clip.
11. Attach the starter motor cable.
Tighten to 10 Nm.
12. Attach the starter motor solenoid harness.
Tighten to 7 Nm.

Tighten to 100 Nm.
Tighten to 35 Nm.

Engine - TDV6 2.7L Diesel - Exhaust Manifold
Removal


3. Remove the RH turbocharger.
For additional information, refer to: Turbocharger RH (303-04B Fuel
Charging and Controls - Turbocharger - TDV6 2.7L Diesel, Removal and
Installation).
4. Disconnect the EGR valve inlet tube.
Discard the gasket.
5. Remove the exhaust manifold front heat shield.
6. Remove the exhaust manifold heat shield.

7. NOTE: New exhaust manifold retaining studs must be fitted if the old
studs are removed.
Remove the exhaust manifold.
Remove and discard the retaining nuts.
8. Remove and discard the exhaust manifold gasket.
Installation
1. NOTE: New exhaust manifold retaining studs must be fitted if the old
studs are removed.
Install a new exhaust manifold gasket.
Install new retaining nuts.
Tighten to 23 Nm.
Engine - TDV6 2.7L Diesel - Flexplate
Special Tool(s)
303-1123
Removal
3. Remove the automatic transmission.
4. Remove the starter motor retaining bracket.

7. NOTE: Some variation in the illustrations may occur, but the essential
information is always correct.
Remove the starter motor.
9. NOTE: Prevent the flexplate from rotating.
Remove the flexplate.
Remove and discard the bolts.
Installation
1. NOTE: Make sure that all the component mating faces are clean.
NOTE: Loosely install all retaining bolts.
Install the flexplate.
Prevent the flexplate from rotating.
Install new retaining bolts.

2. CAUTION: Tighten the bolts evenly in the stages shown.
Tighten the flexplate securing bolts.
Stage 2: Tighten to 45 degrees.
Stage 3: Tighten to 45 degrees.
Install the starter motor.
6. Tighten to 7 Nm.
8. Install the automatic transmission.

Engine - TDV6 2.7L Diesel - Oil Filter Element
Special Tool(s)
Remover - Oil Filter Element
303-1128
Removal
2. Remove the oil filter element housing.
Rotate the oil filter element housing five complete turns counter-
clockwise.
Allow the engine oil to drain from the oil filter element housing for
two minutes.
Using the special tool, remove the oil filter element.
Installation
Install the oil filter element.

2. Install the oil filter element housing.
Tighten to 25 Nm.

4. Check and top-up the engine oil.
5. Start and run the engine.
6. Check and if necessary top up the engine oil.
Engine - TDV6 2.7L Diesel - Oil Pan
Special Tool(s)
Lifting Brackets - Engine
303-1129
303-021
Removal



7. Drain the engine oil.
For additional information, refer to: Engine Oil Draining and Filling
(303-01A Engine - TDV6 2.7L Diesel, General Procedures).
switches may occur.

connector.

13. Loosen the RH turbocharger outlet tube securing clips.
14. Remove the RH turbocharger outlet tube.
15. Remove the LH engine mount retaining nut.

17. Raise the LH side of the engine.
19. Disconnect the engine oil temperature sensor electrical connector.
20. Reposition the oil pan.
Remove the 21 bolts.
21. Remove the oil strainer bolt.
22. Reposition the oil strainer.
23. NOTE: Discard the gasket.
Remove the oil pan.

Remove the oil strainer pick-up assembly.
25. NOTE: Do not disassemble further if the component is removed for

access only.
Remove the engine oil temperature sensor.
Installation
1. CAUTIONS:
Make sure that the mating faces are clean and free of foreign
material.
Install a new seal.
Install the oil temperature sensor.
Tighten to 24 Nm.
2. CAUTION: Install a new seal.
NOTE: Make sure that all the components are clean.
NOTE: Do not fully install the component at this stage.
Position the oil strainer pick-up assembly.

NOTE: Install a new gasket.
Position the oil pan.

4. Install the oil strainer pick-up assembly.
Tighten to 10 Nm.
5. Install the oil pan.
6. CAUTION: Make sure the gasket is installed correctly.
Install the 21 bolts.
Tighten to 10 Nm.
7. Connect the engine oil temperature sensor electrical connector.
8. Lower the engine onto the engine mount.

9. Install the LH engine mount retaining nut.
Tighten to 63 Nm.
10. Install the RH turbocharger outlet tube.
11. Install the RH turbocharger outlet tube retaining bolt.
Tighten to 10 Nm.
Tighten to 100 Nm.
Connect the steering column lower shaft.
Tighten to 35 Nm.
14. Connect the steering gear control valve actuator electrical connector.

16. Remove the engine support.
18. Fill the engine with the recommended oil to the correct level.
Engine - TDV6 2.7L Diesel - Oil Pan Extension
Special Tool(s)
303-1129
303-021
Removal


3. Remove the transmission assembly.
For additional information, refer to: Transmission - TDV6 2.7L Diesel
(307-01 Automatic Transmission/Transaxle - V8 4.2L Petrol/V8 S/C 4.2L
Petrol/V6 3.0L Petrol/TDV6 2.7L Diesel, Removal).
switches may occur.

connector.
10. Remove the LH engine mount retaining nut.

12. Raise the LH side of the engine.

15. Reposition the oil pan.
16. Remove the oil strainer bolt.
17. Reposition the oil strainer.

Remove the oil pan.
20. Remove the air conditioning (A/C) pipe retaining bolt.
21. Remove the turbocharger outlet pipe retaining bolt.
22. Disconnect the LH turbocharger outlet pipe.

23. Remove the LH turbocharger outlet pipe.
25. Disconnect the battery positive cable from the starter motor solenoid.
26. Disconnect the switch lead from the starter motor solenoid.
27. Remove the starter motor.
28. Release the oil temperature sensor harness.
29. Remove the A/C compressor lower retaining bolt.
30. Remove the bolt from the accessory drive belt tensioner bracket.
31. Remove the charge air cooler pipe retaining bolt.
Remove the oil pan extension.
Installation
1. Clean the component mating faces.
2. Apply an 8 mm bead of sealant to the cylinder block in the areas shown.
For additional information, refer to: Specifications (303-01A Engine -
TDV6 2.7L Diesel, Specifications).
3. NOTE: Install a new gasket.
NOTE: Loosely install all retaining bolts.
Install the oil pan extension.
4. CAUTION: Tighten the bolts in the sequence shown.
NOTE: The retaining bolts must be tightened within twenty minutes of

applying the sealant.
Tighten the oil pan extension retaining bolts in the sequence shown.
1. Tighten bolts A to 10 Nm.
2. Tighten bolts B to 4 Nm.
3. Tighten bolts A to 24 Nm.
4. Tighten bolts B to 10 Nm.

5. Tighten the charge air cooler retaining bolt.
Tighten to 10 Nm.
6. Install the accessory drive belt tensioner bracket bolt.
Tighten to 24 Nm.
7. Install the A/C compressor lower bolt.
Tighten to 24 Nm.
8. Secure the oil temperature sensor harness clip.

Install the starter motor.
Tighten to 48 Nm.
10. Connect the starter motor solenoid electrical connector.
11. Connect the battery positive cable to the starter motor solenoid.
Tighten to 10 Nm.
12. Install the starter motor support bracket.
Tighten to 23 Nm.
13. Install the LH turbocharger outlet pipe and secure with the clips.
Tighten to 5 Nm.
14. Install the LH turbocharger outlet pipe bolt.
Tighten to 24 Nm.
15. Install the A/C pipe retaining bolt.
Tighten to 24 Nm.
NOTE: Make sure that all the components are clean.
Position the oil strainer pick-up assembly.

Position the oil pan.

Tighten to 10 Nm.
20. CAUTION: Make sure the gasket is installed correctly.
Tighten to 10 Nm.
22. Lower the engine onto the engine mount.

23. Install the LH engine mount retaining nut.
Tighten to 63 Nm.
Tighten to 100 Nm.

Connect the steering column lower shaft.
Tighten to 35 Nm.
26. Connect the steering gear control valve actuator electrical connector.
28. Install the transmission assembly.
Engine - TDV6 2.7L Diesel - Oil Pump
Removal
1. Disconnect the battery ground cable. For additional information, refer
to: Battery Disconnect and Connect (414-01 Battery, Mounting and
Cables, General Procedures).
2. Remove the crankshaft front oil seal.
For additional information, refer to: Crankshaft Front Seal (303-01A
Engine - TDV6 2.7L Diesel, Removal and Installation).


4. Remove the oil pan extension.
For additional information, refer to: Oil Pan Extension (303-01A Engine -
5. Release the accessory drive belt tensioner.
Remove the bolt.
6. Release the RH turbocharger outlet pipe clip.
7. Remove the RH turbocharger outlet pipe.
Remove the bolt.
Release the clip.

Reposition the battery positive cable connector cover.
Remove the nut.
10. Remove the 2 lower bolts from the generator.
11. Release the generator.
Remove the generator upper bolt.
Reposition the generator.
Using a suitable tie strap, secure the generator to the front

subframe.
12. NOTE: The generator mounting bracket upper rear bolt cannot be fully
removed until the generator mounting bracket has been detached from the
engine.
Remove the generator mounting bracket.
Remove the 4 bolts.

13. Remove the timing belt idler pulley.
Remove the bolt.
14. Remove the timing belt cover sealing strips.
15. Remove the oil pump.
Remove and discard the gasket.
Installation
1. Prime the oil pump.
1. Fill the orifice shown with 20 ml of engine oil. For additional

information, refer to: Specifications (303-01A Engine - TDV6
2.7L Diesel, Specifications).
2. Rotate the oil pump drive 2 complete turns.

2. CAUTIONS:
material.
Make sure the gasket is installed correctly.
Install the oil pump.
Lightly tighten the bolts in the position shown.
3. CAUTION: Make sure the base of the oil pump is aligned within
0.2 mm of the base of the engine block. Failure to follow this instruction
may result in damage to the vehicle.
NOTE: Vehicles fitted with oil pumps without dowels.
Check the oil pump to engine block alignment.
4. Secure the oil pump.
Tighten the bolts in the sequence shown to 10 Nm .
5. Install timing belt cover sealing strips.

6. Install the timing belt idler pulley.

7. Install the generator mounting bracket.
Loosely install the 4 bolts.
Tighten the 4 bolts in the sequence shown to 23 Nm.
8. Install the generator.
9. Connect the generator electrical connectors.
Connect the generator electrical connection.
10. Install the RH turbocharger outlet tube.
Secure the 2 clips.
11. Install the accessory drive belt tensioner.
Tighten the bolt to 47 Nm (35 lb.ft).
12. Install the oil pan extension.

For additional information, refer to: Oil Pan Extension (303-01A Engine -
13. Install the crankshaft front oil seal.
For additional information, refer to: Crankshaft Front Seal (303-01A
Engine - TDV6 2.7L Diesel, Removal and Installation).
Engine - TDV6 2.7L Diesel - Timing Belt
Special Tool(s)
Check Pin - Camshaft Pulleys
303-1132
303-1126
303-1117
Removal
2. Remove the timing cover.
For additional information, refer to: Timing Cover (303-01A Engine -


5. Release the starter motor solenoid harness.

6. Release the starter motor cable.
7. Release the starter motor.
8. Remove the crankshaft timing alignment grommet from the engine

block.
9. Rotate the crankshaft clockwise to align the crankshaft alignment hole
in the flywheel or flexplate with the block aperture.
10. Check the camshaft pulley alignment holes are correctly aligned. If the
alignment holes are not aligned, rotate the crankshaft one full turn
clockwise.
Install a starter motor bolt to retain the special tool.

12. Remove the accessory drive belt pulley and bracket assembly.
Remove the 3 retaining bolts.
13. Install the special tools to the exhaust camshaft pulleys.
special tools.
Loosen the six exhaust camshaft pulley damper retaining bolts.
Using a suitable tool, counterhold the camshaft pulley center

retaining bolts.
15. Remove and discard the timing belt tensioner.
Remove and discard the bolt.

16. Remove and discard the timing belt.
Installation
1. Rotate both camshaft pulleys clockwise.
2. Install a new timing belt tensioner.
Install a new bolt, but do not fully tighten at this stage.
3. CAUTION: Make sure the camshaft pulleys remain in the clockwise

position.
Install the new timing belt.
Starting at the crankshaft pulley, install the timing belt in a

counter-clockwise direction, in the sequence shown.
Stage one: Attach the timing belt to the crankshaft pulley.
Stage two: Attach the timing belt to the idler pulley.
Stage three: Attach the timing belt to the left-hand camshaft

pulley.
Stage four: Attach the timing belt to the idler pulley.
Stage five: Attach the timing belt to the RH camshaft pulley.
Stage six: Attach the timing belt to the timing belt tensioner.
4. CAUTION: Make sure the timing belt tensioner window is aligned
with the groove.
Tension the timing belt.
Rotate the tensioner assembly counter-clockwise.
Tighten to 24 Nm.

special tools.
Using a suitable tool, counterhold the camshaft pulley center retaining

bolts.
Tighten the six exhaust camshaft pulley damper retaining bolts.
Tighten to 23 Nm.
6. Remove the special tools from the camshaft pulleys.
7. Remove the special tool from the flexplate.
8. CAUTION: Only rotate the crankshaft clockwise.
Rotate the engine two complete turns clockwise.

Install a starter motor bolt to retain the special tool.

10. Install the special tools to the exhaust camshaft pulleys.
If the special tool does not fit correctly, repeat the timing belt
installation procedure.
Remove the special tools from the camshaft pulleys.
11. Install the accessory drive belt pulley and bracket assembly.
Tighten to 80 Nm.
12. Remove the special tool from the flexplate.
Install the grommet.
13. Install the starter motor.
Tighten to 48 Nm.
14. Connect the starter motor cable.
Tighten to 10 Nm.
Tighten to 7 Nm.
16. Install the starter motor retaining bracket.
Tighten to 23 Nm.
17. Install the timing cover.

For additional information, refer to: Timing Cover (303-01A Engine -
Engine - TDV6 2.7L Diesel - Timing Cover
Special Tool(s)
303-703
Removal


For additional information, refer to: Air Cleaner (303-12A Intake Air
Distribution and Filtering - TDV6 2.7L Diesel, Removal and Installation).
5. Remove the accessory drive belt.
For additional information, refer to: Accessory Drive Belt (303-05A
6. Release the coolant hose.
7. Disconnect the engine coolant temperature (ECT) sensor electrical

connector.
8. Detach the ECT sensor wiring harness.
9. Release the exhaust gas recirculation (EGR) valve outlet tube from the
timing cover.
10. Reposition the oil level indicator tube.
11. Remove the LH timing cover.
12. Release the coolant expansion tank hose from the clips.
13. Remove the retaining bolt.
14. Disconnect the electrical connector.
15. Release the intake air shutoff throttle elbow.
Release the retaining clip.
16. Remove the charge air cooler inlet hose.
17. Release the coolant hose.

18. Release the port deactivation valve retaining bracket.
19. Release the air temperature sensor wiring harness.
Release the 2 wiring harness clips.
20. Release the EGR valve outlet tube from the timing cover
21. Remove the RH timing cover.
22. Remove the crankshaft damper.

23. Release the charge air cooler hose.
1. Remove the hose clamp.
24. Remove the charge air hose.
25. CAUTION: Discard the bolts.
NOTE: Using a suitable bar lock the coolant pump pulley.
Remove the coolant pump pulley.
Remove the 3 coolant pump pulley retaining bolts.
26. Remove the lower timing cover.
Installation
Install the lower timing cover.
Tighten to 10 Nm.
2. NOTE: Make sure that new bolts are installed.
Install the coolant pump pulley.
Tighten to 24 Nm.
3. Install the charge air cooler hose.
1. Tighten to 4 Nm.
2. Tighten to 8 Nm.
4. Install the crankshaft damper.
Tighten to 14 Nm.
Install the RH timing cover.
Tighten to 10 Nm.
6. Secure the EGR valve outlet tube to the timing cover.
Tighten to 4 Nm.
7. Attach the air temperature sensor wiring harness.
8. Secure the port deactivation valve retaining bracket.
Tighten to 8 Nm.
9. Secure the coolant hose.
10. Install the charge air cooler hose.
Tighten to 8 Nm.
11. Secure the intake air shutoff throttle elbow.
Install the retaining clip.
13. Install the retaining bolt.
14. Secure the coolant expansion tank hose.
Install the LH timing cover.
Tighten to 10 Nm.
16. Install the oil level indicator tube.
Tighten to 3 Nm.
17. Install the EGR valve outlet tube to the timing cover.
Tighten to 3 Nm.
18. Secure the ECT sensor wiring harness.
19. Connect the ECT sensor electrical connector.
20. Secure the coolant hose.

Engine - TDV6 2.7L Diesel - Valve Cover
Special Tool(s)
303-703
Removal
1. WARNINGS:



injury.
CAUTIONS:

system.



For additional information, refer to: Secondary Bulkhead Center Panel
Installation).

tensioner counter-clockwise.
8. Release the coolant hose retaining clip.

connector.
10. Detach the coolant temperature sensor wiring harness.
11. Remove the oil level indicator tube retaining bolt.
Reposition the oil level indicator tube.

12. Remove the LH timing cover.

15. Remove the 2 remaining fuel injectors.
16. Detach the electrical connector from the left-hand valve cover.

20. Remove the cover from the engine wiring harness casing.
Release the 7 retaining clips.
21. Remove the engine wiring harness casing.
22. Remove the engine breather hose.

23. Disconnect the vacuum pipe.
25. CAUTION: Make sure that the high-pressure fuel supply line
remains in contact with the fuel injection supply manifold and the fuel
injection diverter rail until both unions have been detached and cleaned.
Failure to follow this instruction may result in foreign matter ingress to the
fuel injection system.
26. Remove the LH fuel injection supply manifold.

Installation
1. WARNINGS:



injury.
CAUTIONS:

system.
Install the LH valve cover.
Tighten to 10 Nm.
Tighten to 10 Nm.
Tighten to 24 Nm.
Install the LH fuel injection supply manifold.

7. Install a new high-pressure fuel supply line.
Remove the blanking caps from the ports.
Loosely install the new high-pressure fuel supply line.
Tighten the fuel injection supply manifold retaining bolts to 23 Nm

(17 lb.ft).
Tighten the fuel injection supply line unions in the sequence shown
in four stages:
Stage 1: Tighten the high-pressure fuel supply line union at the

fuel injection diverter rail to 15 Nm (11 lb.ft).

fuel injection supply manifold to 15 Nm (11 lb.ft).


Tighten to 10 Nm.
9. Connect the vacuum pipe.
10. Install the engine breather hose.
11. Install the engine wiring harness casing.
12. Install the engine wiring harness cover.

17. Install the engine compartment brace.
Tighten to 25 Nm.
Install the LH timing cover.
Tighten to 10 Nm.
Tighten the bolt to 3 Nm (2.2 lb.ft).
20. Refit the engine coolant temperature sensor wiring harness.
21. Connect the engine coolant temperature (ECT) sensor electrical

connector.
22. Install the coolant hose retaining clip.

Using the special tool, rotate the accessory drive belt tensioner
counter-clockwise.

Installation).
28. Install the secondary bulkhead center panel.
Engine - TDV6 2.7L Diesel - Valve Cover LH
Removal
1. WARNINGS:



injury.
CAUTIONS:

system.

4. Release the fuel filter assembly and position aside.
5. Remove the fuel filter bracket.
Remove the 2 nuts.
7. Release the Left hand timing cover.
Remove the 6 bolts.
Release from the cylinder head.


13. Detach the electrical connector from the valve cover.
14. Release the left hand knock sensor (KS) electrical connector.
15. Disconnect the left hand KS electrical connector.
18. Disconnect the swirl plate actuator vacuum hose.

20. Remove the engine breather hose.
21. Remove the left hand fuel injection supply manifold.
24. Remove the left hand valve cover.

Installation
1. WARNINGS:



injury.
CAUTIONS:

system.
Install the left hand valve cover.
Tighten to 10 Nm.
Tighten to 10 Nm.
Tighten to 24 Nm.
Install the left hand fuel injection supply manifold.


(17 lb.ft).
in four stages:




Tighten to 10 Nm.
9. Connect the swirl plate actuator vacuum hose.


14. Connect the left hand KS electrical connector.
15. Secure theleft hand KS electrical connector.
Tighten to 25 Nm.
Attach the left hand timing cover.
Tighten to 10 Nm.
Tighten the bolt to 3 Nm (2.2 lb.ft).
20. Install the fuel filter bracket.
Tighten to 25 Nm.
21. Secure the fuel filter assembly.

Engine - TDV6 2.7L Diesel - Valve Cover RH
Removal
1. WARNINGS:



injury.
CAUTIONS:

system.

3. Detach the coolant hose.
4. Remove the intake air shut off throttle elbow bolt.
5. Disconnect the air charge temperature sensor electrical connector.
6. Detach the intake air shut off throttle elbow.
Release the clip.
Position aside.
7. Release the port deactivation solenoid and bracket assembly.
Remove the 3 bolts.
Position aside.
8. Release the right hand timing cover.
Remove the 5 bolts.
Release from the cylinder head.
9. Disconnect the manifold absolute pressure (MAP) sensor and the fuel
pressure sensor electrical connectors.
10. Disconnect the right hand knock sensor (KS) electrical connector.
Release from the valve cover.

13. Disconnect the 2 vacuum lines from the brake vacuum pump.
Position aside.
14. Disconnect the swirl plate actuator vacuum hose.
Detach the engine harness.
Remove the engine breather hose.

Remove the fuel injection pump supply line retaining bolt.

Remove the right hand fuel injection supply manifold.
Remove the fuel injection supply manifold securing bracket.

Remove the engine cover locating studs.
24. Remove the right hand valve cover.
Installation
1. WARNINGS:



injury.
CAUTIONS:

system.
Install the right hand valve cover.
Tighten to 10 Nm.

Tighten to 10 Nm.
Tighten to 24 Nm.
Install the right-hand fuel injection supply manifold.


(17 lb.ft).
in four stages:




Tighten to 10 Nm.
9. Connect the swirl plate actuator vacuum hose.
10. Connect the brake booster vacuum line to the brake vacuum pump.

15. Connect the right-hand KS electrical connector.
16. Attach the KS electrical connector to the valve cover.

17. Connect the MAP sensor and the fuel pressure sensor electrical
connectors.
Attach the right hand timing cover.
Tighten to 10 Nm.
19. Install the port deactivation solenoid and and bracket assembly.
20. Attach the intake air shutoff throttle elbow.
21. Connect the air charge temperature sensor electrical connector.

22. Install the intake air shutoff throttle elbow retaining bolt.
23. Attach the coolant hose.

Removal
Special Tool(s)
303-703
303-1129
303-021
Removal
All vehicles
2. W ARNING: Make sure to support the vehicle with axle stands.

Procedures).
4. Recover the air conditioning (A/C) refrigerant.
5. Remove the cooling fan motor and shroud.
For additional information, refer to: Cooling Fan Motor and Shroud
(303-03A Engine Cooling - TDV6 2.7L Diesel, Removal and Installation).
6. Remove the transmission.
7. Remove the injector sound proofing.
8. Remove the radiator top hose.
9. Disconnect the hose from the radiator.
10. Disconnect the brake booster vacuum pipe.
11. Disconnect the glow plug harness electrical connectors.

13. Disconnect the air intake hose.
14. Detach the coolant expansion tank coolant hose from the intake air
shutoff throttle elbow.
15. Remove the intake air shutoff throttle elbow retaining bolt.
16. Disconnect the intake air temperature (IAT) sensor electrical

connector.
17. Remove the intake air shutoff throttle elbow.

18. Disconnect the exhaust gas recirculation (EGR) coolant hose.
19. Disconnect the coolant hose.
20. Disconnect the charge air cooler inlet hose.
21. CAUTION: Be prepared to collect escaping coolant.
Disconnect the thermostat housing lower radiator hose.

22. Release and reposition the wiring harness.
All vehicles
23. Release the diesel particulate filter (DPF) differential pressure sensor.
24. Remove the RH secondary bulkhead panel.

25. Remove the RH pedestrian protection actuator and bracket.
26. Remove the engine control module (ECM) cover.
27. Disconnect the ECM electrical connectors.

28. Disconnect the engine wiring harness electrical connector.
29. Release the fuel line safety clip.
30. 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 install blanking plugs to any open orifices or lines. Failure to follow
this instruction may result in foreign matter ingress to the fuel injection
system.
Disconnect the high pressure fuel pump supply line from the fuel filter.
system.
Disconnect the high-pressure fuel pump return line from the fuel filter.

system.
Disconnect the fuel line.

Release and reposition the power steering pump.
Tie aside.
36. Disconnect the air conditioning (A/C) compressor supply and return
lines.

38. Disconnect the 2 transmission fluid cooler hoses.

41. Release the battery positive cable protective cover.

43. Disconnect the engine earth strap.
Remove the engine mounts lower retaining nuts.

48. Install the lifting equipment to the vehicle.
Install the lifting chains.
49. Remove the engine.
With assistance, carefully remove the engine.

Installation
Special Tool(s)
303-703
303-1129
303-021
Installation
All vehicles
1. Install the engine.
With assistance, carefully install the engine.
2. Remove the engine lifting equipment.
Remove the lifting chains.
Rotate the special tool adjustment bolt a suitable amount of turns

to support the engine.

Install the engine mounts lower retaining nuts.
Tighten to 63 Nm.
7. Connect the engine earth strap.
Tighten to 25 Nm.
Tighten to 15 Nm.
9. Attach the battery positive cable protective cover.
Tighten to 10 Nm.

12. Connect the 2 coolant hoses to the transmission fluid cooler.
13. Connect the coolant hose.
14. Connect the A/C lines.
Remove the blanking plugs.
Tighten to 10 Nm.
Attach the power steering pump.
Tighten to 25 Nm.
Using the special tool, rotate the accessory drive belt tensioner
counter-clockwise.
17. Install the fuel filter support bracket.
Tighten to 25 Nm.
18. NOTE: Remove and discard the blanking caps.
Connect the fuel line.

Connect the high-pressure fuel pump return line to the fuel filter.
Connect the high pressure fuel pump supply line to the fuel filter.
21. Attach the fuel line safety clip.

22. Connect the engine wiring harness electrical connector.
Tighten to 10 Nm.
23. Connect the ECM electrical connectors.
24. Install the ECM cover.
Tighten to 10 Nm.
25. Install the RH pedestrian protection actuator and bracket.
Tighten to 25 Nm.
26. Install the RH secondary bulkhead panel.
27. Attach the DPF differential pressure sensor.
Tighten to 2 Nm.

28. Attach the wiring harness.
All vehicles
29. Connect the thermostat housing to the radiator.
Attach the retaining clip.
30. Connect the charge air cooler inlet hose.
Tighten to 5 Nm.

32. Connect the RH EGR coolant hose.
33. Install the intake air shutoff throttle elbow.
34. Connect the intake air temperature (IAT) sensor electrical connector.
35. Install the intake air shutoff throttle elbow retaining bolt.
Tighten to 10 Nm.
36. Attach the coolant expansion tank coolant hose to the intake air
shutoff throttle elbow.
37. Connect the air intake hose.
Tighten to 5 Nm.
Tighten to 25 Nm.
39. Connect the glow plug harness electrical connectors.
40. Connect the brake booster vacuum pipe.

41. Connect the coolant hose to the radiator.
42. Connect the coolant top hose.
43. Install the injector sound proofing.

44. Install the transmission.
45. Install the cooling fan motor and shroud.
46. Charge the A/C refrigerant.
47. Refill and bleed the cooling system.
Procedures).
Published: 13-Sep-2011
Engine - V6 3.0L Petrol -
Engine oil, SAE 5W-30 (ROW) API SJ / EC and ACEA A1 or A3 Jaguar WSSM2C913B preferred
Engine oil, SAE 5W-30 (NAS) API SL and ILSAC GF4
Engine assembly lubricant W SP-M2C197-A
Sealant W SS-M4G320-A4
Hose assembly surfactant ESE-M99 B144-B
Engine Firing Order
Firing Order
1:2:3:4:5:6
Engine Valve Clearance (cold)
Intake Valve Exhaust Valve
0.200 mm 0.025 0.350 mm 0.025
Capacities
Description Liters
Engine oil, initial fill 7.0
Engine oil, service fill with oil filter change 6.5
Accessory drive belt idler pulley retaining bolt 25 18 -
Accessory drive belt tensioner retaining bolt 48 35
A/C compressor retaining bolts 25 18 -
A/C compressor mounting bracket retaining bolts 25 18 -
Camshaft bearing caps retaining bolts A - -
Camshaft position sensor retaining bolt 7 - 62
Connecting rod cap retaining bolts Stage 1: 23 - -
Stage 2: 43
Stage 3: 100
Coolant by-pass tube to cylinder head retaining bolts 10 7 -

Crankshaft position sensor retaining bolt 10 7 -
Crankshaft pulley retaining bolt A - -
Cylinder head retaining bolts A - -
Engine ground strap retaining bolt 10 7 -
Engine front cover retaining bolts A - -
Engine mounting bracket retaining bolts 90 66 -
Engine mount bracket to engine mount retaining nuts 48 35 -
Engine mount retaining bolts to crossmember retaining nuts 63 46 -
Engine mount/oil filter housing retaining bolts A - -
Engine wiring harness retaining bracket 7 - 62
Exhaust manifold heat shield retaining bolts 10 7 -
Exhaust manifold retaining studs 9 - 80
Exhaust manifold retaining nuts A - -
Flexplate retaining bolts 80 59 -
Generator retaining bolts 48 35 -
Ignition coils retaining bolts 7 - 62
Knock sensor retaining bolts 25 18 -
Lower cylinder block retaining bolts A - -
Lower intake manifold retaining bolts A - -
Oil level indicator tube retaining bolt 10 7 -
Oil pan retaining bolts A - -
Oil pan drain plug 24 18 -
Oil pressure sensor 16 12 -
Oil separator blanking plate 10 7 -
Oil temperature sensor 14 10 -
Power steering pump retaining bolts 25 18 -
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 retaining bolts 10 7 -
Variable camshaft timing oil control unit retaining bolt 40 + 90 30 + 90 -
Valve cover studs and retaining bolts A - -
W ater pump retaining bolts 25 18 -
W iring harness to valve cover retaining nuts 10 7 -
A = refer to the procedure for correct torque sequence - - -
Engine - V6 3.0L Petrol - Engine - Component Location
External View
Engine - V6 3.0L Petrol - Engine - Overview
Overview
The 3.0 V6 engine is a liquid cooled 6 cylinder unit, arranged in 2 planes having a 60 degree 'V' configuration. It features a strong, forged
steel crankshaft having 3 throws and 4 main bearings.
The lightweight aluminum cylinder block is equipped with steel dry liners and provides 4 main bearings. These are supported by an
aluminum structural bedplate with cast iron inserts. This design increases the torsional stiffness of the crankcase/bed-plate assembly and
minimizes vibration levels. A die-cast aluminum oil pan is bolted to the bed-plate and adds further stiffness.
The 4 cast iron camshafts, 2 per cylinder head, are chain-driven and operate a total of 24 valves (4 valves per cylinder). All valves are
directly activated via mechanical bucket tappets and the inlet camshaft features continuously VCT (variable camshaft timing).
The continuously VCT adjusts the timing of the inlet camshafts. This ensures maximum performance throughout the speed range and for all
engine demands. The system is controlled by the engine management system.
Engine - V6 3.0L Petrol - Engine - System Operation and Component Description
System Operation
Refer to: Electronic Engine Controls (303-14B Electronic Engine Controls - V6 3.0L Petrol, Description and Operation).
General
The engine includes the following features:
10.5 : 1 compression ratio.

Lightweight valve gear.
Unique camshaft lift and duration.
The engine has an aluminum cylinder block with dry steel liners. A forged steel, three-throw crankshaft is carried in four main bearings
supported by an aluminum structural bedplate with cast iron inserts. This design increases the engine's torsional stiffness and minimizes
vibration levels. Torsional stiffness is further increased by a die-cast aluminum oil pan bolted to the bedplate.
Four chain-driven cast iron camshafts, two per cylinder head, operate four valves per cylinder. All valves are directly activated via
mechanical bucket tappets, and the intake camshafts feature VCT (variable camshaft timing). The RH (right-hand) cylinder bank (bank 1)
contains the odd numbered cylinders, with cylinder No. 1 towards the front of the vehicle. The LH (left-hand) cylinder bank (bank 2) contains
the even numbered cylinders, with cylinder No. 2 towards the front of the vehicle.
Variable Camshaft Timing

Oil is supplied to the front of each VCT actuator via the spider bracket assembly, which contains the VCT actuator solenoid, supply oil
galleries and timing chain guide. Oil pressure advances and retards the camshaft timing which is controlled by the engine management
system via a solenoid valve mounted on top of the oil feed spider assembly. Camshaft timing, dependant on engine speed, load and oil
temperature can be optimised over the adjustment range of 30 degrees.
Engine Lubrication System

The engine lubrication system is of the force-feed type in which oil is supplied under pressure to the:
Crankshaft main bearings.

Crankshaft thrust main bearing.
Connecting rod bearings.
Valve shims.
Camshaft bearings.
VCT.
All other parts are lubricated by splashed oil.
The oil is pressurized by a rotary pump installed at the front of the engine block and 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.
Engine - V6 3.0L Petrol - Engine

REFER to: Engine - V8 4.2L Petrol/V8 S/C 4.2L Petrol/3.0L NA V6 - AJ27 (303-00 Engine System - General Information, Diagnosis and
Testing).
Engine - V6 3.0L Petrol - Engine Oil Draining and Filling
General Procedures
Special Tool(s)
Wrench, Oil filter
303-752
WARNING: The spilling of hot engine oil is unavoidable during this procedure, care must be taken to prevent scalding.
CAUTION: Correct installation of the oil filler cap can be obtained by tightening the cap until an audible click is heard.
NOTE: Clean the components general area prior to dismantling.


Installation).
3. Remove the oil pan drain plug.
Position a container to collect the fluid.
Discard the oil pan drain plug seal.
4. Using the special tool, remove the oil filter.
Discard the oil filter.
5. Using the special tool, install the oil filter.
6. Tighten the drain plug to 25 Nm.
Install a new seal.

8. Start engine and run at idle speed until the oil pressure warning light
extinguishes.
Stop the engine.
Check for leaks.

Installation).
Engine - V6 3.0L Petrol - Valve Clearance Adjustment
General Procedures
Special Tool(s)
Fan nozzle - air gun
303-590
Tappet hold-down tool
303-717

For additional information, refer to: Valve Cover LH (303-01B Engine -
V6 3.0L Petrol, In-vehicle Repair).
2. Remove the RH valve cover.
For additional information, refer to: Valve Cover RH (303-01B Engine -
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 tappet
or valve clearance will be incorrect.
Rotate the engine clockwise to position the camshaft lobe away from
the shim surface.
Using the feeler gauge set, measure the clearance between the
camshaft and the shim surface. Record and check the readings.
Repeat the above procedure for the remaining valves.
4. Remove the camshaft bearing cap.

Make sure the legs of the tool are in contact with the edge of the
valve bucket, compress the bucket.
7. Use the following formula to calculate the required shim thickness.

6. W ARNING: The following operations require the use of compressed
air. Always wearshim
Original suitable eye protection.
thickness + measured clearance - desired clearance =
required shim thickness.
CAUTION: Do not use a magnet to remove shims. Failure to follow

8. CAUTIONS:
Use compressed air to remove the shims that require replacing.

Shims must be fitted with the size markings facing the tappet, not
the camshaft.
Surround the immediate working area with a cloth, to retain any
loose shims displaced by the compressed air.
Use
Do notthe special
use tool to
a magnet 303-590,
install aimed
shims. at the edge
Failure of thethese
to follow shim, to lift
it from
instructions theresult
may tappet. Note thetoposition
in damage of each one.
the vehicle.
SelectRemove, clean
and install theand
newmeasure
shims. the shim.
Apply a light coat of clean engine oil to the replacement valve
shims.
10. Install the camshaft bearing caps in their original position.
Lubricate the journals and camshaft lobes with clean engine oil.
Install the cap.
Install the camshaft bearing cap retaining bolts evenly.
Tighten to 10 Nm.
11. If necessary, repeat the above adjustment procedure.
Check the valve tappet clearances are correct.
camshaft and the valve shim.
Adjust the clearances as necessary.
12. W ARNING: The following operations require the use of

compressed air. Always wear suitable eye protection.
CAUTIONS:

Do not use a magnet to remove shims. Failure to follow these

instructions may result in damage to the vehicle.

13. Install the right-hand valve cover.
14. Install the left-hand valve cover.
Engine - V6 3.0L Petrol - Valve Clearance Check
General Procedures

3. CAUTIONS:

Rotate the engine clockwise to position the camshaft lobe away from
the shim surface.
camshaft and the shim surface. Record and check the readings.
4. Adjust the clearances as necessary.

For additional information, refer to: Valve Clearance Adjustment
(303-01B Engine - V6 3.0L Petrol, General Procedures).
5. Install the right-hand valve cover.
6. Install the left-hand valve cover.
Engine - V6 3.0L Petrol - Camshafts LH
In-vehicle Repair
Removal


3. Remove the timing drive components.
For additional information, refer to: Timing Drive Components (303-01B
Engine - V6 3.0L Petrol, In-vehicle Repair).
4. CAUTION: Note the fitted position of the component prior to

removal.
Remove the camshaft bearing caps evenly.

removal.
Remove the camshafts.
Installation
1. CAUTION: Make sure that these components are installed to the

NOTE: Lubricate the camshafts and the camshaft bearing caps with oil
meeting Jaguar specification prior to installation.

2. CAUTIONS:
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.
Make sure that these components are installed to the noted removal
position.
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 to: Valve Clearance Check (303-01B
Engine - V6 3.0L Petrol, General Procedures).
4. Install the timing drive components.
Engine - V6 3.0L Petrol - Crankshaft Front Seal
In-vehicle Repair
Special Tool(s)
Crankshaft Front Seal Remover
303-700
Crankshaft Front Seal Installer
303-542
Crankshaft Pulley Installer
303-102
Removal
For additional information, refer to: Crankshaft Pulley (303-01B Engine -
4. CAUTION: Avoid scratching or damaging the oil seal sealing

surfaces on the crankshaft and cylinder block.
Using the special tool, remove and discard the crankshaft front seal.
Installation
1. Using the special tools, install the crankshaft front seal.
Lubricate the seal with clean engine oil.
Install the crankshaft front oil seal between flush and 1.0 mm
underflush with the cylinder block.

For additional information, refer to: Crankshaft Pulley (303-01B Engine -
Engine - V6 3.0L Petrol - Crankshaft Pulley
In-vehicle Repair
Special Tool(s)
Wrench strap-universal
303-D055
303-D121
Installer - crankshaft damper pulley
303-102
Thrust Pad
303-D121-01
Crankshaft Pulley Installer 303-335/2
Removal
All vehicles


Bleeding (303-03B Engine Cooling - V6 3.0L Petrol, General Procedures).
Vehicles with secondary air injection (AIR)

4. Remove the secondary air injection (AIR) control valve.
For additional information, refer to: Secondary Air Injection (AIR)
Control Valve (303-08B Engine Emission Control - V6 3.0L Petrol,
All vehicles
For additional information, refer to: Throttle Body (303-04C Fuel
Charging and Controls - V6 3.0L Petrol, Removal and Installation).
Disconnect the coolant hoses.
7. Disconnect the radiator upper hose.
8. Disconnect the ECT sensor electrical connector.

9. Remove the fuel line securing bracket retaining bolt.
Disconnect the 2 coolant hoses.
Disconnect the radiator lower hose.
Position the coolant hoses aside for access.
12. Remove the accessory drive pulley.

For additional information, refer to: Accessory Drive Belt Idler Pulley
(303-05B Accessory Drive - V6 3.0L Petrol, Removal and Installation).
Disconnect and remove the coolant hose.

15. NOTE: This step requires the aid of another technician.

17. Using the special tools, remove the crankshaft pulley.
Installation
All vehicles
1. Using the special tools, install the crankshaft pulley.
Coat the crankshaft pulley keyway with silicone gasket sealant

meeting Jaguar specification.
Install the crankshaft pulley bolt.
Tighten to 120 Nm.
Loosen the bolt (minimum 1 turn).
Tighten to 50 Nm.
Angle torque to 90 degrees.

4. Install the coolant hose.
5. Install the accessory drive pulley.

For additional information, refer to: Accessory Drive Belt Idler Pulley
(303-05B Accessory Drive - V6 3.0L Petrol, Removal and Installation).
6. Connect the radiator lower hose.
7. Connect the 2 coolant hoses.

8. Install the fuel line retaining bracket.
Install the bolt and tighten to 10 Nm
9. Connect the ECT sensor electrical connector.
Attach the retaining clip.
10. Connect the radiator upper hose.

11. Connect the coolant hoses.


13. Install the AIR control valve.
All vehicles
14. Carry out the cooling system filling and bleeding procedure.
Engine - V6 3.0L Petrol - 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
303-384
Crankshaft Rear Seal Installer Draw
303-102
Removal


3. Remove the flexplate.
For additional information, refer to: Flexplate (303-01B Engine - V6 3.0L
Petrol, In-vehicle Repair).
4. CAUTION: Avoid scratching or damaging the oil seal sealing

surfaces on the crankshaft and cylinder block.
Using the special tools, remove the crankshaft rear seal.
Installation
1. Clean and inspect the crankshaft rear seal sealing surfaces.
2. Lubricate the crankshaft flange, the crankshaft rear seal, and the seal
lip.
Use engine assembly lubricant or equivalent meeting Jaguar

specification ESR-M99C80-A.
3. 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 seal.
Install the crankshaft rear oil seal between flush and 2.0 mm
underflush with the engine block.
4. Install the flexplate.

For additional information, refer to: Flexplate (303-01B Engine - V6 3.0L
Engine - V6 3.0L Petrol - Cylinder Head
In-vehicle Repair
Removal


For additional information, refer to: Camshafts LH (303-01B Engine - V6
3.0L Petrol, In-vehicle Repair).
4. Disconnect the fuel pressure regulator electrical connector and vacuum
hose.
5. Remove the fuel supply manifold and lower intake manifold.
Remove and discard the lower intake manifold gaskets.
6. Remove the coolant crossover tube.
Discard the O-ring seals.
7. Remove the catalytic converter.

For additional information, refer to: Catalytic Converter (309-00B
Exhaust System - V6 3.0L Petrol, Removal and Installation).
8. NOTE: LH cylinder head only.
Remove the oil level indicator and tube.
Remove the oil level indicator and tube.
Detach the engine harness earth strap from the rear of the left-hand
cylinder head.
10. NOTE: Remove the retaining bolts in the indicated sequence.
Remove the cylinder head.
Remove the retaining bolts in the indicated sequence.
Remove and discard the cylinder head gasket.
Clean and inspect the cylinder head and cylinder block.
Installation
1. NOTE: The cylinder head gasket must be installed over the cylinder
head to 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 cylinder head gasket may result.
NOTE: Make sure the cylinder head is installed in its original position.
NOTE: Make sure the cylinder head is installed in its original position.
NOTE: Tighten the retaining bolts in the indicated sequence in six

stages.
Install the cylinder head and install new cylinder head retaining bolts
and washers.
Stage 2: Tighten the bolts a further 90 degrees.
Stage 3: Loosen 360 degrees.

Attach the engine harness earth strap to the rear of the left-hand
cylinder head.
Tighten to 10 Nm.
Install the oil level indicator and tube.
Tighten to 10 Nm.
5. Install the catalytic converter.

Install the coolant crossover tube.
Tighten to 10 Nm.
7. NOTE: Install new lower intake manifold gaskets.
Install the fuel injection supply manifold and lower intake manifold.
Install the fuel supply manifold and lower intake manifold gaskets.
Tighten the bolts to the sequence shown.
Tighten to 10 Nm.
8. Connect the fuel pressure regulator electrical connector and vacuum
hose.
9. Install the camshafts.

For additional information, refer to: Camshafts LH (303-01B Engine - V6
3.0L Petrol, In-vehicle Repair).
Engine - V6 3.0L Petrol - Engine Front Cover
In-vehicle Repair
Special Tool(s)
Wrench strap-universal
303-D055
Crankshaft front oil seal remover
303-D121
Crankshaft Pulley Installer
303-102
Thrust Pad
303-D121-01
Removal

Raise and support the vehicle. For additional information, refer to:
(100-02 Jacking and Lifting)

4. Remove the oil pan.
For additional information, refer to: Oil Pan (303-01B Engine - V6 3.0L
For additional information, refer to: Accessory Drive Belt (303-05B
Accessory Drive - V6 3.0L Petrol, Removal and Installation).
9. Disconnect the coolant hose from the radiator upper hose assembly.
10. Disconnect the coolant hose assembly from the coolant pump and
lower hose.
11. Remove the hose assembly.
13. Remove the crankshaft pulley retaining bolt.

16. Remove the crankshaft front oil seal.

18. Remove the coolant hose.
19. Remove the coolant pump.

20. Detach the fuel supply manifold retaining bolt.
21. Remove the accessory drive belt tensioner.
22. Detach the engine harness from the right-hand idler pulley.
Detach the splash shield.
Detach the engine harness.
23. Remove the right-hand idler pulley.
24. Remove the left-hand idler pulley.

25. Remove the power steering pump upper retaining bolts.

27. Reposition the splash shield.
Remove the splash shield retaining clip.
28. Detach the power steering pump.

30. Disconnect the crankshaft position (CKP) sensor electrical connector.
31. NOTE: Right-hand camshaft position sensor shown, left-hand similar.
Disconnect the 2 camshaft position (CMP) sensor electrical conectors.
32. Remove the engine front cover.
33. Remove and discard the engine front cover gaskets.
Installation
1. Install new engine front cover gaskets.
2. Apply a 6 mm diameter dot of silicone sealant meeting Jaguar
specification to the indicated locations.
3. 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.
Tighten to 25 Nm.
4. NOTE: Right-hand camshaft position sensor shown, left-hand similar.
Connect and secure the CMP sensor electrical connectors.
5. Connect the CKP sensor electrical connector.

7. Attach the power steering pump.
Tighten to 25 Nm.
Install the splash shield retaining clip.
9. Install the power steering pump upper retaining bolts.
Tighten to 25 Nm.
10. Install the left-hand idler pulley.
Tighten to 25 Nm.
11. Install the right-hand idler pulley.
Tighten to 25 Nm.
12. Attach the engine splash shield.
Attach the engine harness to the right-hand idler pulley.
Attach the engine splash shield.
Tighten to 25 Nm.
Tighten to 45 Nm.
15. Attach the fuel supply manifold retaining bolt.
Tighten to 10 Nm.
16. Install the coolant pump.
Tighten to 25 Nm.
17. Install the coolant hose.

19. Install the crankshaft front oil seal.
20. Using the special tools, install the crankshaft pulley.
Coat the crankshaft pulley keyway with silicone gasket sealant

meeting Jaguar specification.
Coat the sealing surfaces of the crankshaft pulley with silicone

gasket sealant meeting Jaguar specification.
22. Install the crankshaft pulley bolt.
Tighten to 120 Nm.
Loosen the bolt (minimum 1 turn).
Tighten to 50 Nm.
Tighten a further 90 degrees.
23. Install the coolant hose assembly.

24. Connect the coolant hose assembly to the coolant pump and lower
hose.
25. Connect the coolant hose to the radiator upper hose assembly.
26. Connect the radiator upper hose.

For additional information, refer to: Oil Pan (303-01B Engine - V6 3.0L
30. Install the RH valve cover.
Engine - V6 3.0L Petrol - Engine Mount LH
In-vehicle Repair
Special Tool(s)
502-005
Removal

4. CAUTION: Discard the bolt.
Remove the 3 bolts.

7. Remove the engine mount retaining nut.
Support the engine.
8. W ARNING: Do not remove the front subframe retaining bolts.

Failure to follow this procedure may result in personal injury.
Loosen the front subframe retaining bolts to enable the engine mount to
be removed.
9. Remove the engine mount.
Raise the engine.
Installation
1. CAUTION: Make sure the engine mount locators are correctly

aligned on installation. Failure to follow this procedure may result in
Install the engine mount.
Install a new nut and tighten to 48 Nm.

Install the engine mounts retaining nut.
Tighten to 63 Nm.
Tighten to 100 Nm.
8. CAUTION: Make sure that a new bolt is installed.
Install the steering gear shaft pinch bolt.
Tighten to 35 Nm.

For additional information, refer to: Specifications (414-01 Battery,
Mounting and Cables, Specifications).
Engine - V6 3.0L Petrol - Exhaust Manifold LH
In-vehicle Repair
Removal
All vehicles

All vehicles
2. Remove the left-hand exhaust manifold heat shield.

3. Disconnect the secondary air injection (AIR) control valve to exhaust
manifold left-hand tube.
All vehicles
4. NOTE: Engine shown removed for clarity.
NOTE: When an exhaust manifold retaining stud is removed,it must be

replaced with a new retaining stud and nut.
Remove the left-hand exhaust manifold upper retaining nuts.

6. Detach the steering column lower shaft and tie aside.
7. Disconnect the steering gear control valve actuator electrical connector.

9. Using suitable tie strap(s), secure the steering gear.
All vehicles
10. Remove the left-hand catalytic converter.
NOTE: When an exhaust manifold retaining stud is removed, it must be

replaced with a new retaining stud and nut.
Remove the left-hand exhaust manifold.
Installation
All vehicles
NOTE: Tighten the exhaust manifold retaining nuts in the sequence

shown.
NOTE: When a new exhaust manifold retaining stud is installed, tighten

to 9 Nm.
Tighten to 20 Nm.


All vehicles
Engine - V6 3.0L Petrol - Flexplate
In-vehicle Repair
Removal


2. Remove the automatic transmission.
For additional information, refer to: Transmission - V6 3.0L Petrol
Remove the 8 bolts.
Installation
1. CAUTION: Make sure that the locating pin on the crankshaft is

aligned with the guide hole in the flexplate.
Tighten the bolts in the sequence shown in two stages.
Tighten to 15 Nm.
Tighten to 80 Nm.
2. Install the automatic transmission.

Engine - V6 3.0L Petrol - Oil Cooler
In-vehicle Repair
Special Tool(s)
Wrench, Oil filter
303-752
Removal
2. Carry out the cooling system draining procedure.
3. Remove the left-hand engine mount.
For additional information, refer to: Engine Mount LH (303-01B Engine -
Place a suitable container under the vehicle.
Remove the drain plug and drain the engine oil.
5. Remove and discard the engine oil filter.
6. Disconnect the coolant hoses.
7. Remove the oil filter housing.
Remove the center oil filter housing retaining bolt.
Remove the oil filter housing.

8. Remove the oil cooler.
Remove and discard the oil cooler O-ring seal.
Installation
1. Install the oil cooler.
Install a new oil cooler O-ring seal.
Tighten to 58 Nm.
2. Install the oil filter housing.
Loosely install the oil filter housing retaining bolts.
Loosely install the center oil filter housing retaining bolt.
Install the oil filter housing.
3. NOTE: Tighten the bolts in the indicated sequence.
Tighten all bolts to 25 Nm.
Tighten the M22 bolt to 155 Nm.
Tighten the rest to 40 Nm + 90 degrees.

5. Install a new engine oil filter.
6. Install the left-hand engine mount.

For additional information, refer to: Engine Mount LH (303-01B Engine -
7. Install the oil pan drain plug
Tighten to 24 Nm.

9. Refill the engine with oil.
10. Carry out the coolant fill and bleeding procedure.
Engine - V6 3.0L Petrol - Oil Pan
In-vehicle Repair
Removal


For additional information, refer to: Cowl Vent Screen (501-02 Front End
Body Panels, Removal and Installation).
Remove the engine compartment support.
5. Detach the right-hand valve cover wiring harness.
6. Disconnect the left-hand ignition coil-on plug electrical connectors.

7. Detach the left-hand valve cover wiring harness.
9. Remove the front subframe assembly.

For additional information, refer to: Front Subframe - V6 3.0L Petrol
(502-00 Uni-Body, Subframe and Mounting System, Removal and
Installation).
10. Remove the air conditioning (A/C) compressor.
For additional information, refer to: Air Conditioning (A/C) Compressor -
V6 3.0L Petrol (412-03 Air Conditioning, Removal and Installation).
11. Detach the generator battery positive cable protective cover.
12. Disconnect the generator battery positive cable.
Remove the battery positive cable retaining nut.

14. Remove the generator.

16. Detach the power steering hose.
17. Detach the automatic transmission oil cooler tubes retaining bracket.

19. Using the special tools, raise the engine to a suitable height.

21. Remove the oil pan rear retaining bolts.
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.
Installation
1. CAUTION: Install the oil pan within five minutes of applying the
sealer. Failure to follow this instruction may cause damage to the vehicle.
NOTE: Apply a 10 mm dot of silicone gasket and sealant meeting Jaguar

specification to the engine block and front cover mating surface.
Install the oil pan retaining bolts.
1. Install a new gasket.
2. Install the retaining bolts finger tight.

2. Install and tighten the bolts.
Tighten to 10 Nm.
3. Tighten the oil pan retaining bolts.
Tighten the 4 bolts to 10 Nm.
4. Tighten the oil pan retaining bolts.
Complete the tightening sequence as illustrated.
Tighten to 25 Nm.
5. Tighten the oil pan to transmission housing retaining bolts.
Tighten to 48 Nm.
6. Install the front subframe.

For additional information, refer to: Front Subframe - V6 3.0L Petrol
(502-00 Uni-Body, Subframe and Mounting System, Removal and
Installation).
8. CAUTION: Make sure the engine mounts locate into the correct
position when the engine is repositioned.
Using the special tools, reposition the engine.

Raise the vehicle.

10. Attach the automatic transmission oil cooler tubes retaining bracket.
Tighten to 10 Nm.
11. Attach the power steering hose.
Tighten to 10 Nm.
12. NOTE: Install a new sealing washer.
Install the oil pan drain plug.
Tighten to 24 Nm.
Tighten to 48 Nm.
15. Install the battery positive cable retaining nut.
Tighten to 12 Nm.
16. Attach the generator battery positive cable protective cover.
17. Install the air conditioning (AC) compressor.

18. Install the oil level indicator and tube.
Tighten to 10 Nm.
19. Attach the left-hand valve cover wiring harness.
20. Connect the left-hand ignition coils electrical connectors.
21. Attach the right-hand valve cover wiring harness.
Install the engine compartment support.
Tighten to 25 Nm.
23. Install the cowl vent screen.

25. Refill the engine with oil.
Engine - V6 3.0L Petrol - Oil Pump
In-vehicle Repair
Removal


4. Remove the oil pump tube.
5. Remove the oil pump.
Remove the 4 bolts.
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.
Complete the tightening sequence.
Tighten to 10 Nm.
2. Install the oil pump tube.
Tighten to 10 Nm.

Engine - V6 3.0L Petrol - Timing Drive Components
In-vehicle Repair
Removal


For additional information, refer to: Engine Front Cover (303-01B Engine
- V6 3.0L Petrol, In-vehicle Repair).
4. Remove the spark plugs.
5. 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.
6. 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.
8. Release the timing chain tensioner ratchet.
9. NOTE: Keep the timing chain tensioner ratchet released.
Reposition the timing chain tensioner plunger.
10. Retain the timing chain tensioner plunger.
11. Remove the right-hand timing chain tensioner.
12. Remove the right-hand timing chain outer guide.

13. Remove the right-hand timing chain.
14. CAUTION: Inspect and replace the O-ring if necessary.
Remove the right-hand timing chain inner guide.


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.
16. NOTE: Right-hand bank shown, left-hand bank similar.
Release the timing chain tensioner ratchet.
17. NOTE: Keep the timing chain tensioner ratchet released.
NOTE: Right-hand bank shown, left-hand bank similar.
Reposition the timing chain tensioner plunger.

18. NOTE: Right-hand bank shown, left-hand bank similar.
Retain the timing chain tensioner plunger.
19. Remove the left-hand timing chain tensioner.
20. Remove the left-hand timing chain inner guide.
21. Remove the left-hand timing chain.
Remove the left-hand timing chain outer guide.

23. 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.
24. 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.
Install the crankshaft pulley retaining bolt and washer.
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.
4. Rotate the right-hand intake camshaft clockwise until the camshaft
sprocket alignment mark is at the 5 O'clock position and rotate the
right-hand exhaust camshaft sprocket clockwise until the camshaft
sprocket alignment mark is at the 12 O'clock position.
5. Rotate the crankshaft clockwise until the keyway is at the 11 O'clock

position.
Install the left-hand timing chain outer guide.
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.

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.
Install the right-hand timing chain inner guide.
Stage 1: Tighten bolt 1 to 25 Nm.
Stage 2: Tighten bolts 2 to 25 Nm.

14. CAUTIONS:
Make sure the crankshaft keyway is at the 3 O'clock position, the

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
camshaft sprocket is at the 12 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 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.
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.

Remove the crankshaft pulley retaining bolt and washer.
21. CAUTIONS:
Make sure the crankshaft position (CKP) sensor wheel is correctly

installed with the missing tooth aligned to the crankshaft keyway.
Make sure the crankshaft position (CKP) sensor wheel is correctly

installed with the teeth pointing outwards.
Install the crankshaft position (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 (303-01B Engine
- V6 3.0L Petrol, In-vehicle Repair).
Engine - V6 3.0L Petrol - Valve Cover LH
In-vehicle Repair
Removal
1. Remove the left-hand on-plug coils.
For additional information, refer to: Ignition Coil-On-Plug LH (303-07A
Engine Ignition - V6 3.0L Petrol, Removal and Installation).
2. Detach the left-hand valve cover wiring harness.
3. Detach the engine breather tube.
4. Detach the engine wiring harness retaining bracket.
5. Remove the valve cover.
Installation
1. NOTE: Apply a 5mm diameter bead of silicone gasket sealant or
equivalent meeting Jaguar specification on the half round gaskets and
apply an 8mm diameter on the two places where the cylinder head and
front cover join.
Install new valve cover gaskets.
Tighten to 10 Nm.
Engine - V6 3.0L Petrol - Valve Cover RH
In-vehicle Repair
Removal
1. Remove the right-hand on-plug coils.
For additional information, refer to: Ignition Coil-On-Plug RH (303-07A
Engine Ignition - V6 3.0L Petrol, Removal and Installation).
2. Detach the right-hand valve cover wiring harness.
3. Detach the intake manifold rear retaining bracket.
Installation
1. NOTE: Apply a 5mm diameter bead of silicone gasket sealant or
equivalent meeting Jaguar specification on the half round gaskets and
apply an 8mm diameter on the two places where the cylinder head and
front cover join.
Install new valve cover gaskets.
Tighten to 10 Nm.
Engine - V6 3.0L Petrol - Intake Manifold
Removal
Refer to: Air Cleaner Outlet Pipe (303-12B Intake Air Distribution and Filtering - V6
3.0L Petrol, Removal and Installation).
2. 2. 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 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 these instructions may
3.
4. 4. NOTE: Clamp the coolant hose to minimize coolant lose.

5. 5. NOTE: Remove and discard the O-ring seal.
Torque: 10 Nm
6.
7. Torque: 10 Nm
8. Torque: 10 Nm
9.
10. Torque: 10 Nm
11. Torque:
M5 6 Nm
M6 10 Nm
12. Torque: 10 Nm
13.
14.
15.
16. 16. NOTE: Remove and discard the O-ring seals.
17. Torque: 7 Nm
18.
19. Torque: 20 Nm
Installation

Engine - V6 3.0L Petrol - Lower Intake Manifold
Removal
2. Refer to: Fuel Temperature Sensor (303-14B Electronic Engine Controls - V6 3.0L
Petrol, Removal and Installation).
3. Refer to: Intake Manifold (303-01B Engine - V6 3.0L Petrol, Removal and Installation).
4.
5.
6.
7.
8.
9. 9. NOTE: Remove and discard the O-ring seals.
Installation
1. 1. NOTE: Install new O-ring seals.
NOTE: Tighten the bolts in the indicated sequence.
Torque: 10 Nm
2.
3.
4.
5.
6.
7. Refer to: Intake Manifold (303-01B Engine - V6 3.0L Petrol, Removal and Installation).
8. Refer to: Fuel Temperature Sensor (303-14B Electronic Engine Controls - V6 3.0L
Petrol, Removal and Installation).
Removal
Special Tool(s)
Engine Lifting Bracket
303-661
303-021
Removal
All vehicles
3. Remove the cooling module.
For additional information, refer to: Cooling Module (303-03B Engine
Cooling - V6 3.0L Petrol, Removal and Installation).
4. Remove the front RH fender splash shield.
For additional information, refer to: Fender Splash Shield (501-02 Front
6. Evacuate the A/C system.
7. W ARNING: Make sure that the hood is sufficiently supported

before the gas strut is disconnected.
W ith assistance, remove the hood.
Release the hood support struts and secure the hood in an upright
position.
Remove the 2 nuts.
8. Depressurise the fuel system.

For additional information, refer to: Fuel System Pressure Release - V8
4.2L Petrol/V8 S/C 4.2L Petrol/V6 3.0L Petrol (310-00 Fuel System -
9. Remove the RH secondary bulkhead panel.
For additional information, refer to: Secondary Bulkhead Panel RH - V8
4.2L Petrol/V8 S/C 4.2L Petrol/V6 3.0L Petrol/TDV6 2.7L Diesel (501-02
10. Release the engine junction box (EJB).
11. NOTE: The engine control module (ECM) electrical connector retaining
bolt remains captive in the electrical connector.
Disconnect the 2 electrical connectors.
Disconnect the ECM electrical connector.
Disconnect the engine junction box (EJB).
Detach the engine harness grommet from the RH secondary

bulkhead.
Cut the cable tie.
12. CAUTION: Before disconnecting or removing the components,

make sure the area around the joint faces and connections are clean. Plug
open connections to prevent contamination.
NOTE: Some variation in the illustrations may occur, but the essential
Release the clip and disconnect the purge inlet line.
13. Disconnect the fuel supply manifold spring lock coupling.

14. Disconnect the coolant pipes.
15. Release the power steering fluid reservoir.
16. NOTE: The brake booster vacuum hose is attached to the induction
manifold by a quick release coupling.
Detach the brake booster vacuum hose from the intake manifold.
17. Disconnect the secondary air injection (AIR) control valve supply hose.
18. CAUTIONS:
Cap the power steering line to prevent loses of fluid and dirt
ingress.
NOTE: Drain the fluid into a suitable container.
Disconnect the power steering reservoir to power steering pump supply

line.
19. CAUTIONS:
Cap the power steering line to prevent loses of fluid and dirt
ingress.
NOTE: Drain the fluid into a suitable container.
Disconnect the power steering pump to steering gear suppy line.
Loosen the exhaust manifold retaining nut.
21. Install the special tool to the exhaust mainfold.


23. Replace the fuse box.
24. Install the special tool support bars to the special tool.

27. Detach the battery positive cable protective cover.
28. Remove the battery positive cable retaining nut.
29. Disconnect the air conditioning (A/C) compressor supply and return
lines.
30. Reposition the A/C compressor supply and return lines away from the
engine.
31. Detach the power steering hose.
32. Reposition the power steering hose away from the engine.
Remove the engine mounts lower retaining bolts.
34. Detach the transmission fluid cooler tubes retaining bracket.
35. Reposition the transmission fluid cooler tubes away from the engine.
36. Detach the transmission wiring harness.

39. Remove the engine assembly.
Using the special tools, install a suitable floor crane.

Installation
Special Tool(s)
Engine Lifting Bracket
303-661
303-021
Installation
1. NOTE: Make sure all wiring harnesses and oil pipes are suitably
positioned for engine installation.
Install the engine assembly.
Make sure the engine mounts are correctly located.
Remove the floor crane.

4. NOTE: Left-hand engine mount lower retaining bolt shown, right-hand
similar.
Install the engine mounts lower retaining bolts.
Tighten to 63 Nm.
5. Attach the transmission wiring harness
6. Attach the transmission fluid cooler tubes retaining bracket.
Tighten to 10 Nm.
7. Attach the power steering hose.
Tighten to 10 Nm.
8. Install the battery positive cable retaining nut.
Tighten to 12 Nm.
9. Attach the battery positive cable protective cover.

Install the exhaust manifold retaining nut.
Tighten to 25 Nm.
14. NOTE: Un-cap the exposed ports.
Install new A/C compressor O-ring seals.
Lubricate the new 0-rings with A/C refrigerant oil.

15. Connect the A/C compressor supply and return lines.
16. NOTE: Un-cap the power steering pump exposed ports.
Install new power steering pump supply line O-ring seal.
17. CAUTION: If power steering fluid comes into contact with the
paintwork, the affected area must be immediately washed down with cold
water.
Connect the power steering pump to the steering gear suppy line.
18. CAUTION: If power steering fluid comes into contact with the
paintwork, the affected area must be immediately washed down with cold
water.
Connect the power steering reservoir to the power steering pump supply
line.
19. Attach the brake booster vacuum hose to the intake manifold.
20. Connect the secondary air injection (AIR) control valve supply hose.
Connect the fuel supply manifold spring lock coupling.
22. Connect the purge inlet line.

23. Secure the power steering fluid reservoir.
24. Connect the 2 hoses to the coolant pipes.
25. Connect the 2 electrical connectors.
Connect the ECM electrical connector.
Connect the EJB electrical connector.
Attach the engine harness grommet to the RH secondary bulkhead.
Secure the harness with a new cable tie.
26. Install the RH fender splash shield.

For additional information, refer to: Fender Splash Shield (501-02 Front
27. Install the cooling module.
For additional information, refer to: Cooling Module (303-03B Engine
Cooling - V6 3.0L Petrol, Removal and Installation).
29. Install the secondary bulkhead RH panel.
30. Recharge the A/C system.
For additional information, refer to: Air Conditioning (A/C) System
Recovery, Evacuation and Charging (412-00 Climate Control System -
31. Secure the EJB.
32. Install the hood.
Tighten to 25 Nm
Engine - 4.2L NA V8 - AJV8 -
Engine oil, SAE 5W-30 W SS-M2C-912A
Engine assembly lubricant SQM-2C9003 AA EP90
Sealant W SS M4G 320-A3
Capacities
Description Litres
Accessory drivebelt tensioner retaining bolt 40 30 -
Air conditioning compressor retaining bolts 25 18 -
Air conditioning compressor mounting bracket retaining bolts 25 18 -
Camshaft bearing caps retaining bolts 10 7 -
Connecting rod retaining bolts A - -
Crankshaft pulley retaining bolt 320 236 -
Drive plate retaining bolts A - -
Engine front cover retaining bolts 12 9 -
Engine mounting bracket retaining bolts 47 (+/- 7) 35 (+/- 5) -
Engine mount retaining nuts to crossmember 62 (+/- 10) 46 (+/- 7) -
Engine mount bracket to engine mount retaining nuts 47 (+/- 7) 35 (+/- 5) -
Engine wiring harness retaining bracket 10 7 -
Exhaust manifold heat shield retaining bolts 3 - 27
Exhaust manifold heat shield retaining bolt to cylinder head 50 37 -
Exhaust manifold retaining bolts 24 18 -
Flexiplate retaining bolts A - -
Generator lower retaining bolt 40 30 -
Generator upper retaining bolt 21 15 -
Generator mounting bracket retaining bolts 45 33 -
Ignition coil retaining bolts 5 - -
Intake manifold assembly retaining bolts 22 16 -
Intake camshaft sprocket retaining bolt
Stage 1 20 15 -
Stage 2 Further 90 degrees Further 90 degrees -
Knock sensor retaining nuts 20 15 -
Lower cylinder block to the upper cylinder block retaining bolts A - -
Oil cooler to oil filter housing retaining bolt 21 15 -
Oil filter housing retaining bolts 21 15 -
Oil level indicator tube retaining nut 6 - 51
Oil pan retaining bolts 12 9 -
Oil separator retaining bolts (PVC Valve) 5 - 44
Oil filter 18 13 -
Piston cooling jet retaining bolt 9 - 80
Power steering bracket bracket retaining bolts 25 18 -
Primary timing chain tensioner retaining bolts 12 9 -
Primary timing chain tensioner guide retaining bolts 12 9 -
Secondary timing chain tensioner retaining bolts 12 9 -
Spark plugs 27 20 -
Starter motor retaining bolts 45 33 -
Thermostat housing retaining bolts 10 7 -
W ater pump pulley retaining bolts A - -
Upper oil pan retaining bolts 21 15 -
Valve cover retaining bolts 10 7 -
Variable camshaft timing (VCT) oil control unit housing retaining bolts 22 16 -
VCT sprocket centre retaining bolt
Stage 1 20 15 -
Stage 2 Further 90 degrees Further 90 degrees
A = refer to the procedure for the correct torque sequence - - -
Engine - 4.2L NA V8 - AJV8 - Engine - Component Location
External View
Engine - 4.2L NA V8 - AJV8 - Engine - Overview
Overview
The liquid cooled V8 engine is a 4.2 liter unit, arranged in a 90 degree 'V' configuration, with a 4-throw crankshaft
supported by 5 main bearings.
The lightweight cylinder block is of cast aluminum alloy construction with cast iron liners.
The cylinder heads, which are also manufactured in cast aluminum alloy, are unique for each cylinder bank. Deep seated
bolts reduce distortion and secure the cylinder heads to the cylinder block. Each cylinder head incorporates 2 overhead
camshafts, operating 4 valves per cylinder via valve lifters. A VVT (variable valve timing) system gives improved low and
high-speed engine performance and excellent idle quality. The lightweight valve gear provides good economy and noise
levels and is chain driven, via the crankshaft, for durability.
The aluminum alloy bedplate is a casting bolted to the bottom of the cylinder block to retain the crankshaft and improve
lower structure rigidity. The oil pan assembly consists of a pressed steel oil pan bolted to a structural aluminum alloy
casting, which is then bolted to the bedplate.
Engine - 4.2L NA V8 - AJV8 - Engine - System Operation and Component
Description
System Operation
General
Refer to: Electronic Engine Controls (303-14 Electronic Engine Controls - 2.7L Diesel, Description and Operation).
Variable Valve Timing

When directed by the ECM, the VVT (variable valve timing) unit will be set to the optimum position between full advance
and retard for a particular engine speed and load. This is achieved when the ECM sends the energizing signal to the oil
control solenoid until the target position is met. At this point, the energizing signal is reduced to hold the solenoid
position, and as a result the position of the shuttle valve. This function is under closed-loop control, where the ECM will
alter the energizing signal, when required, to maintain the desired position.
Engine oil properties and temperature can affect the ability of the VVT mechanism to follow demand changes to the cam
phase angle. At very low oil-temperatures, movement of the VVT mechanism is sluggish due to increased viscosity, and at
high oil-temperatures the reduced viscosity may impair operation if the oil pressure is too low. To maintain satisfactory
VVT performance, an increased capacity oil pump is installed, plus an engine oil temperature sensor to enable monitoring
by the ECM. The VVT system is normally under closed-loop control except in extreme temperature conditions, such as cold
starts below 0 C (32 F). At extremely high oil-temperatures, the ECM may limit the amount of VVT advance to prevent
the engine from stalling when returning to idle speed.
The VVT does not operate when engine oil-pressure is below 1.25 bar (18.1 lbf/in), as there is insufficient pressure to
release the VVT unit's internal stopper pin. This usually occurs when the engine is shutting-down and the VVT has returned
to the retarded position. The stopper pin locks the camshaft to the VVT unit to ensure camshaft stability during the next
engine start-up.
Engine Structure
ItemDescription
1 Cylinder head (2 off)
2 Cylinder block
3 Bedplate
4 Structural sump
5 Oil pan

The cylinder block is of a cast aluminum alloy construction with cast iron liners. The 90 degree 'V' configuration provides a
rigid structure with good vibration levels. A low volume coolant jacket improves warm-up times and piston noise levels;
the longitudinal flow design of the jacket, with a single cylinder head coolant transfer port in each bank, improves rigidity
and head gasket sealing. The RH (right-hand) cylinder bank is designated as bank 1, and the LH (left-hand) as bank 2,
viewed from the front of the engine.
Data Locations
ItemDescription
1 Engine part number
2 Engine data (main bearing diameters, cylinder bore diameters, etc), emissions code and engine number
Engine data is marked at 3 locations, 2 on the cylinder block (shown) and 1 on the engine front cover, which consists of a
label displaying the engine number. Component diameters are represented by alpha and numeric codes.
Refer to: Crankshaft Main Bearing Journal Clearance - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8 (303-00 Engine System -

The connecting rods are manufactured from sinter-forged steel and have fracture-split bearing caps. The bearing caps are
produced by fracturing the opposing sides of the connecting rod at the bearing horizontal centre line. As well as being
easier to manufacture, when reassembled the fractured surfaces interlock to form a strong seamless joint. The cylinder
position is marked on adjoining sides of the joint to identify matching connecting rods and bearing caps. The connecting
rod bearings are aluminum/tin split plain bearings.
The pistons are of the open-ended skirt design with a dished crown. Three piston rings, 2 compression and one 3-piece oil
control ring, are installed on each piston. Each piston is installed on a gudgeon pin located in a bronze bushing in the
connecting rod.
Connecting Rod Orientation
ItemDescription
1 Bank 1
2 Bank 2
3 Piston
The piston grade number is stamped on the crown of the piston and must coincide with that for each cylinder bore. The
piston must be assembled in the correct orientation for the designated cylinder bore:
Bank 1 - piston grade number and the thick flange of the connecting rod must face the front of the engine.
Bank 2 - piston grade number and the thin flange of the connecting rod must face the front of the engine.
Crankshaft and Structural Sump Components

ItemDescription
1 Bedplate
2 Main bearings - lower (5 off)
Crankshaft and Main Bearings
ItemDescription
1 Crankshaft
2 Thrust washer
3 Thrust washer
4 Main bearings - upper (5 off)
Six counter-balance weights ensure good vibration levels from the 4 throw, 5 bearing crankshaft. Manufactured in cast iron,
the crankshaft also has undercut and rolled fillets for improved strength.
The crankshaft rear oil seal is a press fit in the bedplate to cylinder block interface.
The main bearings are aluminum/tin split plain bearings. An oil groove in the upper half of each bearing transfers the oil
into the crankshaft for lubrication of the connecting rod bearings. An aluminum/tin thrust washer is installed each side of
the top half of the center main bearing.
Bedplate
The bedplate is a structural casting bolted to the bottom of the cylinder block to retain the crankshaft. The use of a
bedplate further improves rigidity. Iron inserts, cast into the main bearing supports of the bedplate, minimize main bearing
clearance changes due to heat expansion.
Two hollow dowels align the bedplate with the cylinder block.
Beads of sealant seal the joint between the bedplate and the cylinder block.
Oil Pan
ItemDescription
1 Oil pan
2 Structural sump
The aluminum alloy structural sump is bolted to the bedplate. A windage tray attached to the underside of the bedplate
isolates the oil pan from the disturbed air produced by the rotation of the crankshaft, to prevent oil aeration and improve
oil drainage. A rubber plug at the rear of the structural sump seals the port that provides access to the torque converter
securing bolts. The engine oil drain plug is located in the pressed steel oil pan, which attaches to the underside of the
aluminum alloy structural sump.
A bead of sealant seals the joint between the structural sump and the bedplate.
Oil Pump
The oil pump is installed on the crankshaft at the front of the engine. The pump outlet port aligns with oil passages in the
bedplate (see Lubrication System for more information).
Starter Drive Plate
ItemDescription
1 Starter drive plate
2 Bolts (8 off)
The starter drive plate is attached to the rear of the crankshaft. A timing disc, for the CKP (crankshaft position) sensor, is
spot welded to the front face of the drive plate.

ItemDescription
1 Secondary chain tensioner
2 Secondary chain
3 VVT unit
4 Primary chain
5 Primary chain tensioner
Multiple link primary and single row secondary chains drive the camshafts of each cylinder bank. The primary chains
transmit the drive from 2 sprockets on the crankshaft to variable valve timing units on the intake camshafts. The
secondary chains transmit the drive from the variable valve-timing units to sprockets on the exhaust camshafts.
A key locates the 2 drive sprockets on the crankshaft. The crankshaft's torsional vibration damper retains the sprockets in
position. The variable valve timing units and the exhaust camshaft sprockets are non-interference, non-keyed fits on their
respective camshafts; the drive being transmitted by the face to face friction load produced by the valve timing
unit/sprocket securing bolt.
Each chain has a hydraulic tensioner operated by engine oil. The primary chains are lubricated via oil squirt tubes located
at the front of the engine block near the crankshaft drive sprockets. A jet of oil from the end of each secondary chain
tensioner lubricates the secondary chains. The primary chain tensioners act on pivoting flexible tensioner blades. The
secondary chain tensioners act directly on the chains. Guide rails are installed on the drive side of the primary chains.
ItemDescription
1 VVT oil control unit
2 VVT oil control solenoid
3 Bush carrier
The VVT unit is a hydraulic actuator mounted on the end of the intake camshaft, which advances or retards the intake
camshaft timing and thereby alters the camshaft to crankshaft phasing. The oil control solenoid, controlled by the ECM,
routes oil pressure to either the advance or retard chambers located either side of the 3 vanes interspersed within the
machined housing of the unit.
The VVT unit is driven by the primary chain and rotates relative to the exhaust camshaft sprocket. W hen the ECM requests
the camshaft timing to advance, the oil control solenoid is energized moving the shuttle valve to the relevant position to
allow engine oil pressure, via a filter, into the VVT unit's advance chambers. W hen the camshaft timing is requested to
retard, the shuttle valve moves position to allow oil pressure to exit the advance chambers, while simultaneously routing
the oil pressure into the retard chambers.
Timing Cover
The aluminum alloy timing cover accommodates the crankshaft front oil seal (a PTFE (polytetrafluoroethylene) lip seal).
Silicon rubber in-groove gaskets seal the joint between the timing cover and the front face of the engine.

ItemDescription
1 Camshaft bearing cap
2 Tappet
3 Collet
4 Valve spring cap
5 Valve spring
6 Valve stem oil seal
7 Valve
8 intake camshaft
9 Exhaust camshaft
The cylinder heads are unique to each cylinder bank. Deep-seated bolts, to reduce distortion, secure the cylinder heads to
the cylinder block. Two hollow dowels align each cylinder head with the cylinder block. The multi-layered steel cylinder
head gasket has cylinder specific coolant flow cross-sections for uniform coolant flow.
The 14 mm (0.55 in) spark plugs, 1 per cylinder, locate in recesses down the centre line of each cylinder head.
The engine-lifting eyes are bolted to the cylinder heads, 2 on the rear (1 per head) and 1 at the front.
Each cylinder head incorporates dual overhead camshafts operating 4 valves per cylinder via solid shim-less valve lifters.
The lightweight valve gear provides good fuel economy and noise levels. Valve head diameters are 31 mm (1.220 in) for
the exhaust and 35 mm (1.378 in) for the intake. All valves have 5 mm (0.197 in) diameter stems supported in sintered
metal seats and guide inserts. Collets, valve collars and spring seats locate single valve springs on both intake and
exhaust valves. Valve stem seals are integrated into the spring seats.
Camshafts
The camshafts are manufactured in chilled cast iron. Five aluminum alloy caps retain each camshaft. Location numbers, 0
to 4 for the intake camshaft and 5 to 9 for the exhaust camshaft, are marked on the outer faces of the caps.
Sensor Timing Ring
ItemDescription
1 Intake camshaft
2 Timing ring
A camshaft position sensor timing ring is located at the rear of both intake camshafts. A flat, machined near the front of
each camshaft, enables the camshafts to be locked during the valve timing procedure.
Camshaft Covers
The camshaft covers are manufactured from thermoplastic. Bank 1 camshaft cover incorporates an outlet for the part load
engine breather and the pressure control valve. Bank 2 camshaft cover incorporates an outlet for the full load engine
breather and the engine oil filler cap. Identical oil separators are incorporated below the breather outlet in each cover.
Refer to: Engine Emission Control (303-08 Engine Emission Control - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8, Description and
Operation).
NOTE: LH exhaust manifold shown, RH exhaust manifold similar.
Exhaust Manifolds
ItemDescription
1 Cylinder head
2 Gasket
3 Heat shield
4 Bolt
5 Gasket
6 LH exhaust manifold
7 Spacer (8 off)
8 Connector for AIR (secondary air injection) system (where fitted)
9 Bolt (8 off)
10 Heat shield
11 Bolt (4 off)
The cast stainless steel exhaust manifolds are unique for each cylinder bank. Each exhaust manifold installation includes
two metal gaskets and two heat shields. Spacers on the securing bolts allow the manifolds to expand and contract with
changes of temperature while maintaining the clamping loads.
Each exhaust manifold incorporates a connector for the AIR system (where fitted). W here an AIR system is not fitted, each
connector is sealed with a cap nut. The RH exhaust manifold incorporates a connection flange for the EGR (exhaust gas
recirculation) system.
Operation).
Lubrication System
Oil is drawn from the reservoir in the oil pan and pressurized by the oil pump. The output from the oil pump is then
filtered, cooled and distributed through internal oil passages.
All moving parts are lubricated by pressure or splash oil. Pressurized oil is also provided for operation of the variable valve
timing units and the timing gear chain tensioners.
The oil returns to the oil pan under gravity. Large drain holes through the cylinder heads and cylinder block ensure the
quick return of the oil, reducing the volume of oil required and enabling an accurate check of the contents soon after the
engine stops.
System replenishment is through the oil filler cap on the LH camshaft cover.
With the exception of the pump, all oil system components are installed on the structural sump.
Oil Pick-up
The fabricated steel oil pick-up is immersed in the oil reservoir to provide a supply to the oil pump during all normal
vehicle attitudes. A mesh screen in the inlet prevents debris from entering the oil system.
Oil Pump
The oil pump is installed on the crankshaft at the front of the engine. The pump inlet and outlet ports align with oil
passages in the bedplate.
The pumping element is an eccentric rotor, which is directly driven by flats on the crankshaft. An integral pressure relief
valve regulates pump outlet pressure at 4.5 bar (65.25 lbf/in).
Oil Filter Assembly

ItemDescription
1 Oil temperature sensor
2 Oil pressure switch
3 Filter head
4 Seal
5 O-ring seal
6 Engine oil cooler
7 Mounting bolt
8 Gasket
9 Filter
The oil filter is a replaceable cartridge with an internal bypass facility that permits full flow bypass if the filter is blocked.
The oil filter is attached to the engine oil cooler, which is attached to a filter head installed on the front of the structural
sump. The filter head also incorporates:
An oil pressure switch.

Refer to: Instrument Cluster (413-01 Instrument Cluster, Description and Operation).
An oil temperature sensor.
Refer to: Electronic Engine Controls (303-14 Electronic Engine Controls - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8,
The engine oil cooler is a liquid-to-liquid heat exchanger cooled by engine coolant. The coolant feed and return hoses for
the engine oil cooler are connected to the radiator lower hose.
Refer to: Engine Cooling (303-03A Engine Cooling - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8, Description and Operation).
Oil Level Gage

The oil level gage locates along the left side of the oil pan, supported in a tube installed in the bedplate. Two holes in the
end of the gage indicate the minimum and maximum oil levels. There is a difference of approximately 1.0 liter (1.0 US
quart) between the two levels.
Engine - 4.2L NA V8 - AJV8 - Engine

REFER to: Engine - 3.0L NA V6 - AJ27/4.2L NA V8 - AJV8/4.2L SC V8 - AJV8 (303-00 Engine System - General Information,
Engine - 4.2L NA V8 - AJV8 - Engine Oil Draining and Filling
General Procedures
Special Tool(s)
Wrench, Oil filter
303-752
WARNING: The spilling of hot engine oil is unavoidable during this procedure, care must be taken to prevent
scalding.


For additional information, refer to: Air Deflector (501-02,
4. Remove the oil filter.
Install a new seal.

8. Start engine and run at idle speed until the oil pressure
warning light extinguishes.
Stop the engine.
Check for leaks.

Engine - 4.2L NA V8 - AJV8 - Valve Clearance Adjustment
General Procedures
Special Tool(s)
303-540
Tappet hold-down tool adaptor
303-540/02
303-590
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 tappet or valve clearance will be incorrect.

Procedures).
2. Check the valve clearances.
For additional information, refer to: Valve Clearance Check
(303-01A Engine - 4.2L NA V8 - AJV8, General Procedures).
3. Rotate the engine clockwise to position the camshaft lobe
away from the valve tappet.
4. Install the special tool 303-540, to the cylinder head.
Tighten the 2 bolts to 10 Nm
5. CAUTION: Do not rotate the crankshaft while the

special tool 303-540/02 is attached to 303-540.
Attach the special tool 303-540/02 to 303-540.
Secure with the 2 wing nuts.
6. Position the special tool to the tappet as shown.
7. Using the special tool, compress the valve spring.

8. CAUTION: Do not use a magnet to remove shims. Failure
to follow these instructions may result in damage to the vehicle.
NOTE: Use the following formula to calculate the required shim

thickness. Original shim thickness + measured shim clearance -
desired clearance = required shim thickness.
Remove, clean and measure the shim.
Surround the immediate working area with a cloth, to

retain any loose shims displaced by the compressed air.
Use the special tool 303-590, aimed at the edge of the

shim, to lift it from the tappet. Note the position of each
one.
9. CAUTIONS:
Shims must be fitted with the size markings facing the

tappet, not the camshaft.
Do not use a magnet to install shims. Failure to follow

Install the new shim.
Lubricate the shim with clean engine oil.
Release and remove the special tools as required.
10. Using the feeler gauge set, measure the clearance

between the camshaft and the valve shim.
11. Repeat the above procedure for the remaining valves.

Engine - 4.2L NA V8 - AJV8 - Valve Clearance Check
General Procedures
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 tappet or valve clearance will be incorrect.

Procedures).
For additional information, refer to: Valve Cover LH (303-01A
Engine - 4.2L NA V8 - AJV8, In-vehicle Repair).
For additional information, refer to: Valve Cover RH (303-01A
4. 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

tappet or valve clearance will be incorrect.
Rotate the engine clockwise to position the camshaft lobe

5. Using the feeler gauge set, measure the clearance between
the camshaft and the valve shim.
6. Repeat the above procedure for the remaining 11 shims.

7. Adjust the clearance as necessary.
8. For cylinder head data, refer to specifications.
For additional information, refer to: Specifications (303-01A
Engine - 4.2L NA V8 - AJV8, Specifications).
9. Install the RH valve cover.
11. Reconnect the battery ground cable.
Procedures).
Engine - 4.2L NA V8 - AJV8 - Camshafts LH
In-vehicle Repair
Special Tool(s)
Camshaft setting/locking tool
303-530
Timing Setting tool
303-645
Timing chain tensioning tool
303-532
303-540
303-540/02
303-590
Removal
Procedures).


For additional information, refer to: Engine Front Cover
(303-01A Engine - 4.2L NA V8 - AJV8, In-vehicle Repair).
4. Remove the crankshaft position (CKP) sensor.
For additional information, refer to: Crankshaft Position (CKP)
Sensor - 4.2L NA V8 - AJV8 (303-14 Electronic Engine Controls
- 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8, Removal and
Installation).
5. CAUTIONS:

Rotate the crankshaft clockwise to position the engine to

top dead center (TDC) number 1 cylinder.
Lock the crankshaft.
Install the screw.
6. Remove the LH variable camshaft timing (VCT) control

solenoid housing.
Remove the 2 bolts.
Remove the nut.
7. Install the special tool to the LH cylinder head.
Rotate the crankshaft until the flats on the camshafts

are parallel with the cylinder head joint faces.
8. Remove the LH primary timing chain tensioner.
Remove the 2 bolts.
9. Remove the LH upper and lower primary timing chain

tensioner guides.
Remove the 2 bolts.
10. Remove the LH primary timing chain.
11. Release the LH camshaft sprocket assembly.
Remove and discard the 2 Torx bolts.

12. Remove the LH secondary timing chain, tensioner and
sprocket assembly.
Remove the 2 bolts.
13. Remove the special tool from the LH cylinder head.
14. CAUTION: Evenly and progressively, release the

camshaft bearing caps.
NOTE: Remove the camshaft bearing caps. Note: their position,

orientation and markings. Each is marked with its position
(number) and an orientation (arrow).
Installation
Replace the valve shims, with the smallest shim

available.
Lubricate the journals and camshaft lobes.

4. Install the LH secondary timing chain tensioner retaining

bolts.
Tighten to 12 Nm.
5. Install the LH primary timing chain.
Make sure the timing chain slack is on the tensioner side

of the timing chain.
6. Install the LH primary timing chain tensioner guides.
Tighten to 12 Nm.
7. 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.
Install the LH primary timing chain tensioner.
Using 3 mm diameter metal rod, retain the chain

tensioner piston.
Remove the retaining rod.
Tighten to 12 Nm.
8. CAUTIONS:
Using the special tool, apply force to the tool in a counter-

clockwise direction, to tension the primary timing chain on its
drive side.
The intake camshaft sprocket retaining bolt MUST be

tightened before the exhaust camshaft sprocket retaining bolt.
Engine damage will occur if this procedure is not followed.
Make sure that new bolts are installed.
Install the special tool to the LH exhaust camshaft sprocket.
Tighten the intake camshaft sprocket retaining bolt to 20

Nm + 90 deg.
Tighten the exhaust camshaft sprocket retaining bolt to

20 Nm + 90 deg.
9. Install the LH VCT control solenoid housing.

Tighten to 22 Nm.

11. Remove the crankshaft locking tool.
Remove the screw.
12. Install the CKP sensor.

Installation).
15. CAUTION: Camshaft lobes must be 180 degrees away

from each valve tappet or valve clearance will be incorrect.
Using the feeler gauge set, measure the clearance between


Tighten the two bolts to 10 Nm.


21. CAUTION: Do not use a magnet to remove shims.

Failure to follow these instructions may result in damage to the
vehicle.



one.
22. CAUTIONS:




Procedures).
Engine - 4.2L NA V8 - AJV8 - Camshafts RH
In-vehicle Repair
Special Tool(s)
303-530
Timing Setting tool
303-645
303-532
303-540
303-540/02
303-590
Removal
Procedures).


Installation).
5. CAUTIONS:


Install the screw.
6. Remove the RH variable camshaft timing (VCT) control

solenoid housing.
Remove the 3 bolts.
7. Install the special tool to the RH cylinder head.


8. Remove the RH primary timing chain tensioner.
Remove the 2 bolts.
9. Remove the RH upper and lower primary timing chain

tensioner guides.
Remove the 2 bolts.
10. Remove the RH primary timing chain.
11. Release the RH camshaft sprocket assembly.

12. Remove the RH secondary timing chain, tensioner and
sprocket assembly.
13. Remove the special tool from the RH cylinder head.
Remove the 3 bolts.


orientation and markings. Each is marked with its position
(number) and an orientation (arrow).
Installation

available.

Tighten to 10 Nm.

4. CAUTION: Make sure the secondary timing chain and

camshaft sprockets are free to rotate.
Install the RH secondary timing chain, tensioner and sprocket

assembly.
Install the Torx bolts, but do not tighten fully at this

stage.
5. Install the RH secondary timing chain tensioner retaining

bolts.
Tighten to 12 Nm.
6. Install the RH primary timing chain.

7. Install the RH primary timing chain tensioner guides.
Tighten to 12 Nm.
8. 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.
Install the RH primary timing chain tensioner.

tensioner piston.
Tighten to 12 Nm.

9. CAUTIONS:
Using the special tool, apply force to the tool in a

counter-clockwise direction, to tension the primary timing
chain on its drive side.

Install the special tool to the RH exhaust camshaft sprocket.

20 Nm + 90deg.
Tighten the intake camshaft sprocket retaining bolt to

20 Nm + 90 deg.
10. Install the RH VCT control solenoid housing.
Tighten to 22 Nm.
Remove the 3 bolts.
Remove the screw.

Installation).





vehicle.



one.
23. CAUTIONS:




Procedures).
Engine - 4.2L NA V8 - AJV8 - Crankshaft Front Seal
In-vehicle Repair
Removal
For additional information, refer to: Crankshaft Pulley (303-01A
Installation
Engine - 4.2L NA V8 - AJV8 - Crankshaft Pulley
In-vehicle Repair
Special Tool(s)
Crankshaft pulley locking
tool
303-191

tool adapter
303-191/02
Seal extractor
303-751
Seal installer
303-750
remover
303-588
Removal
All vehicles
Procedures).


For additional information, refer to: Oil Filter Housing (303-01A
Rotate the accessory drive belt tensioner counter-

clockwise, using a 3/8 " drive wrench.

connector.
Disconnect the steering column lower shaft from the steering

gear.
Tie aside.
Remove the 3 bolts.
All vehicles
8. Disconnect the secondary air injection (AIR) control valve to
exhaust manifold tube.
9. Release the LH exhaust manifold heat shield.
10. Disconnect the AIR control valve to exhaust manifold tube.
Using a suitable tool, release the crankshaft pulley.
Collect the locking ring.

12. Check the crankshaft pulley and locking ring for damage.
Installation
All vehicles
1. CAUTIONS:
Make sure the crankshaft seal mating faces are clean and
dry.
Do not remove the seal protector at this stage.
2. Remove the seal protector.

Install the locking ring.
4. CAUTION: The screw thread in the crankshaft pulley must

be cleaned out before installing a new crankshaft pulley bolt.
Install, but do not tighten, the new crankshaft pulley bolt.
5. CAUTION: Under no circumstances should the crankshaft

setting peg, 303-645, be used in the following operations, to
restrain the crankshaft.
Using the special tools, retain the crankshaft pulley.
Tighten the crankshaft pulley bolt to 380 Nm.

7. Connect the AIR control valve to exhaust manifold tube.
Tighten to 35 Nm.
8. Secure the LH exhaust manifold heat shield.
Tighten to 10 Nm.
9. Connect the AIR control valve to exhaust manifold tube.
Tighten to 35 Nm.

Tighten to 100 Nm.
11. Connect the steering column lower shaft.
Tighten to 35 Nm.
12. Connect the power steering control valve actuator electrical
connector.
All vehicles
For additional information, refer to: Oil Filter Housing (303-01A
Procedures).
Engine - 4.2L NA V8 - AJV8 - Crankshaft Rear Seal
In-vehicle Repair
Special Tool(s)
Crankshaft rear oil seal
remover/installer
303-538
Removal


For additional information, refer to: Flexplate (303-01B Engine
- 4.2L SC V8 - AJV8, In-vehicle Repair).
3. Install the special tools.
Tighten the 2 nuts to retain the special tool.
4. Using the special tool, pierce the seal to create holes for
the 6 self-tapping screws.
5. Using the special tools, remove and discard the crankshaft
rear oil seal.
Install the 6 self-tapping screws.
Adjust the 2 nuts.
Tighten the center bolt.
Installation
1. CAUTION: Do not lubricate the components.
Partially install the crankshaft rear oil seal.
Make sure the components are clean and dry.
Carefully remove the transit sleeve, leaving the seal on

the crankshaft.
3. Using the special tool, install the crankshaft rear oil seal.
Tighten the special tool nuts evenly and progressively

to fully install the seal.

For additional information, refer to: Flexplate (303-01B Engine
- 4.2L SC V8 - AJV8, In-vehicle Repair).
Engine - 4.2L NA V8 - AJV8 - Cylinder Head LH
In-vehicle Repair
Special Tool(s)
303-530
303-540
303-540/02
Removal

2. WARNING: Do not work on or under a vehicle supported only by a


3. Remove the intake manifold.
For additional information, refer to: Intake Manifold (303-01A Engine -
4.2L NA V8 - AJV8, In-vehicle Repair).
For additional information, refer to: Timing Drive Components (303-01A
5. CAUTION: Evenly and progressively, release the camshaft bearing

caps.

orientation and markings. Each is marked with its position (number) and an
orientation (arrow).

NOTE: Make sure the shim remains with the tappet.
Remove the 16 tappets.
8. Remove the CMP sensor.
9. Release the LH catalytic converter.
10. Remove the oil level indicator and tube.
Discard the O-ring seal.

11. CAUTIONS:
The bolts can only be used twice, mark the bolts with a center punch.
If two punch marks are visible, discard the bolts.
Vehicles fitted with Polydrive cylinder head bolts, the cylinder head
bolts must be removed using a 10 mm Polydrive socket or a 10 mm Allen
key. Failure to follow this instruction may result in damage to the
component.
NOTE: Remove the bolts in the indicated sequence.
Remove the 12 cylinder head bolts.
12. CAUTION: The cylinder head must not be placed mating face down.
With assistance remove the cylinder head.

13. Remove and discard the cylinder head gasket.
Clean the cylinder head locating dowels.

access only.
Remove the LH heat shield.
Remove the 4 screws.

access only.
Remove the 8 spacers.

Remove the bolt.
Installation
2. Check cylinder head face for distortion, across the center and from corner
to corner.
3. For cylinder head face distortion data, refer to specifications.

For additional information, refer to: Specifications (303-01A Engine - 4.2L
NA V8 - AJV8, Specifications).
4. NOTE: For
cylinder head with
distortion above the
maximum allowance,
the cylinder head
material must be
measured.
Measure the
cylinder head
material.
Check
measurement
from the
centre of the
exhaust
dowel to the
cylinder head
face as
shown.
If the
measurement
is less than
51.88 mm
the cylinder
head requires
replacement.

6. Tighten the new bolts in the sequence shown, to 24 Nm.
Install the spacers.
7. Install the heat shield.
Tighten the screws.
8. CAUTION: The head gasket must be installed over the cylinder block
dowels.

9. With assistance install the cylinder head.
10. NOTE: Tighten the bolts 1 to 10 in the sequence shown.
Install the cylinder head bolts.
Lubricate the new cylinder head bolt threads with clean engine oil.
Tighten the bolts 1 to 10 to 20 Nm.
Tighten the bolts 1 to 10 to 35 Nm.
Tighten the bolts 1 to 10, a further 90 degrees.
Tighten the M8 bolts 11 and 12 to 25 Nm.
Lubricate the O-ring seal with clean engine oil.
12. Attach the catalytic coverter.
Tighten to 40 Nm.
13. Install the tappets.
Lubricate the components with clean engine oil.
Tighten the bolts in the sequence shown to 10 Nm .
Install the special tool to the LH cylinder head.
17. NOTE: Do not install the LH valve cover until valve clearance adjustment
has been completed.
Install the timing drive components.

For additional information, refer to: Timing Drive Components (303-01A
18. Rotate the engine clockwise to position the camshaft lobe away from
the valve tappet.
19. CAUTION: Camshaft lobes must be 180 degrees away from each
valve tappet or valve clearance will be incorrect.
Using the feeler gauge set, measure the clearance between the camshaft
and the valve shim.


22. CAUTION: Do not rotate the crankshaft while the special tool
303-540/02 is attached to 303-540.
25. CAUTION: Do not use a magnet to remove shims. Failure to follow

NOTE: Use the following formula to calculate the required shim thickness.
Original shim thickness + measured shim clearance - desired clearance =

Use the special tool 303-590, aimed at the edge of the shim, to lift
it from the tappet. Note the position of each one.
26. CAUTIONS:
the camshaft.
Do not use a magnet to install shims. Failure to follow these


27. Using the feeler gauge set, measure the clearance between the

29. Install the intake manifold.
For additional information, refer to: Intake Manifold (303-01A Engine -
30. Connect the battery ground cable and install the cover.
Engine - 4.2L NA V8 - AJV8 - Engine Front Cover
In-vehicle Repair
Removal
Procedures).
2. Recover the A/C refrigerant.


4. Disconnect the engine oil temperature sensor electrical
connector.
5. Disconnect the engine oil pressure (EOP) sensor electrical

connector.
6. Remove the thermostat housing.

For additional information, refer to: Thermostat Housing - 4.2L
NA V8 - AJV8 (303-03A Engine Cooling - 4.2L NA V8 -
7. Detach the oil filter housing.
Remove the 3 bolts.

For additional information, refer to: Power Steering Pump -
4.2L NA V8 - AJV8 (211-02 Power Steering, Removal and
Installation).
9. Remove the coolant expansion tank.
For additional information, refer to: Coolant Expansion Tank
(303-03A Engine Cooling - 4.2L NA V8 - AJV8/4.2L SC V8 -
Release the clip.
Disconnect the quick release connector.
11. Release the auxiliary coolant pump.
12. Release the radiator lower hose.
Release the clip.

13. NOTE: Restrain the pulley to aid the removal of the bolts.
Remove the 3 bolts.

17. Remove the accessory drive belt idler pulley.
Remove the bolt.
Remove the bolt.

19. CAUTION: Immediately cap all refrigerant lines to
prevent ingress of dirt and moisture.
Disconnect the refrigerant lines from the A/C compressor.
Remove the 2 bolts.
Remove and discard the 2 O-ring seals.
20. Position the A/C compressor aside to access the A/C

compressor mounting bracket.
21. Remove the A/C compressor mounting bracket.
Remove the 4 bolts.
22. Remove the power steering pump mounting bracket.
Remove the 4 bolts.
23. LH side: Release the wiring harness.

Remove and discard the 2 gaskets.
Installation
Apply a bead of sealant 3 mm diameter, by 12 mm

long, to the 8 places indicated.
3. Tighten to 25 Nm
4. Tighten to 25 Nm
7. Tighten to 9 Nm.
Engine - 4.2L NA V8 - AJV8 - Engine Mount LH
In-vehicle Repair
Removal
All vehicles



Detach the steering column lower shaft and tie aside.

connector.
Remove the 3 bolts.

All vehicles
7. Release the engine mount.
Support the engine.
8. Remove the engine mount and bracket.
Raise the engine.
Remove the 4 bolts.

Remove the engine mount.
Installation
Tighten to 48 Nm.

Engine - 4.2L NA V8 - AJV8 - Engine Mount RH
In-vehicle Repair
Removal
All vehicles
Procedures).



Release the universal joint from the steering gear.

Release the steering gear.
Remove the 3 bolts.

All vehicles
Support the engine.
Raise the engine.
Remove the 4 bolts.

Installation
All vehicles
All vehicles

Engine - 4.2L NA V8 - AJV8 - Exhaust Manifold LH
In-vehicle Repair
Removal
All vehicles
Procedures).


3. Release and tie aside the power steering reservoir.
Remove the nut.

5. Remove the LH exhaust manifold heat shield retaining
bolts.

Raise the vehicle.

For additional information, refer to: Catalytic Converter

9. Disconnect the steering column lower shaft from the
steering gear.
Remove the steering column flexible coupling securing

bolts.
10. Disconnect the steering gear control valve actuator
Remove the steering gear retaining bolts.
All vehicles
13. Remove the splash shield retaining clips.
Position the splash shield to one side.

bolts.
Remove the LH exhaust manifold heat shield.

15. Detach the secondary air injection (AIR) control valve to
exhaust manifold tube from the exhaust manifold.
All vehicles
16. Remove the exhaust manifold.
17. Remove and discard the LH exhaust manifold gasket.
Remove the bolt.

Installation
All vehicles
1. Install the LH exhaust manifold gasket.
2. Install the LH exhaust manifold.
Evenly and progressively, tighten the new bolts in the

sequence shown, to 24 Nm.

3. Attach the AIR control valve to exhaust manifold tube to the
exhaust manifold.
Tighten to 35 Nm.
All vehicles
4. Install the LH exhaust manifold heat shield.

6. Connect the steering gear control valve actuator electrical

connector.
7. Connect the lower steering column shaft to the steering
gear.
All vehicles
Install the 2 clips.

12. With
13. Installassistance,
the LH exhaust
installmanifold heat indicator
the oil level shield retaining bolts.
and tube.
Tighten the
Clean the bolts to 8 Nm.
components.

14. Install the power steering fluid reservoir.

Procedures).
Engine - 4.2L NA V8 - AJV8 - Flexplate
In-vehicle Repair
Removal
For additional information, refer to: Transmission - 4.2L NA V8
- AJV8/4.2L SC V8 - AJV8 (307-01 Automatic
Transmission/Transaxle - 2.7L V6 - TdV6/3.0L NA V6 -
AJ27/4.2L NA V8 - AJV8/4.2L SC V8 - AJV8, Removal).


Remove the 8 bolts.
Installation
1. CAUTION: Make sure that the locating pin on the

crankshaft is aligned with the guide hole in the flexplate.
Tighten to 15 Nm.
Tighten to 110 Nm.

Engine - 4.2L NA V8 - AJV8 - Exhaust Manifold RH
In-vehicle Repair
Removal
All vehicles
Procedures).


3. Remove the RH catalytic converter.
4. Release the exhaust heat shield for access.
5. Disconnect the secondary air injection (AIR) control valve to

exhuast manifold right-hand tube from the right-hand
exhaust manifold.
6. Remove the RH exhaust manifold heat shield.

7. Release the EGR valve to exhaust manifold pipe.
Remove the 2 nuts.


10. NOTE: LHD illustration shown, RHD is similar.
Remove the 3 bolts.

12. Disconnect the engine ground cable.
13. Release the starter motor positive cable.

Remove the bolt.
Installation
All vehicles


Engine - 4.2L NA V8 - AJV8 - Intake Manifold
In-vehicle Repair
Special Tool(s)
Fuel spring lock decoupling tool
310-D005
Removal
Procedures).
(303-12A Intake Air Distribution and Filtering - 4.2L NA V8 -
Installation).
4. Disconnect the fuel rail pressure (FRP) sensor electrical
connector.
Disconnect the FRP sensor vacuum line.
5. Disconnnect the throttle body elbow vacuum line.

6. Disconnect the positive crankcase ventilation (PCV) line
from the throttle body elbow.
7. Remove the engine cover LH bracket.
8. Remove the engine cover RH bracket.
9. Release the engine wiring harness from the intake manifold.
10. Release the exhaust gas recirculation (EGR) valve.

11. Release the RH camshaft position (CMP) sensor electrical
connector.
12. Disconnect the fuel line.
13. Release the wiring harness from the rear of the engine.
14. Disconnect the manifold absolute pressure (MAP) sensor

15. Disconnect the 8 fuel injector electrical connectors.
16. Disconnect the fuel temperature sensor electrical

connector.
17. Disconnect the brake booster vacuum hose from the intake
manifold.

Remove the intake manifold.

Remove the foam pad.

20. Remove the throttle body elbow.
21. Remove the intake manifold MAP sensor housing.
22. Remove the 2 intake manifold housings.
Installation

Engine - 4.2L NA V8 - AJV8 - Oil Pan
In-vehicle Repair
Removal
1. WARNING: Do not work on or under a vehicle supported only by

a jack. Always support the vehicle on safety stands.

For additional information, refer to: Air Deflector (501-02, Removal
and Installation).
(303-01A Engine - 4.2L NA V8 - AJV8, General Procedures).
Installation
1. To install,
reverse the
removal
procedure.
Tighten
to 12
Nm.
Engine - 4.2L NA V8 - AJV8 - Oil Pan Extension
In-vehicle Repair
Removal

2. WARNING: Do not work on or under a vehicle supported only


For additional information, refer to: Air Deflector (501-02 Front End
For additional information, refer to: Transmission - 4.2L NA V8 -
AJV8/4.2L SC V8 - AJV8 (307-01 Automatic Transmission/Transaxle -
2.7L V6 - TdV6/3.0L NA V6 - AJ27/4.2L NA V8 - AJV8/4.2L SC V8 -
AJV8, Installation).
For additional information, refer to: Oil Pan (303-01A Engine - 4.2L
NA V8 - AJV8, In-vehicle Repair).
6. Remove the oil strainer pick-up assembly.

connector.
Remove the 3 bolts.
10. Detach the right-hand heated oxygen sensor (HO2S) electrical

connector retaining bracket.
11. Detach the engine wiring harness from the oil pan extension.
12. Disconnect the crankshaft position (CKP) sensor electrical

connector.
14. Remove the transmission bell housing to oil pan retaining bolts.
Disconnect the engine ground cable.
15. Detach the left-hand HO2S electrical connector retaining bracket.
16. Detach the wiring harness from the oil pan.
17. Detach the transmission fluid cooler tubes.

18. Remove the two lower bolts from the air conditioning (A/C)
compressor bracket.
19. Remove the oil pan

extension.
20. NOTE: Use only a plastic scraper when removing old gasket
material.
NOTE: Clean all the mating faces and reusable parts thoroughly and
check for damage.
Apply a continuous bead of RTV sealant (Loctite 5699) 3 mm

diameter, around the flange as indicated.
21. NOTE: It is important that the oil pan extension is bolted to the
bedplate within 20 minutes of applying the RTV sealant.
Apply a continuous bead of RTV sealant ( Loctite 5699 ) 2 mm

diameter, around the diverter valve flange as indicated.
Installation
2.
Tighten
to 21
Nm.
10. Tighten the bolts to 20 Nm.

Engine - 4.2L NA V8 - AJV8 - Oil Pump
In-vehicle Repair
Removal
Procedures).


For additional information, refer to: Timing Drive Components
For additional information, refer to: Oil Pan (303-01A Engine -
5. NOTE: The bolts will remain captive.
Remove the 2 bolts.
6. Remove the oil pump assembly.
Remove the 4 bolts.
Installation
Engine - 4.2L NA V8 - AJV8 - Secondary Timing Chain Tensioner
In-vehicle Repair
Removal
Installation
Engine - 4.2L NA V8 - AJV8 - Timing Drive Components
In-vehicle Repair
Special Tool(s)
303-530
Timing Setting tool
303-645
303-532
Removal
NOTE: This procedure covers the removal and installation of the following components: timing chains, chain guides,
tensioners and sprockets.

Procedures).


Installation).
5. CAUTIONS:


Install the screw.

solenoid housing.
Remove the 3 bolts.

Remove the 2 bolts.

tensioner guides.
Remove the 2 bolts.


solenoid housing.
Remove the 2 bolts.
Remove the nut.
Remove the 2 bolts.

tensioner guides.
Remove the 2 bolts.

sprocket assembly.
Remove the 2 bolts.


sprocket assembly.
20. NOTE: Note the orientation of the crankshaft sprocket.
Remove the crankshaft sprocket.
Remove the crankshaft sprocket key.
Installation
1. Install the crankshaft sprocket.
Install the crankshaft sprocket key.

Install the LH secondary timing chain, tensioner and

sprocket assembly.

stage.
3. Install the special tool to the exhaust camshaft sprocket.
Reposition the camshaft sprockets for the most

advantageous position for use of the special tool.

bolts.
Tighten to 12 Nm.

Tighten to 12 Nm.


tensioner piston.
Tighten to 12 Nm.
8. CAUTIONS:

drive side.


Nm + 90 deg.

20 Nm + 90 deg.
Tighten to 22 Nm.

Install the RH secondary timing chain, tensioner and sprocket

assembly.

stage.

bolts.
Tighten to 12 Nm.

Tighten to 12 Nm.

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.

tensioner piston.
Tighten to 12 Nm.

15. CAUTIONS:



20 Nm + 90 deg.

20 Nm + 90 deg.
Tighten to 22 Nm.
Remove the 3 bolts.
Remove the 3 bolts.

Remove the screw.

Installation).
22. Install the battery ground cable.
Procedures).
Engine - 4.2L NA V8 - AJV8 - Valve Cover LH
In-vehicle Repair
Special Tool(s)
310-D005
Removal

Procedures).
2. Remove the ignition coil-on-plug.
For additional information, refer to: Ignition Coil-On-Plug -
4.2L NA V8 - AJV8 (303-07 Engine Ignition - 4.2L NA V8 -
3. Remove the remaining ignition coil-on-plugs.
Remove the nut.
5. Release the clip and disconnect the purge inlet line.

6. Remove the engine cover bracket.
Remove the 2 nuts.
Position the bracket aside.
7. Release the 3 wiring harness clips.
8. Disconnect the variable camshaft timing (VCT) oil control

solenoid electrical connector.
9. Disconnect the valve cover breather hose.

10. Using the special tool, disconnect the fuel line.
Release the clip.
Position an absorbent cloth to collect fluid spillage.
11. Remove the secondary bulkhead LH panel.

Installation).
12. NOTE: Note the fitted position of the retaining bolts prior
to removal.
Remove the valve cover assembly.
Remove the 14 valve cover retaining bolts.
13. Remove and discard the valve cover gasket.
Carefully remove the sealant.
14. Remove the valve cover plug aperture seals.

15.
16. Remove
NOTE: the disassemble
Do not VCT oil control solenoid
further if theseal.
component is
Remove the oil filler pipe.

Remove the bolts, remove and discard the seals.
Installation
1. NOTE: Install the components to their original fitted positions.
Install the seals and bolts.

2. Install the oil filler pipe.
3. Install new valve cover plug aperture seals.

4. Install a new valve cover gasket.
5. Install the new VCT oil control solenoid seal.
6. NOTE: Apply two beads of silcone gasket sealant as shown
on the illustration. The application of the sealant must be
3mm diameter 12mm long. Install the valve cover immediately
after applying the sealant. The cover should be fitted directly
to the head without smearing the sealant or the seals.
Install the valve cover.
7. Install the valve cover retaining bolts.
Tighten to 12 Nm.
8. Install the secondary bulkhead LH panel.

Installation).
9. Install the engine cover mounting bracket.
Tighten to 10 Nm.
10. Connect the purge line.

Tighten to 6 Nm.
12. Connect the fuel line.
Secure the clip.
13. Connect the VCT oil solenoid electrical connector.

14. Install the ignition coil-on-plug.
15. Install the remaining ignition coil-on-plugs.
Procedures).
Engine - 4.2L NA V8 - AJV8 - Valve Cover RH
In-vehicle Repair
Removal

Procedures).
4. Release the 3 wiring harness clips.
5. Detach the positive crankcase ventilation (PCV) valve from

the RH valve cover.
Disconnect the vacuum hose.

Remove the 2 nuts.
Position the bracket aside.
7. Remove the secondary bulkhead RH panel.

Installation).
8. Remove the valve cover assembly.
10. Remove the valve cover plug aperture seals.

Remove the bolts, remove and discard the seals.
Installation
Tighten to 12 Nm.
3. Tighten to 4 Nm.
Engine - 4.2L NA V8 - AJV8 - Oil Filter Housing
In-vehicle Repair
Special Tool(s)
Wrench, Oil filter
303-752
Removal
Procedures).


connector.

connector.
6. NOTE: Some oil spillage is inevitable during this operation.
NOTE: Clean the components general area prior to

dismantling.
Remove the oil filter.
Drain the engine oil.
7. Detach the oil cooler housing from the oil filter housing.
Remove the 3 bolts.

Remove the engine oil temperature and oil pressure sensors
Installation
Install the engine oil temperature and oil pressure sensors
Tighten to 20 Nm.
3. Attach the oil cooler housing to the oil filter housing.
Tighten to 58 Nm.
Lubricate the oil filter seal with clean engine oil and
tighten to 18 Nm .
5. Connect the EOP sensor electrical connector.

6. Connect the engine oil temperature sensor electrical
connector.
Procedures).
Engine - 4.2L NA V8 - AJV8 - Crankshaft Main Bearing Carrier
Special Tool(s)
Bolts and spacers
303-191-04
Crankshaft pulley locking tool
303-191
Remover, crankshaft seal
303-D121
Timing Setting tool
303-645
303-530
Crankshaft rear oil seal remover/installer
303-538
Seal installer
303-750
Seal extractor
303-751
Crankshaft pulley locking tool adapter
303-191/02
Removal
2. WARNING: Do not work on or under a vehicle supported only


For additional information, refer to: Engine (303-01A Engine - 4.2L
NA V8 - AJV8, Removal).
4. Mount the engine to an engine stand.
5. Disconnect the 2 oil cooler hoses.
Remove the 2 bolts.
Rotate the accessory drive belt tensioner counter-clockwise,

using a 3/8 " drive wrench.
Remove the bolt.
9. NOTE: Note the fitted position of the accessory drive belt.
Remove the accessory drive belt.

Remove the bolt.
Using the special tool, remove the coolant pump pulley.
Remove the 5 bolts.

Remove both the engine mounts and brackets.
Remove the 4 bolts.
Remove the 3 bolts.
Remove the 4 bolts.
Remove the 4 bolts.

Remove the 4 bolts.
18. Disconnect the battery positive cable and the generator electrical
connector.
Release the cover.
Remove the nut.
Remove the nut.
Remove the nut and bolt.

20. RH side: Release the engine wiring harness.
21. Remove the generator mounting bracket.
Remove the 4 bolts.
22. Disconnect the battery positive cable.
Release the cover.
Remove the nut.
23. Disconnect the starter motor solenoid electrical connector.

Remove the 2 bolts.
25. Remove the coolant manifold.
Release the clips and disconnect the 4 coolant hoses.
Remove the 4 bolts.
Disconnect the engine coolant temperature (ECT) sensor


connector.
Remove the 3 bolts.
Release the 2 heated oxygen sensor (HO2S) harness brackets.

connector.
32. Release the engine wiring harness.
Remove the bolt.

33. Release the wiring harness from the LH side of the engine.
Release the clips.
34. Release the wiring harness from the RH side of the engine.
Release the clips.
35. Remove the CKP sensor.
Remove the bolt.

setting peg, 303-645, be used in the following operations, to restrain
the crankshaft.
37. NOTE: The crankshaft pulley retaining bolt will be very tight.
Using the special tools, remove the crankshaft pulley bolt.
Discard the bolt.
38. NOTE: The crankshaft pulley will be very tight.
Using the special tools, remove the crankshaft pulley.

39. Using the special tool, remove and discard the crankshaft front
seal.
Remove both the ignition coil-on-plug covers.
Release from the 2 clips.
41. Disconnect the RH ignition coil-on-plug electrical connector.
42. Remove the RH ignition coil-on-plug.
Remove the bolt.
Remove and discard the seal.
43. Remove the remaining RH ignition coil-on-plugs.

44. Disconnect the positive crankcase ventilation (PCV) line.
45. Disconnect the LH variable camshaft timing ( VCT) oil solenoid

47. Release the engine wiring harness from the retaining bracket.
48. Disconnect the RH variable camshaft timing (VCT) oil solenoid

49. NOTE: Note the
fitted position of the
retaining bolts prior
to removal.
Remove the RH
valve cover.
Remove the
14 valve
cover
retaining
bolts.
Remove the
engine cover
bracket.
50. Remove and discard the RH valve cover gaskets.
Remove and discard the seals.
51. Disconnect the LH ignition coil-on-plug electrical connector.
52. Remove the LH ignition coil-on-plug.
Remove the bolt.
53. Remove the remaining LH ignition coil-on-plugs.

Remove the oil level indicator.
Remove the nut.
Remove the tube.
56. NOTE: Note the

fitted position of the
retaining bolts prior
to removal.
Remove the LH
valve cover.
Remove the
14 valve
cover
retaining
bolts.
57. Remove and discard the LH valve cover gaskets.

58. NOTE: Install the special tool to the crankshaft sensor aperture.
Install the bolt.
59. Remove
the engine
front cover.
Remove
the 24
bolts.
Remove
and
discard
the
gasket.
Remove
and
discard
the 3
O-ring
seals.
60. Remove the RH VCT housing.
Remove the 3 bolts.

62. Remove the RH primary timing chain tensioner assembly.
Remove the 2 bolts.
63. Remove the RH primary timing chain tensioner guide.
Remove the bolt.

65. Remove the LH VCT housing.
Remove the 3 bolts.
Remove the 2 bolts.
68. Remove the LH upper and lower primary timing chain tensioner
guides.
Remove the 2 bolts.

72. Remove the torque converter flexplate.

73. CAUTION: Note the position of the bolts, prior to removal.
Remove the oil pan.
Remove the 2 bolts.

extension.
Remove the 18
bolts.
Remove the 4 bolts.
77. Remove the baffle plate.
Remove the 6 bolts.
78. WARNING: To make sure damage does not occur to the

crankshaft and piston components, the engine must be inverted on the
engine stand. Failure to follow this instruction may result in damage to
the engine.
NOTE: If the crankshaft main bearing carrier retaining bolts have

been marked with a center punch dot, they must be discarded and new
bolts installed.
Remove the crankshaft main bearing carrier.
Remove the crankshaft main bearing carrier retaining bolts in

the indicated sequence.
79. Discard the crankshaft rear main oil seal.
Installation
1. CAUTIONS:
Use only a plastic scraper when removing the sealing material.
If any new bolts are to be installed to retain the crankshaft main

bearing carrier, pre-stress the retaining bolts by installing the
crankshaft main bearing carrier without any sealant and tightening the
new retaining bolts to the specified torque. Remove the crankshaft
main bearing carrier once the bolts have been pre-stressed. Failure to
follow this instruction may result in damage to the vehicle.
Clean all the mating faces and reusable parts thoroughly and check
for damage.
2. NOTE: Install the crankshaft main bearing carrier and tighten bolts
to specification within twenty minutes of applying the sealant.
Apply a 2 mm bead of sealant to the cylinder block in the area

shown.
Use WSS-M4G323-A4-RTV sealant.
3. NOTE: Install the crankshaft main bearing carrier and tighten bolts
to specification within twenty minutes of applying the sealant.
Apply a 1 mm bead of sealant to the cylinder block in the area

shown.
4. CAUTION: Make sure all dowels are fully seated into the
crankshaft main bearing carrier prior to tightening the bolts.
NOTE: Do not lubricate the crankshaft main bearing carrier retaining

bolts.
NOTE: Do not rotate the crankshaft until all the retaining bolts are
tightened to specification.
NOTE: The retaining bolts must be tightened within twenty minutes

of applying the sealant.
NOTE: Tighten the retaining bolts in the sequence shown.
Install the crankshaft main bearing carrier to the cylinder block.
1. Stage 1: Bolts 21 to 32, tighten to 15 Nm.
5. Stage 5: Bolts 1 to 10, tighten to 35 Nm, then a further

135 degrees.

150 degrees.

90 degrees.

150 degrees.
9. Stage 9: Center punch each of the bolt heads to indicate it

has been reused.
5. Rotate the crankshaft to check correct operation.
6. Remove excess sealant which may squeeze out at the front cover
sealing surfaces.
7. Install the baffle plate.

8. NOTE: Carefully remove the transit sleeve, leaving the seal in place.
NOTE: Make sure that the transit sleeve is correctly positioned and
install the new seal over the crankshaft. Do not use any lubricant on
the seal, the transit sleeve or the crankshaft.
Using the special tool, position the crankshaft rear oil seal.
Install the special tool to the crankshaft.
9. CAUTION: Alternate the nut tightening to correctly seat the

crankshaft rear oil seal.
Using the special tool, install the rear crankshaft oil seal.
10. CAUTION: Make sure that the crankshaft rear oil seal is
correctly located.
Install the bolt.
Install the oil pump assembly.
Install the gasket.

Install the torque converter flexplate.
Tighten the bolts evenly in 2 stages to the sequence shown.
Install the oil strainer pick-up assembly.
Install the O-ring seal.
Make sure the timing chain slack is on the tensioner side of the
timing chain.
18. 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 3 mm diameter rod, retain the timing chain tensioner

adjuster.
NOTE: Install new O-ring seals.
Install the LH VCT control solenoid housing.
Install the O-ring seals.
timing chain.
21. Install the RH primary timing chain tensioner guide.


adjuster.
Install the RH VCT control solenoid housing.
Apply a 3 mm diameter bead of sealant, to the area shown.

27. Tighten the oil pan bolts in the sequence shown to 20 Nm.
Remove the bolt.
30. Attach the wiring harness to the LH side of the engine
Secure the clips.
31. Attach the wiring harness to the RH side of the engine.
Secure the clips.
32. Install the power steering pump mounting bracket.

NOTE: Install a new O-ring seal.
Apply a 3 mm diameter bead of sealant 12mm long, to the 8

places shown.
Install the gasket.
34. Tighten the bolts in the sequence shown to 12 Nm.
Secure the clips.
36. NOTE: Install new seals.
Install the LH valve cover plug aperture seals.

NOTE: Apply two beads of silicone gasket sealant as shown on the

illustration. The application of the sealant must be 3 mm (0.118 in)
diameter 12 mm (0.47 in) long. Install the valve cover immediately
after applying the sealant. The cover should be fitted directly to the
head without smearing the sealant or the seals.
Install the valve cover gasket.
38. Install the LH valve cover bolts.
Install the LH valve cover bolts to the positions previously

noted.
Tighten the bolts in the sequence shown to 12 Nm.
39. Connect the LH VCT oil solenoid electrical connector.

40. Attach the engine wiring harness to the retaining bracket.
With assistance, install the oil level indicator and tube.
Install the 4 LH ignition coil-on-plugs.
Install the 4 ignition coil-on-plugs.

44. Install the LH ignition coil-on-plug cover.
Install new RH valve cover plug aperture seals.


diameter 12 mm (0.47 in) long. Install the valve cover immediately
after applying the sealant. The cover should be fitted directly to the
head without smearing the sealant or the seals.
Install the RH valve cover.
Install the gasket.
47. Install the RH valve cover bolts.
Install the RH valve cover bolts to the positons previously

noted.
Install the 4 RH ignition coil-on-plugs.

50. Connect the RH VCT oil solenoid electrical connector.
52. Connect the PCV line to the RH valve cover.
53. Clean the crankshaft pulley mating faces.
54. Using the special tool, install the crankshaft front seal.
Use the discarded crankshaft bolt with the special tool.
56. Install the crankshaft pulley locking ring.
57. CAUTION: The screw thread in the crankshaft pulley must be

cleaned out before installing a new crankshaft pulley bolt.

setting peg, 303-645, be used in the following operations, to restrain
the crankshaft.
Using the special tools, tighten the crankshaft pulley bolt.
60. NOTE: Install a new engine oil filter.
Install the engine oil filter.
Lubricate the oil filter seal with clean engine oil and tighten to
18 Nm .

Install the coolant manifold.
Connect the 4 coolant hoses and install the clips.
Attach the wiring harness bracket.
Tighten the new nut to 7 Nm.
66. Connect the battery positive cable to the starter motor.
Secure the cover.
68. RH side: Attach the wiring harness.
Secure the clips.
Tighten the nut and bolt to 40 Nm.
70. Connect the battery positive cable and generator electrical

connector.
Secure the cover.
71. Install the exhaust manifold heat shield.
Tighten the 2 bolts.
73. Install the A/C compressor mounting bracket.
75. Install the A/C compressor.
76. Install both engine mounts and brackets.

Using the special tool, install the coolant pump pulley.
78. Install the accessory drive belt idler pulley.
Clean and inspect the drive pulleys for damage.
Tighten the accessory drive belt tensioner bolt to 40 Nm.
81. Connect the oil cooler hoses.

82. Remove the engine from the engine stand.
For additional information, refer to: Engine (303-01A Engine - 4.2L
NA V8 - AJV8, Removal).
Removal
Special Tool(s)
303-536
303-749
Removal
Procedures).


For additional information, refer to: Air Conditioning (A/C)
System Recovery, Evacuation and Charging (412-00 Climate
Control System - General Information, General Procedures).
5. Install the torque converter retainer.
For additional information, refer to: Cooling Module - 4.2L NA
V8 - AJV8 (303-03A Engine Cooling - 4.2L NA V8 - AJV8/4.2L
SC V8 - AJV8, Removal and Installation).
7. Remove the hood.

Installation).
Release the engine mounts.

Installation).
14. Release the ECM wiring harnesses and position aside.
15. Disconnect the engine wiring harness.

17. CAUTION: Before disconnecting or removing the

components, make sure the area around the joint faces and
connections are clean. Plug open connections to prevent
contamination.
manifold.
Remove the 2 bolts.


pump.


contamination.

pump.
Release the clip.

connector.
23. Install the special tools to the engine.
Support the engine.
24. Install the lifting equipment to the vehicle.
Install the lifting chains.

Installation
Special Tool(s)
303-536
303-749
Installation
1. Carefully lower the engine onto the engine mounts.
2. Remove the special tools.

3. Connect the brake booster vacuum hose to the intake
manifold.

contamination.
Connect the purge valve.

5. Connect the main engine wiring harness to the ECM.
6. Connect the engine wiring harness.
Tighten to 10 Nm.



contamination.
Connect the low pressure line to the power steering pump.
Secure the clip.

Connect the high-pressure power steering line to the power

steering pump.
Tighten to 20 Nm.
Connect the refrigerant lines to A/C compressor.
Install the engine mounts lower retaining nuts.
Tighten to 63 Nm.
15. Remove the torque converter retainer.

Installation).
For additional information, refer to: Cooling Module - 4.2L NA
Installation).
Tighten to 25 Nm

Procedures).
Engine - 4.2L SC V8 - AJV8 -
Engine oil, SAE 5W-30 W SS-M2C-912B
Engine assembly lubricant SQM-2C9003 AA EP90
Sealant W SE M46323-A4
Capacities
Description Liters
Accessory drivebelt tensioner retaining bolt 40 30 -
Air conditioning compressor retaining bolts 25 18 -
Air conditioning compressor mounting bracket retaining bolts 25 18 -
Camshaft bearing caps retaining bolts 10 7 -
Connecting rod retaining bolts A - -
Crankshaft pulley retaining bolt 377 278 -
Drive plate retaining bolts A - -
Engine front cover retaining bolts 13 10 -
Engine mounting bracket retaining bolts 47 (+/- 7) 35 (+/- 5) -
Engine mount retaining nuts to crossmember 62 (+/- 10) 46 (+/- 7) -
Engine mount bracket to engine mount retaining nuts 47 (+/- 7) 35 (+/- 5) -
Engine wiring harness retaining bracket 10 7 -
Exhaust manifold heat shield retaining bolts 3 - 27
Exhaust manifold heat shield retaining bolt to cylinder head 50 37 -
Exhaust manifold retaining bolts 20 15 -
Flexiplate retaining bolts A - -
Front engine cover retaining bolts 12 9 -
Generator upper retaining bolt 21 15 -
Generator mounting bracket retaining bolts 45 33 -
Ignition coil retaining bolts 5 4 -
Intake manifold assembly retaining bolts 22 16 -
Intake camshaft sprocket retaining bolt
Stage 1 20 15 -
Knock sensor retaining nuts 20 15 -
Lower cylinder block to the upper cylinder block retaining bolts A - -
Oil cooler to oil filter housing retaining bolt 21 15 -
Oil filter housing retaining bolts 21 15 -
Oil level indicator tube retaining nut 6 - 51
Oil pan retaining bolts 12 9 -
Oil separator retaining bolts 5 - 44
Oil filter 18 13 -
Piston cooling jet retaining bolt 9 - 80
Power steering bracket bracket retaining bolts 25 18 -
Primary timing chain tensioner retaining bolts 12 9 -
Primary timing chain tensioner guide retaining bolts 12 9 -
Secondary timing chain tensioner retaining bolts 12 9 -
Spark plugs 27 20 -
Starter motor retaining bolts 45 33 -
W ater pump pulley retaining bolts A - -
Upper oil pan retaining bolts 21 15 -
Valve cover retaining bolts 10 7 -
Variable camshaft timing (VCT) oil control unit housing retaining bolts 22 16 -
VCT sprocket centre retaining bolt
Stage 1 20 15 -
Engine - 4.2L SC V8 - AJV8 - Engine - Component Location
External View
Engine - 4.2L SC V8 - AJV8 - Engine - Overview
Overview
The liquid cooled V8 supercharged engine is a 4.2 liter unit, arranged in a 90 degree V configuration, with a 4-throw
crankshaft supported by 5 main bearings.
The lightweight cylinder block is of cast aluminum alloy construction with cast iron liners.
The cylinder heads, which are also manufactured in cast aluminum alloy, are unique for each cylinder bank. Deep seated
bolts reduce distortion and secure the cylinder heads to the cylinder block. Each cylinder head incorporates 2 overhead
camshafts, operating 4 valves per cylinder via valve lifters. A VVT (variable valve timing) system gives improved low and
high-speed engine performance and excellent idle quality. The lightweight valve gear provides good economy and noise
levels and is chain driven, via the crankshaft, for durability.
The aluminum alloy bedplate is a casting bolted to the bottom of the cylinder block to retain the crankshaft and improve
lower structure rigidity. The oil pan assembly consists of a pressed steel oil pan bolted to a structural aluminum alloy
casting, which is then bolted to the bedplate.
Engine - 4.2L SC V8 - AJV8 - Engine - System Operation and Component
Description
System Operation
General

When directed by the ECM, the VVT (variable valve timing) unit will be set to the optimum position between full advance
and retard for a particular engine speed and load. This is achieved when the ECM sends the energizing signal to the oil
control solenoid until the target position is met. At this point, the energizing signal is reduced to hold the solenoid
position, and as a result the position of the shuttle valve. This function is under closed-loop control, where the ECM will
alter the energizing signal, when required, to maintain the desired position.
Engine oil properties and temperature can affect the ability of the VVT mechanism to follow demand changes to the cam
phase angle. At very low oil-temperatures, movement of the VVT mechanism is sluggish due to increased viscosity, and at
high oil-temperatures the reduced viscosity may impair operation if the oil pressure is too low. To maintain satisfactory
VVT performance, an increased capacity oil pump is installed, plus an engine oil temperature sensor to enable monitoring
by the ECM. The VVT system is normally under closed-loop control except in extreme temperature conditions, such as cold
starts below 0 C (32 F). At extremely high oil-temperatures, the ECM may limit the amount of VVT advance to prevent
the engine from stalling when returning to idle speed.
The VVT does not operate when engine oil-pressure is below 1.25 bar (18.1 lbf/in), as there is insufficient pressure to
release the VVT unit's internal stopper pin. This usually occurs when the engine is shutting-down and the VVT has returned
to the retarded position. The stopper pin locks the camshaft to the VVT unit to ensure camshaft stability during the next
engine start-up.
Engine Structure
ItemDescription
1 Cylinder head (2 off)
2 Cylinder block
3 Bedplate
4 Structural sump
5 Oil pan

The cylinder block is of a cast aluminum alloy construction with cast iron liners. The 90 degree 'V' configuration provides a
rigid structure with good vibration levels. A low volume coolant jacket improves warm-up times and piston noise levels;
the longitudinal flow design of the jacket, with a single cylinder head coolant transfer port in each bank, improves rigidity
and head gasket sealing. The RH (right-hand) cylinder bank is designated as bank 1, and the LH (left-hand) as bank 2,
viewed from the front of the engine.
Data Locations
ItemDescription
1 Engine part number
2 Engine data (main bearing diameters, cylinder bore diameters, etc), emissions code and engine number
Engine data is marked at 3 locations, 2 on the cylinder block (shown) and 1 on the engine front cover, which consists of a
label displaying the engine number. Component diameters are represented by alpha and numeric codes.
Refer to: Crankshaft Main Bearing Journal Clearance - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8 (303-00 Engine System -

The connecting rods are manufactured from sinter-forged steel and have fracture-split bearing caps. The bearing caps are
produced by fracturing the opposing sides of the connecting rod at the bearing horizontal center line. As well as being
easier to manufacture, when reassembled the fractured surfaces interlock to form a strong seamless joint. The cylinder
position is marked on adjoining sides of the joint to identify matching connecting rods and bearing caps. The connecting
rod bearings are aluminum/tin split plain bearings.
The pistons are of the open-ended skirt design with a dished crown. Three piston rings, 2 compression and one 3-piece oil
control ring, are installed on each piston. Each piston is installed on a piston pin located in a bronze bushing in the
connecting rod.
Connecting Rod Orientation
ItemDescription
1 Bank 1
2 Bank 2
3 Piston
The piston grade number is stamped on the crown of the piston and must coincide with that for each cylinder bore. The
piston must be assembled in the correct orientation for the designated cylinder bore:
Bank 1 - piston grade number and the thick flange of the connecting rod must face the front of the engine.
Bank 2 - piston grade number and the thin flange of the connecting rod must face the front of the engine.
Crankshaft and Structural Sump Components

ItemDescription
1 Bedplate
2 Main bearings - lower
Crankshaft and Main Bearings
ItemDescription
1 Crankshaft
2 Thrust washer
3 Thrust washer
4 Main bearings - upper (5 off)
Six counter-balance weights ensure low vibration levels from the 4 throw, 5 bearing crankshaft. Manufactured in cast iron,
the crankshaft also has undercut and rolled fillets for improved strength.
The crankshaft rear oil seal is a press fit in the bedplate to cylinder block interface.
The main bearings are aluminum/tin split plain bearings. An oil groove in the upper half of each bearing transfers the oil
into the crankshaft for lubrication of the connecting rod bearings. An aluminum/tin thrust washer is installed each side of
the top half of the center main bearing.
Bedplate
The bedplate is a structural casting bolted to the bottom of the cylinder block to retain the crankshaft. The use of a
bedplate further improves rigidity. Iron inserts, cast into the main bearing supports of the bedplate, minimize main bearing
clearance changes due to heat expansion.
Two hollow dowels align the bedplate with the cylinder block.
Beads of sealant seal the joint between the bedplate and the cylinder block.
Oil Pan
ItemDescription
1 Oil pan
2 Structural sump
The aluminum alloy structural sump is bolted to the bedplate. A windage tray attached to the underside of the bedplate
isolates the oil pan from the disturbed air produced by the rotation of the crankshaft, to prevent oil aeration and improve
oil drainage. A rubber plug at the rear of the structural sump seals the port that provides access to the torque converter
securing bolts. The engine oil drain plug is located in the pressed steel oil pan, which attaches to the underside of the
aluminum alloy structural sump.
A bead of sealant seals the joint between the structural sump and the bedplate.
Oil Pump
bedplate (see lubrication section for more information).
Starter Drive Plate
ItemDescription
1 Starter drive plate
2 Bolts (8 off)
The starter drive plate is attached to the rear of the crankshaft. A timing disc, for the CKP (crankshaft position) sensor, is
spot welded to the front face of the drive plate.

ItemDescription
1 Secondary chain tensioner
2 Secondary chain
3 VVT unit
4 Primary chain
5 Primary chain tensioner
Multiple link primary and single row secondary chains drive the camshafts of each cylinder bank. The primary chains
transmit the drive from 2 sprockets on the crankshaft to variable valve timing units on the intake camshafts. The
secondary chains transmit the drive from the variable valve-timing units to sprockets on the exhaust camshafts.
A key locates the 2 drive sprockets on the crankshaft. The crankshaft's torsional vibration damper retains the sprockets in
position. The variable valve timing units and the exhaust camshaft sprockets are non-interference, non-keyed fits on their
respective camshafts; the drive being transmitted by the face to face friction load produced by the valve timing
unit/sprocket securing bolt.
Each chain has a hydraulic tensioner operated by engine oil. The primary chains are lubricated via oil squirt tubes located
at the front of the engine block near the crankshaft drive sprockets. A jet of oil from the end of each secondary chain
tensioner lubricates the secondary chains. The primary chain tensioners act on pivoting flexible tensioner blades. The
secondary chain tensioners act directly on the chains. Guide rails are installed on the drive side of the primary chains.
ItemDescription
1 VVT oil control unit
2 VVT oil control solenoid
3 Bush carrier
The VVT unit is a hydraulic actuator mounted on the end of the intake camshaft, which advances or retards the intake
camshaft timing and thereby alters the camshaft to crankshaft phasing. The oil control solenoid, controlled by the ECM,
routes oil pressure to either the advance or retard chambers located either side of the 3 vanes interspersed within the
machined housing of the unit.
The VVT unit is driven by the primary chain and rotates relative to the exhaust camshaft sprocket. W hen the ECM requests
the camshaft timing to advance, the oil control solenoid is energized moving the shuttle valve to the relevant position to
allow engine oil pressure, via a filter, into the VVT unit's advance chambers. W hen the camshaft timing is requested to
retard, the shuttle valve moves position to allow oil pressure to exit the advance chambers, while simultaneously routing
the oil pressure into the retard chambers.
Timing Cover
The aluminum alloy timing cover accommodates the crankshaft front oil seal (a PTFE (polytetrafluoroethylene) lip seal).
Silicon rubber in-groove gaskets seal the joint between the timing cover and the front face of the engine.

ItemDescription
1 Camshaft bearing cap
2 Tappet
3 Collet
4 Valve spring cap
5 Valve spring
6 Valve stem oil seal
7 Valve
8 intake camshaft
9 Exhaust camshaft
The cylinder heads are unique to each cylinder bank. Deep-seated bolts, to reduce distortion, secure the cylinder heads to
the cylinder block. Two hollow dowels align each cylinder head with the cylinder block. The multi-layered steel cylinder
head gasket has cylinder specific coolant flow cross-sections for uniform coolant flow.
The 14 mm (0.55 in) spark plugs, 1 per cylinder, locate in recesses down the center line of each cylinder head.
The engine-lifting eyes are bolted to the cylinder heads, 2 on the rear (1 per head) and 1 at the front.
The lightweight valve gear provides good fuel economy and noise levels. Valve head diameters are 31 mm (1.220 in) for
the exhaust and 35 mm (1.378 in) for the intake. All valves have 5 mm (0.197 in) diameter stems supported in sintered
metal seats and guide inserts. Collets, valve collars and spring seats locate single valve springs on both intake and
exhaust valves. Valve stem seals are integrated into the spring seats.
Camshafts
The camshafts are manufactured in chilled cast iron. Five aluminum alloy caps retain each camshaft. Location numbers, 0
to 4 for the intake camshaft and 5 to 9 for the exhaust camshaft, are marked on the outer faces of the caps.
Sensor Timing Ring
ItemDescription
1 Intake camshaft
2 Timing ring
A camshaft position sensor timing ring is located at the rear of both intake camshafts. A flat, machined near the front of
each camshaft, enables the camshafts to be locked during the valve timing procedure.
Camshaft Cover
The camshaft covers are manufactured from thermoplastic. Bank 1 camshaft cover incorporates an outlet for the part load
engine breather and the pressure control valve. Bank 2 camshaft cover incorporates an outlet for the full load engine
breather and the engine oil filler cap. Identical oil separators are incorporated below the breather outlet in each cover.
Operation).
NOTE: LH exhaust manifold shown, RH exhaust manifold similar.
Exhaust Manifolds
ItemDescription
1 Cylinder head
2 Gasket
3 Heat shield
4 Bolt
5 Gasket
7 Spacer (8 off)
8 Bolt (8 off)
9 Bolt (4 off)
10 Heat shield
11 Connector for AIR (secondary air injection) system (where fitted)
The cast stainless steel exhaust manifolds are unique for each cylinder bank. Each exhaust manifold installation includes
two metal gaskets and two heat shields. Spacers on the securing bolts allow the manifolds to expand and contract with
changes of temperature while maintaining the clamping loads.
Each exhaust manifold incorporates a connector for the AIR system (where fitted). W here an AIR system is not fitted, each
connector is sealed with a cap nut. The RH exhaust manifold incorporates a connection flange for the EGR (exhaust gas
recirculation) system.
Operation).
Lubrication System
Oil is drawn from the reservoir in the oil pan and pressurized by the oil pump. The output from the oil pump is then
filtered, cooled and distributed through internal oil passages.
All moving parts are lubricated by pressure or splash oil. Pressurized oil is also provided for the timing gear chain
tensioners and the piston cooling jets.
The oil returns to the oil pan under gravity. Large drain holes through the cylinder heads and cylinder block ensure the
quick return of the oil, reducing the volume of oil required and enabling an accurate check of the contents soon after the
engine stops.
System replenishment is through the oil filler cap on bank 2 camshaft cover.
Piston Cooling Jets

ItemDescription
1 Piston cooling jet (4 off)
2 Bolt (4 off)
The piston cooling jets lubricate and cool the pistons and piston pins. The jets are located in the cylinder block, one
between each adjacent pair of main bearings. Each jet sprays oil on the underside of two pistons.
Oil Pick-up
The fabricated steel oil pick-up is immersed in the oil reservoir to provide a supply to the oil pump during all normal
vehicle attitudes. A mesh screen in the inlet prevents debris from entering the oil system.
Oil Pump
bedplate.
The pumping element is an eccentric rotor, which is directly driven by flats on the crankshaft. An integral pressure relief
valve regulates pump outlet pressure at 4.5 bar (65.25 lbf/in).
Oil Filter
ItemDescription
1 Seal
2 Gasket
3 Filter
5 Bolt (3 off)
6 Oil pressure switch
7 Filter head
The oil filter is a replaceable cartridge with an internal bypass facility that permits full flow bypass if the filter is blocked.
The oil filter is installed on a filter head attached to the front of the structural sump. The oil cooler feed and return pipes
are connected to the filter head. The filter head also incorporates:
An oil pressure switch.

An oil temperature sensor.
Refer to: Electronic Engine Controls (303-14 Electronic Engine Controls - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8,
The lubrication system has two engine oil coolers. The engine oil coolers are identical liquid-to-air heat exchangers
installed immediately in front of each front wheel arch. Each engine oil cooler is attached to a mounting bracket with
bonded rubber mountings.
Engine oil flows through the coolers in series. Pipes and hoses direct the engine oil from the filter head to the RH engine
oil cooler, then to the LH oil cooler and then back to the filter head.
Cooling air for the oil coolers is taken in through mesh covered openings at the ends of the front bumper. Air ducts connect
the openings to the oil coolers. Exhaust air from the oil coolers flows into the front wheel arches through slots in the
wheel arch liners.
Oil Level Gage

ItemDescription
1 Oil level gage
The oil level gage locates along the left side of the oil pan, supported in a tube installed in the bedplate. Two holes in the
end of the gage indicate the minimum and maximum oil levels. There is a difference of approximately 1.5 liters (1.58 US
quarts) between the 2 levels.
Engine - 4.2L SC V8 - AJV8 - Engine

REFER to: Engine - 3.0L NA V6 - AJ27/4.2L NA V8 - AJV8/4.2L SC V8 - AJV8 (303-00 Engine System - General Information,
Engine - 4.2L SC V8 - AJV8 - Engine Oil Draining and Filling
General Procedures
Special Tool(s)
Wrench, Oil filter
303-752
WARNING: The spilling of hot engine oil is unavoidable during this procedure, care must be taken to prevent
scalding.


4. Remove the oil filter.
Install a new seal.

8. Start engine and run at idle speed until the oil pressure
warning light extinguishes.
Stop the engine.
Check for leaks.

Engine - 4.2L SC V8 - AJV8 - Camshafts LH
In-vehicle Repair
Special Tool(s)
303-530
Timing Setting tool
303-645
303-532
303-540
303-540/02
303-590
Removal
Procedures).


(303-01B Engine - 4.2L SC V8 - AJV8, In-vehicle Repair).
Sensor - Vehicles W ith: Supercharger (303-14, Removal and
Installation).
For additional information, refer to: Valve Cover LH (303-01B
Engine - 4.2L SC V8 - AJV8, In-vehicle Repair).
6. CAUTIONS:


Install the screw.

solenoid housing.
Remove the 3 bolts.


Remove the 2 bolts.

tensioner guides.
Remove the 2 bolts.

sprocket assembly.
Remove the 3 bolts.

NOTE: Remove the camshaft bearing caps. Note: their

position, orientation and markings. Each is marked with its
position (number) and an orientation (arrow).
Installation

available.
Evenly and progressively tighten the bolts in the

sequence shown to 10 Nm.


sprocket assembly.

stage.
bolts.
Make sure the timing chain slack is on the tensioner

side of the timing chain.


tensioner piston.

9. CAUTIONS:



20 Nm + 90 degrees
Tighten the exhaust camshaft retaining bolt to 20 Nm

+ 90 degrees.
Tighten the new bolts to 22 Nm.
Remove the screw.

Sensor - Vehicles W ith: Supercharger (303-14, Removal and
Installation).



Tighten the 2 bolts to 10 Nm



vehicle.



one.
23. CAUTIONS:





Procedures).
Engine - 4.2L SC V8 - AJV8 - Crankshaft Front Seal
In-vehicle Repair
Removal
For additional information, refer to: Crankshaft Pulley (303-01B
Installation
Engine - 4.2L SC V8 - AJV8 - Crankshaft Pulley
In-vehicle Repair
Special Tool(s)
tool
303-191

tool adapter
303-191/02
remover
303-588
Seal extractor
303-751
Seal installer
303-750
Removal
Procedures).


For additional information, refer to: Cooling Fan Motor and
Shroud - 4.2L SC V8 - AJV8 (303-03A Engine Cooling - 4.2L NA
V8 - AJV8/4.2L SC V8 - AJV8, Removal and Installation).
For additional information, refer to: Oil Filter Housing (303-01B
Rotate the accessory drive belt tensioner counter-

clockwise, using a 3/8 " drive wrench.

NOTE: The crankshaft pulley retaining bolt will be very tight.
Using the special tool, retain the crankshaft front pulley.
Remove and discard the crankshaft pulley retaining bolt.
8. Check the crankshaft pulley and locking ring for damage.

Installation
1. CAUTIONS:
Make sure the crankshaft seal mating faces are clean and
dry.
Do not remove the seal protector at this stage.
2. Remove the seal protector.
Install the locking ring.
4. CAUTION: The screw thread in the crankshaft pulley must

be cleaned out before installing a new crankshaft pulley bolt.


For additional information, refer to: Oil Filter Housing (303-01B
8. Install the cooling fan motor and shroud.

Procedures).
Engine - 4.2L SC V8 - AJV8 - Crankshaft Rear Seal
In-vehicle Repair
Special Tool(s)
Crankshaft rear oil seal
remover/installer
303-538
Removal


4. Using the special tool, pierce the seal to create holes for
the 6 self-tapping screws.
5. Using the special tools, remove and discard the crankshaft
rear oil seal.
Install the 6 self-tapping screws.
Adjust the 2 nuts.
Tighten the center bolt.
Installation
1. CAUTION: Do not lubricate the components.
Partially install the crankshaft rear oil seal.
Make sure the components are clean and dry.
Carefully remove the transit sleeve, leaving the seal on

the crankshaft.
3. Using the special tool, install the crankshaft rear oil seal.
Tighten the special tool nuts evenly and progressively

to fully install the seal.

Engine - 4.2L SC V8 - AJV8 - Cylinder Head LH
In-vehicle Repair
Special Tool(s)
303-530
303-540
303-540/02
Removal


For additional information, refer to: Fuel Rail (303-04B Fuel Charging and
Controls - 4.2L SC V8 - AJV8, Removal and Installation).
4. CAUTION: Before disconnecting or removing the components, make

sure the area around the joint faces and connections are clean. Plug open
connections to prevent contamination.
Remove the LH charge air cooler adaptor assembly.
Remove the 5 bolts.
Discard the gasket.

7. CAUTION: Evenly and progressively, release the camshaft bearing

caps.

orientation and markings. Each is marked with its position (number) and an
orientation (arrow).

NOTE: Make sure the shim remains with the tappet.
Remove the 16 tappets.
11. Release the LH catalytic converter.

12. CAUTIONS:
The bolts can only be used twice, mark the bolts with a center punch.
If two punch marks are visible, discard the bolts.
Vehicles fitted with Polydrive cylinder head bolts, the cylinder head
bolts must be removed using a 10 mm Polydrive socket or a 10 mm Allen
key. Failure to follow this instruction may result in damage to the
component.
NOTE: Remove the bolts in the indicated sequence.
Remove the 12 cylinder head bolts.
13. CAUTION: The cylinder head must not be placed mating face down.
With assistance remove the cylinder head.

14. Remove and discard the cylinder head gasket.
Clean the cylinder head locating dowels.

access only.
Remove the LH heat shield.

access only.

Remove the bolt.
Installation
2. Check cylinder head face for distortion, across the center and from corner
to corner.
3. For cylinder head face distortion data, refer to specifications. For

additional information, refer to: Specifications (303-01B Engine - 4.2L SC
V8 - AJV8, Specifications).
4. NOTE: For
cylinder head with
distortion above the
maximum allowance,
the cylinder head
material must be
measured.
Measure the
cylinder head
material.
Check
measurement
from the
centre of the
exhaust
dowel to the
cylinder head
face as
shown.
If the
measurement
is less than
51.88 mm
the cylinder
head requires
replacement.
5. Install the exhaust manifold gasket.

6. Install the exhaust manifold.
Evenly and progressively, tighten the new bolts in the sequence

shown, to 24 Nm (18 lb.ft).
7. Install the heat shield.
Tighten the screws.
8. CAUTION: The head gasket must be installed over the cylinder block
dowels.

9. With assistance install the cylinder head.
10. NOTE: Tighten the bolts 1 to 10 in the sequence shown.
Install the cylinder head bolts.
Lubricate the new cylinder head bolt threads with clean engine oil.
Tighten the bolts 1 to 10 to 20 Nm (15 lb.ft).
Tighten the bolts 1 to 10 to 35 Nm (26 lb.ft).
Tighten the M8 bolts 11 and 12, to 25 Nm (18 lb.ft).
11. Attach the catalytic coverter.
Tighten the nuts to 40Nm (30 lb.ft).
12. Install the CMP sensor.
Tighten the Torx bolt to 7 Nm (5 lb.ft).
13. Install the tappets.
Lubricate the components with clean engine oil.
Evenly and progressively tighten the bolts in the sequence shown to

10 Nm (7 lb.ft).
Install the special tool to the LH cylinder head.
17. NOTE: Do not install the LH valve cover until valve clearance adjustment
has been completed.
Install the timing drive components.

18. Install the charge air cooler adaptor assembly.
19. Install the fuel injection supply manifold.

For additional information, refer to: Fuel Rail (303-04B Fuel Charging and
Controls - 4.2L SC V8 - AJV8, Removal and Installation).
20. Rotate the engine clockwise to position the camshaft lobe away from
the valve tappet.
21. CAUTION: Camshaft lobes must be 180 degrees away from each
valve tappet or valve clearance will be incorrect.
Using the feeler gauge set, measure the clearance between the camshaft
and the valve shim.

Tighten the 2 bolts to 10 Nm (7 lb.ft).

24. CAUTION: Do not rotate the crankshaft while the special tool
303-540/02 is attached to 303-540.
27. CAUTION: Do not use a magnet to remove shims. Failure to follow

NOTE: Use the following formula to calculate the required shim thickness.
Original shim thickness + measured shim clearance - desired clearance =

Use the special tool 303-590, aimed at the edge of the shim, to lift
it from the tappet. Note the position of each one.
28. CAUTIONS:
the camshaft.
Do not use a magnet to install shims. Failure to follow these


29. Using the feeler gauge set, measure the clearance between the

Engine - 4.2L SC V8 - AJV8 - Engine Front Cover
In-vehicle Repair
Removal
Procedures).
2. Recover the A/C refrigerant.


connector.

connector.
6. Detach the oil filter housing.
Remove the 3 bolts.
7. Remove the cooling fan and shroud.

For additional information, refer to: Thermostat Housing - 4.2L
SC V8 - AJV8 (303-03A Engine Cooling - 4.2L NA V8 -
9. Remove the secondary air injection (AIR) tube.
For additional information, refer to: Secondary Air Injection
(AIR) Control Valve to Exhaust Manifold Tube (303-08 Engine
Emission Control - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8,
10. Release the radiator lower hose.
Release the clip.
Remove the 3 bolts.

For additional information, refer to: Power Steering Pump -
4.2L NA V8 - AJV8 (211-02 Power Steering, Removal and
Installation).
For additional information, refer to: Valve Cover RH (303-01B
Remove the bolt.
Remove the bolt.

Remove the 2 bolts.

19. Position the A/C compressor aside to access the A/C
compressor mounting bracket.
Remove the 4 bolts.
Remove the 4 bolts.

22. LH side: Release the wiring harness.
Remove and discard the 2 gaskets.
Installation
Apply a bead of sealant 3 mm diameter, by 12 mm

long, to the 8 places indicated.
3. Tighten to 25 Nm
4. Tighten to 25 Nm
7. Tighten to 9 Nm.
Engine - 4.2L SC V8 - AJV8 - Engine Mount LH
In-vehicle Repair
Removal
All vehicles
1. Remove the cover and disconnect the battery ground cable.
Specifications).


3. Remove the LH front wheel and tire.

Remove the steering gear flexible coupling.
Remove the 3 bolts.
All vehicles
Support the engine.
Raise the engine.
Remove the 4 bolts.

Installation
All vehicles
1. Install the engine mount.
Tighten the new nut to 55 Nm (41 lb.ft).
2. Install the engine mount and bracket.
Lower the engine.
Tighten the new nut to 63 Nm (46 lb.ft).

Tighten the bolts to 100 Nm ( 74 lb.ft).

4. Install the steering gear flexible coupling.
Tighten the new bolts to 35 Nm (26lb.ft).
All vehicles
6. Install the front wheel.
Specifications).
Engine - 4.2L SC V8 - AJV8 - Engine Mount RH
In-vehicle Repair
Removal
All vehicles
Procedures).




Remove the 3 bolts.

All vehicles
Support the engine.
Raise the engine.
Remove the 4 bolts.

Installation
All vehicles
All vehicles

Engine - 4.2L SC V8 - AJV8 - Exhaust Manifold LH
In-vehicle Repair
Removal
All vehicles
Procedures).


3. Release the coolant expansion tank for access.
Remove the retaining nut and bolt.
Remove the clip.
Position the coolant expansion tank aside.
4.
5. Release
Remove and tie level
the oil asideindicator
the power steering
and tube. reservoir.
Remove the nut.

bolts.

Raise the vehicle.


10. Disconnect the steering column lower shaft from the
steering gear.
Remove the steering column flexible coupling securing

bolts.
11. Disconnect the steering gear control valve actuator
Remove the steering gear retaining bolts.
All vehicles
14. Remove the splash shield retaining clips.
Position the splash shield to one side.

bolts.
Remove the LH exhaust manifold heat shield.

16. Detach the secondary air injection (AIR) control valve to
exhaust manifold tube from the exhaust manifold.
All vehicles
18. Remove and discard the LH exhaust manifold gasket.
Remove the bolt.

Installation
All vehicles
1. Install the LH exhaust manifold gasket.
2. Install the LH exhaust manifold.
Evenly and progressively, tighten the new bolts in the

sequence shown, to 24 Nm.

3. Attach the AIR control valve to exhaust manifold tube to the
exhaust manifold.
Tighten to 35 Nm.
All vehicles
4. Install the LH exhaust manifold heat shield.

6. Connect the lower steering column shaft to the steering

gear.

7. Connect the steering gear control valve actuator electrical
connector.
All vehicles
Install the 2 clips.

12. Install the LH exhaust manifold heat shield retaining bolts.

13. With assistance, install the oil level indicator and tube.
14. Install the power steering fluid reservoir.

15. Attach the coolant expansion tank.
Reposition the coolant expansion tank.
Install the clip.

Procedures).
Engine - 4.2L SC V8 - AJV8 - Flexplate
In-vehicle Repair
Removal


Remove the 8 bolts.
Installation
1. CAUTION: Make sure that the locating pin on the

crankshaft is aligned with the guide hole in the flexplate.
Tighten to 15 Nm.
Tighten to 110 Nm.

Engine - 4.2L SC V8 - AJV8 - Oil Filter Housing
In-vehicle Repair
Special Tool(s)
Wrench, Oil filter
303-752
Removal
Connect (414-01, General Procedures).


connector.

connector.
NOTE: Clean the components general area prior to

dismantling.
7. Detach the oil cooler housing from the oil filter housing.
Remove the 3 bolts.

Remove the engine oil temperature sensor.

10. Remove the EOP sensor.
Installation
1. Install the EOP sensor.
Apply sealant of the correct specification to the sensor

thread.
Tighten to 15 Nm.
2. Install the engine oil temperature sensor.
Apply sealant of the correct specification to the sensor

thread.
Tighten to 15 Nm.
4. Connect the engine oil cooler lines.
Tighten to 7 Nm.
Lubricate the oil filter seal with clean engine oil and
tighten to 18 Nm .
7. Connect the engine oil temperature sensor electrical
connector.
Connect (414-01, General Procedures).
Engine - 4.2L SC V8 - AJV8 - Oil Pan
In-vehicle Repair
Removal
1. WARNING: Do not work on or under a vehicle supported only by

a jack. Always support the vehicle on safety stands.

For additional information, refer to: Air Deflector (501-02 Front End
(303-01B Engine - 4.2L SC V8 - AJV8, General Procedures).
Installation
1. To install,
reverse the
removal
procedure.
Tighten
to 12
Nm.
Engine - 4.2L SC V8 - AJV8 - Oil Pump
In-vehicle Repair
Removal
Procedures).


5. NOTE: The bolts will remain captive.
Remove the 2 bolts.
Remove the 4 bolts.
Installation
1. Install the oil pump assembly.
Clean the components mating faces.


Procedures).
Engine - 4.2L SC V8 - AJV8 - Timing Drive Components
In-vehicle Repair
Special Tool(s)
303-530
Timing Setting tool
303-645
303-532
Removal
NOTE: This procedure covers the removal and installation of the following components: timing chains, chain guides,
tensioners and sprockets.

Procedures).


4. Remove both the crankshaft position (CKP) sensors.
Installation).
5. CAUTIONS:


Install the screw.

solenoid housing.
Remove the 3 bolts.

Remove the 2 bolts.

tensioner guides.
Remove the 2 bolts.


solenoid housing.
Remove the 2 bolts.
Remove the nut.
Remove the 2 bolts.

tensioner guides.
Remove the 2 bolts.

sprocket assembly.
Remove the 2 bolts.


sprocket assembly.
Installation


sprocket assembly.

stage.
3. Install the special tool to the exhaust camshaft sprocket.
Reposition the camshaft sprockets for the most

advantageous position for use of the special tool.

bolts.
Tighten to 12 Nm.

Tighten to 12 Nm.


tensioner piston.
Tighten to 12 Nm.
8. CAUTIONS:

drive side.


Nm + 90 degrees
Tighten the exhaust camshaft retaining bolt to 20 Nm +

90 degrees.

Install the RH secondary timing chain, tensioner and

sprocket assembly.

stage.

bolts.
Make sure the timing chain slack is on the tensioner

side of the timing chain.


tensioner piston.
15. CAUTIONS:



20 Nm + 90 degrees
Tighten the exhaust camshaft retaining bolt to 20 Nm

+ 90 degrees.
Remove the 3 bolts.
Remove the 3 bolts.

Remove the screw.
21. Install both the CKP sensors.

Installation).
Procedures).
Engine - 4.2L SC V8 - AJV8 - Twin Oil Coolers
In-vehicle Repair
Removal


3. CAUTION: Before the disconnection or removal of any

components, ensure the area around joint faces and
connections are clean. Plug any open connections to prevent
contamination.
Disconnect the 2 oil cooler lines.
Position a container to collect the engine oil.
Remove the 2 nuts.
Remove the 2 brackets.
Remove the oil cooler.
Remove the 4 securing nuts.
Installation
1. Install the oil cooler.
Install the support brackets.
Install the retainer.
Tighten to 5 Nm.
2. Connect the oil cooler lines.
Tighten to 7 Nm.

Engine - 4.2L SC V8 - AJV8 - Valve Cover LH
In-vehicle Repair
Removal
Procedures).
2. Remove the evaporative emission canister purge valve.
For additional information, refer to: Evaporative Emission
Canister Purge Valve - 4.2L SC V8 - AJV8 (303-13 Evaporative
Emissions - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8, Removal and
Installation).
Installation).
4.2L SC V8 - AJV8 (303-07 Engine Ignition - 4.2L NA V8 -
Remove the nut.

8. Disconnect fuel line from the fuel rail.
For additional information, refer to: Spring Lock Couplings
(310-00 Fuel System - General Information, General
Procedures).
9. Release the wiring harness.
10. Disconnect the 2 electrical connectors.
12. Detach the fuel vapour valve from the mounting bracket.
13. Detach the mounting bracket and position it to one side.
to removal.
Remove the valve cover.
15. Remove and discard the valve cover retaining bolt O-ring
seals.
17. Remove and discard the valve cover plug aperture seals.
18. Remove and discard the VCT oil control solenoid seal.
Remove the oil filler pipe.
Installation
1. Install the oil filler pipe.

3. Install the new valve cover plug aperture seals.

6. Install valve cover retaining bolts to their position

previously noted.
Install new valve cover bolt O-ring seals.
Secure with the clips.
8. Connect the VCT oil control solenoid electrical connector.

9. Attach the mounting bracket.
10. Attach the fuel vapour valve to the mounting bracket.

12. Connect the two electrical connectors.

Procedures).

Installation).

18. Install the evaporative emission canister purge valve.
For additional information, refer to: Evaporative Emission
Canister Purge Valve - 4.2L SC V8 - AJV8 (303-13 Evaporative
Emissions - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8, Removal and
Installation).
Procedures).
Engine - 4.2L SC V8 - AJV8 - Valve Cover RH
In-vehicle Repair
Removal
Procedures).
Installation).
5. Disconnect the positive crankcase ventilation (PCV) line.
Remove the 3 nuts.
Release the hose.

8. Release the coil-on-plug wiring harness.

to removal.
Remove the valve cover.
11. Remove and discard the valve cover retaining bolt O-ring
seals.

13. Remove and discard the valve cover plug aperture seals.
14. Remove and discard the VCT oil control solenoid seal.
Remove the PCV valve.
Remove the 2 Torx screws.
Installation
1. Install the PCV valve.
Tighten the Torx screws.

3. Install new valve cover plug aperture gaskets.
6. Install valve cover retaining bolts to their position

previously noted.
Install new valve cover bolt O-ring seals.
7. Connect the VCT oil control solenoid electrical connector.
8. Attach the coil-on-plug wiring harness.

10. Install the engine cover bracket.
Secure the wiring harness.
Secure the hose.
Tighten to 6 Nm.
11. Connect the PCV line.

Installation).
Procedures).
Engine - 4.2L SC V8 - AJV8 - Crankshaft Main Bearing Carrier
Special Tool(s)
Adapter
303-191-03
Bolts and spacers
303-191-04
Holding Tool Crankshaft Pulley
303-191
Remover, crankshaft seal
303-D121
Timing Setting tool
303-645
303-530
Crankshaft rear oil seal remover/installer
303-538
Adapter - Crankshaft seal installer
303-1100-01
Installer, crankshaft seal
303-1100
Removal


For additional information, refer to: Engine (303-01B Engine - 4.2L SC
V8 - AJV8, Installation).
4. Mount the engine to an engine stand.
5. Release the supercharger belt.
Rotate the drive belt tensioner clockwise. Use a 1/2 inch square
drive bar to rotate the drive belt tensioner.
6. Remove the supercharger belt.
7. Remove the supercharger belt idler pulley.

8. Remove the mounting bracket.
9. Disconnect the 2 oil cooler hoses.
Remove the 2 bolts.
Rotate the accessory drive belt tensioner counter-clockwise, using

a 3/8 " drive wrench.
Remove the bolt.
13. NOTE: Note the fitted position of the accessory drive belt.
Remove the accessory drive belt.

Remove the bolt.
Using the special tool, remove the coolant pump pulley.
Remove the 5 bolts.

Remove both the engine mounts and brackets.
Remove the 4 bolts.
Remove the 3 bolts.
Remove the 4 bolts.
Remove the 4 bolts.

Remove the 4 bolts.
22. Disconnect the battery positive cable and the generator electrical
connector.
Release the cover.
Remove the nut.
Remove the nut.
Remove the nut and bolt.
24. Remove
25. RH side: the
Release the engine
generator wiring
mounting harness.
bracket.
Release
Remove the
the 5
4 clips.
bolts.
26. Disconnect the battery positive cable.
Release the cover.
Remove the nut.

27. Disconnect the starter motor solenoid electrical connector.
Remove the 2 bolts.
29. Disconnect the coolant hoses from the thermostat housing.

connector.
31. Reposition the thermostat housing hose retaining clip.

33. Disconnect the heater supply hose from the thermostat housing.
35. Remove the thermostat housing retaining bolts.

38. Disconnect the engine oil pressure (EOP) sensor electrical connector.
Remove the 3 bolts.
Release the 2 heated oxygen sensor (HO2S) harness brackets.

Remove the bolt.
44. Release the wiring harness from the LH side of the engine.
Release the clips.
45. Release the wiring harness from the RH side of the engine.
Release the clips.
Remove the bolt.

47. CAUTION: Under no circumstances should the crankshaft setting
peg, 303-645, be used in the following operations, to restrain the
crankshaft.
48. NOTE: The crankshaft pulley retaining bolt will be very tight.
Using the special tools, remove the crankshaft pulley bolt.
Discard the bolt.
49. NOTE: The crankshaft pulley will be very tight.
Using the special tools, remove the crankshaft pulley.

50. Using the special tool, remove and discard the crankshaft front seal.
Remove both the ignition coil-on-plug covers.
52. Disconnect the RH ignition coil-on-plug electrical connector.
53. Remove the RH ignition coil-on-plug.
Remove the bolt.
54. Remove the remaining RH ignition coil-on-plugs.

55. Disconnect the LH variable camshaft timing ( VCT) oil solenoid
58. Disconnect the RH variable camshaft timing (VCT) oil solenoid

59. NOTE: Note the fitted

position of the retaining
bolts prior to removal.
Remove the RH valve

cover.
Remove the 14
valve cover
retaining bolts.
Remove the engine

cover bracket.
60. Remove and discard the RH valve cover gaskets.
61. Disconnect the LH ignition coil-on-plug electrical connector.
62. Remove the LH ignition coil-on-plug.
Remove the bolt.
63. Remove the remaining LH ignition coil-on-plugs.

Remove the oil level indicator.
Remove the nut.
Remove the tube.

66. NOTE: Note the fitted

position of the retaining
bolts prior to removal.
Remove the LH valve

cover.
Remove the 14
valve cover
retaining bolts.
67. Remove and discard the LH valve cover gaskets.
68. NOTE: Install the special tool to the crankshaft sensor aperture.
Install the bolt.

69. Remove the
engine front
cover.
Remove the
24 bolts.
Remove and
discard the
gasket.
Remove and
discard the 3
O-ring seals.
70. Remove the RH VCT housing.
Remove the 3 bolts.

72. Remove the RH primary timing chain tensioner assembly.
Remove the 2 bolts.
73. Remove the RH primary timing chain tensioner guide.
Remove the bolt.
75. Remove the LH VCT housing.
Remove the 3 bolts.

Remove the 2 bolts.
78. Remove the LH upper and lower primary timing chain tensioner guides.
Remove the 2 bolts.

82. Remove the torque converter flexplate.
83. CAUTION: Note the position of the bolts, prior to removal.
Remove the oil pan.
Remove the 2 bolts.

extension.

Remove the 4 bolts.
87. Remove the baffle plate.
Remove the 6 bolts.
88.
WARNING: To make
sure damage does
not occur to the
crankshaft and
piston components,
the engine must be
inverted on the
engine stand.
Failure to follow
this instruction may
result in damage to
the engine.
NOTE: If the
crankshaft main
bearing carrier
retaining bolts have
been marked with a
center punch dot,
they must be
discarded and new
bolts installed.
Remove the
crankshaft main
bearing carrier.
Remove the
crankshaft
main
bearing
carrier
retaining
bolts in the
indicated
sequence.
89. Discard the crankshaft rear main oil seal.
Installation
1. CAUTIONS:
Use only a plastic scraper when removing the sealing material.
If any new bolts are to be installed to retain the crankshaft main

bearing carrier, pre-stress the retaining bolts by installing the crankshaft
main bearing carrier without any sealant and tightening the new retaining
bolts to the specified torque. Remove the crankshaft main bearing carrier
once the bolts have been pre-stressed. Failure to follow this instruction
Clean all the mating faces and reusable parts thoroughly and check for
damage.
2. NOTE: Install the crankshaft main bearing carrier and tighten bolts to
specification within twenty minutes of applying the sealant.
Apply a 2 mm bead of sealant to the cylinder block in the area shown.
3. NOTE: Install the crankshaft main bearing carrier and tighten bolts to
specification within twenty minutes of applying the sealant.
Apply a 1 mm bead of sealant to the cylinder block in the area shown.

4. CAUTION:
Make sure all
dowels are fully
seated into the
crankshaft main
bearing carrier prior
to tightening the
bolts.
NOTE: Do not
lubricate the
crankshaft main
bearing carrier
retaining bolts.
NOTE: Do not
rotate the
crankshaft until all
the retaining bolts
are tightened to
specification.
NOTE: The
retaining bolts must
be tightened within
twenty minutes of
applying the
sealant.
NOTE: Tighten the

retaining bolts in
the sequence
shown.
Install the
crankshaft main
bearing carrier to
the cylinder block.
1. Stage 1:
Bolts 21
to 32,
tighten
to 15
Nm.
2. Stage 2:
Bolts 33
to 34,
tighten
to 15
Nm.
3. Stage 3:
Bolts 1
to 10,
tighten
to 25
Nm.
4. Stage 4:
Bolts 11
to 20,
tighten
to 15
Nm.
5. Stage 5:
Bolts 1
to 10,
tighten
to 35
Nm,
then a
further
135
degrees.
6. Stage 6:
Bolts 11
to 20,
tighten
to 20
Nm,
then a
further
150
degrees.
7. Stage 7:
Bolts 21
to 32,
tighten
to 20
Nm,
then a
further
90
degrees.
8. Stage 8:
Bolts 33
to 34,
tighten
to 20
Nm,
then a
further
150
degrees.
9. Stage 9:
Center
punch
each of
the bolt
heads
to
indicate
it has
been
reused.
5. Rotate the crankshaft to check correct operation.

6. Remove excess sealant which may squeeze out at the front cover
sealing surfaces.
7. Install the baffle plate.
8. NOTE: Carefully remove the transit sleeve, leaving the seal in place.
NOTE: Make sure that the transit sleeve is correctly positioned and
install the new seal over the crankshaft. Do not use any lubricant on the
seal, the transit sleeve or the crankshaft.
Using the special tool, position the crankshaft rear oil seal.
Install the special tool to the crankshaft.
9. CAUTION: Alternate the nut tightening to correctly seat the

crankshaft rear oil seal.
Using the special tool, install the rear crankshaft oil seal.
10. CAUTION: Make sure that the crankshaft rear oil seal is correctly
located.
Install the bolt.
Install the oil pump assembly.
Install the gasket.
Install the torque converter flexplate.
Tighten the bolts evenly in 2 stages to the sequence shown.
Install the oil strainer pick-up assembly.
timing chain.


adjuster.
NOTE: Install new O-ring seals.
Install the LH VCT control solenoid housing.
timing chain.
21. Install the RH primary timing chain tensioner guide.


adjuster.
Install the RH VCT control solenoid housing.

Apply a 3 mm diameter bead of sealant, to the area shown.
27. Tighten the oil pan bolts in the sequence shown to 20 Nm.
Remove the bolt.
30. Attach the wiring harness to the LH side of the engine
Secure the clips.
31. Attach the wiring harness to the RH side of the engine.
Secure the clips.
NOTE: Install a new O-ring seal.
Apply a 3 mm diameter bead of sealant 12mm long, to the 8

places shown.
Install the gasket.
34. Tighten the bolts in the sequence shown to 12 Nm.
Secure the clips.
Install the LH valve cover plug aperture seals.


diameter 12 mm (0.47 in) long. Install the valve cover immediately after
applying the sealant. The cover should be fitted directly to the head
without smearing the sealant or the seals.
Install the valve cover gasket.
38. Install the LH valve cover bolts.
Install the LH valve cover bolts to the positions previously noted.
39. Connect the LH VCT oil solenoid electrical connector.

With assistance, install the oil level indicator and tube.
Install the 4 LH ignition coil-on-plugs.

44. Install the LH ignition coil-on-plug cover.
Install new RH valve cover plug aperture seals.


diameter 12 mm (0.47 in) long. Install the valve cover immediately after
applying the sealant. The cover should be fitted directly to the head
without smearing the sealant or the seals.
Install the RH valve cover.
Install the gasket.

47. Install the RH valve cover bolts.
Install the RH valve cover bolts to the positons previously noted.
Install the 4 RH ignition coil-on-plugs.

Install the coolant manifold.
Connect the 4 coolant hoses and install the clips.
Attach the wiring harness bracket.
51. Install the thermostat housing.
52. Connect the coolant hoses to the thermostat housing.

53. Connect and secure the ECT sensor electrical connector.
55. Connect the heater supply hose to the thermostat housing.
56. Connect the RH VCT oil solenoid electrical connector.

58. Reposition the thermostat housing hose retaining clip.

60. Clean the crankshaft pulley mating faces.
61. Using the special tool, install the crankshaft front seal.
Use the discarded crankshaft bolt with the special tool.
63. Install the crankshaft pulley locking ring.
64. CAUTION: The screw thread in the crankshaft pulley must be

cleaned out before installing a new crankshaft pulley bolt.
65. CAUTION: Under no circumstances should the crankshaft setting

peg, 303-645, be used in the following operations, to restrain the
crankshaft.
Using the special tools, tighten the crankshaft pulley bolt.
67. NOTE: Install a new engine oil filter.
Install the engine oil filter.
Lubricate the oil filter seal with clean engine oil and tighten to 18
Nm .


Tighten the new nut to 7 Nm.
72. Connect the battery positive cable to the starter motor.
Secure the cover.
74. RH side: Attach the wiring harness.
Secure the clips.
76. Connect the battery positive cable and generator electrical connector.
Secure the cover.
77. Install the exhaust manifold heat shield.
Tighten the 2 bolts.
79. Install the A/C compressor mounting bracket.
81. Install the A/C compressor.
82. Install both engine mounts and brackets.
Using the special tool, install the coolant pump pulley.
84. Install the accessory drive belt idler pulley.

Clean and inspect the drive pulleys for damage.
Tighten the accessory drive belt tensioner bolt to 40 Nm.
87. Install the mounting bracket.
88. Install the supercharger belt idler pulley.
89. Install the supercharger belt.
Rotate the drive belt tensioner clockwise. Use a 1/2 inch square
drive bar to rotate the drive belt tensioner.
90. Connect the oil cooler hoses.

91. Remove the engine from the engine stand.

For additional information, refer to: Engine (303-01B Engine - 4.2L SC
V8 - AJV8, Installation).
Removal
Special Tool(s)
303-536
303-749
Removal
Procedures).


For additional information, refer to: Cooling Module - 4.2L SC
7. Remove the hood.

Installation).
9. Remove the pedestrian protection hood actuator.
For additional information, refer to: Pedestrian Protection Hood
Actuator LH (501-20C Pedestrian Protection System, Removal
and Installation).
12. Disconnect the engine wiring harness.
13. Release the secondary air injection (AIR) vacuum reservoir.

15. Release the pedestrian protection actuator bracket.


contamination.
manifold.
Remove the 2 bolts.


pump.


contamination.

pump.
Release the clip.

connector.
Release the engine mounts.

26.
27. Install
Install thethe special
lifting tools to to
equipment the engine.
the vehicle.
Support
Install the the engine.
lifting chains.

Installation
Special Tool(s)
303-536
303-749
Installation
2. Carefully lower the engine onto the engine mounts.
Tighten to 63 Nm.
3. Remove the special tools.


6. Connect the main engine wiring harness to the engine
control module (ECM).
7. Connect the engine wiring harness.
Tighten to 10 Nm.


contamination.
Connect the low pressure line to the power steering pump.
Secure the clip.

Connect the high-pressure power steering line to the power

steering pump.
Tighten to 20 Nm.

Connect the refrigerant lines to A/C compressor.
Tighten to 9 Nm.
12. Connect the brake booster vacuum hose to the intake
manifold.
13. Secure the secondary air injection (AIR) vacuum reservoir.

contamination.
Connect the purge valve.

16. Secure the pedestrian protection actuator bracket.
18. Install the pedestrian protection hood actuator.

For additional information, refer to: Pedestrian Protection Hood
Actuator LH (501-20C Pedestrian Protection System, Removal
and Installation).
Installation).
For additional information, refer to: Cooling Module - 4.2L SC
23. Fill and bleed the cooling system.
For additional information, refer to: Cooling System Draining,
Filling and Bleeding (303-03, General Procedures).
Procedures).
Tighten to 25 Nm
Engine Cooling - TDV6 2.7L Diesel -
Jaguar Premium Cooling System Fluid W SS M97B44-D
Jaguar Premium Cooling System Flush EGR-M14P7-A
Capacities
Description Liters
Cooling system refill 13.5
Coolant expansion tank retaining bolt 7 - 62
Coolant expansion tank bleed screw 3 - 27
Cooling fan motor and shroud retaining bolts 6 - 53
W ater pump retaining bolts 10 - 89
W ater pump pulley retaining bolts 24 18 -
Charge air cooler to radiator retaining bolts 7 - 62
Air conditioning condenser retaining bolts 7 - 62
Radiator mounting bracket retaining bolts 7 - 62
Charge air cooler intake elbow 7 - 62
Radiator drain plug 2 - 13
Engine Cooling - TDV6 2.7L Diesel - Engine Cooling - Component Location
Component Location
ItemDescription
1 Radiator
2 Expansion tank
3 Outlet connector assembly
4 Engine oil and fuel coolers
5 LH (left-hand)EGR (exhaust gas recirculation) cooler
6 Inlet connector assembly
7 Transmission oil cooler
8 Coolant pump
9 Thermostat
10 Auxiliary coolant pump
11 Cooling fan
12 RH (right-hand)EGR cooler
13 Heater core supply and return connections
Engine Cooling - TDV6 2.7L Diesel - Engine Cooling - Overview
Overview
The engine cooling system maintains the engine within an optimum temperature range under changing ambient and engine operating
conditions. It also provides:
Heating for the passenger compartment.

Refer to: Heating and Ventilation (412-01 Climate Control, Description and Operation).
Cooling for:
- The engine oil.
- The fuel.
- The EGR (exhaust gas recirculation) system.
- The transmission fluid.
Refer to: Transmission Cooling - Vehicles With: ZF 6HP26 (307-02 Transmission/Transaxle Cooling - V8 4.2L Petrol/V8 S/C 4.2L
Petrol/V6 3.0L Petrol/TDV6 2.7L Diesel, Description and Operation).
Engine Cooling - TDV6 2.7L Diesel - Engine Cooling - System Operation and Component
Description
System Operation
When the engine is running the coolant is circulated around the engine cooling system by the coolant pump and the auxiliary coolant pump.
From the outlet of the coolant pump, coolant flows through the cylinder block and the cylinder heads to the outlet connector. Some of the
coolant in the cylinder block is diverted through the engine oil and fuel coolers before returning to the outlet connector. From the outlet
connector the bulk of the coolant flows to the thermostat, either directly or via the radiator, depending on the temperature of the coolant.
From the outlet of the thermostat the coolant flows to the inlet connector and then to the coolant pump.
Coolant from the outlet connector also flows through the EGR (exhaust gas recirculation) coolers and then the heater core. From the heater
core outlet, the coolant flows to the inlet connector via the auxiliary coolant pump.
The transmission coolant control valve controls the flow and temperature of coolant to the transmission oil cooler from the radiator and/or
the engine outlet. The transmission control valve regulates the temperature of the coolant supplied to the transmission oil cooler to
maintain the transmission oil at the optimum operating temperature. The coolant from the outlet of the transmission oil cooler returns to
the inlet connector with the flow of coolant from the thermostat.
If the coolant level in the expansion tank decreases below a predetermined value, the level sensor connects a ground to the instrument
cluster, which activates the appropriate warning.
The cooling fan is operated by a fan control module integrated into the cooling fan motor. The fan control module regulates the voltage, and
thus speed, of the cooling fan motor in response to a PW M (pulse width modulation) signal from the ECM (engine control module). The ECM
calculates the required fan speed from the engine temperature, A/C (air conditioning) system pressure and transmission oil temperature.
Under hot operating conditions, the fan may continue to operate for four minutes after the engine has been switched off.
Engine Cooling Flow Diagram

ItemDescription
1 Bleed screw
2 Outlet connector
3 Engine oil cooler and fuel cooler
4 RH (right-hand)EGR cooler
5 Engine
6 Heater core
7 LH (left-hand)EGR cooler
8 Inlet connector
9 Coolant pump
10 Transmission (coolant) control valve
11 Transmission cooler
12 Thermostat
13 Radiator
15 Expansion tank
General
The primary components of the engine cooling system are the:
Coolant pump.
Thermostat.
Radiator.
Cooling fan.
Expansion tank.
Engine oil and fuel coolers.
Connecting hoses and pipes.
The engine cooling system also supplies coolant to:
The heater core.

The EGR coolers.
The transmission oil cooler.
Coolant Pump
ItemDescription
1 Bolt (3 off)
2 Drive hub
3 Housing
4 Impeller
5 Pulley
The coolant pump has a housing that supports a shaft with an impeller attached to one end and a drive hub at the other. The housing is
attached to the front of the cylinder block with the impeller located in a pumping chamber. The pump is driven by a pulley attached to the
drive hub and driven by the accessory drive belt.
Refer to: Accessory Drive (303-05 Accessory Drive - 2.7L Diesel, Description and Operation).
Thermostat
ItemDescription
1 From engine outlet connector
2 To engine inlet connector
3 Radiator end tank connection
The thermostat is an ambient bias thermostat located in a sealed housing attached to the LH end tank of the radiator. The thermostat
opens at a nominal temperature of 82 C (180 F). This opening is delayed at lower ambient temperatures to improve heater performance.
When the engine is cold the thermostat is closed and directs coolant from the outlet connector to the coolant pump. When the engine is
warm the thermostat is open and directs coolant from the radiator to the coolant pump.
Radiator
ItemDescription
1 Locating spigot (2 off)
2 Coolant inlet
3 Support (2 off)
4 Drain plug
5 Coolant outlet (to thermostat)
6 Coolant outlet (to transmission (coolant) control valve)
The radiator is a cross flow type with an aluminum core and plastic end tanks. The radiator is located in the vehicle by locating spigots and
supports integrated into the end tanks. The supports are installed in rubber bushes in the upper chassis rails. The locating spigots are
installed in rubber bushes in the front end carrier. A drain plug is integrated into the LH end tank. Coolant inlet and outlet connections are
incorporated into the RH and LH end tanks respectively.
Cooling Fan
ItemDescription
1 Shroud
2 Electrical connector
3 Fan
4 Motor and fan control module
An electric, variable speed cooling fan is installed in a shroud attached to the rear of the radiator. The cooling fan is operated by a fan
control module, integrated into the electric motor, under the control of the ECM. Electrical connectors at the RH side of the shroud provides
the interface between the cooling fan harness and the vehicle wiring.
Expansion Tank
ItemDescription
1 Bleed screw
2 Level markings
3 Vent hose connection
4 Expansion hose connection
5 Level sensor
6 Filler cap
A pressurized expansion tank system is used which continuously separates the air from the cooling system and replenishes the system
through a hose connected between the expansion tank and the heater return hose. A continuous vent into the expansion tank, through a
hose connected to the engine's coolant outlet connector, prevents air locks from forming in the cooling system.
The expansion tank is installed behind the top right corner of the radiator. A filler cap, bleed screw and level sensor are incorporated into
the expansion tank. MAX and MIN level markings are molded into the interior of the tank below the filler cap. The expansion tank provides
the following functions:
Service fill.
Coolant expansion during warm-up.
Air separation during operation.
System pressurization by the filler cap.
The expansion tank has an air space of approximately 0.5 to 1 liter (1.06 to 2,11 US pints), above the MAX level, to allow for coolant
expansion.
Engine Oil and Fuel Coolers

ItemDescription
1 Engine oil filter
2 Locator pin
3 Engine oil cooler
4 Coolant inlet (from cylinder block)
5 Adapter assembly
6 Fuel cooler
7 Fuel inlet and outlet connections
8 Coolant outlet (to engine coolant outlet connector)
The engine oil cooler and the fuel cooler are attached to a common adapter assembly located in the vee of the cylinder block. Inlet and
outlet ports for engine oil, and an inlet port for coolant, are incorporated into the cylinder block mating face of the adapter assembly. A
metal gasket seals the joint between the adapter assembly and the cylinder block.
From the cylinder block, coolant flows through the adapter assembly and into the two coolers. After passing through the two coolers, the
coolant then flows into the engine coolant outlet connector via an outlet on the fuel cooler.
Engine Coolant
The engine coolant is formulated to last for ten years or 240,000 km (150,000 miles). The coolant is silicate free and must not be mixed
with conventional engine coolant.
Engine Cooling - TDV6 2.7L Diesel - Engine Cooling
Principles of Operation
For detailed description of the diesel engine cooling system, refer to the relevant Description and Operation sections in the workshop
manual. REFER to: (303-03A Engine Cooling - TDV6 2.7L Diesel)
Engine Cooling (Description and Operation),

Engine Cooling (Description and Operation).

Visual Inspection
Leaks Fuse
Coolant expansion tank Wiring harness
Electric fan Loose or corroded connector(s)
Radiator Engine Coolant Temperature (ECT) sensor
3. 3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next
step.
4. 4. If there are clear symptoms refer to the table below, alternatively, check for Diagnostic Trouble Codes (DTCs) and refer to the DTC
Index.
Symptom Chart

Coolant loss Hoses GO to Pinpoint Test A.
Hose connections
Radiator
Coolant pump
Heater core
Gaskets
Engine casting cracks
Engine block core plugs
Engine overheating Engine coolant (level/condition) GO to Pinpoint Test B.

Thermostat
Fan motor
Fan motor fuses and/or circuits
ECT sensor
Engine control module (ECM)
Fan speed module
Engine not reaching normal operating temperature Thermostat GO to Pinpoint Test C.

Electric fan
Fan speed module
DTC Index
CAUTION: W hen probing connectors to take measurements in the course of the pinpoint tests, use the adaptor kit, part number
3548-1358-00.
NOTE: If the module or a component is suspect and the vehicle remains under the Manufacturers warranty, refer to the Warranty Policy
and Procedure manual (section B1.2), or determine if any prior approval programme is in operation, prior to the Check and installation of a
new module/component.
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 extra information read by the manufacturer
approved diagnostic system).
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: 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.

P011626 Engine Coolant Signal rate of change Refer to the electrical circuit diagrams and check ECT sensor circuits for
Temperature Sensor 1 below threshold short, open circuit and poor connection. From engine cold, check and record
Circuit 'Engine coolant temperature' datalogger signal. After approximately 20
Range/Performance minutes, check and record signal, if value has NOT increased by more than
10C install a new sensor as required
P011716 Engine Coolant Circuit voltage below Carry out any pinpoint tests associated with this DTC using the
Temperature Sensor 1 threshold manufacturer approved diagnostic system. Refer to the electrical circuit
Circuit Low Input Engine coolant diagrams and check ECT sensor signal circuit for short to ground. Check and
temperature sensor install a new sensor as required
failure
P011817 Engine Coolant Circuit voltage above Carry out any pinpoint tests associated with this DTC using the
Temperature Sensor 1 threshold manufacturer approved diagnostic system. Refer to the electrical circuit
Circuit High Input Engine coolant diagrams and check ECT sensor signal circuit for short to power. Check and
temperature sensor install a new sensor as required
failure
P011927 Engine Coolant Signal rate of change Refer to the electrical circuit diagrams and check engine coolant
Temperature Sensor 1 above threshold temperature sensor circuits for short, open circuit and poor connections.
Circuit Engine coolant Run engine to normal operating temperature, check and record 'Engine
Intermittent/Erratic temperature sensor coolant temperature' datalogger signal, increase engine speed by 2000
failure rpm, after 120 seconds check and record signal. If value of signal has
increased faster than 5C/second install new sensor as required
P048011 Fan 1 Control Circuit Cooling fan 1 control Refer to the electrical circuit diagrams and check the fan 1 control circuit for
circuit - short to short to ground
ground
circuit - short to short to power
power
circuit - open circuit open circuit
P048397 Fan Rationality Check Cooling fan Check and clear any blockage or restriction from fan
obstructed or blocked
P048400 Fan Circuit Over Current Cooling fan seizure Check and clear any blockage or restriction from fan. Check and install new
Cooling fan rotor components as required, refer to the new module/component installation
jammed/blocked note at the top of the DTC Index
Cooling fan motor
damage/fault
P069100 Fan 1 Control Circuit Low Cooling fan control Carry out any pinpoint tests associated with this DTC using the
circuit - short to manufacturer approved diagnostic system. Refer to the electrical circuit
ground, open circuit diagrams and check cooling fan control circuit for short to ground, open
circuit
P069200 Fan 1 Control Circuit High Cooling fan control Refer to the electrical circuit diagrams and check cooling fan control circuit
circuit - short to for short to power
power
Pinpoint Tests
PINPOINT TEST A : LOSS OF COOLANT

CONDITIONS
A1: VISUAL INSPECTION
1 Visually inspect for loss of coolant.
2 Carry out a system pressure test. See component tests in this section.
Is the engine cooling system leaking?
Yes
Rectify the leak as indicated by the test result. Top-up and fill the cooling system to the correct level with the correct
specification fluid as necessary. REFER to: (303-03A Engine Cooling - TDV6 2.7L Diesel)
Cooling System Draining, Filling and Bleeding (General Procedures).
TEST the system for correct operation.
No
Verify the customer complaint.
PINPOINT TEST B : THE ENGINE OVERHEATS

CONDITIONS
B1: CHECK COOLANT
WARNING: The cooling system is pressurized! Ensure the reservoir cap is never released until the system has cooled. Failure to follow
1 Check the coolant level and condition.
Does the system contain sufficient coolant of the correct specification?
Yes
GO to B2.
No
Top-up and fill the cooling system to the correct level with the correct specification fluid as necessary. REFER to:
(303-03A Engine Cooling - TDV6 2.7L Diesel)
Check for coolant loss. GO to Pinpoint Test A.
B2: CHECK COOLANT EXPANSION TANK PRESSURE CAP
1 Check the coolant expansion tank pressure cap for damage/correct operation. REFER to the coolant expansion tank
pressure cap pressure test in this section.
Is the coolant expansion tank pressure cap operating correctly?
Yes
GO to B3.
No
INSTALL a new coolant expansion tank pressure cap. TEST the system for correct operation.
B3: CHECK THERMOSTAT
1 Check the thermostat for correct operation. REFER to the thermostat component test in this section.
Is the thermostat operating correctly?
Yes
Check for correct operation of cooling fans, circuits, sensors, modules, etc.
REFER to: Electronic Engine Controls - 2.7L Diesel (303-14A, Diagnosis and Testing).
No
INSTALL a new thermostat.
REFER to: Thermostat (303-03A Engine Cooling - TDV6 2.7L Diesel, Removal and Installation).
PINPOINT TEST C : THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURE
C1: CHECK THERMOSTAT
Yes
REFER to: Electronic Engine Controls - 2.7L Diesel (303-14A, Diagnosis and Testing).
No
Component Tests
Cooling System Pressure Test
WARNING: Never, under any circumstances, remove the coolant expansion tank pressure cap while the engine is operating. To avoid
having scalding hot water or steam blow out of the cooling system, use extreme care when removing the coolant expansion tank pressure
cap from a hot cooling system. Wait until the engine has cooled, then wrap a thick cloth around the coolant expansion tank 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 expansion tank pressure cap. Failure to follow these instructions
may result in damage to the cooling system, engine and/or cause personal injury.
1. 1. Switch the engine off.
2. 2. Open the hood and install protective fender covers.
3. 3. Carefully remove the coolant expansion tank pressure cap from the coolant expansion tank to relieve pressure in the cooling
system. Add coolant to coolant expansion tank as necessary.
4. 4. Install the pressure tester equipment to the cooling system following manufacturers instructions. Reinstall the coolant expansion
tank pressure cap (if pressure test equipment is not installed to the coolant expansion tank).
5. 5. Pressurize the cooling system to the coolant expansion tank pressure cap lower limit.
6. 6. Observe the gauge reading for approximately two minutes. Pressure should not drop during this time.
If system holds pressure, continue from step 8.

If the pressure drops, check the complete cooling system for leaks. Also refer to engine system checks if a leak cannot be
located in the cooling system. Correct any leaks found and recheck the system.
7. 7. Release the system pressure and remove the pressure test equipment. Check the coolant level. Replenish as necessary with the
correct coolant solution.
REFER to: Specifications (303-03A Engine Cooling - TDV6 2.7L Diesel, Specifications).
8. 8. Check the radiator overflow hose for any obstructions which may block the flow of coolant either to or from the coolant expansion
tank.
9. 9. Conduct the coolant expansion tank pressure cap pressure test in this section.
Coolant Expansion Tank Pressure Cap Pressure Test
1. 1. Remove the expansion tank pressure cap from the coolant expansion tank.
2. 2. Use water to clean cap in area of rubber seal and vacuum relief valve. Following manufacturers instructions, install the coolant
expansion tank pressure cap to the pressure tester.
3. NOTE: If the pressure tester is pressurised too quickly, an erroneous pressure reading may result.
3. Slowly pressurise the system until the pressure gauge reading stops increasing, and note highest pressure reading obtained.
4. 4. Release pressure and repeat Step 3 at least twice to make sure the pressure test reading is repeatable and within specification.
5. 5. If the pressure test gauge readings are not within specification, install a new coolant expansion tank pressure cap.
Thermostat Test
Remove the thermostat

Inspect for visible damage, note its opening temperature and immerse it in water. Heat the water until this temperature is reached. The
thermostat should begin to open. If it does not begin to open, install a new thermostat.
If thermostat begins to open, continue to heat the water until the thermostat fully opens, 5.8 mm (0.2 in) or more off the seat. If it does
not fully open, install a new thermostat.
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 aluminium. If a separate tank is not available, drain and rinse the test tank
before testing an aluminium radiator.
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.
Engine Cooling - TDV6 2.7L Diesel - Cooling System Draining, Filling and Bleeding
General Procedures
W ARNINGS:
Never remove the coolant expansion tank cap under any circumstances while the engine is operating. Failure to follow this instruction
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:
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.
may result in damage to the engine.
2. W ARNING: Release the cooling system pressure by slowly turning

the coolant expansion tank cap a quarter of a turn. Cover the expansion
tank cap with a thick cloth to prevent the possibility of scalding. Failure to
Release the cooling system pressure.
Remove the coolant expansion tank cap.

4. Drain the coolant.
Remove the drain plug.
5. CAUTION: Do not over tighten the drain plug. Failure to follow this
instruction may result in damage to the vehicle.
Remove the drain tray.

7. Loosen the coolant expansion tank bleed screw.
8. CAUTION: Anti-freeze concentration must be maintained at 50%.
Refill the cooling system.
When coolant runs from the expansion tank bleed point

bubble-free, tighten the bleed screw.
Tighten to 3 Nm.
9. Set the heating to the COLD position.

Set the ignition to the ON position.

11. After 3 minutes, set the heating system to the HOT position.
12. Maintain the coolant level in the coolant expansion tank at the MAX
mark using a 50% mixture of Jaguar Premium Cooling System Fluid or
equivalent, meeting Jaguar specification W SS M97B44-D and 50% water.
13. After 4 minutes, refit the coolant expansion tank pressure cap.
14. Start the engine and allow to idle for 5 minutes.
15. Raise the engine to 2500 RPM for 30 seconds.
16. Set the ignition to the OFF position.
17. Allow the engine to cool.
18. After 2 minutes, release the cooling system pressure.
Remove the coolant expansion tank pressure cap.
19. NOTE: Make sure the heating system is set to the HOT position.
Set the ignition to the ON position.

21. After 3 minutes, refit the coolant expansion tank pressure cap.
22. Drive the vehicle on the road at varying speeds until the engine
reaches normal operating temperature.
24. Release the cooling system pressure.
25. 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
27. Visually check the engine and cooling system for signs of coolant
leakage.
Engine Cooling - TDV6 2.7L Diesel - Coolant Expansion Tank
Removal
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
1. CAUTION: Take extra care when releasing the vent hose, failure to
follow this instruction may result in damage to the coolant expansion
tank.
NOTE: Cap the vent hose to minimize coolant loss.
Release the coolant expansion tank.
Disconnect the vent hose.
Release the coolant expansion tank from its mountings for access.
2. Disconnect the coolant expansion tank low level sensor electrical

connector.
3. NOTE: Make sure the retaining clip is not removed.
NOTE: Cap the coolant expansion tank lower hose to minimize coolant
loss.
Disconnect the coolant expansion tank lower hose.
Remove the coolant expansion tank.
Installation
2. Fill the cooling system to the upper level mark of the coolant expansion
tank.
Engine Cooling - TDV6 2.7L Diesel - Cooling Fan Motor and Shroud
Removal
1. Remove fuse F17 from the engine junction box (EJB).
Remove the engine compartment fuse box cover.
Remove the engine compartment fuse box inner cover.

Installation).
5. Release and remove the cooling fan lower shroud from the cooling pack.
6. Disconnect the two electrical connectors from the cooling module wiring
harness.
Release the 2 electrical connectors from the clips.

Disconnect the auxillary coolant flow pump electrical connector
8. Release the A/C line from the cooling fan shroud.
9. Release the coolant hose from the cooling fan shroud.

12. NOTE: Cap the vent hose to minimize coolant loss.
Release the coolant expansion tank.
Release the vent hose.
Release the expansion tank from its mountings for access

13. Disconnect the coolant expansion tank low level sensor electrical
connector.
15. Release the coolant hose from the cooling fan shroud.
16. Remove the cooling fan motor and shroud securing bracket.
17. Remove the cooling fan motor and shroud retaining bolt
Remove the cooling fan motor and shroud.
Reposition the wiring harness.
Installation
Install the cooling fan motor and shroud retaining bolt.
Tighten to 6 Nm.
2. Tighten to 6 Nm.
3. Tighten to 6 Nm.
Engine Cooling - TDV6 2.7L Diesel - Coolant Pump
Removal


6. Remove the coolant pump pulley.
Using a suitable 6mm bar, retain the coolant pump pulley.
Discard the bolts.
Remove the coolant pump.
Installation
1. CAUTION: Make sure that the mating faces are clean and free of
foreign material.
NOTE: Lubricate the O-ring seal with clean coolant.
Tighten to 10 Nm.
Engine Cooling - TDV6 2.7L Diesel - Radiator
Removal
CAUTION: Engine coolant will damage the paint finished surfaces. If spilt, immediately remove the coolant and clean the area with
water.


4. Disconnect the coolant top hose from the radiator.
5. Remove the air intake elbow pipe.
6. Detach the charge air cooler intake elbow.

9. Remove the radiator upper mountings.
10. Remove the right-hand A/C condensor retaining bolt.
11. Remove the left-hand A/C condensor retaining stud.

12. Tie the A/C condenser forwards, clear of the radiator.
13. With assistance, remove the radiator assembly.
14. Remove the foam insulation pads.
15. Remove the charge air cooler from the radiator.
1. Remove the charge air cooler retaining bolts.
Installation
Tighten to 7 Nm.
2. Tighten to 7 Nm.
3. Tighten to 7 Nm.
4. Tighten to 7 Nm.
5. Tighten to 7 Nm.
Engine Cooling - TDV6 2.7L Diesel - Thermostat
Special Tool(s)
Remover/Install, Cooling Hose Clamp
303-397
Removal

Procedures).
5. Detach the charge air cooler inlet hose.
6. Remove the charge air cooler inlet elbow.
7. Detach the coolant hoses.

8. Detach the transmission fluid cooler hose.
9. Remove the coolant expansion tank.

For additional information, refer to: Coolant Expansion Tank (303-03B
Engine Cooling - V6 3.0L Petrol, Removal and Installation).
11. Detach the thermostat and hose assembly.
12. Remove the thermostat and hose assembly.
Installation
1. Install the thermostat and hose assembly.
2. Attach the thermostat and hose assembly.
4. Install the coolant expansion tank.

For additional information, refer to: Coolant Expansion Tank (303-03B
Engine Cooling - V6 3.0L Petrol, Removal and Installation).
5. Attach the transmission fluid cooler hose.
6. Attach the coolant hoses.
7. Install the charge air cooler inlet elbow.
Tighten to 7 Nm.
8. Attach the charge air cooler inlet hose.

10. Refill the cooling system.
Procedures).
11. Reconnect the battery ground cable.
Published: 24-Jun-2011
Engine Cooling - V6 3.0L Petrol -
Engine Capacity
3.0L 9.4L
Coolant bleed screw(s) 3 - 27
Cooling fan motor and shroud retaining nuts 7 - 62
Thermostat housing retaining bolts 10 - 89
W ater pump retaing bolts 25 18 -
Radiator mouning bracket retaining bolts 7 - 62
Engine block drain plug 50 37
Engine Cooling - V6 3.0L Petrol - Engine Cooling - Component Location
Component Location (Sheet 1 of 2)
ItemDescription
1 Radiator
2 Expansion tank
3 Throttle body
4 Intake manifold
5 Bypass (Outlet) tube assembly
7 Transfer (Inlet) connector
8 Engine oil cooler
9 Thermostat
10 Cooling fan
11 Coolant pump
Component Location (Sheet 2 of 2)
ItemDescription
1 Engine block heater
Comments:
240 V ac version shown, 110 V ac version similar.
2 Harness
3 Connecter
Engine Cooling - V6 3.0L Petrol - Engine Cooling - Overview
Overview
The engine cooling system maintains the engine within an optimum temperature range under changing ambient and engine operating
conditions. It also provides:
Heating for:
- The passenger compartment.
- The inlet manifold and throttle body.
Cooling for:
- The engine lubrication system.
- The transmission lubrication system.
Engine Cooling - V6 3.0L Petrol - Engine Cooling - System Operation and Component
Description
System Operation
When the engine is running the coolant is circulated around the engine cooling system by the coolant pump. From the outlet of the coolant
pump, coolant flows through the cylinder block and cylinder heads, then into the radiator upper hose. W hen the coolant is cold, the
thermostat is closed and the coolant returns to the inlet of the coolant pump through the thermostat housing. When the coolant is warm,
the thermostat is open and the coolant flows to the inlet of the coolant pump via the radiator, the radiator lower hose and the thermostat
housing.
When the thermostat is open, the coolant flow through the radiator lower hose generates a coolant flow through the engine oil cooler.
The heater core and the inlet manifold/throttle body are on parallel circuits that are unaffected by the position of the thermostat. A
constant flow of coolant is supplied to the heater core and the inlet manifold/throttle body from the radiator upper hose. The return flow
from the inlet manifold/throttle body joins the supply to the heater core. From the heater core, the coolant returns to a dedicated inlet on
the coolant pump. Expansion and contraction of the coolant is accommodated by the hose connection between the expansion tank and the
heater return hose.
If the coolant level in the expansion tank decreases below a predetermined value, the level sensor connects a ground to the instrument
cluster, which activates the appropriate warning.
The cooling fan is operated by a fan control module integrated into the cooling fan motor. The fan control module regulates the voltage, and
thus speed, of the cooling fan motor in response to a PW M (pulse width modulation) signal from the ECM (engine control module). The ECM
calculates the required fan speed from the engine temperature, A/C (air conditioning) system pressure and transmission oil temperature.
Under hot operating conditions, the fan may continue to operate for four minutes after the engine has been switched off.
Engine Cooling Flow Diagram
ItemDescription
1 Coolant pump
2 Throttle body
3 Inlet manifold
4 Engine
5 Heater core
6 Engine oil cooler
7 Thermostat
8 Radiator lower hose
9 Radiator
10 Coolant expansion tank
11 Radiator upper hose
General
Coolant pump.
Thermostat.
Radiator.
Cooling fan.
Expansion tank.
Engine oil cooler.
The heater core.

The transmission oil cooler.
In markets subject to very cold climatic conditions, an engine block heater is incorporated into the engine cooling system.
Coolant Pump
ItemDescription
1 Pulley
2 Outlet connection to cylinder block
3 Inlet connection from thermostat
4 Inlet connection from heater core
The coolant pump consists of a body that contains an impeller connected to a pulley at the rear of the body. Coolant inlet and outlet
connections are incorporated into the body, which is attached to the front cover of the engine. The pulley is driven by the accessory drive
belt.
Refer to: Accessory Drive (303-05 Accessory Drive - 3.0L, Description and Operation).
Thermostat
ItemDescription
1 Radiator upper hose connection
2 Coolant pump inlet hose connection
3 Thermostat
4 O-ring
5 Inlet connector
6 Bolt (2 off)
7 Radiator lower hose connection
8 Thermostat housing
The thermostat allows rapid engine warm-up, by restricting coolant flow through the radiator when the engine is cold, and helps to keep the
engine operating temperature within predetermined limits. The thermostat is installed in a housing at the junction of the coolant pump inlet
hose, the radiator lower hose and the radiator upper hose. The thermostat begins to open at 88 - 92 C (190 - 198 F) and is fully open at
102 C (216 F).
Radiator
ItemDescription
2 Coolant inlet
3 Support (2 off)
4 Coolant outlet
5 Transmission oil outlet
6 Drain plug
7 Transmission oil inlet
The radiator is a cross flow type with an aluminum core and plastic end tanks. The radiator is located in the vehicle by locating spigots and
supports integrated into the end tanks. The supports are installed in rubber bushes in the upper chassis rails. The locating spigots are
installed in rubber bushes in the front end carrier. The transmission oil cooler and a drain plug are integrated into the LH (left-hand) end
tank. Coolant inlet and outlet connections are incorporated into the RH (right-hand) and LH end tanks respectively.
Cooling Fan
ItemDescription
1 Shroud
2 Electrical connectors
3 Fan
An electric, variable speed cooling fan is installed in a shroud attached to the rear of the radiator. The cooling fan is operated by a fan
control module, integrated into the electric motor, under the control of the ECM. Two electrical connectors at the RH side of the shroud
provide the interface between the cooling fan harness and the vehicle wiring.
Expansion Tank
ItemDescription
1 Filler cap
2 Bleed screw
5 Level sensor
6 Level markings
A pressurized expansion tank system is used which continuously separates the air from the cooling system and replenishes the system
through a hose connected between the expansion tank and the heater return hose. A continuous vent into the expansion tank, through a
hose connected to the radiator upper hose, prevents air locks from forming in the cooling system.
The expansion tank is installed behind the top right corner of the radiator. A filler cap, bleed screw and level sensor are incorporated into
the expansion tank. MAX and MIN level markings are molded into the interior of the tank below the filler cap. The expansion tank provides
the following functions:
Service fill.
The expansion tank has an air space of approximately 0.5 to 1 liter (1.06 to 2,11 US pints), above the MAX level, to allow for coolant
expansion.
Engine Oil Cooler
ItemDescription
1 Coolant outlet
2 Coolant inlet
The engine oil cooler is located on the LH side of the engine, on the oil filter adapter. Engine oil is cooled as it flows from the filter back to
the cylinder block. The coolant supply and return hoses for the engine oil cooler are connected to a T insert in the radiator lower hose. A
restrictor in the T insert, between the two oil cooler connections, induces the flow of coolant through the oil cooler.
Engine Block Heater
ItemDescription
1 110 V ac version
2 240 V ac version
For vehicle markets subject to very cold climatic conditions, an engine block heater is installed in place of the cylinder block drain plug. The
engine block heater is either a 110 V ac or 240 V ac electric heater element, depending on the market, which can be connected to a
domestic power supply via a connector in the lower center grill of the front bumper.
Engine Coolant
The engine coolant is formulated to last for ten years or 240,000 km (150,000 miles). The coolant is silicate free and must not be mixed
with conventional engine coolant.
Engine Cooling - V6 3.0L Petrol - Engine Cooling
For a detailed description of the petrol engine cooling system, refer to the relevant Description and Operation sections in the workshop
manual. REFER to: (303-03B Engine Cooling - V6 3.0L Petrol)

Engine Cooling (Description and Operation).

Visual Inspection
Leaks Fuse
step.
4. 4. If there are clear symptoms refer to the table below, alternatively, check for Diagnostic Trouble Codes (DTCs) and refer to the DTC
Index.
Symptom Chart

Hose connections
Radiator
Coolant pump
Heater core
Gaskets

Thermostat
Fan motor
ECT sensor
Fan speed module

Electric fan
Fan speed module
DTC Index
3548-1358-00.
first five digits of the seven digit code listed to identify the fault (the last two digits give extra information read by the manufacturer
NOTE: When performing voltage or resistance tests, always use a digital multimeter (DMM) accurate to three decimal places, and with a

P011623 Engine Coolant Temperature Low coolant level Fill cooling system to correct level and specification.
Sensor 1 Circuit ECT sensor sensing circuit - REFER to: Specifications (303-03B Engine Cooling - V6 3.0L
Range/Performance intermittent high resistance Petrol, Specifications).
Engine thermostat failure . Carry out any pinpoint tests associated with this DTC using the
ECT sensor failure manufacturer approved diagnostic system. Refer to the electrical
circuit diagrams and check ECT sensor circuits for intermittent
high resistance. Check and install new engine thermostat as
required. Check and install a new ECT sensor as required
Engine thermostat failure . Carry out any pinpoint tests associated with this DTC using the
Engine thermostat failure Carry out any pinpoint tests associated with this DTC using the
P011700 Engine Coolant Temperature ECT sensor sensing circuit - Carry out any pinpoint tests associated with this DTC using the
Sensor 1 Circuit Low short to power, high manufacturer approved diagnostic system. Refer to the electrical
resistance, open circuit, circuit diagrams and check ECT sensor circuits for short to power,
disconnected high resistance, open circuit, disconnected connector. Check and
ECT sensor failure install a new ECT sensor as required
P011800 Engine Coolant Temperature Engine overheat Check for cooling fan circuit DTCs and refer to relevant action
Sensor 1 Circuit High condition/cooling fan failure specified in DTC Index. Carry out any pinpoint tests associated
ECT sensor sensing circuit - with this DTC using the manufacturer approved diagnostic
short to ground system. Refer to the electrical circuit diagrams and check ECT
ECT sensor failure sensor circuits for short to ground. Check and install a new ECT
sensor as required
P012500 Insufficient Coolant Temp Low coolant level Fill cooling system to correct level and specification.
For Closed Loop Fuel Control ECT sensor sensing circuit - REFER to: Specifications (303-03B Engine Cooling - V6 3.0L
intermittent high resistance Petrol, Specifications).
Engine thermostat failure Carry out any pinpoint tests associated with this DTC using the
circuit diagrams and check ECT sensor sensing circuit for
intermittent high resistance. Check and install new engine
thermostat as required. Check and install a new ECT sensor as
required
P012800 Coolant Thermostat (Coolant Low/contaminated coolant Drain and re-fill cooling system to correct level and specification.
Temp Below Thermostat Engine thermostat failure REFER to: Specifications (303-03B Engine Cooling - V6 3.0L
Regulating Temperature) Cooling fan circuit(s)/module Petrol, Specifications).
Check and install a new engine thermostat as required. Refer to
the electrical circuit diagrams and check cooling fan circuits for
short, open circuit. Check for correct operation of cooling fan,
check for DTCs and refer to DTC Index
P048023 Fan 1 Control Circuit Electric cooling fan control Carry out any pinpoint tests associated with this DTC using the
circuit - short to ground, high manufacturer approved diagnostic system. Refer to the electrical
resistance circuit diagrams and check electric cooling fan control circuit for
short to ground, high resistance
P048024 Fan 1 Control Circuit Electric cooling fan control Carry out any pinpoint tests associated with this DTC using the
circuit - short to power manufacturer approved diagnostic system. Refer to the electrical
circuit diagrams and check electric cooling fan control circuit for
short to power
P048309 Fan Performance Cooling fan difficult to Carry out any pinpoint tests associated with this DTC using the
turn/obstructed manufacturer approved diagnostic system. Clear any obstruction
Fan/Motor damaged and Check and install a new fan as required
P048316 Fan Performance Cooling fan control module Carry out any pinpoint tests associated with this DTC using the
reports battery voltage less manufacturer approved diagnostic system. Check the battery is in
than nine volts fully charged and serviceable condition. Refer to the electrical
circuit diagrams and check the charging system and cooling fan
circuits for short, open circuit
P048317 Fan Performance Fan control module reports Carry out any pinpoint tests associated with this DTC using the
battery voltage greater than manufacturer approved diagnostic system. Refer to the electrical
18 volts circuit diagrams and check the charging system and cooling fan
P048397 Fan Performance Cooling fan jammed Clear any obstruction from cooling fan
Pinpoint Tests

CONDITIONS
Yes
Rectify the leak as indicated by the test result. Top-up and fill the cooling system to the correct level with the correct
specification fluid as necessary. REFER to: (303-03B Engine Cooling - V6 3.0L Petrol)
No

CONDITIONS
B1: CHECK COOLANT
WARNING: The cooling system is pressurized! Ensure the reservoir cap is never released until the system has cooled. Failure to follow
Yes
GO to B2.
No
Top-up and fill the cooling system to the correct level with the correct specification fluid as necessary. REFER to:
(303-03B Engine Cooling - V6 3.0L Petrol)
1 Check the coolant expansion tank pressure cap for damage/correct operation. REFER to the coolant expansion tank
pressure cap pressure test in this section.
Yes
GO to B3.
No
Yes
REFER to: Electronic Engine Controls (303-14B Electronic Engine Controls - V6 3.0L Petrol, Diagnosis and Testing).
No
REFER to: Thermostat (303-03B Engine Cooling - V6 3.0L Petrol, Removal and Installation).
Yes
REFER to: Electronic Engine Controls (303-14B Electronic Engine Controls - V6 3.0L Petrol, Diagnosis and Testing).
No
Component Tests
3. 3. Carefully remove the coolant expansion tank pressure cap from the coolant expansion tank to relieve pressure in the cooling
system. Add coolant to coolant expansion tank as necessary.
4. 4. Install the pressure tester equipment to the cooling system following manufacturers instructions. Reinstall the coolant expansion
tank pressure cap (if pressure test equipment is not installed to the coolant expansion tank).

If the pressure drops, check the complete cooling system for leaks. Also refer to engine system checks if a leak cannot be
located in the cooling system. Correct any leaks found and recheck the system.
7. 7. Release the system pressure and remove the pressure test equipment. Check the coolant level. Replenish as necessary with the
correct coolant solution.
REFER to: Specifications (303-03B Engine Cooling - V6 3.0L Petrol, Specifications).
8. 8. Check the radiator overflow hose for any obstructions which may block the flow of coolant either to or from the coolant expansion
tank.
2. 2. Use water to clean cap in area of rubber seal and vacuum relief valve. Following manufacturers instructions, install the coolant
expansion tank pressure cap to the pressure tester.
3. Slowly pressurise the system until the pressure gauge reading stops increasing, and note highest pressure reading obtained.
4. 4. Release pressure and repeat Step 3 at least twice to make sure the pressure test reading is repeatable and within specification.
5. 5. If the pressure test gauge readings are not within specification, install a new coolant expansion tank pressure cap.
Thermostat Test
Remove the thermostat

Inspect for visible damage, note its opening temperature and immerse it in water. Heat the water until this temperature is reached. The
thermostat should begin to open. If it does not begin to open, install a new thermostat.
If thermostat begins to open, continue to heat the water until the thermostat fully opens, 5.8 mm (0.2 in) or more off the seat. If it does
not fully open, install a new thermostat.
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 aluminium. If a separate tank is not available, drain and rinse the test tank
before testing an aluminium radiator.
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.
Engine Cooling - V6 3.0L Petrol - Cooling System Draining, Filling and Bleeding
General Procedures
W ARNINGS:
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:
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.
may result in damage to the engine.
All vehicles


All vehicles
5. CAUTION: Do not over tighten the drain plug. Failure to follow this

7. Loosen the cooling system bleed screw.

8. NOTE: Position cloth to collect fluid spillage.
Loosen the cooling system bleed screw.


All vehicles
11. Install the coolant expansion tank cap.
12. CAUTION: Do not RUN the engine with the coolant expansion
tank pressure cap removed. Failure to follow this instruction may cause
Start and run the engine.
13. Set the heating system to MAX heat, the blower motor to MAX speed
and the air distribution to the instrument panel registers.
14. CAUTION: Observe the engine temperature warning light. If the

warning light is displayed, switch off immediately and allow to cool.
Failure to follow this instruction may cause damage to the vehicle
Allow the engine to run until hot air is emitted from the instrument
panel registers, while observing the engine tempreture warning light.
15. Switch the engine off.
19. Install the coolant expansion tank pressure cap.
Engine Cooling - V6 3.0L Petrol - Coolant Expansion Tank
Removal

2. For additional information, refer to: Cooling System Draining, Filling and
Bleeding (303-03C Engine Cooling - V8 4.2L Petrol/V8 S/C 4.2L Petrol,
3. CAUTION: Take extra care when handling the component.
4.
5.
6. TORQUE: 3 Nm
Installation
1. Install is the reverse of removal.
Engine Cooling - V6 3.0L Petrol - Cooling Fan Shroud
Removal
2. Refer to: Coolant Expansion Tank (303-03B Engine Cooling - V6 3.0L Petrol, Removal
and Installation).
3. Refer to: Radiator Splash Shield (501-02 Front End Body Panels, Removal and
Installation).
4. Refer to: Air Cleaner (303-12B Intake Air Distribution and Filtering - V6 3.0L Petrol,
6.
7.
8.
9. Torque: 7 Nm
10. Torque: 7 Nm
11.
12.
13.
14. 14. CAUTION: Be prepared to collect escaping oil.
15.
16.
Installation

Engine Cooling - V6 3.0L Petrol - Cooling Module
Removal
1. For additional information, refer to: Battery Disconnect and Connect

3. For additional information, refer to: Radiator Splash Shield (501-02
4. For additional information, refer to: Air Cleaner (303-12B Intake Air
Distribution and Filtering - V6 3.0L Petrol, Removal and Installation).
6.
7. For additional information, refer to: Air Conditioning (A/C) System

Recovery, Evacuation and Charging (412-00 Climate Control System -
8.
9. TORQUE: 7 Nm
10.
11.
12.
13.
14. CAUTION: Be prepared to collect escaping oil.
TORQUE: 20 Nm
15.
TORQUE: 20 Nm
17. NOTE: Cap the coolant expansion tank lower hose to minimize coolant
loss.
18. TORQUE: 10 Nm
19. TORQUE: 10 Nm
20.
Installation
2. Check and top-up the transmission fluid level.
For additional information, refer to: Transmission Fluid Level Check
Engine Cooling - V6 3.0L Petrol - Thermostat
Removal
Bleeding (303-03C Engine Cooling - V8 4.2L Petrol/V8 S/C 4.2L Petrol,
For additional information, refer to: Air Cleaner Outlet Pipe (303-12,
6. Remove the thermostat.
Installation
Tighten to 10 Nm.
2. 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 (303-14C, General Procedures).
Engine Cooling - V6 3.0L Petrol - Radiator
Removal
All vehicles
For additional information, refer to Cooling Fan Motor and Shroud in this
section.
Vehicles with automatic transmission

2. Detach the transmission oil cooler inlet and return pipes.
Cap the oil cooler inlet and return pipes and the oil cooler.
3. Detach the lower coolant hose.
Vehicles with manual transmission

4. Detach the lower coolant hose.
All Vehicles
5. Disconnect the front crash sensor.
6. Detach the wiring harness.
7. Detach the radiator seal.
Left-hand shown, right-hand similar.

Remove the double-sided adhesive tape.

9. Remove the radiator lower cowl.

10. Remove the water pump. For additional information, refer to Section
303-03A Engine Cooling / 303-03B Engine Cooling / 303-03C Engine
Cooling / 303-03D Supercharger Cooling.
11. Remove the water pump retaining bracket.
2. Remove the water pump retaining bracket.

12. Remove the cooling module retaining bolt.
13. Remove the cooling module retaining bolt.
Secure the supercharger cooling radiator, condenser core and

engine oil cooler using suitable retaining straps.

Detach the power steering oil cooler.
Remove the condenser core retaining stud.
Secure the condenser core and PAS cooler using suitable retaining
straps.
All vehicles
17. CAUTION: Make sure that the radiator is not damaged when
removed.
Remove the radiator.
Installation
All vehicles
1. CAUTION: Make sure that the radiator is not damaged when

installed.

Tighten to 7 Nm.
Tighten to 7 Nm.

4. Tighten to 7 Nm.
5. Tighten to 7 Nm.
6. Tighten to 7 Nm.
Vehicles with automatic transmission

Tighten to 20 Nm.
8. Carry out transmission fluid level check.

For additional information, refer to Section 307-01 Automatic
Transmission/Transaxle.
Engine Cooling - V6 3.0L Petrol - Water Pump
Removal


3. For additional information, refer to: Air Cleaner Outlet Pipe (303-12B,
4. For additional information, refer to: Accessory Drive Belt (303-05B
5. For additional information, refer to: Secondary Air Injection (AIR)
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18. TORQUE: 25 Nm
Installation
Engine Cooling - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8 -
Engine Capacity
4.2L 13.3L
Cooling fan motor and shroud retaining nuts 7 - 62
Thermostat housing retaining bolts 9 - 80
W ater pump retaining bolts A - -
W ater pump drive pully retaining bolts A - -
Radiator mounting bracket retaining bolts 7 - 62
Engine Cooling - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8 - Engine Cooling -
Component Location
Component Location (Sheet 1 of 2 - Vehicles W ithout Supercharger)
ItemDescription
1 Radiator
2 Expansion tank
3 Thermostat cover
4 EGR (exhaust gas recirculation) valve
5 Throttle body
7 Inlet duct
8 Outlet assembly
10 Cooling fan
11 Coolant pump
12 Engine oil cooler
Component Location (Sheet 1 of 2 - Vehicles W ith Supercharger)
ItemDescription
1 Expansion hose connection to intercooler radiator
2 Radiator
3 Outlet assembly
4 Inlet duct
5 Throttle body
7 Expansion tank
8 Thermostat cover
10 Cooling fan
11 Coolant pump
12 EGR valve
Component Location (Sheet 2of 2)
ItemDescription
1 Engine block heater
Comments:
110 V ac version shown, 240 V ac version similar.
2 Harness
3 Connector
Overview
Overview
The engine cooling system maintains the engine within an optimum temperature range under changing ambient and engine
operating conditions. It also provides:
Heating for:
- The passenger compartment.
- The throttle body.
Cooling for:
- The engine lubrication system.
- The transmission lubrication system.
Refer to: Transmission Cooling - Vehicles With: ZF 6HP26 (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).
- The EGR (exhaust gas recirculation) valve.
Refer to: Engine Emission Control (303-08 Engine Emission Control - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8,
System Operation
General
When the engine is running, the coolant is circulated around the engine cooling system by the coolant pump and the
auxiliary coolant pump. From the outlet of the coolant pump, coolant flows through the cylinder block and cylinder heads,
then into the outlet assembly. W hen the coolant is cold, the thermostat is closed and the coolant flows direct from the
outlet assembly back to the coolant pump. When the coolant is warm, the thermostat is open and the coolant flows from
the outlet assembly to the inlet of the coolant pump via the radiator upper hose, radiator, radiator lower hose and
thermostat.
On vehicles without supercharger, when the thermostat is open, the coolant flow through the radiator lower hose
generates a coolant flow through the engine oil cooler.
The EGR (exhaust gas recirculation) valve/throttle body and the heater core are on parallel circuits that are unaffected by
the position of the thermostat. A constant flow of coolant is supplied to the EGR valve/throttle body from the outlet
assembly. From the throttle body the coolant flows back to a dedicated inlet connection of the coolant pump. A constant
flow of coolant is supplied to the heater core from the radiator upper hose. From the heater core outlet, the coolant flows
back to the inlet of the coolant pump via the auxiliary coolant pump.
Expansion and contraction of the coolant is accommodated by the hose connection between the expansion tank and the
heater return hose.
If the coolant level in the expansion tank decreases below a predetermined value, the level sensor connects a ground to
the instrument cluster, which activates the appropriate warning.
The cooling fan is operated by a fan control module integrated into the cooling fan motor. The fan control module
regulates the voltage, and thus speed, of the cooling fan motor in response to a PWM (pulse width modulation) signal
from the ECM (engine control module). The ECM calculates the required fan speed from the engine temperature, A/C (air
conditioning) system pressure and transmission oil temperature. Under hot operating conditions, the fan may continue to
operate for four minutes after the engine has been switched off.
Refer to: Electronic Engine Controls (303-14 Electronic Engine Controls - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8, Description
and Operation).
Engine Cooling Flow Diagram (Vehicles W ithout Supercharger)

ItemDescription
1 EGR valve
2 Throttle body
3 Heater core
4 Coolant pump
5 Engine
6 Thermostat
7 Engine oil cooler
8 Bleed screw
9 Expansion tank
10 Radiator
Engine Cooling Flow Diagram (Vehicles W ith Supercharger)
ItemDescription
1 EGR valve
2 Throttle body
3 Heater core
4 Expansion tank
5 Engine
6 Coolant pump
7 Thermostat
8 Radiator
9 Connection with supercharger cooling system
Comments:
Refer to: Supercharger Cooling (303-03B Supercharger Cooling - 4.2L SC V8 - AJV8, Description and Operation).
General
Coolant pump.
Thermostat.
Radiator.
Cooling fan.
Expansion tank.
Engine oil cooler.
The heater core.

The EGR cooler.
Refer to: Engine Emission Control (303-08 Engine Emission Control - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8,
The transmission oil cooler (vehicles without supercharger only).
Refer to: Transmission Cooling - Vehicles With: ZF 6HP26 (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).
In markets subject to very cold climatic conditions, an engine block heater is incorporated into the engine cooling system.
Coolant Pump
ItemDescription
1 Drive hub
2 Adapter
3 Gasket
4 Pump body
5 Bolt (2 off)
6 Pulley
7 Bolt (3 off)
8 Impeller
The coolant pump has a body that supports a shaft with an impeller attached to one end and a drive hub at the other. The
body is attached to the front of the cylinder block with an adapter, which encloses the impeller to form the pumping
chamber. The pump is driven by a pulley attached to the drive hub and driven by the accessory drive belt. Refer to:
Accessory Drive (303-05 Accessory Drive - 4.2L, Description and Operation).
Thermostat (Vehicles Without Supercharger)

ItemDescription
1 Outlet pipe
2 Seal
3 Thermostat
4 Thermostat cover
5 Bolt (3 off)
Thermostat (Vehicles With Supercharger)
ItemDescription
1 Seal
2 Thermostat cover
3 Bolt (3 off)
4 Thermostat
5 Outlet pipe
The thermostat is located in the outlet assembly, under the thermostat cover, and allows rapid engine warm-up by
restricting coolant flow through the radiator when the engine is cold. The thermostat also assists in keeping the engine
operating temperature within predetermined limits. On vehicles without supercharger, the thermostat begins to open at 88
- 92 C (190 - 198 F) and is fully open at 102 C (216 F). On vehicles with supercharger, the thermostat begins to open
at 84 C (183 F) and is fully open at 98 C (208 F).
Radiator
ItemDescription
2 Coolant inlet
3 Support (2 off)
4 Drain plug
5 Transmission oil outlet
6 Coolant outlet
7 Transmission oil inlet
The radiator is a cross flow type with an aluminum core and plastic end tanks. The radiator is located in the vehicle by
locating spigots and supports integrated into the end tanks. The supports are installed in rubber bushes in the upper
chassis rails. The locating spigots are installed in rubber bushes in the front end carrier. The transmission oil cooler and a
drain plug are integrated into the LH (left-hand) end tank. Coolant inlet and outlet connections are incorporated into the
RH (right-hand) and LH end tanks respectively.
Cooling Fan
ItemDescription
1 Shroud
2 Electrical connectors
3 Fan
An electric, variable speed cooling fan is installed in a shroud attached to the rear of the radiator. The cooling fan is
operated by a fan control module, integrated into the electric motor, under the control of the ECM. Two electrical
connectors at the RH side of the shroud provide the interface between the cooling fan harness and the vehicle wiring.
Expansion Tank (Vehicles Without Supercharger)

ItemDescription
1 Filler cap
2 Bleed screw
5 Level sensor
6 Level markings
Expansion Tank (Vehicles With Supercharger)
ItemDescription
1 Filler cap
4 Level sensor
A pressurized coolant expansion tank system is used, which continuously separates the air from the cooling system and
replenishes the system through a hose connected between the expansion tank and the heater return hose. A continuous
vent into the expansion tank, through a hose connected to the outlet assembly, prevents air locks from forming in the
cooling system.
On vehicles without supercharger, the expansion tank is installed behind the top right corner of the radiator. A filler cap,
bleed screw and level sensor are incorporated into the expansion tank. MAX and MIN level markings are molded into the
interior of the tank below the filler cap
On vehicles with supercharger, the expansion tank is installed on the LH front upper suspension housing. A filler cap and
level sensor are incorporated into the expansion tank. A MAX level marking is molded into the interior of the tank below
the filler cap. Cold fill levels are molded onto the exterior of the tank.
On all vehicles, the expansion tank provides the following functions:
Service fill.
The expansion tank has an air space of approximately 0.5 to 1 liter (1.06 to 2,11 US pints), above the MAX level, to allow
for coolant expansion.
Engine Oil Cooler (Vehicles Without Supercharger Only)
ItemDescription
2 coolant inlet connection
The engine oil cooler is installed at the front of the engine sump, between the engine oil filter head and the engine oil
filter. Engine oil is cooled as it flows back to the filter head from the filter. The coolant supply and return hoses for the
engine oil cooler are connected to a T insert in the radiator lower hose. A restrictor in the T insert, between the two oil
cooler connections, induces the flow of coolant through the oil cooler.
NOTE: On vehicles with supercharger, there are two air cooled engine oil coolers.
Engine Block Heater
ItemDescription
1 110 V ac version
2 240 V ac version
For vehicle markets subject to very cold climatic conditions, an engine block heater is installed in place of the cylinder
block drain plug. The engine block heater is either a 110 V ac or 240 V ac electric heater element, depending on the
market, which can be connected to a domestic power supply via a connector in the lower center grill of the front bumper.
Engine Coolant
The engine coolant is formulated to last for ten years or 240,000 km (150,000 miles). The coolant is silicate free and must
not be mixed with conventional engine coolant.
Engine Cooling - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8 - Engine Cooling
For a detailed description of the petrol engine cooling system, refer to the relevant Description and Operation sections in
the workshop manual. REFER to:
Engine Cooling (303-03A Engine Cooling - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8, Description and Operation),
Supercharger Cooling (303-03B Supercharger Cooling - 4.2L SC V8 - AJV8, Description and Operation),
Supercharger Cooling (303-03B Supercharger Cooling - 4.2L SC V8 - AJV8, Description and Operation),
Supercharger Cooling (303-03B Supercharger Cooling - 4.2L SC V8 - AJV8, Description and Operation).

Visual Inspection
Leaks Fuse
4. 4. If there are clear symptoms refer to the table below, alternatively, check for Diagnostic Trouble Codes (DTCs)
and refer to the DTC Index.
Symptom Chart

Hose connections
Radiator
Coolant pump
Heater core
Gaskets

Thermostat
Fan motor
ECT sensor
Fan speed module

Electric fan
Fan speed module
DTC Index
NOTE: If the module or a component is suspect and the vehicle remains under the Manufacturers warranty, refer to the
Warranty Policy and Procedure manual (section B1.2), or determine if any prior approval programme is in operation, prior to
the Check and installation of a new module/component.
places, and with a current calibration certificate. When testing resistance, always take the resistance of the DMM leads
into account.
P011623 Engine Coolant Low coolant level Fill cooling system to correct level and specification.
Temperature Sensor 1 ECT sensor sensing REFER to:
Circuit circuit - intermittent high Specifications (303-03A Engine Cooling - 4.2L NA
Range/Performance resistance V8 - AJV8/4.2L SC V8 - AJV8, Specifications),
Engine thermostat failure Specifications (303-03B Supercharger Cooling -
ECT sensor failure 4.2L SC V8 - AJV8, Specifications).
Carry out any pinpoint tests associated with this DTC
using the manufacturer approved diagnostic system.
Refer to the electrical circuit diagrams and check ECT
sensor circuits for intermittent high resistance. Check
and install new engine thermostat as required. Check
and install a new ECT sensor as required
P011700 Engine Coolant ECT sensor sensing Carry out any pinpoint tests associated with this DTC
Temperature Sensor 1 circuit - short to power, using the manufacturer approved diagnostic system.
Circuit Low high resistance, open Refer to the electrical circuit diagrams and check ECT
circuit, disconnected sensor circuits for short to power, high resistance,
ECT sensor failure open circuit, disconnected connector. Check and install
a new ECT sensor as required
P011800 Engine Coolant Engine overheat Check for cooling fan circuit DTCs and refer to relevant
Temperature Sensor 1 condition/cooling fan action specified in DTC Index. Carry out any pinpoint
Circuit High failure tests associated with this DTC using the manufacturer
ECT sensor sensing approved diagnostic system. Refer to the electrical
circuit - short to ground circuit diagrams and check ECT sensor circuits for short
ECT sensor failure to ground. Check and install a new ECT sensor as
required
P012500 Insufficient Coolant Temp Low coolant level Fill cooling system to correct level and specification.
For Closed Loop Fuel ECT sensor sensing REFER to:
Control circuit - intermittent high Specifications (303-03A Engine Cooling - 4.2L NA
resistance V8 - AJV8/4.2L SC V8 - AJV8, Specifications),
sensor sensing circuit for intermittent high resistance.
Check and install new engine thermostat as required.
Check and install a new ECT sensor as required
P012800 Coolant Thermostat Low/contaminated Drain and re-fill cooling system to correct level and
(Coolant Temp Below coolant specification. REFER to:
Thermostat Regulating Engine thermostat failure Specifications (303-03A Engine Cooling - 4.2L NA
Temperature) Cooling fan V8 - AJV8/4.2L SC V8 - AJV8, Specifications),
circuit(s)/module Specifications (303-03B Supercharger Cooling -
4.2L SC V8 - AJV8, Specifications).
Check and install a new engine thermostat as
required. Refer to the electrical circuit diagrams and
check cooling fan circuits for short, open circuit. Check
for correct operation of cooling fan, check for DTCs and
refer to DTC Index
P048023 Fan 1 Control Circuit Electric cooling fan Carry out any pinpoint tests associated with this DTC
control circuit - short to using the manufacturer approved diagnostic system.
ground, high resistance Refer to the electrical circuit diagrams and check
electric cooling fan control circuit for short to ground,
high resistance
P048024 Fan 1 Control Circuit Electric cooling fan Carry out any pinpoint tests associated with this DTC
control circuit - short to using the manufacturer approved diagnostic system.
power Refer to the electrical circuit diagrams and check
electric cooling fan control circuit for short to power
P048309 Fan Performance Cooling fan difficult to Carry out any pinpoint tests associated with this DTC
turn/obstructed using the manufacturer approved diagnostic system.
Fan/Motor damaged Clear any obstruction and Check and install a new fan
as required
P048316 Fan Performance Cooling fan control Carry out any pinpoint tests associated with this DTC
module reports battery using the manufacturer approved diagnostic system.
voltage less than nine Check the battery is in fully charged and serviceable
volts condition. Refer to the electrical circuit diagrams and
check the charging system and cooling fan circuits for
short, open circuit
P048317 Fan Performance Fan control module Carry out any pinpoint tests associated with this DTC
reports battery voltage using the manufacturer approved diagnostic system.
greater than 18 volts Refer to the electrical circuit diagrams and check the
charging system and cooling fan circuits for short,
open circuit
P260100 Coolant Pump Control Incorrect installation of Check for correct installation of the charge air cooler
Circuit electrical connector coolant pump electrical connector. Check for restriction
Range/Performance Restricted coolant flow in charge air cooler coolant pump and pipes. Check
Charge air cooler coolant and install a new pump as required. Check for relay
pump failure failure related DTCs and refer to relevant DTC Index.
Charge air cooler coolant Check and install a new relay as required
pump relay failure
Pinpoint Tests

CONDITIONS
Yes
Rectify the leak as indicated by the test result. Top-up and fill the cooling system to the correct
level with the correct specification fluid as necessary. REFER to:
Specifications (303-03A Engine Cooling - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8, Specifications),
Specifications (303-03B Supercharger Cooling - 4.2L SC V8 - AJV8, Specifications),
Cooling System Draining, Filling and Bleeding (303-03A Engine Cooling - 4.2L NA V8 -
AJV8/4.2L SC V8 - AJV8, General Procedures).
No

CONDITIONS
B1: CHECK COOLANT
WARNING: The cooling system is pressurized! Ensure the reservoir cap is never released until the system has cooled.
Failure to follow these instructions may result in personal injury.
Yes
GO to B2.
No
Top-up and fill the cooling system to the correct level with the correct specification fluid as
necessary. REFER to:
Specifications (303-03B Supercharger Cooling - 4.2L SC V8 - AJV8, Specifications),
Cooling System Draining, Filling and Bleeding (303-03A Engine Cooling - 4.2L NA V8 -
1 Check the coolant expansion tank pressure cap for damage/correct operation. REFER to the coolant
expansion tank pressure cap pressure test in this section.
Yes
GO to B3.
No
1 Check the thermostat for correct operation. REFER to the thermostat component test in this
section.
Yes
REFER to: Electronic Engine Controls (303-14 Electronic Engine Controls - 4.2L NA V8 - AJV8/4.2L SC
V8 - AJV8, Diagnosis and Testing).
No
INSTALL a new thermostat. REFER to: (303-03A Engine Cooling - 4.2L NA V8 - AJV8/4.2L SC V8 -
AJV8)
Thermostat - 4.2L SC V8 - AJV8 (Removal and Installation),
Thermostat - 4.2L NA V8 - AJV8 (Removal and Installation).
CONDITIONS
1 Check the thermostat for correct operation. REFER to the thermostat component test in this
section.
Yes
REFER to: Electronic Engine Controls (303-14 Electronic Engine Controls - 4.2L NA V8 - AJV8/4.2L
SC V8 - AJV8, Diagnosis and Testing).
No
INSTALL a new thermostat. REFER to: (303-03A Engine Cooling - 4.2L NA V8 - AJV8/4.2L SC V8 -
AJV8)
Component Tests
WARNING: Never, under any circumstances, remove the coolant expansion tank pressure cap while the engine is
operating. To avoid having scalding hot water or steam blow out of the cooling system, use extreme care when removing
the coolant expansion tank pressure cap from a hot cooling system. W ait until the engine has cooled, then wrap a thick
cloth around the coolant expansion tank pressure cap and turn it slowly until the pressure begins to release, step back
while the pressure is released from the system. W hen certain all the pressure has been released (still with a cloth) turn
and remove the coolant expansion tank pressure cap. Failure to follow these instructions may result in damage to the
cooling system, engine and/or cause personal injury.
3. 3. Carefully remove the coolant expansion tank pressure cap from the coolant expansion tank to relieve pressure in
the cooling system. Add coolant to coolant expansion tank as necessary.
4. 4. Install the pressure tester equipment to the cooling system following manufacturers instructions. Reinstall the
coolant expansion tank pressure cap (if pressure test equipment is not installed to the coolant expansion tank).

If the pressure drops, check the complete cooling system for leaks. Also refer to engine system checks if a
leak cannot be located in the cooling system. Correct any leaks found and recheck the system.
7. 7. Release the system pressure and remove the pressure test equipment. Check the coolant level. Replenish as
necessary with the correct coolant solution. REFER to:

Specifications (303-03B Supercharger Cooling - 4.2L SC V8 - AJV8, Specifications).
8. 8. Check the radiator overflow hose for any obstructions which may block the flow of coolant either to or from the
coolant expansion tank.
WARNING: Never, under any circumstances, remove the coolant expansion tank pressure cap while the engine is
operating. To avoid having scalding hot water or steam blow out of the cooling system, use extreme care when removing
the coolant expansion tank pressure cap from a hot cooling system. W ait until the engine has cooled, then wrap a thick
cloth around the coolant expansion tank pressure cap and turn it slowly until the pressure begins to release, step back
while the pressure is released from the system. W hen certain all the pressure has been released (still with a cloth) turn
and remove the coolant expansion tank pressure cap. Failure to follow these instructions may result in damage to the
cooling system, engine and/or cause personal injury.
2. 2. Use water to clean cap in area of rubber seal and vacuum relief valve. Following manufacturers instructions,
install the coolant expansion tank pressure cap to the pressure tester.
3. Slowly pressurise the system until the pressure gauge reading stops increasing, and note highest pressure
reading obtained.
4. 4. Release pressure and repeat Step 3 at least twice to make sure the pressure test reading is repeatable and
within specification.
5. 5. If the pressure test gauge readings are not within specification, install a new coolant expansion tank pressure
cap.
Thermostat Test
Remove the thermostat REFER to: (303-03A Engine Cooling - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8)

Inspect for visible damage, note its opening temperature and immerse it in water. Heat the water until this temperature is
reached. The thermostat should begin to open. If it does not begin to open, install a new thermostat. REFER to: (303-03A
Engine Cooling - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8)
If thermostat begins to open, continue to heat the water until the thermostat fully opens, 5.8 mm (0.2 in) or more off the
seat. If it does not fully open, install a new thermostat. REFER to: (303-03A Engine Cooling - 4.2L NA V8 - AJV8/4.2L SC
V8 - AJV8)
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 aluminium. If a separate tank is not
available, drain and rinse the test tank before testing an aluminium radiator.
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.
Engine Cooling - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8 - Cooling System
Draining, Filling and Bleeding
General Procedures
W ARNINGS:
Never remove the coolant expansion tank cap under any circumstances while the engine is operating. Failure to
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:
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.
follow this instruction may result in damage to the engine.
All vehicles

stands.
2. W ARNING: Release the cooling system pressure by

slowly turning the coolant expansion tank cap a quarter of a turn.
Cover the expansion tank cap with a thick cloth to prevent the
possibility of scalding. Failure to follow this instruction may

All vehicles
5. CAUTION: Do not over tighten the drain plug. Failure to


9. CAUTION: Anti-freeze concentration must be maintained

at 50%.

10. CAUTION: Anti-freeze concentration must be

maintained at 50%.
W hen coolant runs from the expansion tank bleed point

All vehicles
12. CAUTION: Do not RUN the engine with the coolant

expansion tank pressure cap removed. Failure to follow this
instruction may cause damage to the vehicle.

13. Set the heating system to MAX heat, the blower motor to
MAX speed and the air distribution to the instrument panel
registers.
14. CAUTION: Observe the engine temperature warning

light. If the warning light is displayed, switch off immediately
and allow to cool. Failure to follow this instruction may cause
damage to the vehicle
Allow the engine to run until hot air is emitted from the
instrument panel registers, while observing the engine
tempreture warning light.
18. Maintain the coolant level in the coolant expansion tank at

the MAX mark using a 50% mixture of Jaguar Premium Cooling
System Fluid or equivalent, meeting Jaguar specification W SS
M97B44-D and 50% water.
Engine Cooling - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8 - Coolant Expansion
Tank
Removal

2. For additional information, refer to: Cooling System Draining,
3. CAUTION: Take extra care when handling the

component.
NOTE: Cap the vent hose to minimize coolant loss.
4.
5. NOTE: Cap the coolant expansion tank lower hose to
minimize coolant loss.
6. TORQUE: 3 Nm
Installation
Engine Cooling - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8 - Cooling Fan Motor
and Shroud4.2L SC V8 - AJV8
Removal

2. Refer to: Cooling System Draining, Filling and Bleeding (303-03,

3. Refer to: Radiator Splash Shield (501-02 Front End Body Panels,
4. Refer to: Air Cleaner LH (303-12, Removal and Installation).
5. Refer to: Air Cleaner RH (303-12, Removal and Installation).
6. Refer to: Air Cleaner Outlet Pipe (303-12B Intake Air Distribution
and Filtering - 4.2L SC V8 - AJV8, Removal and Installation).

stands.
8.
9.
10.
11. Torque: 7 Nm
12.
13.
14.
15.
16.
17.
18.
Installation

Engine Cooling - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8 - Cooling Fan Motor
and Shroud4.2L NA V8 - AJV8
Removal

Procedures).
2. For additional information, refer to: Coolant Expansion Tank
(303-03A Engine Cooling - 4.2L NA V8 - AJV8/4.2L SC V8 -
4. For additional information, refer to: Air Cleaner (303-12,

stands.

6.
7.
8.
9. TORQUE: 7 Nm
10. TORQUE: 7 Nm
11.
12.
13.
15.
16.
17.
Installation
Engine Cooling - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8 - Coolant
Manifold4.2L SC V8 - AJV8
Removal
CAUTION: Engine coolant will damage the paint finished surfaces. If spilt, immediately remove the coolant and clean
the area with water.



5. Refer to: Supercharger Belt (303-05B Accessory Drive - 4.2L SC V8 -

6.
7.
8.
9. Torque: 10 Nm
Installation

Engine Cooling - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8 - Cooling Module4.2L
SC V8 - AJV8
Removal
Procedures).

stands.

5. For additional information, refer to: Air Cleaner LH (303-12,
6. For additional information, refer to: Air Cleaner RH (303-12,
7. For additional information, refer to: Air Conditioning (A/C)
TORQUE: 7 Nm

10. NOTE: Some variation in the illustrations may occur, but
the essential information is always correct.


TORQUE: 7 Nm


TORQUE: 20 Nm

TORQUE: 20 Nm

TORQUE: 10 Nm
TORQUE: 10 Nm





Installation
For additional information, refer to: Transmission Fluid Level
Check (307-01 Automatic Transmission/Transaxle - 2.7L V6 -
Engine Cooling - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8 - Cooling Module4.2L
NA V8 - AJV8
Removal
Procedures).
Filling and Bleeding (303-03A Engine Cooling - 4.2L NA V8 -
4. For additional information, refer to: Air Cleaner Element
5. Raise and support the vehicle
6.

8.
9. TORQUE: 7 Nm
10.
11.
12. TORQUE: 7 Nm
13.
14.

16.

19.
20.
21.
Installation
Engine Cooling - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8 - Coolant Pump4.2L
SC V8 - AJV8
Removal


3. Refer to: Engine Cover - 4.2L SC V8 - AJV8 (501-05 Interior Trim and
6.
7.
Loosen only.
8.
9. Torque: 7 Nm
10. Torque: 10 Nm
11. Torque: 20 Nm
Installation

Engine Cooling - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8 - Coolant Pump4.2L
NA V8 - AJV8
Removal


3. Refer to: Engine Cover - 4.2L NA V8 - AJV8 (501-05 Interior Trim and
4. Refer to: Air Cleaner Outlet Pipe (303-12A Intake Air Distribution
and Filtering - 4.2L NA V8 - AJV8, Removal and Installation).

stands.
6.
7.
Loosen only.
8.
9. Torque: 7 Nm
10. Torque:
M6 10 Nm
M8 20 Nm
Installation

Engine Cooling - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8 - Radiator4.2L SC V8
- AJV8
Removal


6. Refer to: Cooling Fan Motor and Shroud (303-03A, Removal and
Installation).
7. Refer to: Radiator (303-03B Supercharger Cooling - 4.2L SC V8 -

8.
9. 9. CAUTION: Always plug any open connections to
10. Torque: 10 Nm
11.
12. 12. CAUTIONS:
Be prepared to collect escaping coolant.
Be prepared to collect escaping oil.
Installation

Engine Cooling - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8 - Radiator4.2L NA V8
- AJV8
Removal

Procedures).
3. For additional information, refer to: Cooling Fan Motor and
Shroud - 4.2L NA V8 - AJV8 (303-03A Engine Cooling - 4.2L NA
4. For additional information, refer to: Air Cleaner (303-12,
6. CAUTIONS:
Make sure that all openings are sealed. Use new

blanking caps.
7.
8. CAUTIONS:
Make sure that all openings are sealed. Use new

blanking caps.
9. TORQUE: 7 Nm
10. TORQUE: 7 Nm
11.
12. CAUTIONS:
Installation
Engine Cooling - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8 - Thermostat4.2L SC
V8 - AJV8
Removal
W ARNINGS:
CAUTIONS:
1. Remove the engine cover. For additional information, refer to:

Engine Cover - 4.2L SC V8 - AJV8 (501-05 Interior Trim and
2.
3.
Clamp the relevant hose, to minimise coolant loss.
5.
Installation
3. CAUTION: Anti-freeze concentration must be

maintained at 50%.
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.
W hen coolant runs from the bleed point bubble-free,

tighten the bleed screw.


6. Set the heating system to MAX heat, the blower motor to MAX
speed and the air distribution to the instrument panel
registers.
7. CAUTION: Observe the engine temperature warning light.

If the warning light is displayed, switch off immediately and
allow to cool. Failure to follow this instruction may cause damage
to the vehicle
temperature warning light.
11. Top up the cooling system.

Premium Cooling System Fluid or equivalent, meeting
Jaguar specification WSS M97B44-D and fifty percent
water.

13. Install the engine cover. For additional information, refer to:
Engine Cover - 4.2L SC V8 - AJV8 (501-05 Interior Trim and
Engine Cooling - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8 - Thermostat4.2L NA
V8 - AJV8
Removal
W ARNINGS:
CAUTIONS:
1.
Clamp the relevant hose, to minimise coolant loss.

2.
3.
Installation
3. CAUTION: Anti-freeze concentration must be maintained

at 50%.

expansion tank using a fifty percent mixture of Jaguar Premium
Cooling System Fluid or equivalent, meeting Jaguar
specification W SS M97B44-D and fifty percent water.



6. Set the heating system to MAX heat, the blower motor to MAX
speed and the air distribution to the instrument panel
registers.
7. CAUTION: Observe the engine temperature warning light.

If the warning light is displayed, switch off immediately and
allow to cool. Failure to follow this instruction may cause damage
to the vehicle
temperature warning light.
11. Top up the cooling system.

Premium Cooling System Fluid or equivalent, meeting
Jaguar specification WSS M97B44-D and fifty percent
water.

Engine Cooling - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8 - Thermostat
Housing4.2L SC V8 - AJV8
Removal


5.
6.
7.
8. Torque: 10 Nm
Installation

Engine Cooling - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8 - Thermostat
Housing4.2L NA V8 - AJV8
Removal
CAUTIONS:
Anti-freeze concentration must be maintained at 50%.
Engine coolant will damage the paint finished surfaces. If spilt, immediately remove the coolant and clean the area
with water.

Procedures).

stands.
3. W ARNING: Since injury such as scalding could be caused

by escaping steam or coolant, do not remove the filler cap from
the coolant expansion tank while the system is hot.
Drain the cooling system.

Installation).
5. Release the clips and disconnect the 5 coolant hoses.
Disconnect the engine coolant temperature (ECT)

sensor electrical connector.
Remove the 4 bolts.

Remove the engine coolant temperature (ECT) sensor.
Remove the retaining clip.
8. Remove the thermostat.

9. Release and remove the thermostat.
Installation
Tighten to 4 Nm.
Supercharger Cooling - 4.2L SC V8 - AJV8 -
Engine oil cooler retaining bolts 7 - 62
Cooling module retaining bolts 7 - 62
Charge air cooler water pump bracket retaining bolts 7 - 62
Charge air cooler radiator drain plug 1 - 9
Supercharger coolant fill plug 45 33 -
Jaguar Premium Cooling System Fluid WSS M97B44-D
Supercharger Cooling - 4.2L SC V8 - AJV8 - Supercharger Cooling -
Component Location
Component Location
ItemDescription
1 Charge air coolant pump
2 Expansion hose (connects to engine cooling system)
3 Bleed screw
4 RH (right-hand) charge air cooler
5 Supercharger outlet elbow
6 LH (left-hand) charge air cooler
7 Charge air radiator
Supercharger Cooling - 4.2L SC V8 - AJV8 - Supercharger Cooling -
Overview
Overview
The supercharger cooling system is installed on 4.2L vehicles with supercharger to cool the pressurized charge air.
Supercharger Cooling - 4.2L SC V8 - AJV8 - Supercharger Cooling - System
System Operation
The charge air coolant pump is energized continuously while the ignition is in power mode 6. Coolant flows from the pump
outlet through the charge air coolers, the charge air radiator and back to the pump inlet.
Supercharger Cooling Flow Diagram
ItemDescription
1 RH (right-hand) charge air cooler
2 Supercharger outlet elbow
3 LH (left-hand) charge air cooler
4 Engine
5 Charge air radiator
6 Charge air coolant pump
7 Bleed screw
8 Connection with engine cooling system
Comments:
Refer to: Engine Cooling (303-03A Engine Cooling - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8, Description and Operation).
General
The supercharger cooling system consists of:
A charge air coolant pump.

A charge air radiator.
Two charge air coolers.
The supercharger cooling system is operationally independent of the engine cooling system, but connected to it by a hose
installed between the charge air radiator and the heater core return line. The connection with the engine cooling system
accommodates thermal expansion and retraction of the coolant in the supercharger cooling system, and assists with filling
and draining of the supercharger cooling system. A bleed screw, in the end of a hose attached to the charge air radiator,
allows air to be bled from the supercharger and engine cooling systems when filling from empty. A filler plug for the
supercharger cooling system is incorporated into the supercharger outlet elbow.
Refer to: Engine (303-01B Engine - 4.2L SC V8 - AJV8, Description and Operation).
Charge Air Coolant Pump
ItemDescription
2 Coolant inlet connection
The charge air coolant pump is an electric pump attached to the RH side of the charge air radiator.
Charge Air Radiator

ItemDescription
1 Intercooler return hose connection
2 Pump inlet hose connection
3 Engine cooling system connection
4 Bleed hose connection
The charge air radiator is a cross flow type with an aluminum core and plastic end tanks. The charge air radiator is
installed in the cooling module, in front of the A/C (air conditioning) condenser.
Charge Air Coolers

A charge air cooler is attached to each cylinder bank.
Refer to: Intake Air Distribution and Filtering (303-12B Intake Air Distribution and Filtering - 4.2L SC V8 - AJV8, Description
and Operation).
Supercharger Cooling - 4.2L SC V8 - AJV8 - Supercharger Cooling

REFER to: Engine Cooling (303-03A Engine Cooling - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8, Diagnosis and Testing).
Supercharger Cooling - 4.2L SC V8 - AJV8 - Radiator
Removal


6. Torque: 7 Nm
7.
8.
9. Torque: 5 Nm
stands.
11.
12.
13. 13. CAUTION: Be prepared to collect escaping
coolant.
14.
15. 15. NOTE: Support the air conditioning (A/C) condenser.
Torque: 10 Nm
16. 16. NOTE: Support the air conditioning (A/C) condenser.
Torque: 10 Nm
coolant.
Installation

Fuel Charging and Controls - TDV6 2.7L Diesel -
High-pressure fuel supply line unions A
High-pressure fuel supply line support bracket retaining nut 10 89
Fuel injector retaining bolts 10 89
Fuel injector high pressure fuel inlet adaptor union 42 31
Fuel injection diverter rail retaining bolts 23 16
Fuel injection supply manifold retaining bolts 23 16
Fuel injection supply manifold support bracket retaining bolts 23 16
Fuel pump retaining bolts 23 16
Fuel injection pump belt rear cover retaining bolts 7 62
Camshaft rear pulley retaining bolt A
Fuel injection pump belt tensioner retaining bolt 25 18
Fuel injection pump pulley retaining nut 50 37
Fuel injection pump high pressure fuel outlet adaptor union 37 27
Exhaust gas recirculation (EGR) valve retaining bolts 10 89
Intake manifold retaining nuts 15 11
A = refer to the procedure for the correct torque sequence
Fuel Charging and Controls - TDV6 2.7L Diesel - Fuel Charging and Controls -
Component Location
Component Location
ItemDescription
1 Fuel rail (2 off)
2 HP (high pressure) pipe - fuel rail to injector (6 off)
3 Fuel injector (6 off)
4 LP (low pressure) pipe - fuel return
5 HP pipe - HP pump to fuel diverter rail
6 LP pipe - injector leak-back
7 LP pipe connection to injector
8 HP pump
9 HP pump pulley
10 HP diverter rail
11 READ (rear end accessory drive) belt tensioner
12 LH (left-hand) exhaust camshaft pulley
Fuel Charging and Controls - TDV6 2.7L Diesel - Fuel Charging and Controls - Overview
Overview
The 2.7L V6 diesel engine is equipped with a HP common rail fuel injection system. With this fuel injection process, a HP pump delivers a
uniform level of pressure to the shared fuel lines (the common rails), which serve all 6 fuel injectors. Pressure is controlled to the optimum
level for smooth operation.
The common rail system supports a pre-injection (pilot) phase, which reduces combustion noise levels, more commonly referred to as 'diesel
knock'.
Fuel injection pressure is generated independently of engine speed and fuel injection events.
The fuel injection timing and volume are calculated by the ECM (engine control module), which then energizes the appropriate piezo
actuated injector. The common rail fuel injection system has the following features:
High fuel injection pressures of up to 1650 bar (23930 lbf/in) for greater atomisation of fuel (increasing performance and lowering
emissions).
Variable injection to optimize combustion in all engine operating conditions.
Low tolerances and high precision throughout the life of the system.
The fuel system is divided into two sub systems:
LP system.
HP system.
The LP system features the following components:
In-tank fuel pump.

Fuel pressure regulator (integral to the fuel delivery module).
Fuel filter.
Return pipes.
Injector return pipes.
Fuel coolers (engine and vehicle).
The LP system is regulated to 0.5 bar (7.25 lbf/in).
The HP system features the following components:
HP pump.
Fuel rails and diverter rail
HP fuel pipes.
Injectors.
Fuel Charging and Controls - TDV6 2.7L Diesel - Fuel Charging and Controls - System
System Operation
Engine Starting
During starting, the fuel rail pressure must be at least 150 bar (2175 lbf/in). Should the pressure be below this figure, the injectors will not
operate, resulting in the vehicle not starting.
Engine Stopped
To stop the engine the ECM (engine control module) stops energizing the piezo actuators, therefore, no fuel is injected and the engine
speed drops to zero.
LP System
In-tank Fuel Pump
The electric fuel pump is located inside the fuel tank. Fuel is pumped from the tank via the in-tank fuel pump, to the HP pump via the fuel
filter.
Refer to: Fuel Tank and Lines (310-01 Fuel Tank and Lines - 2.7L Diesel, Description and Operation).
Fuel Filter
The fuel filter is located in the engine compartment on the left hand side, packaged to be protected against damage. Incorporated in the
fuel filter housing is a bimetallic temperature valve, which will start to close at 30 C (86 F) and will fully close at 50 C (122 F). This
allows pre-heated diesel fuel to circulate inside the fuel filter to prevent waxing in cold operating conditions.
Fuel Cooler
Two fuel coolers are fitted to the vehicle. One is located in the 'vee' of the engine block, and has a coolant system connection to aid heat
transfer. The second cooler is located in the fuel return line and is a fuel to air cooler.
HP System
HP Pump
The HP pump is a three-piston (120 degree apart) radial plunger pump with a HP displacement of 0.8 cc (0.05 in). As mentioned, it has the
ability to produce a maximum pressure of 1650 bar (23930 lbf/in). The housing is cast from iron, the flange is cast from aluminum.
The HP pump is driven from the camshaft via a toothed belt. It does not need to be timed to the engine during belt replacement in service.
The required supply pressure to the HP pump is -0.3 to +0.5 bar (-4.4 to 7.25 lbf/in). The return pressure is -0.3 bar to +0.8 bar (-4.4 to
11.6 lbf/in).
The pump is sized to deliver sufficient fuel to the fuel rails for all engine-operating conditions.
The HP pump consists of the following components:
ITP (internal transfer pump).

VCV (volume control valve).
HP pumping elements (3 off).
PCV (pressure control valve).
The ITP is a five vane pump. This conveys fuel to the VCV.
The VCV is a variable position solenoid valve electronically controlled by the ECM. The VCV is located between the ITP and the HP pumping
elements. The VCV determines the amount of fuel that is delivered to the HP pumping elements. W hen there is no signal to the VCV the
valve is closed and there is no fuel delivery.
The three HP pumping elements are connected together in a fuel ring circuit within the pump. There is a single HP outlet connection for the
HP pipe to the HP diverter rail.
The PCV is a variable position solenoid valve electronically controlled by the ECM. The PCV is located between the HP pumping elements
and the HP outlet connection. The PCV regulates the amount of fuel pressure in the fuel rails. W hen there is no signal to the PCV the valve
is open, therefore no fuel rail pressure can be generated.
HP Fuel Flow
ItemDescription
A LP fuel supply
B Fuel supply to the HP pumping elements
C HP outlet connection to the HP diverter rail
D LP fuel return (spill)
1 LP side of ITP
2 ITP pressure relief valve
3 Screen filter
4 VCV
5 ITP
6 Edge filter - to protect PCV
7 PCV
8 N/A
9 Eccentric on HP pump drive shaft
10 Pumping element inlet valve
11 Pumping element outlet valve
12 HP ring line
13 HP pump elements (3 off)
14 Lubricating valve
The fuel induced by the ITP (5) is conveyed to the VCV (4) and the lubricating valve (14). W hen the VCV is closed, the ITP pressure relief
valve (2), lying parallel to the transfer pump, opens and conveys the fuel back to the LP side (1) of the transfer pump. The fuel passes
through the lubricating valve (14) into the interior of the HP pump and from there to the fuel return (D). The fuel is used to lubricate the
pump.
The VCV (4) determines the quantity of fuel (B) that is supplied to the pumping elements (13). The fuel from the HP outlets (11) of the
three pumping elements comes together in a ring line (12) and is conveyed through the HP outlet of the HP pump to the fuel rails.
The PCV (7) regulates the fuel pressure in the fuel rails. Reducing pressure via the PCV results in fuel returning from the fuel rails to the LP
fuel return (D).
HP Pump Pressure/Speed Graph
ItemDescription
A Pump pressure (bar)
B Pump speed (rpm)
The HP pump can supply up to 1600 bar (23206 lbf/in) fuel pressure continuously with short excursions to 1650 bar (23930 lbf/in). Pump
speed is 5/6 engine speed. However, it is calibrated to deliver fuel pressure dependant upon engine speed and load.
When the HP pump is rotated, pressure is created when the VCV is open and the PCV is closed. The VCV and PCV are electronically
controlled to allow variable fuel delivery and pressure control.
When the ECM actuates the piezo actuators, the fuel rail pressure drop is off-set by additional fuel being delivered to the fuel rails by the
PCV.
The fuel pressure in the system is reduced within a few seconds after the engine has stopped as the PCV no longer has the holding current
it requires, and therefore opens. No residual pressure remains in the system and the fuel is returned to the fuel return line (D) through the
open PCV.
High Pressure Element Fuel Induction

ItemDescription
A Fuel inlet flow
1 Inlet valve
2 Outlet valve
3 Piston
4 Driveshaft
5 Eccentric cam
During the downward motion of the piston (3), a vacuum in the pump cylinder is generated, which opens the inlet valve (1) against the force
exerted by the valve spring. The fuel (A), which is flowing past the VCV, is sucked in. At the same time the outlet valve (2) is closed due to
the pressure difference between the pump cylinder and the HP fuel in the ring line.
High Pressure Element Fuel Delivery
ItemDescription
B Fuel outlet flow to ring line
1 Inlet valve
2 Outlet valve
3 Piston
4 Driveshaft
5 Eccentric cam
The eccentric cam on the HP pump driveshaft (5) presses the piston (3) upwards. The inlet valve (1) is then closed through the force
exerted by the valve spring and the pressure being built up in the pump cylinder. The outlet valve (2) opens when the pressure in the pump
cylinder is greater than the fuel pressure in the ring line (B).
Volume Control Valve
ItemDescription
1 Piston
2 Sleeve
4 Coil
5 Armature
6 VCV
The VCV is fixed directly to the HP pump. The VCV regulates the fuel supply (and hence the quantity of fuel) from the transfer pump to the
HP pump elements, depending on the pressure in the fuel rails. This makes it possible to match the delivery of the HP pump to the
requirements of the engine from the LP side. The quantity of fuel flowing back to the main fuel supply line is kept to a minimum. In
addition, this adjustment reduces the power consumption of the HP pump, improving the efficiency of the engine.
The VCV default position is closed without electrical supply. An open circuit connector will prevent the engine from running.
ItemDescription
A VCV not actuated
B VCV actuated
1 Fuel supply from the transfer pump
2 Piston
3 Fuel supply to the HP pump
4 Coil energized
5 Quantity of fuel
6 Control current
7 VCV at constant engine speed
VCV Not Actuated (A)
When there is no power supplied, the piston (2) closes the opening between the two connections (1) and (3) through the force of the
compression spring. The fuel supply to the HP pump is interrupted.
VCV Actuated (B)
The ECM energizes the coil (4) of the valve, according to the engines requirements. The armature force is proportional to the control current
and counteracts the compression spring through the moving piston (2).
As a result, the opening between the two connections (1) and (3) and hence the quantity of fuel (5) supplied through the connector (3) to
the HP pump is also proportional to the control current (6). This means that the greater the opening cross-section, the greater the quantity
of fuel supplied.
Pressure Control Valve

The PCV is located on the HP pump. It governs the fuel pressure at the HP outlet of the HP pump and thus the pressure within the fuel
rails. In addition, the PCV dampens any fluctuations in pressure, which occur during the delivery of fuel through the HP pump and through
the injection process. The PCV ensures that optimum pressure exists in the fuel rails for every operating condition of the engine.
The PCV is an electro-magnetically operated valve with spring support. The current supplied by the ECM through the solenoid pulls back the
control pin. This allows fuel to flow through the ball valve and into the common rails. The entire armature is coated with fuel for lubrication
and cooling.
ItemDescription
A PCV non-controlled
B PCV controlled
1 Fuel from the HP pump
2 To fuel return
3 Ball valve
5 Armature
6 Coil energized
7 Control pin
8 HP fuel
9 Control current
10 Characteristic of the PCV
PCV Non-controlled (A)
The ball valve (3) will only be operated through the force exerted upon it by the spring (4). Thereby, the PCV is classed as open.
PCV Controlled (B)
The current flowing through the solenoid (6) draws the pin (7) down. This in turn transfers the magnetic force via the pin to the ball valve
(3). The pull of the pin, and the pressure on the ball valve, is proportional to the valve flow (9).
Fuel Rails
The fuel rails are manufactured from forged steel. They store the fuel at high pressure and prevent pressure fluctuations in the HP system.
All HP pipes have an internal diameter of 2.5 mm (0.098 in.) except the pipes to the injectors, which are 3.0 mm (0.118 in.). Total rail
volume is 33 cc (2.01 in).
Fuel Injectors
ItemDescription
1 Harness connection
2 HP connection
3 Control piston
4 Nozzle needle
5 Nozzle HP chamber
6 Nozzle spray holes
7 Valve mushroom
8 Fuel return
9 Valve piston
10 Piezo actuator
The fuel injectors are controlled by piezo-electric action, activated directly by the ECM to precisely match instantaneous speed and load
conditions. The piezo injector operates four times faster than traditional solenoid injectors, with switching times as little as 0.2
milliseconds. This enables minimal quantities of fuel to be metered with extreme accuracy, and the start of injection to be determined with
even greater precision and at multiple times during each engine stroke. The injectors have six orifices, each having a diameter of 145
microns (0.0057 in.). This produces an extremely fine spray of fuel, which ensures the most uniform fuel-air mixture possible. As a result,
the combustion process is more complete. The operating components of the piezo fuel injectors are:
The piezo actuator.

The injector body containing the hydraulic servo system.
The fuel injector nozzle.
Each injection event is controlled by a charge and discharge cycle allowing energy to dissipate in, and recover from, the injector. Never
disconnect the wiring connector when the vehicle is running. The injector may remain open thus causing engine damage.
Fuel Injector Not Actuated (Not Injecting Fuel)

ItemDescription
1 Piezo actuator
2 HP connection
3 Hydraulic force applied on control piston
4 Hydraulic force acting on tip of nozzle
5 Control piston
6 Fuel return
7 Fuel return
8 Control piston
9 Nozzle needle
10 HP chamber of nozzle
11 Control chamber
12 Valve mushroom
The HP fuel from the fuel rail passes through the HP connection (2) into the control chamber (11) and into the HP chamber (10) of the fuel
injector nozzle. The piezo actuator (1) is de-energized and the valve mushroom (12) closes the bore to the fuel return (7) by means of
spring pressure. There is a continuous fuel return (6) to vent internal leakage within the injector. The hydraulic force (3), which is now
applied on the control piston by the fuel under high pressure in the control chamber (11) through the control piston (8), is greater than the
hydraulic force (4) acting on the tip of the nozzle (since the area of the control piston in the control chamber is greater than the area of the
tip of the nozzle).
Fuel Injector Actuated (Injecting Fuel)

ItemDescription
1 HP supply
2 Valve piston
3 Hydraulic force applied on control piston
4 Hydraulic force acting on tip of nozzle
5 Control piston
6 Fuel return
7 Piezo actuator
8 Fuel return
9 Valve piston
10 Valve mushroom
11 Control chamber
12 Control piston
13 Nozzle needle
The piezo actuator (7) energized by the ECM extends (charging phase) and presses on the valve piston (9). The valve mushroom (10) opens
the bore, which connects the control chamber (11) to the fuel return (8 then 6). As a result, the pressure in the control chamber drops, and
the hydraulic force (4) acting on the tip of the nozzle needle is now greater than the force (3) acting on the control piston in the control
chamber. The nozzle needle (13) moves upwards and the fuel passes through the six spray holes into the combustion chamber.
Fuel Charging and Controls - TDV6 2.7L Diesel - Fuel Charging and Controls
For a detailed description of the diesel engine fuel charging and controls, refer to the relevant Description and Operation sections in the
workshop manual. REFER to: (303-04A Fuel Charging and Controls - TDV6 2.7L Diesel)
Fuel Charging and Controls (Description and Operation),

Fuel Charging and Controls (Description and Operation),
Fuel Charging and Controls (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.
Visual Inspection
Fuel level Fuses
Fuel leaks Loose or corroded electrical connectors
Damaged fuel lines Harnesses
Damaged push connect fittings Sensor(s)
Fuel contamination/grade/quality Engine Control Module (ECM)
Throttle body
3. 3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step
4. 4. If the cause is not visually evident, verify the symptom and refer to the Symptom Chart, alternatively, check for Diagnostic
Trouble Codes (DTCs) and refer to the DTC Index.
Symptom Chart

Engine cranks but Fuel level Check fuel level and for contamination. Check fuel and air intake system integrity.
does not start Contaminated fuel Check for DTCs and refer to the relevant DTC Index
Fuel system
leaking/blocked
Air intake system
Electronic engine controls
Difficult to start Fuel level Check fuel level and for contamination. Check fuel and air intake system integrity.
Contaminated fuel Check for DTCs and refer to the relevant DTC Index
Fuel system
leaking/blocked
Air intake system
Rough idle Low/contaminated fuel Check fuel level/condition. Check integrity of fuel and engine control systems.
Fuel system Check for DTCs and refer to relevant DTC Index
leaking/blocked
Lack of power under Contaminated fuel Check for fuel contamination. Check for DTCs and refer to relevant DTC Index.
acceleration Air intake system Check integrity of air intake, exhaust, turbocharger, and engine control systems
Blocked exhaust/catalytic
converter
Turbocharger fault
Fuel system
Low engine compressions
Engine stops/stalls Low/contaminated fuel Check for fuel contamination. Check for DTCs and refer to the relevant DTC Index.
Fuel system Check integrity of fuel, air intake, and engine systems
Air intake system
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 programme is in operation, prior to the installation of a new
module/component.
first five digits of the seven digit code listed to identify the fault (the last two digits give extra information read by the manufacturer-
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 before beginning diagnostic routines that involve pinpoint tests.

P000113 Fuel Volume Regulator Fuel volume regulator Refer to the electrical circuit diagrams and check fuel volume regulator
Control Circuit/Open control circuit - open control circuit for open circuit. Check resistance across fuel regulator
circuit control valve is between 1.5 and 15 Ohms, install a new valve as required
Fuel volume regulator
control valve failure
P000200 Fuel Volume Regulator Fuel volume regulator Carry out any pinpoint tests associated with this DTC using the
Control Circuit control circuit - short to manufacturer approved diagnostic system. Refer to the electrical circuit
Range/Performance ground, power, high diagrams and check fuel volume regulator control circuit for short to
resistance ground, power, high resistance. Check and install new fuel volume
Fuel volume regulator regulator control valve/ECM as required, refer to the new
control valve failure module/component installation note at the top of the DTC Index
ECM failure
Control Circuit Low control circuit - short to control circuit for short to ground. Check resistance across fuel regulator
ground control valve is between 1.5 and 15 Ohms, install a new valve as required
Control Circuit Low control circuit - current manufacturer approved diagnostic system. Refer to electrical circuit
above threshold diagrams and check fuel volume regulator control valve circuit for short,
Fuel volume regulator open circuit. Check resistance across fuel regulator control valve is
control valve failure between 1.5 and 15 Ohms, install a new valve as required
Control Circuit High control circuit - short to control circuit for short to ground, power, open circuit. Check resistance
ground, power, high across fuel regulator control valve is between 1.5 and 15 Ohms, install a
resistance new valve as required
P000E21 Fuel Volume Regulator Signal amplitude < Carry out any pinpoint tests associated with this DTC using the
Control Exceeded minimum manufacturer approved diagnostic system. Refer to the electrical circuit
Learning Limit diagrams and check fuel volume regulator control circuit for short to
ground, power, open circuit
P000E22 Fuel Volume Regulator Signal amplitude > Carry out any pinpoint tests associated with this DTC using the
Control Exceeded maximum manufacturer approved diagnostic system. Refer to the electrical circuit
P008772 Fuel Rail/System Lift pump relay driven, Refer to the electrical circuit diagrams: check fuel lift pump relay power
Pressure - Too Low pump not activated and control circuits are operational. Check power supply to rear junction
box. Check lift pump motor ground is not open circuit or high resistance.
Check Fuse 25 (25 amp) in output to lift pump. Check lift pump relay is
operating correctly, remove relay and test winding and contact circuits.
Check pump run conditions are met, check run dry switch circuit. Check
the fuel lift pump is operating correctly.
P008873 Fuel Rail/System Lift pump relay not Refer to the electrical circuit diagrams and check fuel lift pump relay
Pressure - Too High driven, pump activated circuits for short to ground, power, open circuit
P009013 Fuel Pressure Regulator Fuel pressure control Refer to the electrical circuit diagrams and check fuel pressure control
Control Circuit valve control circuit - valve control circuit for open circuit. Check resistance across fuel pressure
open circuit control valve is 2.7 Ohms 2.7 Ohms
Fuel pressure control
valve failure
Control Circuit Low valve control circuit - valve control circuit for short to ground, power, open circuit. Check
short to ground, power, resistance across fuel pressure control valve is 2.7 Ohms 2.7 Ohms
open circuit
valve failure
P009119 Fuel Pressure Regulator Fuel pressure control Carry out any pinpoint tests associated with this DTC using the
Control Circuit Low valve control circuit - manufacturer approved diagnostic system. Refer to the electrical circuit
current above threshold diagrams and check fuel pressure control valve control circuit for short to
ground, power, open circuit. Check resistance across fuel pressure control
valve is 2.7 Ohms 2.7 Ohms
Control Circuit High valve control circuit - valve control circuit for short to power. Check resistance across fuel
short to power pressure control valve is 2.7 Ohms 2.7 Ohms
P018126 Fuel Temperature Signal rate of change NOTE: This test can only be carried out when the fuel temperature is
Sensor A Circuit below threshold below 30C
Range/Performance Fuel temperature sensor
failure Refer to the electrical circuit diagrams and check fuel temperature sensor
circuits for short, open circuit and poor connections. Check and record fuel
temperature sensor signal, start engine and allow to idle for
approximately 10 minutes, check and record fuel temperature sensor
signal. If the value of the signal has NOT increased by more than 8C
install a new sensor as required
P018216 Fuel Temperature Circuit voltage below Carry out any pinpoint tests associated with this DTC using the
Sensor A Circuit Low threshold manufacturer approved diagnostic system. Refer to the electrical circuit
Input Fuel temperature sensor diagrams and check fuel temperature sensor signal circuit for short to
failure ground. Check and install a new sensor as required
P018317 Fuel Temperature Circuit voltage above Carry out any pinpoint tests associated with this DTC using the
Sensor A Circuit High threshold manufacturer approved diagnostic system. Refer to the electrical circuit
failure power. Check and install a new sensor as required
P018427 Fuel Temperature Signal rate of change Refer to the electrical circuit diagrams and check fuel temperature sensor
Sensor A Circuit above threshold circuits for short, open circuit and poor connections. Run engine to normal
Intermittent Fuel temperature sensor operating temperature, check and record fuel temperature sensor signal,
failure increase engine speed to 2000 rpm, after approximately 120 seconds
check and record signal. If value of signal has increased by more than
10C/100ms install a new sensor as required
P019123 Fuel Rail Pressure Signal stuck low Carry out any pinpoint tests associated with this DTC using the
Sensor A Circuit manufacturer approved diagnostic system. Refer to the electrical circuit
Range/Performance diagrams and check fuel pump circuits for short to ground, power, open
circuit. Check fuel pump for correct operation. Check fuel pressure sensor
circuits for short, open circuit. Check for low fuel level and blocked fuel
lines
P019124 Fuel Rail Pressure Signal stuck high Carry out any pinpoint tests associated with this DTC using the
circuit. W ith engine at idle check and record 'Fuel pressure' datalogger
signal, stop engine check and record signal. If signal is greater than
10MPa after approximately 0.40 seconds suspect the fuel pump, check
and install a new pump as required
P019165 Fuel Rail Pressure Signal has too few Carry out any pinpoint tests associated with this DTC using the
Sensor A Circuit transitions/events manufacturer approved diagnostic system. Refer to the electrical circuit
Range/Performance diagrams and check fuel pump circuits for open circuit. Run engine to
normal operating temperature, check and record 'Fuel pressure'
datalogger signal, increase engine speed to 2000 rpm, check and record
signal. If value of signal changes by more than 40MPa/10ms suspect the
fuel pump, check and install a new pump as required
P019216 Fuel Rail Pressure Circuit voltage below Carry out any pinpoint tests associated with this DTC using the
Input diagrams and check fuel pump circuits for short to power. Start engine,
check and record 'Fuel pressure' datalogger signal. If value of signal is
0MPa suspect the fuel pump, check and install a new pump as required
P019317 Fuel Rail Pressure Circuit voltage above Carry out any pinpoint tests associated with this DTC using the
more than 180MPa suspect the fuel pump, check and install a new pump
as required
P019427 Fuel Rail Pressure Signal rate of change Carry out any pinpoint tests associated with this DTC using the
Sensor A Circuit above threshold manufacturer approved diagnostic system. Refer to the electrical circuit
Intermittent/Erratic diagrams and check fuel pump circuit for open circuit. Run engine at idle
speed, check and record 'Fuel pressure' datalogger signal, increase
engine speed to 2000 rpm, check and record signal. If value of signal
changes by more than 40MPa/10ms suspect the fuel pump, check and
install a new pump as required
P020101 Injector Circuit/Open - General Electrical Failure Carry out any pinpoint tests associated with this DTC using the
Cylinder 1 manufacturer approved diagnostic system. Check injector connections.
Disconnect and check resistance (200kOhm20kOhm) of injector. Refer to
the electrical circuit diagrams and check injector circuits for high
resistance, short to ground, power, open circuit. Clear DTC and re-test, if
DTC remains disconnect the ECM connector and with injector connected
check resistance and capacitance of wiring across injector pins, look for
intermittent wiring/connector faults. If this is still within specification
install a new injector
P020A33 Cylinder 1 Injection Signal low time > Carry out any pinpoint tests associated with this DTC using the
Timing maximum manufacturer approved diagnostic system. Check injector connections.
P020A35 Cylinder 1 Injection Signal high time > Carry out any pinpoint tests associated with this DTC using the
P020B33 Cylinder 2 Injection Signal low time > Carry out any pinpoint tests associated with this DTC using the
P020B35 Cylinder 2 Injection Signal high time > Carry out any pinpoint tests associated with this DTC using the
P020C33 Cylinder 3 Injection Signal low time > Carry out any pinpoint tests associated with this DTC using the
P020C35 Cylinder 3 Injection Signal high time > Carry out any pinpoint tests associated with this DTC using the
P020D33 Cylinder 4 Injection Signal low time > Carry out any pinpoint tests associated with this DTC using the
P020D35 Cylinder 4 Injection Signal high time > Carry out any pinpoint tests associated with this DTC using the
P020E33 Cylinder 5 Injection Signal low time > Carry out any pinpoint tests associated with this DTC using the
P020E35 Cylinder 5 Injection Signal high time > Carry out any pinpoint tests associated with this DTC using the
P020F33 Cylinder 6 Injection Signal low time > Carry out any pinpoint tests associated with this DTC using the
P020F35 Cylinder 6 Injection Signal high time > Carry out any pinpoint tests associated with this DTC using the
P026300 Cylinder 1 Fuel injector closed Refer to the electrical circuit diagrams and check fuel injector circuit and
Contribution/Balance connector. Disconnect fuel injector connector and inspect for fuel ingress,
if fuel is evident, suspect a leaking fuel injector. Clear DTC, start and run
engine to 60C, allow engine to idle (cylinder balance diagnosis is
active). If cylinder balance diagnosis detects same DTC again carry out
cylinder compression check. If compression check passed, check fuel
injector blow-by, install a new fuel injector sealing washer and clamp as
required. If no blow-by evident, suspect the fuel injector, check and
install a new injector as required
P029A00 Cylinder 1 Balance - Fuel injector circuits - Refer to the electrical circuit diagrams and check fuel injector circuit and
Fuel Trim at Max Limit short to ground, power, connector. Disconnect fuel injector connector and inspect for fuel ingress,
open circuit if fuel is evident, suspect a leaking fuel injector. Clear DTC, start and run
Fuel injector leaking engine to 60C, allow engine to idle (cylinder balance diagnosis is
Cylinder compression active). If cylinder balance diagnosis detects same DTC again carry out
low cylinder compression check. If compression check passed, check fuel
Fuel injector blow-by injector blow-by, install a new fuel injector sealing washer and clamp as
Fuel injector failure required. If no blow-by evident, suspect the fuel injector, check and
P029B00 Cylinder 1 Balance - Fuel injector circuits - Refer to the electrical circuit diagrams and check fuel injector circuit and
Fuel Trim at Min Limit short to ground, power, connector. Disconnect fuel injector connector and inspect for fuel ingress,
P029C00 Cylinder 1 Balance - Fuel injector circuits - Refer to the electrical circuit diagrams and check fuel injector circuit and
Injector Restricted short to ground, power, connector. Disconnect fuel injector connector and inspect for fuel ingress,
P029D00 Cylinder 1 Balance - Fuel injector circuits - Refer to the electrical circuit diagrams and check fuel injector circuit and
Injector Leaking short to ground, power, connector. Disconnect fuel injector connector and inspect for fuel ingress,
P029E00 Cylinder 2 Balance - Fuel injector circuits - Refer to the electrical circuit diagrams and check fuel injector circuit and
P029F00 Cylinder 2 Balance - Fuel injector circuits - Refer to the electrical circuit diagrams and check fuel injector circuit and
P02AA00 Cylinder 5 Balance - Fuel injector circuits - Refer to the electrical circuit diagrams and check fuel injector circuit and
P02AB00 Cylinder 5 Balance - Fuel injector circuits - Refer to the electrical circuit diagrams and check fuel injector circuit and
P02AC00 Cylinder 5 Balance - Fuel injector circuits - Refer to the electrical circuit diagrams and check fuel injector circuit and
P02AD00 Cylinder 5 Balance - Fuel injector circuits - Refer to the electrical circuit diagrams and check fuel injector circuit and
P02AE00 Cylinder 6 Balance - Fuel injector circuits - Refer to the electrical circuit diagrams and check fuel injector circuit and
P02AF00 Cylinder 6 Balance - Fuel injector circuits - Refer to the electrical circuit diagrams and check fuel injector circuit and
P062D01 Fuel Injector Driver Bank 1 injector(s) Carry out any pinpoint tests associated with this DTC using the
Circuit Performance disconnected manufacturer approved diagnostic system. Check injector connections to
Bank 1 Injector failure Bank 1 cylinders. Disconnect injectors and check resistance
Bank 1 injector circuit(s) (200kOhm20) of each injector, if out of specification install new
- high resistance, short injector(s). Refer to the electrical circuit diagrams and check Bank 1
to ground, short to injector circuits for high resistance, short to ground, power, open circuit.
power, open circuit Clear DTC and re-test. If DTC remains, disconnect ECM connector, and
with injector(s) connected check resistance across injector pins, this
should be no higher than the injector resistance.
P062E01 Fuel Injector Driver Bank 2 injector(s) Carry out any pinpoint tests associated with this DTC using the
Circuit Performance disconnected manufacturer approved diagnostic system. Check injector connections to
Bank 2 Injector failure Bank 2 cylinders. Disconnect injectors and check resistance
Bank 2 injector circuit(s) (200kOhm20) of each injector, if out of specification install new
- high resistance, short injector(s). Refer to the electrical circuit diagrams and check Bank 2
to ground, short to injector circuits for high resistance, short to ground, power, open circuit.
power, open circuit Clear DTC and re-test. If DTC remains, disconnect ECM connector, and
with injector(s) connected check resistance across injector pins, this
should be no higher than the injector resistance.
P150A00 Injector Circuit Injector cylinder 1 - error Carry out any pinpoint tests associated with this DTC using the
Range/Performance - detected by engine manufacturer approved diagnostic system. Check injector connections.
Cylinder 1 speed evaluation fuel Disconnect and check resistance (200kOhm20kOhm) of injector. Refer to
mass (high/low the electrical circuit diagrams and check injector circuits for high
deviation) resistance, short to ground, power, open circuit. Clear DTC and re-test, if
P150A01 Injector Circuit Injector circuit range Carry out any pinpoint tests associated with this DTC using the
Range/Performance - (PPS injector charge) manufacturer approved diagnostic system. Check injector connections.
Cylinder 1 Disconnect and check resistance (200kOhm20kOhm) of injector. Refer to
P150B00 Injector Circuit Injector cylinder 2 - error Carry out any pinpoint tests associated with this DTC using the
P150B01 Injector Circuit Injector circuit range Carry out any pinpoint tests associated with this DTC using the
P150C00 Injector Circuit Injector cylinder 3 - error Carry out any pinpoint tests associated with this DTC using the
P150C01 Injector Circuit Injector circuit range Carry out any pinpoint tests associated with this DTC using the
P155400 Injector Circuit Injector cylinder 4 - error Carry out any pinpoint tests associated with this DTC using the
P155401 Injector Circuit Injector circuit range Carry out any pinpoint tests associated with this DTC using the
P155500 Injector circuit Injector cylinder 5 - error Carry out any pinpoint tests associated with this DTC using the
range/performance detected by engine manufacturer approved diagnostic system. Check injector connections.
cylinder 5 speed evaluation fuel Disconnect and check resistance (200kOhm20kOhm) of injector. Refer to
P155600 Injector Circuit Injector cylinder 6 - error Carry out any pinpoint tests associated with this DTC using the
P158200 Electronic Throttle Flight recorder data Download flight recorder data using manufacturer approved diagnostic
Monitor Data Available stored system, if required, and clear DTC
P210502 Throttle Actuator Engine stop by throttle Carry out any pinpoint tests associated with this DTC using the
Control System - Forced manufacturer approved diagnostic system. Check for additional related
Engine Shutdown DTCs and refer to the relevant DTC Index
P213E01 Fuel Injection System Engine stop by electrical Check for additional related DTCs and refer to the relevant DTC Index
Fault - Forced Engine
Shutdown
P213F07 Fuel Pump System Fault Engine stop by hydraulic Check for additional related DTCs and refer to the relevant DTC Index
- Forced Engine
Shutdown
P228800 Injector Control Fuel injector control Check for additional DTCs and refer to the relevant DTC Index. Refer to
Pressure Too High pressure - too high the electrical circuit diagrams and check fuel system circuits for short,
FPCV circuit fault open circuit. Check integrity of fuel system components
FPCV failure
Fuel pump module circuit
- short to power
Fuel pump module
failure
Fuel injection pump
failure
Pressure Too Low pressure - too low the electrical circuit diagrams and check fuel system circuits for short,
Fuel line leak open circuit. Check integrity of fuel system components
Fuel filter/system
restriction
FPCV circuit fault
FPCV failure
Fuel pump module circuit
- short to ground
Fuel pump module
failure
Fuel injection pump
failure
Pressure Erratic pressure - erratic the electrical circuit diagrams and check fuel system circuits for short,
FPCV circuit fault open circuit. Check integrity of fuel system components
FPCV failure
Fuel pump module
circuit(s) - high
resistance, short to
ground, power
Fuel pump module
failure
Fuel injection pump
failure
Fuel Charging and Controls - TDV6 2.7L Diesel - Fuel Injection Component Cleaning
General Procedures
General Equipment
Pneumatic vacuum gun
Materials
Name Specification
Cleaning Fluid W-M5B411-A
W ARNINGS:
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.
Do not carry out any repairs to the fuel system with the engine running. The fuel pressure within the high-pressure system can be as
high as 1650 bar. 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
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.
Fuel Charging and Controls - TDV6 2.7L Diesel - Fuel Injector
Special Tool(s)
Fuel Injector remover
303-1127
Removal
W ARNINGS:
flammable vapors 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
W ait at least 30 seconds after the engine stops before commencing any repair to the high-pressure fuel injection system. Failure to
Do not carry out any repairs to the fuel system with the engine running. The fuel pressure within the system can be as high as 1650
bar (23,931 lb-sq-in). Failure to follow this instruction may result in personal injury.
CAUTIONS:
Do not disconnect the fuel injector electrical connectors with the engine running. Failure to follow this instruction may result in
serious damage to the engine.
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.
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. Failure to follow
this instruction may result in foreign matter ingress to the fuel injection system.
Do not disassemble the fuel injectors or clean the nozzles, even with an ultrasonic cleaner. Always install new fuel injectors when
required.

2. Remove the exhaust gas recirculation (EGR) valve outlet tube.
For additional information, refer to: Exhaust Gas Recirculation (EGR)
Valve Outlet Tube (303-08A Engine Emission Control - TDV6 2.7L Diesel,
4. Remove the engine harness cover.
6. Disconnect the fuel injector electrical connectors.
7. Detach the fuel injection wiring harness.
8. CAUTIONS:
Make sure that the high-pressure fuel supply line remains in contact
with the fuel injection supply manifold and the fuel injection diverter rail
system.
Do not use any aggressive cleaning fluid or a wire brush to clean the
fuel injector nozzle.
Using the pneumatic vacuum gun, vacuum foreign material from the
high-pressure fuel rail supply lines, the fuel injectors, the fuel rail and
the fuel pump.
(303-04A Fuel Charging and Controls - TDV6 2.7L Diesel, General
Procedures).
9. CAUTIONS:
system.
Make sure that the fuel injector adaptor union does not move when
loosening the high-pressure fuel supply lines. Failure to follow this
instruction may result in damage to the fuel injector or the fuel injector
adaptor union.
Loosen the high-pressure fuel supply line from the fuel injector and fuel
rail.
10. CAUTION: Make sure that all openings are sealed. Use new
blanking caps.
Disconnect the fuel return line from the fuel injector.

12. Remove the two fuel injector retaining bolts.
13. Install the special tool studs.
14. CAUTIONS:
Make sure the fuel injector remover legs are correctly engaged to
the fuel injector. Failure to follow this instruction may result in damage to
the component.
Make sure the puller bolts are rotated evenly. Failure to follow this
instruction may result in damage to the special tool or the fuel injector.
Install the special tool remover legs to the studs.
15. Install the special tool locking plate to the remover legs.
blanking caps.
Remove the fuel injector.
Rotate the special tool bolts evenly, in a clockwise direction.
Remove and discard the fuel injector retaining clamp.
Remove and discard the sealing washer.
Installation
1. CAUTION: Do not use tools to install the new fuel return line
retaining clip. Failure to follow this instruction will result in damage to the
retaining clip.
NOTE: Install a new fuel injector sealing washer.
NOTE: Install a new fuel return line retaining clip.
Install a new fuel injector retaining clamp.
Tighten to 10 Nm.
3. CAUTION: Make sure the fuel return line clip is correctly installed
to the fuel injector before installing the fuel return line.
Connect the fuel return line to the fuel injector.
Visually inspect the fuel return line O-ring seal for damage.
Apply a light coating of petroleum jelly to the fuel return line

O-ring seals.
Connect the fuel return line to the fuel injector.

4. CAUTIONS:
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 high-pressure fuel
supply line and allow foreign matter to enter the fuel injection system.
Maintain pressure on the high-pressure fuel supply lines to keep the

olives in contact with the fuel rail and the fuel injector cones while
installing unions.
NOTE: Remove and discard the blanking caps.
Install the new high-pressure fuel supply lines.
Install the new high-pressure fuel supply line, tighten the fuel
supply line unions finger tight.
Tighten the high-pressure fuel supply line in the shown sequence.
Tighten the high-pressure fuel supply line union 1 to fuel injector

to 15 Nm.
Tighten the high-pressure fuel supply line union 2 to fuel rail to 15

Nm.
Tighten the high-pressure fuel supply line union 1 to fuel injector

to 30 Nm.
Tighten the high-pressure fuel supply line union 2 to fuel rail to 30

Nm.
Attach the fuel injector wiring harness.
Connect the fuel injector electrical connectors.
Tighten to 4 Nm.
10. Install the EGR valve outlet tube.

12. W ARNING: Do not carry out any repairs to the fuel system with
the engine running. The fuel pressure within the system can be as high as
1650 bar (23,931 lb-sq-in). Failure to follow this instruction may result in
personal injury.
Visually check for fuel leaks.
The fuel return line must be renewed if any leaks are found from
the fuel return line O-rings.
Fuel Charging and Controls - TDV6 2.7L Diesel - Fuel Injection Pump
Special Tool(s)
Holder - Fuel Pump Pulley
310-139
Reaction Arm - Fuel Pump Pulley
310-138
Removal
1. WARNINGS:

injury.

CAUTIONS:

system.
Do not remove the fuel rail pressure sensor from the fuel injection
diverter rail.

4. Using the special tool, remove the fuel injection pump pulley retaining
nut.
Using the special tool, retain the fuel injection pump pulley.
5. Using the special tool, remove the fuel injection pump pulley.
6. Remove the fuel injection pump belt cover backplate retaining bolt.
7. Remove the fuel injector sound proofing.
blanking caps.
Disconnect the low pressure fuel inlet and return lines.

Detach the high-pressure fuel supply lines.
Loosen the high-pressure fuel supply lines.
12. Clean around the fuel injector, high-pressure fuel supply line and
surrounding areas.
blanking caps.
Remove and discard the high-pressure fuel supply lines.

14. CAUTIONS:
system.
Make sure that all openings are sealed. Use new blanking caps.
Remove and discard the high-pressure fuel diverter rail supply line.
15. Remove the fuel line retaining nut.
16. Disconnect the fuel rail pressure (FRP) sensor electrical connector.
Release the fuel charging wiring harness.
17. Reposition the fuel line.
18. Remove the FRP and fuel injection diverter rail assembly.
Remove the 2 studs.

blanking caps.
Disconnect the fuel line.
20. Disconnect the left-hand valve cover breather hose.
21. Disconnect the right-hand valve cover breather hose.
22. Disconnect the left-hand inlet port deactivation vacuum pipe.
23. Remove the oil separator housing.
Remove and discard the oil separator housing and engine block
seals.
24. Disconnect the fuel injection pump electrical connectors.
25. Detach the glow plug electrical connectors.
26. Remove the fuel injection pump.
Installation
1. WARNINGS:

injury.

CAUTIONS:

system.
diverter rail.
Install the fuel injection pump.
Tighten to 23 Nm.
2. Attach the glow plug electrical connectors.
3. Connect the fuel pump electrical connectors.
4. Install the oil separator housing.
Install new oil separator housing and engine block seals.
5. Connect the left-hand inlet port deactivation vacuum pipe.

6. Connect the right-hand valve cover breather hose.
7. Connect the left-hand valve cover breather hose.
Connect the fuel line.
9. Install the FRP and fuel injection diverter rail assembly.
Install the two retaining studs, but do not fully tighten at this
stage.
10. Attach the fuel line.

11. Connect the FRP sensor electrical connector.
12. Install the fuel line retaining nut.
Tighten to 7 Nm.
Install a new high-pressure fuel supply line.
Install a new high-pressure fuel supply line but do not fully tighten
at this stage.
Tighten the fuel injection diverter rail retaining studs to 23 Nm.

fuel injection pump to 15 Nm.

fuel injection diverter rail to 15 Nm.


Install the new high-pressure fuel rail supply line.


fuel injection rail to 15 Nm.


Attach the high-pressure fuel supply lines.
Tighten to 10 Nm.
Tighten to 7 Nm.
17. Attach the low-pressure fuel line.
18. Install the fuel injector sound proofing.

19. Install the fuel injection pump belt rear cover retaining bolts.
Tighten to 7 Nm.
20. Install the fuel injection pump pulley.

21. Install the retaining nut.
Tighten to 50 Nm.
Tighten to 25 Nm.

25. Bleed the fuel system.
Fuel Charging and Controls - TDV6 2.7L Diesel - Intake Air Shutoff Throttle
Removal
2. Release the coolant expansion tank hose from the clips.
3. Remove the intake air shutoff throttle elbow retaining bolt.
5. Release the clip and disconnect the intake air shutoff throttle elbow.
6. Release the vacuum hose clip from the stud.
7. Remove the bolt.
8. Remove both exhaust gas recirculation (EGR) valve outlet tubes.

10. Release the fuel return line valve.

11. Reposition the intake air shutoff throttle.
13. CAUTION: Discard the seals.
Installation
1. CAUTION: Install the new seals.
Tighten to 10 Nm.
Fuel Charging and Controls - TDV6 2.7L Diesel - Swirl Plate Actuator Diaphragm
Removal
1. For additional information, refer to: Engine Cover - TDV6 2.7L Diesel
2. For additional information, refer to: Secondary Bulkhead Center Panel
3. Remove the wiring harness cover.
4. Remove the wiring harness carrier.
Remove the 4 bolts.
5. Remove the RH injector sound proofing.
6. Check the port deactivation hoses are a secure fit onto the stub pipe
and for signs of being trapped or chaffing.
If the valve does not hold vacuum continue with the replacement of
the diaphragm.
If the valve holds vacuum check the valve on the other side of the
engine.
If one side is found not to hold vacuum then both diaphragms are
to be changed.
7. Disconnect the port deactivation valve vacuum hoses.
8. NOTE: Check the vacuum gauge and any hoses to be used for leaks
prior to using on the vehicle.
NOTE: Make sure the vacuum gauge hose is a secure fit to the port
deactivation diaphragm caps.
Using a vacuum gauge, check the port deactivation valve diaphragms.
Remove the engine bay brace.

10. Release the port deactivation valve connecting rod.
11. NOTE: Cut the retaining clips off the old port deactivation diaphragm
caps to aid removal.
NOTE: Make sure the valve cover is not damaged during removal of the
port deactivation diaphragm cap.
Remove the port deactivation valve cap.
Check the diaphragm for splits or damage.
12. Remove the port deactivation valve spring.

13. Remove the port deactivation valve connecting rod and diaphragm.
Installation
1. NOTE: Apply a small amount water to the diaphragm to aid installation.
NOTE: Make sure the diaphragm is fully seated on the connecting rod.
Install the new port deactivation diaphragm to the new connecting rod.
2. CAUTIONS:
material.
Make sure the port deactivation rod is correctly aligned to the port
deactivation valve arm.
NOTE: Make sue the new port deactivation diaphragm and rod are
installed in the correct orientation to the port deactivation linkage.
Install the port deactivation vale connecting rod and diaphram.

3. Install the port deactivation valve spring.
4. CAUTIONS:
Using a mirror check all clips are fully latched.
Make sure the port deactivation rod is not rotated once the cap has
been installed, if rotation occurs the diaphragm will be damaged.
NOTE: An audible click is heard when the clips are fully latched.
Install the port deactivation valve cap.
Make sure the cap is correctly aligned within the timing marks.
Secure the clips in the sequence shown.

5. Attach the port deactivation valve connecting rod.

7. NOTE: Check the vacuum gauge and any hoses to be used for leaks
prior to using on the vehicle.
Check the port deactivation valve diaphragms using a vacuum gauge.

8. NOTE: W hen the LH hose is re-connected to the valve the right angle
bend must be turned downwards, make sure the hose lies correctly in the
gap between the engine cover support and the valve cover.
Connect the port deactivation valve vacuum hoses.
9. Position the port deactivation hose as shown in illustration.

10. Install the RH injector sound proofing.
11. Install the wiring harness cover.
Secure in the clips.

12. Install the wiring harness carrier.
Install the bolts. TORQUE: 10 Nm
13. For additional information, refer to: Secondary Bulkhead Center Panel
14. For additional information, refer to: Engine Cover - TDV6 2.7L Diesel
Fuel Charging and Controls - Turbocharger - TDV6 2.7L Diesel -
Oil supply tube union to turbocharger retaining bolt 30 22
Oil supply tube to cylinder block retaining bolt 10 89
Oil return tube to turbocharger retaining bolts 10 89
Oil return tube to cylinder block retaining bolt 10 89
Exhaust gas recirculation (EGR) valve to cylinder head retaining bolts 10 89
EGR cooler mount bracket retaining bolt 10 89
EGR valve tube to exhaust manifold retaining bolts 10 89
Turbocharger to exhaust manifold retaining nuts 23 17
Turbocharger support bracket retaining bolts 23 17
Turbocharger heatshield retaining bolts 10 89
Exhaust manifold retaining nuts 23 17
Engine wiring harness retaining bolts 4 - 35
Fuel Charging and Controls - Turbocharger - TDV6 2.7L Diesel - Turbocharger -
Component Location
NOTE: Refer to: Intake Air Distribution and Filtering (303-12A Intake Air Distribution and Filtering - TDV6 2.7L Diesel, Description and
Operation).
Component Location
ItemDescription
1 Rotary electronic actuator
2 Oil supply pipe
3 Rotary electronic actuator linkage
4 Oil drain pipe
5 Turbine housing
6 Compressor housing
7 Exhaust manifold
Fuel Charging and Controls - Turbocharger - TDV6 2.7L Diesel - Turbocharger -
Overview
Overview
Fuel Charging and Controls - Turbocharger - TDV6 2.7L Diesel - Turbocharger - System
System Operation
Fuel Charging and Controls - Turbocharger - TDV6 2.7L Diesel - Turbocharger
For a detailed description of the turbocharger system, refer to the relevant Description and Operation sections in the workshop manual.
REFER to: (303-04B Fuel Charging and Controls - Turbocharger - TDV6 2.7L Diesel)
Turbocharger (Description and Operation),

Turbocharger (Description and Operation),
Turbocharger (Description and Operation).
Visual Inspection
Intake air system Fuses
Hoses/hose connections Loose or corroded electrical connectors
Turbochargers Harnesses
General engine conditions Sensors/actuators
step.
4. 4. If the cause is not visually evident, verify the symptom and refer to the Symptom Chart.
Symptom Chart

Poor performance Low/Contaminated Check the fuel level and condition. Draw off approximately 1 ltr (2.11 pints) of fuel and allow
(off-boost) fuel to stand for 1 minute. Check to make sure there is no separation of the fuel indicating water
Restricted intake air or other liquid in the fuel. Check the intake air system for restriction. Check the engine
system condition, compressions, etc for indications of a mechanical fault. Check for DTCs and refer
General engine to the relevant DTC Index
mechanical condition
Electronic engine
control systems
failure
No boost Electrical connections Check the electrical connections and harnesses. Check the intake air system for
and harnesses restriction/leakage. Refer to the electrical circuit diagrams and check the turbocharger
Restricted intake air actuators and circuits. Check the turbochargers for wear. Disconnect the turbocharger intake
system and outlet pipework and turn the turbochargers by hand. Any roughness indicates a fault.
Charge air cooler Check any up and down movement in the turbocharger shafts. Excessive movement indicates
restricted/leaking a fault. If in doubt, compare the suspect unit with a new turbocharger. Check for DTCs and
Turbocharger refer to the relevant DTC Index
actuator failure
Turbocharger failure
Electronic engine
control systems
failure
No Turbocharger Disconnect the turbocharger intake and outlet pipework and turn the turbochargers by hand.
boost/excessive failure(s) Any roughness indicates a fault. Check any up and down movement in the turbocharger
noise shafts. Excessive movement indicates a fault. If in doubt, compare the suspect unit with a
new turbocharger
DTC Index
3548-1358-00
module/component.

P004711 Turbocharger/Supercharger Turbocharger Carry out any pinpoint tests associated with this DTC using the
Boost Control Solenoid A boost control manufacturer approved diagnostic system. Refer to the electrical circuit
Circuit Low solenoid A circuit diagrams and check turbocharger boost control solenoid A circuit for short to
- short to ground ground. Suspect the turbocharger boost control solenoid A, check and install
Turbocharger a new turbocharger as required, refer to the new module/component
boost control installation note at the top of the DTC Index
solenoid A
failure
P004812 Turbocharger/Supercharger Turbocharger Carry out any pinpoint tests associated with this DTC using the
Boost Control Solenoid A boost control manufacturer approved diagnostic system. Refer to the electrical circuit
Circuit High solenoid A circuit diagrams and check turbocharger boost control solenoid A circuit for short to
- short to power power. Suspect the turbocharger boost control solenoid A, check and install
Turbocharger a new turbocharger as required, refer to the new module/component
boost control installation note at the top of the DTC Index
solenoid A
failure
P004C00 Turbocharger/Supercharger Turbocharger Refer to the electrical circuit diagrams and check turbocharger boost control
Boost Control Solenoid B boost control solenoid B circuit for short to ground. Suspect the turbocharger boost control
Circuit Low solenoid B circuit solenoid B, check and install a new turbocharger as required, refer to the
- short to ground new module/component installation note at the top of the DTC Index
Turbocharger
boost control
solenoid B
failure
P004D00 Turbocharger/Supercharger Turbocharger Refer to the electrical circuit diagrams and check turbocharger boost control
Boost Control Solenoid B boost control solenoid B circuit for short to power. Suspect the turbocharger boost control
Circuit High solenoid B circuit solenoid B, check and install a new turbocharger as required, refer to the
- short to power new module/component installation note at the top of the DTC Index
Turbocharger
boost control
solenoid B
failure
P006A21 MAP - Mass or Volume Air Signal amplitude Check high pressure air intake system for leaks and integrity
Flow Correlation < minimum
P006A22 MAP - Mass or Volume Air Signal amplitude Refer to the electrical circuit diagrams and check MAP sensor and
Flow Correlation > maximum turbocharger boost control solenoid A and B VREF circuits for short to
P007C16 Charge Air Cooler Circuit voltage Carry out any pinpoint tests associated with this DTC using the
Temperature Sensor Circuit below threshold manufacturer approved diagnostic system. Refer to the electrical circuit
Low diagrams and check charge air cooler temperature sensor signal circuit for
short to ground. Check and install a new sensor as required
P007D17 Charge Air Cooler Circuit voltage Refer to the electrical circuit diagrams and check charge air cooler
Temperature Sensor Circuit above threshold temperature sensor signal circuit for short to power. Check and install a new
High sensor as required
P007E27 Charge Air Cooler Signal rate of Carry out any pinpoint tests associated with this DTC using the
Temperature Sensor change above manufacturer approved diagnostic system. Refer to the electrical circuit
Intermittent/Erratic threshold diagrams and check charge air cooler temperature sensor circuits for poor
connections. Check and install a new sensor as required
P023627 Turbocharger/Supercharger MAP sensor Refer to the electrical circuit diagrams and check MAP sensor circuits for poor
Boost Sensor A Circuit signal rate of connections. Start engine and allow to idle, check and record 'Manifold air
Range/Performance change above pressure' datalogger signal, increase engine speed to 1500 rpm, check and
threshold record signal. If value of signal has increased by more than 500hPa/10ms
suspect the MAP sensor
P023716 Turbocharger/Supercharger Circuit voltage Carry out any pinpoint tests associated with this DTC using the
Boost Sensor A Circuit Low below threshold manufacturer approved diagnostic system. Refer to the electrical circuit
MAP sensor diagrams and check MAP sensor signal circuit for short to ground. Suspect
failure the MAP sensor, check and install a new sensor as required
P023817 Turbocharger/Supercharger Circuit voltage Carry out any pinpoint tests associated with this DTC using the
Boost Sensor A Circuit High above threshold manufacturer approved diagnostic system. Refer to the electrical circuit
MAP sensor diagrams and check MAP sensor signal circuit for short to power. Suspect the
failure MAP sensor, check and install a new sensor as required
P023D21 Manifold Absolute Pressure - Signal amplitude Carry out any pinpoint tests associated with this DTC using the
Turbocharger/Supercharger below minimum manufacturer approved diagnostic system. Check low pressure air intake
Boost Sensor A Correlation system integrity. Check turbocharger rod connection and oil seals. Check for
oil ingestion in intake air system. Set ignition status to 'ON', engine 'OFF',
check and record 'Boost Pressure Actuator Bank 1 - Measured Position'
datalogger signal, command 'Boost pressure adjustment bank 0'
datalogger signal from 5% to 95% in 5% increments. Value of signal at 5%
should be between 0-20%, value of signal at 95% should be between
80-99%, the incremental data should follow a smooth curve. If turbocharger
vanes sticking install a new turbocharger
P023D22 Manifold Absolute Pressure - Signal amplitude Carry out any pinpoint tests associated with this DTC using the
Turbocharger/Supercharger above maximum manufacturer approved diagnostic system. Check high pressure air intake
Boost Sensor A Correlation system integrity. Check turbocharger rod connection and oil seals. Set
ignition status to 'ON', engine 'OFF', check and record 'Boost Pressure
Actuator Bank 1 - Measured Position' datalogger signal, command 'Boost
pressure adjustment bank 0' datalogger signal from 5% to 95% in 5%
increments. Value of signal at 5% should be between 0-20%, value of signal
at 95% should be between 80-99%, the incremental data should follow a
smooth curve. If turbocharger vanes sticking install a new turbocharger
P123A21 Barometric - Signal amplitude Carry out any pinpoint tests associated with this DTC using the
Turbocharger/Supercharger < minimum manufacturer approved diagnostic system. Recover freeze frame data to
Boost Sensor A Correlation determine conditions when DTC logged. Refer to the electrical circuit
diagrams and check MAP sensor circuits for short to ground, power, open
circuit. Set ignition status to 'ON' engine 'OFF' with engine coolant
temperature >0C, check and record 'Manifold air pressure' and 'Ambient
pressure' datalogger signals. If signal values are the same, clear DTCs and
re-test. If not, value of 'Ambient pressure' signal should be between
85-106% of 1 atmosphere, if not suspect the ECM, check and install a new
ECM as required. If 'Ambient pressure' signal correct, start engine and
allow to idle, value of 'Manifold air pressure' signal should be between
580-3000hPa, if not install a new MAP sensor
P123A22 Barometric - Signal amplitude Carry out any pinpoint tests associated with this DTC using the
Turbocharger/Supercharger > maximum manufacturer approved diagnostic system. Recover freeze frame data to
Boost Sensor A Correlation determine conditions when DTC logged. Refer to the electrical circuit
diagrams and check MAP sensor circuits for short to ground, power, open
circuit. Set ignition status to 'ON' engine 'OFF' with engine coolant
temperature >0C, check and record 'Manifold air pressure' and 'Ambient
pressure' datalogger signals. If signal values are the same, clear DTCs and
re-test. If not, value of 'Ambient pressure' signal should be between
85-106% of 1 atmosphere, if not suspect the ECM, check and install a new
ECM as required. If 'Ambient pressure' signal correct, start engine and
allow to idle, value of 'Manifold air pressure' signal should be between
580-3000hPa, if not install a new MAP sensor
P132A00 Turbocharger/Supercharger Turbocharger Carry out any pinpoint tests associated with this DTC using the
Boost Control A Electrical boost pressure manufacturer approved diagnostic system. Set ignition status to 'ON' engine
actuator - 'OFF', check and record 'EGR throttle position' datalogger signal, command
H-Bridge failure 'EGR throttle command' actuator to 100%, value of signal should be
between 85-99%. Command 'EGR throttle command' actuator to 0%, value
of signal should be between 0-15%. If the signal values are outside of
specification, suspect the throttle, check and install a new throttle as
required. If the signal values are within specification, manually close and
open the throttle and check the feedback voltage/resistance, voltage should
range from 0.20-4.80volts, resistance should range from 300-2500 Ohms. If
these values are out of specification, suspect the throttle, check and install
a new throttle as required. If new throttle has been installed and DTC
remains, suspect the ECM, check and install a new module as required, refer
to the new module/component installation note at the top of the DTC Index
P132A19 Turbocharger/Supercharger Turbocharger Carry out any pinpoint tests associated with this DTC using the
Boost Control A Electrical boost pressure manufacturer approved diagnostic system. Set ignition status to 'ON' engine
H-Bridge 'EGR throttle command' actuator to 100%, value of signal should be
overcurrent between 85-99%. Command 'EGR throttle command' actuator to 0%, value
P132B00 Turbocharger/Supercharger PW M duty cycle Set ignition status to 'ON' engine 'OFF'. Check and record 'Boost Pressure
Boost Control A Performance too low - PWM Actuator Bank 1 - Measured Position' and 'Boost Pressure Actuator
frequency Bank 2 - Measured Position' datalogger signals, and then command 'Boost
incorrect pressure adjustment bank 0' and 'Boost pressure adjustment bank 1'
commands first to 0% and then to 99%. The value of the signals should be
comparable to the commanded position
P132B21 Turbocharger/Supercharger Turbocharger Refer to the electrical circuit diagrams and check turbocharger A circuits for
Boost Control A Performance boost pressure short, open circuit. Check and record 'Boost Pressure Actuator Bank 1 -
actuator control Measured Position' datalogger signal at idle and at 3000rev/min, then
deviation below quickly apply and release full throttle. Value of signal should be; at idle,
minimum approximately 95%, at 3000 rev/min, approximately 40%, quick
threshold - Bank application/release of throttle, smooth transition at approximately
1 25%/100ms. If angle does not change smoothly, or rate of change is slower
than expected, suspect the turbocharger vanes are sticking, check and
install a new turbocharger as required
P132B22 Turbocharger/Supercharger Turbocharger Refer to the electrical circuit diagrams and check turbocharger A circuits for
Boost Control A Performance boost pressure short, open circuit. Check and record 'Boost Pressure Actuator Bank 1 -
deviation above quickly apply and release full throttle. Value of signal should be; at idle,
maximum approximately 95%, at 3000 rev/min, approximately 40%, quick
P132D00 Turbocharger/Supercharger Turbocharger Carry out any pinpoint tests associated with this DTC using the
Boost Control B Electrical boost pressure manufacturer approved diagnostic system. Set ignition status to 'ON' engine
H-Bridge failure 'EGR throttle command' actuator to 100%, value of signal should be
between 85-99%. Command 'EGR throttle command' actuator to 0%, value
P132D19 Turbocharger/Supercharger Turbocharger Carry out any pinpoint tests associated with this DTC using the
Boost Control B Electrical boost pressure manufacturer approved diagnostic system. Set ignition status to 'ON' engine
H-Bridge 'EGR throttle command' actuator to 100%, value of signal should be
overcurrent between 85-99%. Command 'EGR throttle command' actuator to 0%, value
P132E00 Turbocharger/Supercharger PW M duty cycle Set ignition status to 'ON' engine 'OFF'. Check and record 'Boost Pressure
Boost Control B Performance too low - PWM Actuator Bank 1 - Measured Position' and 'Boost Pressure Actuator
frequency Bank 2 - Measured Position' datalogger signals, and then command 'Boost
incorrect pressure adjustment bank 0' and 'Boost pressure adjustment bank 1'
commands first to 0% and then to 99%. The value of the signals should be
comparable to the commanded position
P132E21 Turbocharger/Supercharger Turbocharger Refer to the electrical circuit diagrams and check turbocharger B circuits for
Boost Control B Performance boost pressure short, open circuit. Check and record 'Boost Pressure Actuator Bank 2 -
deviation below quickly apply and release full throttle. Value of signal should be; at idle,
minimum approximately 95%, at 3000 rev/min, approximately 40%, quick
P132E22 Turbocharger/Supercharger Turbocharger Refer to the electrical circuit diagrams and check turbocharger B circuits for
Boost Control B Performance boost pressure short, open circuit. Check and record 'Boost Pressure Actuator Bank 2 -
deviation above quickly apply and release full throttle. Value of signal should be; at idle,
maximum approximately 95%, at 3000 rev/min, approximately 40%, quick
P138E21 Turbocharger Boost Control Turbocharger Carry out any pinpoint tests associated with this DTC using the
Position Sensor A boost pressure manufacturer approved diagnostic system. Refer to the electrical circuit
Minimum/Maximum Stop actuator diagrams and check turbocharger bank 1 circuits for short, open circuit. Set
Performance adaption ignition status to 'ON' engine 'OFF', check and record 'Boost Pressure
diagnosis below Actuator Bank 1 - Measured Position' datalogger signal, then command
bottom limit - 'Boost pressure adjustment - bank 0' first to 5% then 95%. If value of
Bank 1 signal at 5% is not between 0-15%, or at 95% is not between 85-99%,
suspect bank 1 turbocharger, check and install a new turbocharger as
required
P138E22 Turbocharger Boost Control Turbocharger Carry out any pinpoint tests associated with this DTC using the
Position Sensor A boost pressure manufacturer approved diagnostic system. Refer to the electrical circuit
diagnosis above Actuator Bank 1 - Measured Position' datalogger signal, then command
top limit - Bank 'Boost pressure adjustment - bank 0' first to 5% then 95%. If value of
1 signal at 5% is not between 0-15%, or at 95% is not between 85-99%,
required
P138F21 Turbocharger Boost Control Turbocharger Carry out any pinpoint tests associated with this DTC using the
Position Sensor B boost pressure manufacturer approved diagnostic system. Refer to the electrical circuit
diagnosis below Actuator Bank 2 - Measured Position' datalogger signal, then command
bottom limit - 'Boost pressure adjustment - bank 1' first to 5% then 95%. If value of
Bank 2 signal at 5% is not between 0-15%, or at 95% is not between 85-99%,
required
P138F22 Turbocharger Boost Control Turbocharger Carry out any pinpoint tests associated with this DTC using the
Position Sensor B boost pressure manufacturer approved diagnostic system. Refer to the electrical circuit
diagnosis above Actuator Bank 2 - Measured Position' datalogger signal, then command
top limit - Bank 'Boost pressure adjustment - bank 1' first to 5% then 95%. If value of
2 signal at 5% is not between 0-15%, or at 95% is not between 85-99%,
required
P256327 Turbocharger Boost Control Signal rate of Carry out any pinpoint tests associated with this DTC using the
Position Sensor A Circuit change above manufacturer approved diagnostic system. Refer to the electrical circuit
Range/Performance threshold diagrams and check turbocharger boost control sensor A circuits for loose
contacts, open circuit. Clear DTC and re-test
P256421 Turbocharger Boost Control Signal amplitude Carry out any pinpoint tests associated with this DTC using the
Position Sensor A Circuit Low < minimum manufacturer approved diagnostic system. Refer to the electrical circuit
diagrams and check turbocharger boost control sensor A circuit for short to
ground. Check and install a new sensor as required
Position Sensor A Circuit High > maximum manufacturer approved diagnostic system. Refer to the electrical circuit
diagrams and check turbocharger boost control sensor A circuit for short to
power. Check and install a new sensor as required
P258727 Turbocharger Boost Control Signal rate of Carry out any pinpoint tests associated with this DTC using the
Position Sensor B Circuit change above manufacturer approved diagnostic system. Refer to the electrical circuit
Range/Performance threshold diagrams and check turbocharger boost control sensor B circuits for loose
contacts, open circuit. Clear DTC and re-test
Position Sensor B Circuit Low < minimum manufacturer approved diagnostic system. Refer to the electrical circuit
diagrams and check turbocharger boost control sensor B circuit for short to
ground. Check and install a new sensor as required
Fuel Charging and Controls - Turbocharger - TDV6 2.7L Diesel - Turbocharger LH
Removal
All vehicles


3. Remove the left-hand catalytic converter.

switches may occur.

connector.
All vehicles
9. Release the EGR valve inlet tube.
Remove and discard the clamp.
10. Remove the EGR inlet pipe.

11. Remove the LH turbocharger heat shield.
12. Remove the turbocharger support bracket.
13. Remove the turbocharger outlet pipe retaining bolt.
14. Disconnect the turbocharger outlet pipe.
15. Disconnect the turbocharger outlet pipe.
Reposition the LH turbocharger outlet pipe.

16. Detach the crankshaft position (CKP) sensor wiring harness from the
oil return tube retaining plate.
17. Release the LH turbocharger oil return tube.
18. Remove the LH turbocharger oil return tube.
19. Disconnect the LH turbocharger intake tube.
20. Disconnect the turbocharger electrical connector.

22. Disconnect the LH turbocharger oil supply pipe.
Remove and discard the copper sealing washer.

24. Remove the LH turbocharger.
Remove and discard the studs.
Installation
All vehicles
1. Install the LH turbocharger.
Install new studs and nuts.
Tighten to 23 Nm.

3. Connect the turbocharger oil supply tube.
Install a new copper sealing washer.
Tighten to 30 Nm.

5. Connect the LH turbocharger electrical connector.
6. Connect the LH turbocharger intake tube.

7. Install the LH turbocharger oil return tube.
Tighten to 10 Nm.
8. Secure the LH turbocharger oil return tube.
Tighten to 10 Nm.
9. Attach the CKP sensor wiring harness to the oil return tube retaining
plate.
10. Install the turbocharger outlet pipe.

11. Install the turbocharger outlet pipe.
12. Install the LH turbocharger outlet pipe bolt.
Tighten to 10 Nm.
13. Install the turbocharger support bracket.
Tighten to 23 Nm.
14. Install the LH turbocharger heat shield.
Tighten to 9 Nm.
15. Install the EGR inlet pipe.
Tighten to 10 Nm.
16. Attach the EGR valve inlet tube.
Install a new clamp.

Tighten to 100 Nm.
Tighten to 35 Nm.
All vehicles
Fuel Charging and Controls - Turbocharger - TDV6 2.7L Diesel - Turbocharger RH
Special Tool(s)
303-703
HTJ1200-2
Removal
All vehicles


3. Remove the RH catalytic converter.

switches may occur.

connector.
All vehicles
13. Remove the RH turbocharger heat shield.
14. Remove the turbocharger support bracket.

15. Release the RH turbocharger oil return tube.
16. Remove the turbocharger oil return tube retaining bolt.
17. Remove the turbocharger oil return tube.

Remove the bolt.

21. Release and reposition the generator.
23. Detach the engine mount.

25. Release the engine mount bracket.
26. Release the RH turbocharger intake tube.
27. Disconnect the RH turbocharger electrical connector.
blanking caps.
Disconnect the RH turbocharger oil supply pipe.
Remove and discard the copper sealing washer.
29. Remove the RH turbocharger.
Remove and discard the studs.

Installation
All vehicles
1. Install the RH turbocharger.
Install new studs and nuts.
Tighten to 23 Nm.
2. Connect the RH turbocharger oil supply pipe.
Install a new copper sealing washer.
Tighten to 30 Nm.
3. Connect the RH turbocharger electrical connector.
4. Secure the RH turbocharger intake tube.

5. Secure the engine mount bracket.
Tighten to 90 Nm.
7. Attach the engine mount.
Tighten to 63 Nm.

9. Secure the generator.
Tighten to 47 Nm.
Tighten to 20 Nm.

13. Install the turbocharger oil return tube.
14. Install the turbocharger oil return tube retaining bolt.
Tighten to 10 Nm.
15. Secure the RH turbocharger oil return tube.
Tighten to 10 Nm.
16. Install the RH turbocharger support bracket.
Tighten to 35 Nm.
17. Install the RH turbocharger heat shield.
Tighten to 10 Nm.
Tighten to 48 Nm.
Tighten to 10 Nm.
20. Attach the starter motor solenoid harness.
Tighten to 7 Nm.
21. Install the starter motor support bracket.
Tighten to 23 Nm.

Tighten to 100 Nm.
Tighten to 35 Nm.
All vehicles
25. Install the RH catalytic converter.
Fuel Charging and Controls - V6 3.0L Petrol -
Lower intake manifold retaining bolts 10 - 89
Fuel pressure regulator 4 - 35
Throttle body 10 - 89
Fuel Charging and Controls - V6 3.0L Petrol - Fuel Charging and Controls - Component
Location
Component Location
ItemDescription
1 Fuel supply pipe
2 Electric throttle
4 Fuel rail
Fuel Charging and Controls - V6 3.0L Petrol - Fuel Charging and Controls - Overview
Overview
The fuel charging and control system comprises a fuel pump, FPDM (fuel pump driver module), fuel rail and six fuel injectors. The fuel pump
supplies fuel from the tank, via a pipe routed along the outside of the LH (left-hand) chassis box section, to the fuel rail.
Refer to: Fuel Tank and Lines (310-01B Fuel Tank and Lines - V6 3.0L Petrol, Description and Operation).
The fuel rail distributes the fuel equally to each of the fuel injectors. The fuel injectors, which are controlled by the ECM (engine control
module), are installed in the fuel rail positioned in the center of the air intake manifold.
Fuel Charging and Controls - V6 3.0L Petrol - Fuel Charging and Controls - System
System Operation
Operation of the fuel charging and control system is controlled by the ECM (engine control module).
Fuel Pump
ItemDescription
2 Fuel pump module
3 Fuel level sensor
4 Fuel level float
The fuel pump module is mounted in the RH (right-hand) side of the fuel tank and delivers fuel at variable flow and pressure to the fuel rail,
which supplies fuel to all fuel injectors. The fuel pump operation is regulated by the FPDM (fuel pump driver module), which is controlled by
the ECM.
Refer to: Fuel Tank and Lines (310-01A Fuel Tank and Lines - TDV6 2.7L Diesel, Description and Operation).
Fuel Pump Driver Module
The FPDM is used to control the speed of the fuel pump based upon the fuel demand of the engine. The ECM controls the FPDM in response
to inputs from the FRP (fuel rail pressure) sensor, MAP (manifold absolute pressure) sensor, MAF (mass air flow) sensor and the IAT (intake
air temperature) sensor. The FPDM is attached to the RH end of the evaporative emission canister, which is installed on the underside of
the center floor pan, above the rear stabilizer bar.
The ECM sends a PWM (pulse width modulation) signal to the FPDM. The frequency of the signal determines the duty cycle of the pump. The
PWM signal to the pump represents half the ON time of the pump. If the ECM transmits a 50% ON time, this drives the pump at 100%. If
the ECM transmits a 5% ON time, the FPDM drives the pump at 10%. The FPDM will only turn the fuel pump ON if it receives a valid signal
between 4% and 50%. To turn the fuel pump OFF, the ECM transmits a duty cycle signal of 75%.
The status of the FPDM is monitored by the ECM. Any errors can be retrieved from the ECM using the Jaguar approved diagnostic system.
The FPDM cannot be interrogated for diagnostic purposes.
Fuel Injectors
Six fuel injectors are installed in the fuel rail. Two O-rings seal each injector to the fuel rail. The fuel jets from the injectors are directed
onto the back of the intake valves.
The injectors are electromagnetic solenoid valves controlled by the ECM. Each injector contains a solenoid-operated needle valve, which is
closed while the solenoid winding is de-energized. The solenoid winding is connected to a power feed from the main relay and to an earth
through the ECM. The ECM switches the earth to control the opening and closing of the needle valve. W hile the needle valve is open, fuel is
sprayed into the cylinder intake tract onto the back of the intake valves. The ECM meters the amount of fuel injected by adjusting the time
that the needle valve is open.
Electric Throttle
The electric throttle controls the engine torque and is located on the air intake manifold at the front of the engine. The main components
are an electric throttle control valve, an APP (accelerator pedal position) sensor and the ECM.
The APP sensor determines the driver demand to control throttle opening. This value is received by the ECM and the throttle is then opened
to the correct angle by means of an integral electric motor. Sensors in the throttle body are used to determine the position of the throttle
plate and the rate of change in its angle.
Fuel Rail
ItemDescription
1 Fuel injector
2 Fuel rail
3 FRP sensor
4 Fuel rail pressure damper
5 Fuel temperature sensor
6 Fuel supply pipe
The fuel rail maintains a fuel pressure of typically 4.5 bar (65 lbf/in), however, this pressure will vary depending on engine requirements;
lower at idle, higher at full load. Three fuel injectors are installed in each cylinder head and are connected to the fuel rail. O-ring seals are
used to seal the injectors to the fuel rail.
Fuel Pressure Damper
A fuel pressure damper is attached to the fuel rail. The damper acts to damp pressure pulses from the fuel pump.
The fuel temperature sensor is located in the fuel supply pipe at the front of the engine. The sensor is an NTC (negative temperature
coefficient) sensor, which is connected to the ECM by two wires.
Fuel Rail Pressure Sensor
The FRP sensor continuously monitors the fuel pressure in the fuel rail. This value is used by the ECM to calculate the injector pulse-width
required to deliver the correct mass of fuel per injection. The ECM also uses this information to demand a specific fuel flow-rate from the
fuel pump via the FPDM.
Fuel Charging and Controls - V6 3.0L Petrol - Fuel Charging and Controls
For a detailed description of the petrol engine fuel charging and controls system, refer to the relevant Description and Operation sections in
the workshop manual. REFER to:
Fuel Charging and Controls (303-04C Fuel Charging and Controls - V6 3.0L Petrol, Description and Operation),
Fuel Charging and Controls (303-04D Fuel Charging and Controls - V8 4.2L Petrol, Description and Operation),
Fuel Charging and Controls (303-04E Fuel Charging and Controls - V8 S/C 4.2L Petrol, Description and Operation),
Fuel Charging and Controls (303-04E Fuel Charging and Controls - V8 S/C 4.2L Petrol, Description and Operation),
Fuel Charging and Controls (303-04E Fuel Charging and Controls - V8 S/C 4.2L Petrol, Description and Operation).
Visual inspection
Fuel level Fuses
Throttle body
Damaged fuel tank filler pipe cap
Damaged fuel tank filler pipe
step.
4. 4. If the cause is not visually evident and there are clear symptoms refer to the Symptom Chart below, alternatively, check for
Diagnostic Trouble Codes (DTCs) and refer to the DTC Index.
Symptom Chart

Engine cranks, but does not fire Engine breather system Ensure the engine breather system is free from restriction and is
disconnected/restricted correctly installed. Check for ignition system, fuel system and
Ignition system electronic engine control DTCs and refer to the relevant DTC Index
Fuel system
Electronic engine control
Engine cranks and fires, but will Evaporative emissions purge Check for evaporative emissions, fuel system and ignition system
not start valve related DTCs and refer to the relevant DTC Index
Fuel pump
Spark plugs
HT short to ground (tracking)
check rubber boots for
cracks/damage
Ignition system
Difficult cold start Engine coolant level/anti- Check the engine coolant level and condition. Ensure the battery is
freeze content in a fully charged and serviceable condition. Check for electronic
Battery engine controls, engine emissions, fuel system and evaporative
Electronic engine controls emissions system related DTCs and refer to the relevant DTC Index
Exhaust Gas Recirculation
(EGR) valve stuck open
Fuel pump
Purge valve
Difficult hot start Injector leak Check for injector leak, install new injector as required. Check for
Electronic engine control electronic engine controls, evaporative emissions, fuel system,
Purge valve ignition system and engine emission system related DTCs and refer
Fuel pump to the relevant DTC Index
Ignition system
EGR valve stuck open
Difficult to start after hot soak Injector leak Check for injector leak, install new injector as required. Check for
(vehicle standing, engine off, Electronic engine control electronic engine controls, evaporative emissions, fuel system,
after engine has reached Purge valve ignition system and engine emission system related DTCs and refer
operating temperature) Fuel pump to the relevant DTC Index
Ignition system
Engine stalls soon after start Breather system Ensure the engine breather system is free from restriction and is
disconnected/restricted correctly installed. Check for electronic engine control, ignition
ECM relay system and fuel system related DTCs and refer to the relevant DTC
Electronic engine control Index. Check for blockage in air filter element and air intake system.
Ignition system Check for air leakage in air intake system
Air intake system restricted
Air leakage
Fuel lines
Engine hesitates/poor Fuel pressure, fuel pump, fuel Check for fuel system related DTCs and refer to the relevant DTC
acceleration lines Index. Check for injector leak, install new injector as required. Check
Injector leak for air leakage in air intake system. Ensure accelerator pedal is free
Air leakage from restriction. Check for electronic engine controls, ignition, engine
Electronic engine control emission system and transmission related DTCs and refer to the
Throttle motor relevant DTC Index
Restricted accelerator pedal
travel (carpet, etc)
Ignition system
Transmission malfunction
Engine backfires Fuel pump/lines Check for fuel system failures. Check for air leakage in intake air
Air leakage system. Check for electronic engine controls, ignition system and
Electronic engine controls VCT system related DTCs and refer to the relevant DTC Index
Ignition system
Sticking variable camshaft
timing (VCT) hub
Engine surges Fuel pump/lines Check for fuel system failures. Check for electronic engine controls,
Electronic engine controls throttle system and ignition system related DTCs and refer to the
Ignition system
Engine detonates/knocks Fuel pump/lines Check for fuel system failures. Check for air leakage in intake air
Air leakage system. Check for electronic engine controls and VCT system related
Electronic engine controls DTCs and refer to the relevant DTC Index
Sticking VCT hub
No throttle response Electronic engine controls Check for electronic engine controls and throttle system related DTCs
Throttle motor and refer to the relevant DTC Index
Poor throttle response Breather system Ensure the engine breather system is free from restriction and is
disconnected/restricted correctly installed. Check for electronic engine controls, transmission
Electronic engine control and traction control related DTCs and refer to the related DTC Index.
Transmission malfunction Check for air leakage in intake air system
Traction control event
Air leakage
DTC Index
3548-1358-00
module/component.

P008700 Fuel Rail/System Fuel rail pressure (Fuel rail Carry out any pinpoint tests associated with this DTC using the
Pressure - Too Low pressure) sensor, sensing manufacturer approved diagnostic system. Refer to the electrical
circuit - short to ground, circuit diagrams and check Fuel rail pressure sensor circuits for short
open circuit to ground, open circuit, high resistance. Check and install a new Fuel
Fuel rail pressure sensor rail pressure sensor as required. Check fuel system for failure
supply circuit - high
resistance
Fuel rail pressure sensor
failure
Fuel pump failure
Fuel line leak, restriction
P008800 Fuel Rail/System Fuel rail pressure sensor Carry out any pinpoint tests associated with this DTC using the
Pressure - Too High supply/sensing circuits - manufacturer approved diagnostic system. Refer to the electrical
short to each other circuit diagrams and check Fuel rail pressure sensor circuits for short
Fuel rail pressure sensor to each other, power, open circuit, high resistance. Check and install
sensing circuit - short to a new Fuel rail pressure sensor as required. Check fuel system for
power failure
ground circuit - high
resistance
failure
Restricted fuel line
Fuel pump short circuit to
power
P017100 System too lean (bank Air intake leak between MAF Check for leak from air intake system. Check for fuel system
1) sensor and cylinder head blockage/restriction. Check for additional MAF sensor related DTCs
Fuel filter, injector, system and refer to relevant DTC Index. Check and rectify any exhaust leak
restriction prior to catalytic converter
MAF sensor fault (low intake
air flow)
Exhaust leak (forward of
catalytic converter)
P017200 System Too Rich (Bank Restricted air cleaner Check air cleaner element is free from restriction. Check for leaking
1) Leaking fuel injector(s) injectors, install new injector(s) as required. Check for contaminated
Engine oil contaminated with engine oil, drain and refill engine oil as required. Check for additional
fuel (too many cold starts MAF sensor related DTCs and refer to relevant DTC Index
with vehicle subsequently
not getting hot enough for
long enough)
MAF sensor fault (high intake
air flow)
P017400 System Too Lean (Bank Air intake leak between MAF Check for leak from air intake system. Check for fuel system
2) sensor and cylinder head blockage/restriction. Check for additional MAF sensor related DTCs
Fuel filter, injector, system and refer to relevant DTC Index. Check and rectify any exhaust leak
restriction prior to catalytic converter
MAF sensor fault (low intake
air flow)
P017500 System Too Rich (Bank Restricted air cleaner Check air cleaner element is free from restriction. Check for leaking
2) Leaking fuel injector(s) injectors, install new injector(s) as required. Check for contaminated
Engine oil contaminated with engine oil, drain and refill engine oil as required. Check for additional
fuel (too many cold starts MAF sensor related DTCs and refer to relevant DTC Index
with vehicle subsequently
not getting hot enough for
long enough)
MAF sensor fault (high intake
air flow)
P018123 Fuel Temperature Fuel temperature sensor Carry out any pinpoint tests associated with this DTC using the
Sensor A Circuit sensing circuit - short to manufacturer approved diagnostic system. Refer to the electrical
Range/Performance ground, short to power, high circuit diagrams and check fuel temperature sensor circuits for short
resistance to ground, power, high resistance. Check and install a new Fuel
Fuel temperature sensor temperature sensor as required
resistance
Fuel temperature sensor
failure
resistance
failure
resistance
failure
Sensor A Circuit Low sensing circuit - short to manufacturer approved diagnostic system. Refer to the electrical
ground circuit diagrams and check fuel temperature sensor circuits for short
Fuel temperature sensor to ground, power, high resistance. Check and install a new Fuel
ground circuit - short circuit temperature sensor as required
failure
Sensor A Circuit High sensing circuit - short to manufacturer approved diagnostic system. Refer to the electrical
power, high resistance, circuit diagrams and check fuel temperature sensor circuits for short
disconnected to ground, power, high resistance. Check and install a new Fuel
resistance
failure
Fuel Charging and Controls - V6 3.0L Petrol - Fuel Charging Wiring Harness
Removal
1. Remove the lower intake manifold.
For additional information, refer to: Lower Intake Manifold (303-01B
Engine - V6 3.0L Petrol, Removal and Installation).
Installation
Fuel Charging and Controls - V6 3.0L Petrol - Fuel Injection Supply Manifold
Removal
1. Remove the fuel injectors.
For additional information, refer to Fuel Injectors in this section.
2. Remove the fuel pressure regulator.
Installation
Tighten to 10 Nm.
Fuel Charging and Controls - V6 3.0L Petrol - Fuel Injectors
Removal
1. Remove the fuel charging wiring harness.
For additional information, refer to Fuel Charging W iring Harness in this
section.
Remove the fuel injector locating clips.
3. Remove and discard the O-ring seals.
Installation
1. NOTE: Install new fuel injector O-ring seals.
Lubricate the fuel injector O-ring seals with clean engine oil.
Fuel Charging and Controls - V6 3.0L Petrol - Fuel Pressure Regulator
Removal
1. Remove the lower intake manifold.
For additional information, refer to: Lower Intake Manifold (303-01B
Engine - V6 3.0L Petrol, Removal and Installation).
Installation
Fuel Charging and Controls - V6 3.0L Petrol - Throttle Body
Removal
1. W ARNING: W hen relieving cooling system pressure, cover the

expansion tank cap with a thick cloth to prevent the possibility of scalding.
Remove the expansion tank cap to relieve the cooling system pressure.
3. Disconnect the throttle body electrical connector.
4. CAUTION: Clamp the coolant hose to minimize coolant loss.
5. CAUTION: Clamp the coolant hose to minimize coolant loss.

7. Remove and discard the O-ring seal.
Installation
1. 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.
3. Check and top up the cooling system as required.

Fuel Charging and Controls - 4.2L NA V8 - AJV8 -
Fuel injection supply manifold vehicles with supercharger 21 15 -
Fuel injection supply manifold vehicles without supercharger 22 16 -
Fuel pressure regulator 5 - 44
Throttle body 10 - 89
Fuel Charging and Controls - 4.2L NA V8 - AJV8 - Fuel Charging and
Controls
COMPONENT LOCATION

1 - RH fuel rail
2 - LH fuel rail
3 - Injectors (8 off)
4 - Fuel supply pipe
5 - Electric throttle body
6 - Fuel supply cross over pipe
OVERVIEW
The fuel charging and control system comprises a fuel pump, fuel pump driver module (FPDM), fuel rails and 8 injectors.
The fuel pump supplies fuel from the tank, via a pipe routed along the outside of the left hand chassis box section, to the
fuel rail. The fuel rail distributes the fuel equally to each of the 8 injectors. The fuel injectors, which are controlled by the
engine control module (ECM), are installed in the fuel rails on each side of the air intake manifold. A cross over pipe
connects the 2 fuel rails together at the front of the engine. For additional information, refer to:
Fuel Tank and Lines (310-01C, Description and Operation),

Electronic Engine Controls (303-14C, Description and Operation).
Controls - Component Location
Component Location
ItemDescription
1 RH (right-hand) fuel rail
2 LH (left-hand) fuel rail
3 Injector (8 off)
4 Fuel supply pipe
5 Electric throttle
6 Fuel supply cross over pipe
Controls - Overview
Overview
The fuel charging and control system comprises a fuel pump, FPDM (fuel pump driver module), fuel rails and eight fuel
injectors. The fuel pump supplies fuel from the tank, via a pipe routed along the outside of the left hand chassis box
section, to the fuel rail. The fuel rail distributes the fuel equally to each of the fuel injectors. The fuel injectors, which are
controlled by the ECM (engine control module), are installed in the fuel rails on each side of the air intake manifold. A
cross over pipe connects the two fuel rails together at the front of the engine.
Refer to: Fuel Tank and Lines (310-01 Fuel Tank and Lines - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8, Description and
Operation).
Controls - System Operation and Component Description
System Operation
and Operation).
Fuel Pump
ItemDescription
2 Fuel pump module
3 Fuel level sensor
4 Fuel level float
The fuel pump module is mounted in the RH (right-hand) side of the saddle type fuel tank and delivers fuel at variable
flow and pressure to the fuel rails, which supply fuel to all fuel injectors. The fuel pump operation is regulated by the
FPDM (fuel pump driver module), which is controlled by the ECM.
Operation).

The FPDM is used to control the speed of the fuel pump based upon the fuel demand of the engine. The ECM controls the
FPDM in response to inputs from the FRP (fuel rail pressure) sensor, MAP (manifold absolute pressure) sensor, MAF (mass
air flow) sensor and the IAT (intake air temperature) sensor. The FPDM is attached to the RH end of the evaporative
emission canister, which is installed on the underside of the center floor pan, above the rear stabilizer bar.
The ECM sends a PWM (pulse width modulation) signal to the FPDM, the frequency of the signal determines the duty cycle
of the pump. The PW M signal to the pump represents half the ON time of the pump. If the ECM transmits a 50% ON time,
this drives the pump at 100%. If the ECM transmits a 5% ON time, the FPDM drives the pump at 10%. The FPDM will only
turn the fuel pump ON if it receives a valid signal between 4% and 50%. To turn the fuel pump OFF, the ECM transmits a
duty cycle signal of 75%.
The status of the FPDM is monitored by the ECM. Any errors can be retrieved from the ECM using the Jaguar approved
diagnostic system. The FPDM cannot be interrogated for diagnostic purposes.
Fuel Injectors
Eight, top fed, 12 hole, fuel injectors are installed in the fuel rails. Two O-rings seal each injector to the fuel rails. The
fuel jets from the injectors are directed onto the back of the intake valves.
The injectors are electromagnetic solenoid valves controlled by the ECM. Each injector contains a solenoid-operated needle
valve, which is closed while the solenoid winding is de-energized. The solenoid winding is connected to a power feed from
the main relay and to an earth through the ECM. The ECM switches the earth to control the opening and closing of the
needle valve. While the needle valve is open, fuel is sprayed into the cylinder intake tract onto the back of the intake
valves. The ECM meters the amount of fuel injected by adjusting the time that the needle valve is open.
The solenoid winding of the fuel injector has a resistance of 13.8 0.7 ohms @ 20 C (68 F).
Electric Throttle
The electric throttle controls the engine torque and is located on the induction elbow at the front of the engine. Its main
components are an electric throttle control valve, an APP (accelerator pedal position) sensor and the ECM.
The APP sensor determines the driver demand to control throttle opening. This value is received by the ECM and the
throttle is then opened to the correct angle by means of an integral electric motor. Sensors in the throttle body are used
to determine the position of the throttle plate and the rate of change in its angle.
and Operation).
Fuel Rails
ItemDescription
1 FRP sensor
3 Fuel rail
4 Fuel rail temperature sensor
5 Fuel rail
7 Fuel rail inlet
8 Fuel rail connection pipe
9 Fuel injector
Each fuel rail maintains a fuel pressure of typically 4.5 bar (65 lbf/in), however, this pressure will vary depending on
engine requirements; lower at idle, higher at full load. Four fuel injectors are installed in each cylinder head and are
connected to the related fuel rail. O-ring seals are used to seal the injectors to the fuel rails.

A fuel pressure damper is attached centrally to each of the fuel rails. The damper acts to damp pressure pulses from the
fuel pump.
The fuel temperature sensor is located in the rear of the RH fuel rail. The sensor is a NTC (negative temperature
and Operation).
The FRP sensor continuously monitors the fuel pressure in the fuel rail. This value is used by the ECM to calculate the
injector pulse-width required to deliver the correct mass of fuel per injection. The ECM also uses this information to
demand a specific fuel flow-rate from the fuel pump via the FPDM.
and Operation).
Controls
For a detailed description of the petrol engine fuel charging and controls system, refer to the relevant Description and
Operation sections in the workshop manual. REFER to:
Fuel Charging and Controls (303-04A Fuel Charging and Controls - 4.2L NA V8 - AJV8, Description and Operation),
Fuel Charging and Controls (303-04B Fuel Charging and Controls - 4.2L SC V8 - AJV8, Description and Operation),
Fuel Charging and Controls (303-04B Fuel Charging and Controls - 4.2L SC V8 - AJV8, Description and Operation),
Fuel Charging and Controls (303-04B Fuel Charging and Controls - 4.2L SC V8 - AJV8, Description and Operation).
vehicle.
Visual inspection
Fuel level Fuses
Throttle body
Damaged fuel tank filler pipe cap
Damaged fuel tank filler pipe
4. 4. If the cause is not visually evident and there are clear symptoms refer to the Symptom Chart below,
alternatively, check for Diagnostic Trouble Codes (DTCs) and refer to the DTC Index.
Symptom Chart

Engine cranks, but does not Engine breather system Ensure the engine breather system is free from
fire disconnected/restricted restriction and is correctly installed. Check for ignition
Ignition system system, fuel system and electronic engine control DTCs
Fuel system and refer to the relevant DTC Index
Engine cranks and fires, but Evaporative emissions purge Check for evaporative emissions, fuel system and
will not start valve ignition system related DTCs and refer to the relevant
Fuel pump DTC Index
Spark plugs
HT short to ground
(tracking) check rubber
boots for cracks/damage
Ignition system
Difficult cold start Engine coolant level/anti- Check the engine coolant level and condition. Ensure the
freeze content battery is in a fully charged and serviceable condition.
Battery Check for electronic engine controls, engine emissions,
Electronic engine controls fuel system and evaporative emissions system related
Exhaust Gas Recirculation DTCs and refer to the relevant DTC Index
Fuel pump
Purge valve
Difficult hot start Injector leak Check for injector leak, install new injector as required.
Electronic engine control Check for electronic engine controls, evaporative
Purge valve emissions, fuel system, ignition system and engine
Fuel pump emission system related DTCs and refer to the relevant
Ignition system DTC Index
Difficult to start after hot Injector leak Check for injector leak, install new injector as required.
soak (vehicle standing, Electronic engine control Check for electronic engine controls, evaporative
engine off, after engine has Purge valve emissions, fuel system, ignition system and engine
reached operating Fuel pump emission system related DTCs and refer to the relevant
temperature) Ignition system DTC Index
Engine stalls soon after start Breather system Ensure the engine breather system is free from
disconnected/restricted restriction and is correctly installed. Check for electronic
ECM relay engine control, ignition system and fuel system related
Electronic engine control DTCs and refer to the relevant DTC Index. Check for
Ignition system blockage in air filter element and air intake system.
Air intake system restricted Check for air leakage in air intake system
Air leakage
Fuel lines
Engine hesitates/poor Fuel pressure, fuel pump, Check for fuel system related DTCs and refer to the
acceleration fuel lines relevant DTC Index. Check for injector leak, install new
Injector leak injector as required. Check for air leakage in air intake
Air leakage system. Ensure accelerator pedal is free from restriction.
Electronic engine control Check for electronic engine controls, ignition, engine
Throttle motor emission system and transmission related DTCs and
Restricted accelerator pedal refer to the relevant DTC Index
Ignition system
Engine backfires Fuel pump/lines Check for fuel system failures. Check for air leakage in
Air leakage intake air system. Check for electronic engine controls,
Electronic engine controls ignition system and VCT system related DTCs and refer
Ignition system to the relevant DTC Index
timing (VCT) hub
Engine surges Fuel pump/lines Check for fuel system failures. Check for electronic
Electronic engine controls engine controls, throttle system and ignition system
Throttle motor related DTCs and refer to the relevant DTC Index
Ignition system
Engine detonates/knocks Fuel pump/lines Check for fuel system failures. Check for air leakage in
Air leakage intake air system. Check for electronic engine controls
Electronic engine controls and VCT system related DTCs and refer to the relevant
Sticking VCT hub DTC Index
No throttle response Electronic engine controls Check for electronic engine controls and throttle system
Poor throttle response Breather system Ensure the engine breather system is free from
Electronic engine control engine controls, transmission and traction control
Transmission malfunction related DTCs and refer to the related DTC Index. Check
Traction control event for air leakage in intake air system
Air leakage
DTC Index
NOTE: If the control module/component is suspect and the vehicle remains under manufacturer warranty, refer to the
account.

P008700 Fuel Rail/System Fuel rail pressure (Fuel Carry out any pinpoint tests associated with this DTC
Pressure - Too Low rail pressure) sensor, using the manufacturer approved diagnostic system.
sensing circuit - short to Refer to the electrical circuit diagrams and check Fuel rail
ground, open circuit pressure sensor circuits for short to ground, open circuit,
Fuel rail pressure sensor high resistance. Check and install a new Fuel rail
supply circuit - high pressure sensor as required. Check fuel system for failure
resistance
failure
Fuel pump failure
P008800 Fuel Rail/System Fuel rail pressure sensor Carry out any pinpoint tests associated with this DTC
Pressure - Too High supply/sensing circuits - using the manufacturer approved diagnostic system.
short to each other Refer to the electrical circuit diagrams and check Fuel rail
Fuel rail pressure sensor pressure sensor circuits for short to each other, power,
sensing circuit - short to open circuit, high resistance. Check and install a new
power Fuel rail pressure sensor as required. Check fuel system
Fuel rail pressure sensor for failure
resistance
failure
power
P017100 System too lean (bank Air intake leak between Check for leak from air intake system. Check for fuel
1) MAF sensor and cylinder system blockage/restriction. Check for additional MAF
head sensor related DTCs and refer to relevant DTC Index.
Fuel filter, injector, Check and rectify any exhaust leak prior to catalytic
system restriction converter
MAF sensor fault (low
intake air flow)
P017200 System Too Rich (Bank Restricted air cleaner Check air cleaner element is free from restriction. Check
1) Leaking fuel injector(s) for leaking injectors, install new injector(s) as required.
Engine oil contaminated Check for contaminated engine oil, drain and refill engine
with fuel (too many cold oil as required. Check for additional MAF sensor related
starts with vehicle DTCs and refer to relevant DTC Index
subsequently not getting
hot enough for long
enough)
MAF sensor fault (high
intake air flow)
P017400 System Too Lean Air intake leak between Check for leak from air intake system. Check for fuel
(Bank 2) MAF sensor and cylinder system blockage/restriction. Check for additional MAF
head sensor related DTCs and refer to relevant DTC Index.
Fuel filter, injector, Check and rectify any exhaust leak prior to catalytic
system restriction converter
MAF sensor fault (low
intake air flow)
P017500 System Too Rich (Bank Restricted air cleaner Check air cleaner element is free from restriction. Check
2) Leaking fuel injector(s) for leaking injectors, install new injector(s) as required.
Engine oil contaminated Check for contaminated engine oil, drain and refill engine
with fuel (too many cold oil as required. Check for additional MAF sensor related
starts with vehicle DTCs and refer to relevant DTC Index
subsequently not getting
hot enough for long
enough)
intake air flow)
P018123 Fuel Temperature Fuel temperature sensor Carry out any pinpoint tests associated with this DTC
Sensor A Circuit sensing circuit - short to using the manufacturer approved diagnostic system.
Range/Performance ground, short to power, Refer to the electrical circuit diagrams and check fuel
high resistance temperature sensor circuits for short to ground, power,
Fuel temperature sensor high resistance. Check and install a new Fuel
ground circuit - high temperature sensor as required
resistance
failure
P018124 Fuel Temperature Fuel temperature sensor Carry out any pinpoint tests associated with this DTC
Sensor A Circuit sensing circuit - short to using the manufacturer approved diagnostic system.
Range/Performance ground, short to power, Refer to the electrical circuit diagrams and check fuel
high resistance temperature sensor circuits for short to ground, power,
Fuel temperature sensor high resistance. Check and install a new Fuel
ground circuit - high temperature sensor as required
resistance
failure
Fuel Charging and Controls - 4.2L NA V8 - AJV8 - Fuel Injectors
Removal
W ARNINGS:
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.
After carrying out repairs, the fuel system must be checked visually for leaks. Failure to follow this instruction may
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.

Procedures).
For additional information, refer to: Fuel Injection Supply
Manifold (303-04A Fuel Charging and Controls - 4.2L NA V8 -
3. Remove the injector retaining clips.
Repeat the above procedure for the remaining injectors.
Installation
Fuel Charging and Controls - 4.2L NA V8 - AJV8 - Fuel Injection Supply
Manifold
Special Tool(s)
310-D005
Removal
W ARNINGS:
After carrying out repairs, the fuel system must be checked visually for leaks. Failure to follow this instruction may

Procedures).
For additional information, refer to: Engine Cover - 4.2L NA V8
- AJV8 (501-05 Interior Trim and Ornamentation, Removal and
Installation).
3. Remove the engine cover RH bracket.
Remove the 2 nuts.
4. Remove the engine cover LH bracket.
Remove the 2 nuts.
Release the 2 electrical connectors.
Remove the purge valve bolt.

6. Release the purge valve.
Disconnect the quick release connector.
7. Using the special tool, disconnect the fuel line.
8. Disconnect the fuel rail pressure (FRP) sensor electrical

connector.
9. Disconnect the FRP sensor vacuum line.

10. Disconnect the fuel temperature sensor electrical
connector.

contamination.
Remove the fuel injection supply manifold.

Remove the fuel injector.
Remove the clip.
Repeat the above procedure for the remaining injectors.

14. Remove the FRP sensor.
Remove the 2 bolts.
15. Remove the fuel temperature sensor.
Installation
2. Tighten to 7 Nm.
3. Tighten to 5 Nm.
5. Tighten to 6 Nm.
6. Tighten to 6 Nm.
Fuel Charging and Controls - 4.2L NA V8 - AJV8 - Fuel Pressure Regulator
Removal
W ARNINGS:
Do not smoke or carry lighted tobacco or 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.
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.

Installation).
2. Depressurize the fuel system.
For additional information, refer to: Fuel System Pressure
Release - 3.0L NA V6 - AJ27/4.2L NA V8 - AJV8/4.2L SC V8 -
AJV8 (310-00 Fuel System - General Information, General
Procedures).
3. Disconnect the fuel pressure regulator electrical connector
and vacuum hose.
4. Remove the fuel pressure regulator.
Installation
Tighten to 10 Nm.
Fuel Charging and Controls - 4.2L NA V8 - AJV8 - Throttle Body
Removal
Installation).
2. Remove the air intake duct.
Disconnect the breather hose.
3. Disconnect the throttle position (TP) sensor electrical

connector.
4. Release the throttle body.
Remove the 4 bolts.
Remove and discard the throttle body gasket.
5. W ARNING: Since injury such as scalding could be caused

by escaping steam or coolant, do not remove the filler cap from
the coolant expansion tank while the system is hot.
NOTE: Do not disassemble further if the component is removed

for access only.
Disconnect the coolant hoses from the throttle body.
Clamp the throttle body coolant hoses to minimize

coolant loss.
Release the throttle body hose clips
Installation
1. Connect the coolant hoses to the throttle body.
Remove the hose clamps from the throttle body hoses.
Secure the throttle body hoses clips.
Tighten the 4 bolts to 10 Nm (7 lb.ft).
3. Connect the TP sensor electrical connector.

4. Install the intake air duct.
Tighten the clips.
Connect the breather hose.

Installation).
6. Check and top-up the coolant.
Fuel Charging and Controls - 4.2L SC V8 - AJV8 - Fuel Charging and Controls
- Component Location
Component Location
ItemDescription
1 Inlet air duct
2 Charge air ducts
3 Supercharger
4 RH (right-hand) intercooler
6 Fuel rail adapter
7 RH fuel rail
8 By-pass valve
9 Induction elbow
10 Electric throttle
11 LH (left-hand) fuel rail
12 LH intercooler
- Overview
Overview
The fuel charging and control system comprises a supercharger and air induction system, fuel pump, FPDM (fuel pump
driver module), fuel rails and fuel injectors. The fuel pump supplies fuel from the tank, via a pipe routed along the outside
of the LH (left-hand) chassis box section, to the fuel rail. The fuel rail distributes the fuel equally to each of the fuel
injectors. The fuel injectors, which are controlled by the ECM (engine control module), are installed in the fuel rails on each
side of the intercoolers. A cross over pipe connects the two fuel rails together at the front of the engine. The supercharger
delivers compressed air into the engine through the air induction system.
and Operation).
- System Operation and Component Description
System Operation
and Operation).
Air Induction System
ItemDescription
1 Air inlet duct
2 Vacuum operated by-pass valve assembly
3 Supercharger
4 Supercharger exit port
5 Intercoolers
6 Cooling water
7 Cylinder heads
8 Induction elbow
9 Electronic throttle body
The air induction system comprises the supercharger and a series of ducts and ports which direct compressed air into the
engine. Air is drawn into the engine through the air inlet duct and into the induction elbow at the back of the engine,
which houses the electronic throttle. The air is directed through the induction elbow into the supercharger, where it is
compressed above atmospheric pressure. The compressed air exits the supercharger through a port in the upper surface
and through the charge air ducts into the two intercoolers, one above each cylinder bank.
After compression in the supercharger, the intake air temperature often exceeds 160 C (320 F). For this reason the
intercoolers are liquid cooled and act as separate air to liquid heat exchanger matrices for each bank of cylinders. The
cooled and denser compressed air passes from the intercoolers to the fuel rail adapters and into the engine.
A vacuum operated bypass valve, situated downstream of the throttle body, opens during part throttle operation. This has
the effect of recirculating and controlling the compressed air pressure and reducing unnecessary supercharger pumping
operation.
Fuel Pump
ItemDescription
2 Fuel pump module
3 Fuel level sensor
4 Fuel level float
The high flow rate fuel pump module is mounted in the RH (right-hand) side of the saddle type fuel tank and delivers fuel
at variable flow and pressure to the fuel rails, which supply fuel to all fuel injectors. The fuel pump operation is regulated
by the FPDM (fuel pump driver module), which is controlled by the ECM.
Operation).
The FPDM is used to control the speed of the fuel pump based upon the fuel demand of the engine. The ECM controls the
FPDM in response to inputs from the FRP (fuel rail pressure) sensor, MAP (manifold absolute pressure) sensor, MAF (mass
air flow) sensor and the IAT (intake air temperature) sensor. The FPDM is attached to the RH end of the evaporative
emission canister, which is installed on the underside of the center floor pan, above the rear stabilizer bar.
The ECM sends a PWM (pulse width modulation) signal to the FPDM, the frequency of the signal determines the duty cycle
of the pump. The PW M signal to the pump represents half the ON time of the pump. If the ECM transmits a 50% ON time
this drives the pump at 100%. If the ECM transmits a 5% ON time the FPDM drives the pump at 10%. The FPDM will only
turn the fuel pump ON if it receives a valid signal between 4% and 50%. When the ECM requires the fuel pump to be
turned OFF, it transmits a duty cycle signal of 75%.
The status of the FPDM is monitored by the ECM. Any errors can be retrieved from the ECM using the Jaguar approved
diagnostic system. The FPDM cannot be interrogated for diagnostic purposes.
Fuel Injectors
Eight, top fed, 12 hole, fuel injectors are installed in the fuel rails. Two O-rings seal each injector to the fuel rails. The
fuel jets from the injectors are directed onto the back of the intake valves.
The injectors are electromagnetic solenoid valves controlled by the ECM. Each injector contains a solenoid-operated needle
valve, which is closed while the solenoid winding is de-energized. The solenoid winding is connected to a power feed from
the main relay and to an earth through the ECM. The ECM switches the earth to control the opening and closing of the
needle valve. While the needle valve is open, fuel is sprayed into the cylinder intake tract onto the back of the intake
valves. The ECM meters the amount of fuel injected by adjusting the time that the needle valve is open.
The solenoid winding of the fuel injector has a resistance of 13.8 0.7 ohms @ 20 C (68 F).
Electric Throttle
The electric throttle controls the engine torque and is located on the induction elbow at the rear of the engine. Its main
components are an electronic throttle control valve, an APP (accelerator pedal position) sensor and the ECM.
The APP sensor determines the driver demand to control throttle opening. This value is received by the ECM and the
throttle is then opened to the correct angle by means of an integral electric motor. Sensors in the throttle body are used
to determine the position of the throttle plate and the rate of change in its angle.
and Operation).
Fuel Rails
ItemDescription
1 RH fuel rail
2 RH fuel pressure damper
4 FRP sensor
5 Fuel supply
6 LH (left-hand) fuel pressure damper
7 LH fuel rail
8 Fuel injectors (8 off)
9 Fuel supply cross over pipe
Each fuel rail maintains a fuel pressure of typically 4.5 bar (65 lbf/in), however, this pressure will vary depending on
engine requirements; lower at idle, higher at full load. Four fuel injectors are installed in each cylinder head and are
connected to the fuel rail. O-ring seals are used to seal the fuel injectors to the fuel rails.

A fuel pressure damper is attached centrally to each of the fuel rails. The damper acts to damp pressure pulses from the
fuel pump.
The fuel temperature sensor is located in the rear of the RH fuel rail. The sensor is a NTC (negative temperature
and Operation).
The FRP sensor continuously monitors the fuel pressure in the fuel rail, this value is used by the ECM to calculate the
injector pulse-width required to deliver the correct mass of fuel per injection. The ECM also uses this information to
demand a specific fuel flow-rate from the fuel pump via the FPDM.
and Operation).

REFER to: Fuel Charging and Controls (303-04A Fuel Charging and Controls - 4.2L NA V8 - AJV8, Diagnosis and Testing).
Fuel Charging and Controls - 4.2L SC V8 - AJV8 - Fuel Injectors
Removal


stands.
3. Refer to: Charge Air Cooler (303-12B Intake Air Distribution and
Filtering - 4.2L SC V8 - AJV8, Removal and Installation).
4. Refer to: Spring Lock Couplings (310-00 Fuel System - General

5.
6.
7.
8. 8. CAUTIONS:
A new O-ring seal is to be installed.
Cap the fuel injector nozzle to prevent damage

before storing vertically.
Torque: 10 Nm
Installation

Fuel Charging and Controls - 4.2L SC V8 - AJV8 - Fuel Rail
Removal

2. Refer to: Charge Air Cooler (303-12B Intake Air Distribution and
Filtering - 4.2L SC V8 - AJV8, Removal and Installation).
3. Refer to: Spring Lock Couplings (310-00 Fuel System - General

4.
5.
6.
7. 7. CAUTIONS:
Cap the fuel injector nozzle to prevent damage

before storing vertically.
Torque: 10 Nm
8. 8. NOTE: Do not disassemble further if the component
is removed for access only.
Torque: 5 Nm
9. 9. NOTE: Install a new gasket.
Torque: 7 Nm
10. 10. CAUTION: A new O-ring seal is to be
installed.
Installation

Fuel Charging and Controls - 4.2L SC V8 - AJV8 - Throttle Body
Removal

3. Refer to: Secondary Bulkhead Center Panel (501-02 Front End Body
5. Torque: 25 Nm
6.
7.
8.
9.
10.
11. Torque: 10 Nm
Installation

Accessory Drive - TDV6 2.7L Diesel -
Accessory drive belt tensioner retaining bolt 47 35 -
Fuel injection pump belt rear cover retaining bolts 10 7 -
Camshaft rear pulley retaining bolt 80 (+90 degrees) 59 (+90 degrees) -
Fuel injection pump pulley retaining nut 50 37 -
Fuel injection pump belt tensioner retaining bolt 26 19 -
A=refer to procedure for correct tightening sequence - - -
Accessory Drive - TDV6 2.7L Diesel - Accessory Drive - Component Location
Component Location
ItemDescription
1 Generator
2 Idler
4 A/C (air conditioning) compressor
5 Coolant pump
6 Crankshaft
7 Belt tensioner
Accessory Drive - TDV6 2.7L Diesel - Accessory Drive - Overview
Overview
The combined crankshaft pulley and torsional vibration damper drives a single, 6-ribbed vee belt. The belt drives all of the engine-mounted
accessories such as the generator, the power steering pump, the A/C (air conditioning) compressor and the coolant pump.
The accessory drive belt, which is a maintenance free poly-V type belt, is automatically pre-loaded by the belt tensioner and routed over
idlers in order to maintain sufficient adhesion about the drive wheels. This ensures slip-free drive of the accessory components.
The torsional vibration damper incorporates compressed rubber between its inner and outer diameters to absorb vibration and shock loads.
The belt tensioner is calibrated to provide the correct amount of tension to the belt for a given 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.
The accessory drive belt should be inspected at every routine service for excessive wear and damage.
Belt tensioner
The belt tensioner consists of an idler pulley, which is free to rotate on a bearing located at the end of a spring-loaded pivot arm.
The accessory drive belt wear indicators are incorporated on the bottom of the accessory drive belt tensioner. When the indicators are
aligned the accessory drive belt requires replacing.
Accessory Drive - TDV6 2.7L Diesel - Accessory Drive
The 2.7L diesel engine uses two accessory drive systems, the Front End Accessory Drive (FEAD), and the fuel injection pump drive.
FEAD Belt
The FEAD belt drives: the coolant pump, the generator, the power assisted steering pump and the air conditioning compressor, driven from
the crankshaft pulley via a single six-ribbed belt.
The fuel injection pump is driven from the exhaust camshaft of the left-hand cylinder bank, by a single, toothed belt. The fuel injection
pump is NOT timed to the engine.
For a detailed description of the diesel engine accessory drive belts, refer to the relevant Description and Operation sections in the
Accessory Drive (303-05A Accessory Drive - TDV6 2.7L Diesel, Description and Operation),
Accessory Drive (303-05A Accessory Drive - TDV6 2.7L Diesel, Description and Operation),
Accessory Drive (303-05A, Description and Operation).

FEAD Belt Fuel Injection Pump Belt

Belt condition (cracking/damage/contamination) Security/correct fitment of cover
Belt tension Check for debris inside the cover
Function of driven components (seized, etc) Belt condition (cracking/damage/contamination)
Pulley alignment Belt tension
step.
Noise Definitions
Description of
Noise Definition/Possible Cause
Squeal Continuous shriek, most noticeable when the engine is accelerated (usually associated with lack of belt tension,
contamination or wet slip)
Chirp Continuous shriek, most noticeable when the engine is accelerated (usually associated with lack of belt tension,
W hine Continuous noise, changing frequency with engine speed, generally associated with rotating components (generator,
idler, etc)
Rattle Metallic knocking, often a loose component or tensioner fault
Rumble Bearing noise
Symptom Chart
CAUTION: The engine should not be run for long periods of time with the FEAD belt removed. Failure to follow this instruction may
FEAD Belt
Noise (see Belt condition Check the belt condition. Check the tensioner operation. Check the pulley alignment. Check the
definitions above) Belt tension driven components for excessive resistance to rotation. Remove FEAD belt and start engine to
Pulleys eliminate from source of noise. Rectify as required
misaligned
Driven
components
Drive belt does Belt condition Check the belt condition (see visual inspection). Check the tensioner function. Rectify as
not hold tension Tensioner necessary.
fault

Noise (see definitions Belt condition Check the belt condition. Check the belt cover for indications of fouling (this may indicate a
above) Belt fouling cover pump misalignment),
Tensioner REFER to: Fuel Injection Pump (303-04A Fuel Charging and Controls - TDV6 2.7L Diesel,
bearing failure Removal and Installation).
Fuel injection . The belt tensioner must be renewed if the belt is removed, making a check of the bearing
pump failure impractical. Remove the belt, check the fuel injection pump pulley for security. Check the
fuel injection pump for excessive resistance to rotation (excessive resistance in the pump
will cause the pulley securing nut to loosen as a design feature). Check for DTCs indicating
a pump malfunction and refer to the relevant DTC Index
Loss of drive (with no Belt Investigate the cause of the belt breakage/damage. Check the fuel injection pump for
drive to the fuel broken/stripped excessive resistance to rotation (excessive resistance in the pump will cause the pulley
injection pump, the teeth securing nut to loosen as a design feature). Check for DTCs indicating a pump malfunction
engine will not run) Drive pulleys and refer to the relevant DTC Index
loose
Accessory Drive - TDV6 2.7L Diesel - Accessory Drive Belt
Special Tool(s)
303-703
Removal
Installation).
4. Release the air cleaner outlet pipe.

Installation
1. CAUTION: Make sure that the accessory drive belt is correctly

aligned to the pulleys. Failure to follow this instruction may result in
Clean and inspect the accessory drive belt pulleys for damage.
Tighten to 25 Nm.
Accessory Drive - TDV6 2.7L Diesel - Accessory Drive Belt Idler Pulley
Special Tool(s)
303-703
Removal


Installation
Tighten to 45 Nm.
Accessory Drive - TDV6 2.7L Diesel - Accessory Drive Belt Tensioner
Removal
Installation).

2. Detach the accessory drive belt.
Installation
Tighten to 45 Nm.
Accessory Drive - TDV6 2.7L Diesel - Fuel Injection Pump Belt
Removal

6. Remove the fuel injection pump belt cover.

7. Cut off and discard the fuel injection pump belt.
8. NOTE: The fuel injection pump is not timed to the engine.
Remove and discard the fuel injection pump belt tensioner.
Installation
1. CAUTIONS:
Make sure that the fuel injection pump belt tensioner tang is
correctly located to the fuel injection pump belt rear cover. Failure to
Make sure that the fuel injection pump belt tensioner locking pin is
not removed until the fuel injection pump belt tensioner is fully installed.
NOTE: Do not remove the fuel injection pump belt tensioner locking pin
before installing the new tensioner.
Install the fuel injection pump belt tensioner retaining bolt.
Locate the tang on the new fuel injection pump belt tensioner into
the fuel injection pump rear cover.
Tighten to 25 Nm.
2. CAUTION: Make sure that the fuel injection pump belt tensioner
tang is correctly located to the fuel injection pump belt rear cover. Failure
to follow this instruction may result in damage to the engine.
Install the new fuel injection pump belt.

3. Remove and discard the fuel injection pump belt tensioner locking pin.
4. Install the fuel injection pump belt cover.

Accessory Drive - TDV6 2.7L Diesel - Fuel Injection Pump Pulley
Special Tool(s)
Holder - Fuel Pump Pulley
310-139
Reaction Arm - Fuel Pump Pulley
310-138
Removal
3. Using the special tool, remove the fuel injection pump pulley retaining
nut.
Using the special tool, retain the fuel injection pump pulley.
4. Using the special tool, remove the fuel injection pump pulley.
Installation
1. Install the fuel injection pump pulley.
Tighten to 50 Nm.

Accessory Drive - V6 3.0L Petrol -
Accessory Drive - V6 3.0L Petrol - Accessory Drive - Component Location
Component Location
ItemDescription
1 Idler
2 Coolant pump
3 Idler
6 Belt tensioner
7 Crankshaft
8 Generator
Accessory Drive - V6 3.0L Petrol - Accessory Drive - Overview
Overview
The combined crankshaft pulley and torsional vibration damper drives a single, 6-ribbed vee belt. The belt drives all of the engine-mounted
accessories such as the generator, the power steering pump, the A/C (air conditioning) compressor and the coolant pump.
The accessory drive belt, which is a maintenance free poly-V type belt, is automatically pre-loaded by the belt tensioner and routed over
idlers in order to maintain sufficient adhesion about the drive wheels. This ensures slip-free drive of the accessory components.
The torsional vibration damper incorporates compressed rubber between its inner and outer diameters to absorb vibration and shock loads.
The belt tensioner is calibrated to provide the correct amount of tension to the belt for a given 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.
Belt tensioner
The belt tensioner consists of an idler pulley, which is free to rotate on a bearing located at the end of a spring-loaded pivot arm.
The accessory drive belt wear indicators are incorporated on the bottom of the accessory drive belt tensioner. When the indicators are
aligned the accessory drive belt requires replacing.
Accessory Drive - V6 3.0L Petrol - Accessory Drive
For a detailed description of the petrol engine accessory drive belts, refer to the relevant Description and Operation sections in the
Accessory Drive (303-05B Accessory Drive - V6 3.0L Petrol, Description and Operation),
Accessory Drive (303-05B Accessory Drive - V6 3.0L Petrol, Description and Operation),
Accessory Drive (303-05B, Description and Operation),
Accessory Drive (303-05C Accessory Drive - V8 4.2L Petrol, Description and Operation),
Accessory Drive (303-05C Accessory Drive - V8 4.2L Petrol, Description and Operation),
Accessory Drive (303-05C, Description and Operation),
Accessory Drive (303-05D Accessory Drive - V8 S/C 4.2L Petrol, Description and Operation),
Accessory Drive (303-05D Accessory Drive - V8 S/C 4.2L Petrol, Description and Operation),
Accessory Drive (303-05D, Description and Operation).

Visual Inspection
Mechanical
FEAD belt
FEAD belt tension
FEAD belt tensioner
FEAD belt pulleys
Supercharger belt
Supercharger belt tension
Supercharger belt tensioner
Supercharger belt pulley
step.
Noise Definitions
Description of
Squeal Continuous shriek, most noticeable when the engine is accelerated (usually associated with lack of belt tension,
Chirp Continuous shriek, most noticeable when the engine is accelerated (usually associated with lack of belt tension,
W hine Continuous noise, changing frequency with engine speed, generally associated with rotating components (generator,
idler, etc)
Symptom Chart

FEAD belt noise or FEAD belt pulley(s) Determine where the noise is coming from (refer to the noise definitions above). Check
squeal Lubricant or other pulley for correct alignment, freedom of rotation or damage. Install new components as
contamination required. Check FEAD belt for contamination. If contaminated, install a new belt as required.
FEAD belt Check FEAD belt for correct application
FEAD belt does not FEAD belt cracking Inspect FEAD belt for cracking or damage. Install a new belt as required. Check FEAD belt
hold tension or damaged tensioner for damage and correct operation. Install a new FEAD belt tensioner as required
Tensioner worn or
damaged
Supercharger belt Supercharger belt Determine where the noise is coming from (refer to the noise definitions above). Check
noise or squeal pulley(s) pulley for correct alignment, freedom of rotation or damage. Install new components as
Lubricant or other required. Check supercharger belt for contamination. If contaminated, install a new belt as
contamination required. Check supercharger belt for correct application
Supercharger belt
Supercharger belt Supercharger belt Inspect supercharger belt for cracking or damage. Install a new belt as required. Check
does not hold cracking or supercharger belt tensioner for damage and correct operation. Install a new supercharger
tension damaged belt tensioner as required
Tensioner worn or
damaged
Component Tests
FEAD Belt Tensioner
Static
The only checks required for the FEAD belt tensioner are for stick, grab or bind.
1. 1. Remove the drive belt in the area of the tensioner.

2. 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.
3. 3. If the tensioner meets the above criteria, proceed to the dynamic test. If the tensioner does not meet the above criteria install a
new tensioner. REFER to:
Accessory Drive Belt Tensioner (303-05B Accessory Drive - V6 3.0L Petrol, Removal and Installation),
Accessory Drive Belt Tensioner (303-05C Accessory Drive - V8 4.2L Petrol, Removal and Installation),
Accessory Drive Belt Tensioner (303-05D Accessory Drive - V8 S/C 4.2L Petrol, Removal and Installation).
Dynamic
The FEAD belt tensioner can be checked dynamically as follows:
4. 4. With the engine running, observe drive belt tensioner movement, the FEAD belt tensioner should move (respond) when the air
conditioning clutch cycles (if equipped), the FEAD belt tensioner should move (respond) when the engine speed is increased
rapidly. If the drive belt tensioner movement is erratic without air conditioning clutch cycling or engine acceleration, a pulley or
shaft may be bent, or distorted. Excessive drive belt rideout (uneven depth of grooves in the drive belt) can also cause excessive
drive belt tensioner movement. Check condition by installing a known good belt. REFER to:
Accessory Drive Belt (303-05B Accessory Drive - V6 3.0L Petrol, Removal and Installation),
Accessory Drive Belt (303-05C Accessory Drive - V8 4.2L Petrol, Removal and Installation),
Accessory Drive Belt (303-05D Accessory Drive - V8 S/C 4.2L Petrol, Removal and Installation).
FEAD belt
1. 1. With the engine off, check routing of the drive belt. REFER to:
2. 2. Inspect the drive belt tensioner wear indicator to confirm the drive belt is within operating range. Install a new drive belt as
required . REFER to:
Accessory Drive - V6 3.0L Petrol - Accessory Drive Belt
Removal
Installation).

Rotate the accessory drive belt tensioner counter-clockwise, using

a 3/8 " drive wrench.
Installation
Accessory Drive - V6 3.0L Petrol - Accessory Drive Belt Idler Pulley
Removal

Installation
Tighten to 25 Nm
Accessory Drive - V6 3.0L Petrol - Accessory Drive Belt Tensioner
Removal

Installation
Tighten to 45 Nm.
Accessory Drive - 4.2L NA V8 - AJV8 -
Accessory Drive - 4.2L NA V8 - AJV8 - Accessory Drive - Component
Location
Component Location
ItemDescription
1 Generator
2 Coolant pump
5 Belt tensioner
6 Crankshaft
7 Idler
Accessory Drive - 4.2L NA V8 - AJV8 - Accessory Drive - Overview
Overview
The combined crankshaft pulley and torsional vibration damper drives a single, 6-ribbed vee belt. The belt drives all of the
engine-mounted accessories such as the generator, the power steering pump, the A/C (air conditioning) compressor and
the coolant pump.
The accessory drive belt, which is a maintenance free poly-V type belt, is automatically pre-loaded by the belt tensioner
and routed over idlers in order to maintain sufficient adhesion about the drive wheels. This ensures slip-free drive of the
accessory components.
The torsional vibration damper incorporates compressed rubber between its inner and outer diameters to absorb vibration
and shock loads.
The belt tensioner is calibrated to provide the correct amount of tension to the belt for a given 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.
Belt Tensioner
The belt tensioner consists of an idler pulley, which is free to rotate on a bearing located at the end of a spring-loaded
pivot arm.
The accessory drive belt wear indicators are incorporated on the bottom of the accessory drive belt tensioner. When the
indicators are aligned the accessory drive belt requires replacing.
Accessory Drive - 4.2L NA V8 - AJV8 - Accessory Drive
For a detailed description of the petrol engine accessory drive belts, refer to the relevant Description and Operation
sections in the workshop manual. REFER to:
Accessory Drive (303-05C, Description and Operation),

Accessory Drive (303-05A Accessory Drive - 4.2L NA V8 - AJV8, Description and Operation),
Accessory Drive (303-05A Accessory Drive - 4.2L NA V8 - AJV8, Description and Operation),
Accessory Drive (303-05D, Description and Operation),
Accessory Drive (303-05B Accessory Drive - 4.2L SC V8 - AJV8, Description and Operation),
Accessory Drive (303-05B Accessory Drive - 4.2L SC V8 - AJV8, Description and Operation).

Visual Inspection
Mechanical
FEAD belt
FEAD belt tension
FEAD belt tensioner
FEAD belt pulleys
Supercharger belt
Supercharger belt tension
Supercharger belt tensioner
Supercharger belt pulley
Noise Definitions
Description of
Squeal Continuous shriek, most noticeable when the engine is accelerated (usually associated with lack of belt
tension, contamination or wet slip)
Chirp Continuous shriek, most noticeable when the engine is accelerated (usually associated with lack of belt
tension, contamination or wet slip)
W hine Continuous noise, changing frequency with engine speed, generally associated with rotating
components (generator, idler, etc)
Symptom Chart

FEAD belt noise FEAD belt pulley(s) Determine where the noise is coming from (refer to the noise definitions
or squeal Lubricant or other above). Check pulley for correct alignment, freedom of rotation or damage.
contamination Install new components as required. Check FEAD belt for contamination. If
FEAD belt contaminated, install a new belt as required. Check FEAD belt for correct
application
FEAD belt does FEAD belt cracking Inspect FEAD belt for cracking or damage. Install a new belt as required.
not hold tension or damaged Check FEAD belt tensioner for damage and correct operation. Install a new
Tensioner worn or FEAD belt tensioner as required
damaged
Supercharger belt Supercharger belt Determine where the noise is coming from (refer to the noise definitions
noise or squeal pulley(s) above). Check pulley for correct alignment, freedom of rotation or damage.
Lubricant or other Install new components as required. Check supercharger belt for
contamination contamination. If contaminated, install a new belt as required. Check
Supercharger belt supercharger belt for correct application
Supercharger belt Supercharger belt Inspect supercharger belt for cracking or damage. Install a new belt as
does not hold cracking or required. Check supercharger belt tensioner for damage and correct
tension damaged operation. Install a new supercharger belt tensioner as required
Tensioner worn or
damaged
Component Tests
FEAD Belt Tensioner

Static
The only checks required for the FEAD belt tensioner are for stick, grab or bind.
1. 1. Remove the drive belt in the area of the tensioner.
2. 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.
3. 3. If the tensioner meets the above criteria, proceed to the dynamic test. If the tensioner does not meet the above
criteria install a new tensioner. REFER to:
Accessory Drive Belt Tensioner (303-05A Accessory Drive - 4.2L NA V8 - AJV8, Removal and Installation),
Accessory Drive Belt Tensioner (303-05B Accessory Drive - 4.2L SC V8 - AJV8, Removal and Installation).
Dynamic
The FEAD belt tensioner can be checked dynamically as follows:
4. 4. With the engine running, observe drive belt tensioner movement, the FEAD belt tensioner should move (respond)
when the air conditioning clutch cycles (if equipped), the FEAD belt tensioner should move (respond) when the
engine speed is increased rapidly. If the drive belt tensioner movement is erratic without air conditioning clutch
cycling or engine acceleration, a pulley or shaft may be bent, or distorted. Excessive drive belt rideout (uneven
depth of grooves in the drive belt) can also cause excessive drive belt tensioner movement. Check condition by
installing a known good belt. REFER to:
Accessory Drive Belt (303-05A Accessory Drive - 4.2L NA V8 - AJV8, Removal and Installation),
Accessory Drive Belt (303-05B Accessory Drive - 4.2L SC V8 - AJV8, Removal and Installation).
FEAD belt
1. 1. With the engine off, check routing of the drive belt. REFER to:
2. 2. Inspect the drive belt tensioner wear indicator to confirm the drive belt is within operating range. Install a new
drive belt as required . REFER to:
Accessory Drive - 4.2L NA V8 - AJV8 - Accessory Drive Belt
Special Tool(s)
303-703
Removal
Procedures).
Installation).
4. Remove the air cleaner housing cover.
Using the special tool, rotate the accessory drive belt

Installation
Accessory Drive - 4.2L NA V8 - AJV8 - Accessory Drive Belt Tensioner
Removal


Procedures).
Installation).
Installation
Tighten to 40 Nm.
Accessory Drive - 4.2L NA V8 - AJV8 - Accessory Drive Belt Idler Pulley
Removal
Procedures).

Release the accessory drive belt.
Installation
Tighten to 25 Nm.
Accessory Drive - 4.2L SC V8 - AJV8 -
Supercharger belt tensioner retaining bolt 40 30 -
Supercharger belt idler pulley retaining bolt 40 30 -
Accessory Drive - 4.2L SC V8 - AJV8 - Accessory Drive - Component
Location
Component Location
ItemDescription
A Primary drive
B Secondary drive
1 Generator
2 Coolant pump
3 Primary belt tensioner
6 Crankshaft
7 Idler
8 Secondary belt tensioner
9 Idler
10 Supercharger
Accessory Drive - 4.2L SC V8 - AJV8 - Accessory Drive - Overview
Overview
The combined crankshaft pulley and torsional vibration damper drives a single, 6-ribbed primary belt and a double-sided,
8-ribbed secondary belt. The primary belt drives all of the engine-mounted accessories such as the generator, the power
steering pump, the A/C (air conditioning) compressor and the coolant pump and the secondary belt drives the
supercharger.
The accessory drive belts, which are maintenance free poly-V type belts, are automatically pre-loaded by the belt tensioner
and routed over idlers in order to maintain sufficient adhesion about the drive wheels. This ensures slip-free drive of the
accessory components.
The torsional vibration damper incorporates compressed rubber between its inner and outer diameters to absorb vibration
and shock loads.
The belt tensioner is calibrated to provide the correct amount of tension to the belt for a given 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.
Belt Tensioner
The belt tensioner consists of an idler pulley, which is free to rotate on a bearing located at the end of a spring-loaded
pivot arm.
The accessory drive belt wear indicators are incorporated on the bottom of the accessory drive belt tensioner. When the
indicators are aligned the accessory drive belt requires replacing.
Accessory Drive - 4.2L SC V8 - AJV8 - Accessory Drive

REFER to: Accessory Drive (303-05A Accessory Drive - 4.2L NA V8 - AJV8, Diagnosis and Testing).
Accessory Drive - 4.2L SC V8 - AJV8 - Accessory Drive Belt
Special Tool(s)
303-703
Removal
Procedures).


For additional information, refer to: Supercharger Belt
(303-05B Accessory Drive - 4.2L SC V8 - AJV8, Removal and
Installation).

Installation
Accessory Drive - 4.2L SC V8 - AJV8 - Accessory Drive Belt Tensioner
Removal
Procedures).
Installation).
Installation
Tighten to 40 Nm.
Accessory Drive - 4.2L SC V8 - AJV8 - Accessory Drive Belt Idler Pulley
Removal
Procedures).
2. Remove the air filter outlet tube.
Installation).

Release the accessory drive belt.
Installation
Tighten to 25 Nm.
Accessory Drive - 4.2L SC V8 - AJV8 - Supercharger Belt
Removal
Procedures).
2. Remove the RH air cleaner assembly.
For additional information, refer to: Air Cleaner RH (303-12B
Intake Air Distribution and Filtering - 4.2L SC V8 - AJV8,
Remove the 2 bolts.
Rotate the drive belt tensioner clockwise. Use a 1/2

inch square drive bar to rotate the drive belt tensioner.


8. Release the supercharger belt tensioner.
Installation
Tighten to 40 Nm.
Accessory Drive - 4.2L SC V8 - AJV8 - Supercharger Belt Tensioner
Removal
Procedures).
Remove the 2 bolts.



8. Remove the supercharger belt tensioner.
Installation
Tighten to 40 Nm.
Accessory Drive - 4.2L SC V8 - AJV8 - Supercharger Belt Idler Pulley
Removal
Procedures).
Remove the 2 bolts.

6. Remove the supercharger belt idler pulley.
Installation
Tighten to 40 Nm.
Starting System - TDV6 2.7L Diesel -
Starter motor bolts 48 35 -
Battery positive terminal integral connector retaining nut 13 10 -
Solenoid terminal integral connector nut 7 - 62
Starting System - TDV6 2.7L Diesel - Starting System - Component Location
Component Location
Starting System - TDV6 2.7L Diesel - Starting System - Overview
Overview
The starter motor is rated as 2.0 kW and is a Denso level 3-sealed unit. It is a P76S type starter motor and is of conventional design with
the motor in line and the drive pinion and solenoid mounted above. Each starter motor is of the pre-engaged type and comprises a series
wound motor, an overrunning clutch and an integral solenoid. This starter incorporates labyrinth-breathing tubes to help with sealing and
drainage.
The starter solenoid is energised by a signal from the ECM (engine control module) when the ignition switch is moved to the crank position.
When engine cranking is requested, the ECM checks that a valid key code has been received before granting the crank request. The power
for starter operation is supplied on a substantial single cable connected direct from the battery positive terminal. The cable is connected to
the solenoid via a copper threaded stud and secured with a nut.
The starter motor is located on the rear RH (right-hand) side of the engine block and protrudes through an aperture to drive the flywheel via
a ring gear. The motor is secured to the cylinder block by 2 bolts and to the ladder frame by four bolts and a support bracket. The bracket
provides crucial support for the starter motor and must not be omitted when installing or reinstalling the unit.
Starting System - TDV6 2.7L Diesel - Starting System
For a detailed description of the starting system, refer to the relevant Description and Operation section in the workshop manual. REFER to:
Starting System (303-06A Starting System - TDV6 2.7L Diesel, Description and Operation),
Starting System (303-06A Starting System - TDV6 2.7L Diesel, Description and Operation),
Starting System (303-06A, Description and Operation),
Anti-Theft - Passive (419-01B Anti-Theft - Passive, Description and Operation),
Anti-Theft - Passive (419-01B Anti-Theft - Passive, Description and Operation).
Visual Inspection
Starter Motor Battery
Battery Fuses
Wiring harness
Damaged, loose or corroded connectors
Starter relay
step.
4. 4. If the concern is not visually evident, verify the symptom and refer to the symptom chart, alternatively, check for Diagnostic
Symptom Chart

The engine does not Gear selector not in P or Make sure the gear selector is in the P or N position. Check the battery is in fully
crank (starter motor N position charged and serviceable condition. Check the starter motor and harness. Check
does not turn) Battery for related DTCs and refer to the relevant DTC Index
Harness/Connectors
Starter motor
Starter relay
Start switch
Transmission control
module (TCM)
Engine control module
(ECM)
Engine seized
The engine does not Starter motor Check the starter motor installation (fasteners tight, starter motor square to
crank (starter motor installation engine, etc). Check the ring gear teeth for damage, foreign objects, etc.
does turn) Starter motor
Ring gear
Engine cranks too slowly Battery Check the battery is in fully charged and serviceable condition. Refer to the
Harness/Connectors electrical circuit diagrams and test the starter motor and starter motor circuits
Starter motor
Engine oil incorrect
grade
Engine cranks too fast Low engine compression Check the engine compressions.
REFER to: Engine - TDV6 2.7L Diesel (303-00 Engine System - General
Information, Diagnosis and Testing).
Excessive starter motor Starter motor Check the starter motor installation (fasteners tight, motor square to engine,
noise Starter motor etc). Check the starter motor casing condition. Check the ring gear teeth for
installation/casing damage, foreign objects, etc.
Ring gear
DTC Index
3548-1358-00. Failure to follow this instruction may result in damage to the vehicle.
first five digits of the seven digit code listed to identify the fault (the last two digits give additional information read by the manufacturer
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. W hen testing resistance, always take the resistance of the DMM leads into account.
NOTE: If DTCs are recorded and, after performing the pinpoint tests, the fault is not present, an intermittent concern may be the cause.

B100951 Ignition Authorisation Faulty instrument cluster Check ignition, power and ground supplies to CJB and
Target SID re-synchronisation error instrument cluster. Re-synchronize ID by re-configuring the
following programming instrument cluster as a new module. Check CAN
CAN fault communications between instrument cluster and tester
B100962 Ignition Authorisation Low speed CAN fault Check CAN communications between CJB and instrument
CJB fault cluster. Check ignition, power and ground supplies to CJB and
Instrument cluster fault instrument cluster. Confirm correct module is installed.
Incorrect module installed Re-synchronise ID by re-configuring the instrument cluster as a
(CJB/Instrument cluster) new module. Check CAN network for interference/EMC related
Target SID synchronisation error issues
following re-programming
B100963 Ignition Authorisation CJB fault Check Power and Ground supplies to CJB and instrument
Low speed CAN fault cluster. Check CAN communications between CJB and
Instrument cluster fault instrument cluster. Check battery is in fully charged and
Low battery voltage <9V serviceable condition, refer to the battery care manual
B100964 Ignition Authorisation CJB fault Check power and ground supplies to CJB and instrument
Low speed CAN fault cluster. Check CAN communications between CJB and
Instrument cluster fault instrument cluster
B100A51 Fuel Pump Authorisation RJB fault Check power and ground supplies to RJB. Check CAN
Low speed CAN fault communications between RJB and instrument cluster. Check
Instrument cluster fault power and ground supplies to instrument cluster
B100A62 Fuel Pump Authorisation Low speed CAN fault Check CAN communications between RJB and instrument
RJB fault cluster. Check power and ground supplies to RJB and
Instrument cluster fault instrument cluster. Confirm correct module installed.
Incorrect module installed Re-synchronise ID by re-configuring the RJB as a new module.
(RJB/Instrument cluster) Check CAN network for interference/EMC related issues
W rite target SID synchronisation
B100A63 Fuel Pump Authorisation RJB fault Check power and ground supplies to RJB and instrument
Low speed CAN fault cluster. Check CAN communications between RJB and
B100D51 Column lock Not programmed Check ignition, power and ground supplies to steering column
authorisation lock and instrument cluster. Re-synchronise ID by
re-configuring the steering column lock as a new module
authorisation - signal Steering column lock fault instrument cluster. Check power and ground supplies to
compare failure Instrument cluster fault steering column lock and instrument cluster. Confirm the
Incorrect module installed correct modules are installed. Re-synchronize ID by
(Steering column lock/Instrument re-configuring the steering column lock as new. Check CAN
cluster) network for interference/EMC related issues
Target ID synchronisation error
B100D64 Column lock CAN fault Check CAN network to steering column lock. Check power and
authorisation - signal Steering column lock fault ground supplies to steering column lock and instrument cluster
plausibility failure Instrument cluster fault
B100D87 Column lock CAN fault Carry out any pinpoint tests associated with this DTC using
authorisation - missing Steering column lock fault the manufacturer approved diagnostic system. Check CAN
message Instrument cluster fault network between steering column lock and instrument cluster.
Low voltage at steering column Check power and ground supplies to steering column lock and
lock < 8V instrument cluster
B102611 Steering Column Lock Steering column lock power circuit Carry out any pinpoint tests associated with this DTC using
- short to ground the manufacturer approved diagnostic system. Refer to the
electrical circuit diagrams and check steering column lock
power circuit for short to ground
B102612 Steering Column Lock Steering column lock ground circuit Refer to the electrical circuit diagrams and check steering
- short to power column lock ground circuit for short to power
B102615 Steering Column Lock Steering column lock power circuit Carry out any pinpoint tests associated with this DTC using
- short to power, open circuit the manufacturer approved diagnostic system. Refer to the
electrical circuit diagrams and check steering column lock
power circuit for short to power, open circuit
B102B67 Passive Key CJB fault Check power and ground supplies to CJB and RKE module.
Low speed CAN fault Check CAN communications between CJB and RKE module.
Remote Keyless Entry (RKE) Re-synchronise ID by re-configuring the RKE module as a new
module fault module
B102B87 Passive Key CJB fault Check power and ground supplies to CJB, RKE module and
Low speed CAN fault receiver. Check CAN communications between CJB and
RKE module fault instrument cluster. Check key fob battery. Confirm vehicle
Key fob battery low/battery surroundings, move vehicle. Check CAN network for
contact issue interference/EMC related issues. Disconnect battery, then
Interference from other RF signal re-connect - confirm operation by re-programming keys. Check
EMC/noise serial circuit between receiver and RKE module. Confirm spare
Receiver fault key works. Refer to the electrical circuit diagrams and test
Receiver not programmed correctly circuits to all 3 antennas. Check whereabouts of key
Serial communications fault
(between receiver and RKE
module)
Key fault
Passive antenna fault
Confirm placement of key within
vehicle
B108A11 Start Button Start/Stop switch analogue input Refer to the electrical circuit diagrams and check Start/Stop
circuits 1 or 2 - short to ground switch analogue input circuits 1 and 2 for short to ground
B108A12 Start Button Start/Stop switch analogue input Refer to the electrical circuit diagrams and check Start/Stop
circuits 1 or 2 - short to power switch analogue input circuits 1 and 2 for short to power
B108A23 Start Button Start/Stop switch digital input Carry out any pinpoint test associated with this DTC using the
signal circuit - stuck low manufacturer approved diagnostic system. Refer to the
electrical circuit diagrams and check Start/Stop switch digital
input signal circuit for short to ground
B10DE11 Low Fuel Warning Switch Diesel run-dry switch analogue Carry out any pinpoint test associated with this DTC using the
input circuit - short to ground manufacturer approved diagnostic system. Refer to the
electrical circuit diagrams and check diesel run-dry switch
analogue input circuit for short to ground
B10DE15 Low Fuel Warning Switch Diesel run-dry switch analogue Carry out any pinpoint test associated with this DTC using the
input circuit - short to power, open manufacturer approved diagnostic system. Refer to the
circuit electrical circuit diagrams and check diesel run-dry switch
analogue input circuit for short to power, open circuit
B10E511 PCM Wake-up Signal ECM wake-up signal circuit - short Refer to the electrical circuit diagrams and check ECM wake-up
to ground signal circuit for short to ground
B10F111 Key In Switch Keyless vehicle module, key IN Carry out any pinpoint tests associated with this DTC using
status circuit - short to ground the manufacturer approved diagnostic system. Refer to the
electrical circuit diagrams and check keyless vehicle module,
key IN status circuit for short to ground
B10FA93 Delayed Power Off relay ADRC ECM, roof header console Carry out any pinpoint tests associated with this DTC using
lamp, glove box lamp , RH/LH foot the manufacturer approved diagnostic system. Refer to the
well lamps, JAG Sense glove box electrical circuit diagrams and check ADRC ECM, roof header
module, RH/LH sun visor lamps, console lamp, glove box lamp , RH/LH foot well lamps, JAG
rear dome lamps switched power Sense glove box module, RH/LH sun visor lamps, rear dome
circuits - short to power, open lamps switched power circuits for short to power, open circuit
circuit
B10FF11 Ignition control ECM and FPDB ignition control Carry out any pinpoint tests associated with this DTC using
circuit - short to ground the manufacturer approved diagnostic system. Refer to the
electrical circuit diagrams and check ECM and FPDB ignition
control circuit for short to ground
B10FF15 Ignition control ECM and FPDB ignition control Carry out any pinpoint tests associated with this DTC using
circuit - short to power, open the manufacturer approved diagnostic system. Refer to the
circuit electrical circuit diagrams and check ECM and FPDB ignition
control circuit for short to power, open circuit
B114011 Engine Crank Engine crank authorisation signal Carry out any pinpoint tests associated with this DTC using
Authorisation circuit - short to ground the manufacturer approved diagnostic system. Refer to the
electrical circuit diagrams and check engine crank authorisation
signal circuit for short to ground
B114015 Engine Crank Engine crank authorisation signal Carry out any pinpoint tests associated with this DTC using
Authorisation circuit - short to power, open the manufacturer approved diagnostic system. Refer to the
circuit electrical circuit diagrams and check engine crank authorisation
signal circuit for short to power, open circuit
B114211 Ignition Status 1 Ignition supply 1 circuits - short to Carry out any pinpoint tests associated with this DTC using
ground the manufacturer approved diagnostic system. Refer to the
electrical circuit diagrams and check all ignition supply 1
circuits for short to ground
power, open circuit the manufacturer approved diagnostic system. Refer to the
circuits for short to power, open circuit
ground the manufacturer approved diagnostic system. Refer to the
power, open circuit the manufacturer approved diagnostic system. Refer to the
circuits for short to power, open circuit
B123711 Gear Shift Module Early Transmission shift module wake-up Carry out any pinpoint tests associated with this DTC using
W ake-up control circuit - short to ground the manufacturer approved diagnostic system. Refer to the
electrical circuit diagrams and check transmission shift module
wake-up control circuit for short to ground
B123E13 Crank Enable OK to crank signal circuit - open Refer to the electrical circuit diagrams and check OK to crank
circuit signal circuit for open circuit
P033578 Crankshaft Position Crankshaft position (CKP) sensor Refer to the electrical circuit diagrams and check CKP sensor
Sensor A Circuit or circuits - short to ground, and circuits for short to ground, power, open circuit. Check and
power, open circuit install a new sensor/target wheel as required
CKP sensor failure
Target wheel failure
Range/Performance power, open circuit install a new sensor/target wheel as required
CKP sensor failure
CKP sensor failure
CKP sensor failure
CKP sensor failure
P034129 Camshaft Position Camshaft position (CMP) sensor or Carry out any pinpoint tests associated with this DTC using
Sensor A Circuit circuits - short to ground, power, the manufacturer approved diagnostic system. Refer to the
Range/Performance open circuit electrical circuit diagrams and check CMP sensor and circuits
CMP sensor failure for short to ground, power, open circuit. Check and install a
new sensor as required
P03413A Camshaft Position Camshaft position (CMP) sensor or Carry out any pinpoint tests associated with this DTC using
Sensor A Circuit circuits - short to ground, power, the manufacturer approved diagnostic system. Refer to the
Range/Performance open circuit electrical circuit diagrams and check CMP sensor and circuits
P034231 Camshaft Position Camshaft position (CMP) sensor or Carry out any pinpoint tests associated with this DTC using
Sensor A Circuit Low circuits - short to ground, power, the manufacturer approved diagnostic system. Refer to the
Input open circuit electrical circuit diagrams and check CMP sensor and circuits
P038072 Glow Plug/Heater Circuit Glowplug relay circuits - short to Refer to the electrical circuit diagrams and check glowplug
A ground, power, open circuit relay circuits for short to ground, power, open circuit. Check
Glowplug relay failure battery voltage. Check and install a new relay as required
P038073 Glow Plug/Heater Circuit Glowplug relay circuits - short to Refer to the electrical circuit diagrams and check glowplug
A ground, power, open circuit relay circuits for short to ground, power, open circuit. Check
Glowplug relay failure battery voltage. Check and install a new relay as required
P038311 Glow Plug Control Glowplug relay control circuit - Refer to the electrical circuit diagrams and check glowplug
Module Control Circuit short to ground relay control circuit for short to ground. Check and install a
Low Glowplug relay failure new relay as required
P038412 Glow Plug Control Glowplug relay control circuit - Refer to the electrical circuit diagrams and check glowplug
Module Control Circuit short to power relay control circuit for short to power. Check and install a new
High Glowplug relay failure relay as required
P046100 Fuel Level Sensor A Low fuel level Carry out any pinpoint tests associated with this DTC using
Circuit Fuel level sensor signal circuit - the manufacturer approved diagnostic system. Check for
Range/Performance short to ground, open circuit sufficient amount of fuel in fuel tank. Refer to the electrical
Fuel level sensor failure circuit diagrams and check fuel level sensor circuits for short to
ground, open circuit. Check and install a new fuel level sensor
as required
P04611A Fuel Level Sensor A Low fuel level Carry out any pinpoint tests associated with this DTC using
Circuit Circuit resistance below threshold the manufacturer approved diagnostic system. Check for
Range/Performance Fuel level sensor failure sufficient amount of fuel in fuel tank. Refer to the electrical
circuit diagrams and check fuel level sensor circuits for short
circuit. Check and install a new fuel level sensor as required
P04611B Fuel Level Sensor A Low fuel level Carry out any pinpoint tests associated with this DTC using
Circuit Circuit resistance above threshold the manufacturer approved diagnostic system. Check for
Range/Performance Fuel level sensor failure sufficient amount of fuel in fuel tank. Refer to the electrical
circuit diagrams and check fuel level sensor circuits for High
resistance. Check and install a new fuel level sensor as
required
P051300 Incorrect Immobilizer Security key invalid Programme all keys using the manufacturer approved
Key diagnostic system
P061712 Starter relay circuit high Starter relay control circuit - short Refer to the electrical circuit diagrams and check starter relay
to power control circuit for short to power. Check and install a new relay
Starter relay failure as required
P067013 Glow Plug Control Glow plug relay control circuit - Refer to the electrical circuit diagrams and check glow plug
Module Control open circuit relay control circuit for open circuit. Check and install a new
Circuit/Open Glow plug relay failure relay as required
P085013 Park/Neutral Switch Park/Neutral signal circuit - open Refer to the electrical circuit diagrams and check Park/Neutral
Input Circuit circuit signal circuit for open circuit
P085062 Park/Neutral Switch Park/Neutral signal circuit - short Carry out any pinpoint tests associated with this DTC using
Input Circuit to ground, power, open circuit the manufacturer approved diagnostic system. Refer to the
electrical circuit diagrams and check Park/Neutral signal circuit
for short to ground, power, open circuit
P085212 Park/Neutral Switch Park/Neutral signal circuit - short Refer to the electrical circuit diagrams and check Park/Neutral
Input Circuit High to power signal circuit for short to power
P115B68 Low fuel Level - Forced Low level fuel condition Check the fuel level. If there is sufficient fuel, refer to the
Engine Shutdown Critical fuel level switch signal electrical circuit diagrams and check the critical fuel level
circuit - short to ground, power, switch and fuel level sensor circuits for short, open circuit.
open circuit Check and install a new critical fuel level switch/fuel level
Critical fuel level switch failure sensor as required
Fuel level sensor signal circuit -
short to ground, power, open
circuit
Fuel level sensor failure
P125900 Immobilizer to PCM Incorrect ID received from Re-programme all ignition keys using the manufacturer
Signal Error instrument cluster approved diagnostic system
P133600 Crankshaft/Camshaft CMP and CKP sensor circuits - Carry out any pinpoint tests associated with this DTC using
Sensor short to ground, power, open the manufacturer approved diagnostic system. Refer to the
Range/Performance circuit electrical circuit diagrams and check CMP and CKP sensor
CMP/CKP sensor failure circuits for short to ground, power, open circuit. Check and
install a new CMP/CKP sensor as required
P162413 Anti-theft System RJB anti-theft signal circuit - open Refer to the electrical circuit diagrams and check RJB anti-theft
P162413 Anti-theft System Anti-theft signal circuit from CJB - Refer to the electrical circuit diagrams and check anti-theft
open circuit signal circuit from CJB for open circuit
P213E01 Fuel Injection System Engine stop by electrical Check for additional related DTCs and refer to the relevant
Fault - Forced Engine DTC Index
Shutdown
P213F07 Fuel Pump System Fault Engine stop by hydraulic Check for additional related DTCs and refer to the relevant
- Forced Engine DTC Index
Shutdown
U016700 Lost Communication ECM-ID transfer failed Carry out any pinpoint tests associated with this DTC using
with Vehicle Immobilizer the manufacturer approved diagnostic system. Carry out CAN
Control Module network integrity tests using the manufacturer approved
diagnostic system. Refer to the electrical circuit diagrams and
check power and ground supplies and CAN harness to vehicle
immobilizer module
U032600 Software Incompatibility Challenge does not match Re-configure the instrument cluster and ECM as new using the
W ith Vehicle Immobilizer manufacturer approved diagnostic system
Control Module
Starting System - TDV6 2.7L Diesel - Starter Motor
Removal
Installation).


5. Remove the steering gear shaft pinch bolt.


connector.

Installation
Tighten to 48 Nm.
3. Tighten to 7 Nm.
Starting System - V6 3.0L Petrol -
Battery positive terminal integral connector retaining nut 12 9 -
Starting System - V6 3.0L Petrol - Starting System - Component Location
Component Location
Starting System - V6 3.0L Petrol - Starting System - Overview
Overview
The starter motor is rated as a 1.8 kW and is a Denso level 3-sealed unit. It is an RA type starter motor, which is of the offset design with
the solenoid being directly behind the pinion to give a more positive engagement to the ring gear. The motor is geared directly to the
pinion. Each starter motor is of the pre-engaged type and comprises a series wound motor and an overrunning clutch. This starter
incorporates labyrinth-breathing tubes to help with sealing and drainage.
The starter solenoid is energised by a signal from the ECM (engine control module) when the ignition switch is moved to the crank position.
When engine cranking is requested, the ECM checks that a valid key code has been received before granting the crank request.
The power for starter operation is supplied on a substantial single cable connected direct from the battery positive terminal. The cable is
connected to the solenoid via a copper threaded stud with an anti-rotational device and secured with a nut.
The starter motor is located on the rear RH (right-hand) side of the engine block. The motor is secured to the block and protrudes through
an aperture to drive the flywheel via a ring gear.
Starting System - V6 3.0L Petrol - Starting System
For a detailed description of the starting system, refer to the relevant Description and Operation section in the workshop manual. REFER to:
Starting System (303-06B Starting System - V6 3.0L Petrol, Description and Operation),
Starting System (303-06B Starting System - V6 3.0L Petrol, Description and Operation),
Starting System (303-06B, Description and Operation),
Starting System (303-06C Starting System - V8 4.2L Petrol/V8 S/C 4.2L Petrol, Description and Operation),
Starting System (303-06C Starting System - V8 4.2L Petrol/V8 S/C 4.2L Petrol, Description and Operation),
Starting System (303-06C, Description and Operation),
Visual Inspection
Battery Fuses
Wiring harness
Starter relay
step.
4. 4. If the concern is not visually evident, verify the symptom and refer to the symptom chart, alternatively, check for Diagnostic
Symptom Chart

The engine does not Gear selector not in P or Make sure the gear selector is in the P or N position. Check the battery is in fully
crank (starter motor N position charged and serviceable condition. Check the starter motor and harness. Check
does not turn) Battery for related DTCs and refer to the relevant DTC Index
Harness/Connectors
Starter motor
Starter relay
Start switch
module (TCM)
(ECM)
Engine seized
The engine does not Starter motor Check the starter motor installation (fasteners tight, starter motor square to
crank (starter motor installation engine, etc). Check the ring gear teeth for damage, foreign objects, etc.
does turn) Starter motor
Ring gear
Engine cranks too slowly Battery Check the battery is in fully charged and serviceable condition. Refer to the
Harness/Connectors electrical circuit diagrams and test the starter motor and starter motor circuits
Starter motor
grade
Engine cranks too fast Low engine compression Check the engine compressions.
REFER to: Engine - V8 4.2L Petrol/V8 S/C 4.2L Petrol/3.0L NA V6 - AJ27 (303-00
Engine System - General Information, Diagnosis and Testing).
Excessive starter motor Starter motor Check the starter motor installation (fasteners tight, motor square to engine,
noise Starter motor etc). Check the starter motor casing condition. Check the ring gear teeth for
installation/casing damage, foreign objects, etc.
Ring gear
DTC Index
3548-1358-00. Failure to follow this instruction may result in damage to the vehicle.
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. W hen testing resistance, always take the resistance of the DMM leads into account.
NOTE: If DTCs are recorded and, after performing the pinpoint tests, the fault is not present, an intermittent concern may be the cause.

B100951 Ignition Faulty instrument cluster Check ignition, power and ground supplies to CJB and instrument
Authorisation Target SID re-synchronisation error cluster. Re-synchronize ID by re-configuring the instrument cluster
following programming as a new module. Check CAN communications between instrument
CAN fault cluster and tester
B100962 Ignition Low speed CAN fault Check CAN communications between CJB and instrument cluster.
Authorisation CJB fault Check ignition, power and ground supplies to CJB and instrument
Instrument cluster fault cluster. Confirm correct module is installed. Re-synchronise ID by
Incorrect module installed re-configuring the instrument cluster as a new module. Check CAN
(CJB/Instrument cluster) network for interference/EMC related issues
Target SID synchronisation error
B100963 Ignition CJB fault Check Power and Ground supplies to CJB and instrument cluster.
Authorisation Low speed CAN fault Check CAN communications between CJB and instrument cluster.
Instrument cluster fault Check battery is in fully charged and serviceable condition, refer
Low battery voltage <9V to the battery care manual
B100964 Ignition CJB fault Check power and ground supplies to CJB and instrument cluster.
Authorisation Low speed CAN fault Check CAN communications between CJB and instrument cluster
Instrument cluster fault
B100A51 Fuel Pump RJB fault Check power and ground supplies to RJB. Check CAN
Authorisation Low speed CAN fault communications between RJB and instrument cluster. Check power
Instrument cluster fault and ground supplies to instrument cluster
B100A62 Fuel Pump Low speed CAN fault Check CAN communications between RJB and instrument cluster.
Authorisation RJB fault Check power and ground supplies to RJB and instrument cluster.
Instrument cluster fault Confirm correct module installed. Re-synchronise ID by
Incorrect module installed re-configuring the RJB as a new module. Check CAN network for
(RJB/Instrument cluster) interference/EMC related issues
B100A63 Fuel Pump RJB fault Check power and ground supplies to RJB and instrument cluster.
Authorisation Low speed CAN fault Check CAN communications between RJB and instrument cluster.
Instrument cluster fault Check battery is in fully charged and serviceable condition, refer
Low battery voltage <9V to the battery care manual
B100D51 Column lock Not programmed Check ignition, power and ground supplies to steering column lock
authorisation and instrument cluster. Re-synchronise ID by re-configuring the
steering column lock as a new module
B100D62 Column lock CAN fault Check CAN network between steering column lock and instrument
authorisation - Steering column lock fault cluster. Check power and ground supplies to steering column lock
signal compare Instrument cluster fault and instrument cluster. Confirm the correct modules are installed.
failure Incorrect module installed (Steering Re-synchronize ID by re-configuring the steering column lock as
column lock/Instrument cluster) new. Check CAN network for interference/EMC related issues
Target ID synchronisation error
B100D64 Column lock CAN fault Check CAN network to steering column lock. Check power and
authorisation - Steering column lock fault ground supplies to steering column lock and instrument cluster
signal plausibility Instrument cluster fault
failure
B100D87 Column lock CAN fault Carry out any pinpoint tests associated with this DTC using the
authorisation - Steering column lock fault manufacturer approved diagnostic system. Check CAN network
missing message Instrument cluster fault between steering column lock and instrument cluster. Check
Low voltage at steering column lock power and ground supplies to steering column lock and instrument
< 8V cluster
B102611 Steering Column Steering column lock power circuit - Carry out any pinpoint tests associated with this DTC using the
Lock short to ground manufacturer approved diagnostic system. Refer to the electrical
circuit diagrams and check steering column lock power circuit for
short to ground
B102612 Steering Column Steering column lock ground circuit - Refer to the electrical circuit diagrams and check steering column
Lock short to power lock ground circuit for short to power
B102615 Steering Column Steering column lock power circuit - Carry out any pinpoint tests associated with this DTC using the
Lock short to power, open circuit manufacturer approved diagnostic system. Refer to the electrical
circuit diagrams and check steering column lock power circuit for
short to power, open circuit
B102B67 Passive Key CJB fault Check power and ground supplies to CJB and RKE module. Check
Low speed CAN fault CAN communications between CJB and RKE module.
Remote Keyless Entry (RKE) module Re-synchronise ID by re-configuring the RKE module as a new
fault module
B102B87 Passive Key CJB fault Check power and ground supplies to CJB, RKE module and
Low speed CAN fault receiver. Check CAN communications between CJB and instrument
RKE module fault cluster. Check key fob battery. Confirm vehicle surroundings,
Key fob battery low/battery contact move vehicle. Check CAN network for interference/EMC related
issue issues. Disconnect battery, then re-connect - confirm operation by
Interference from other RF signal re-programming keys. Check serial circuit between receiver and
EMC/noise RKE module. Confirm spare key works. Refer to the electrical
Receiver fault circuit diagrams and test circuits to all 3 antennas. Check
Receiver not programmed correctly whereabouts of key
(between receiver and RKE module)
Key fault
Confirm placement of key within
vehicle
B108A11 Start Button Start/Stop switch analogue input Refer to the electrical circuit diagrams and check Start/Stop switch
circuits 1 or 2 - short to ground analogue input circuits 1 and 2 for short to ground
B108A12 Start Button Start/Stop switch analogue input Refer to the electrical circuit diagrams and check Start/Stop switch
circuits 1 or 2 - short to power analogue input circuits 1 and 2 for short to power
B108A23 Start Button Start/Stop switch digital input Carry out any pinpoint test associated with this DTC using the
signal circuit - stuck low manufacturer approved diagnostic system. Refer to the electrical
circuit diagrams and check Start/Stop switch digital input signal
circuit for short to ground
B10E511 PCM Wake-up Signal ECM wake-up signal circuit - short Refer to the electrical circuit diagrams and check ECM wake-up
to ground signal circuit for short to ground
B10F111 Key In Switch Keyless vehicle module, key IN Carry out any pinpoint tests associated with this DTC using the
status circuit - short to ground manufacturer approved diagnostic system. Refer to the electrical
circuit diagrams and check keyless vehicle module, key IN status
B10FA93 Delayed Power Off ADRC ECM, roof header console Carry out any pinpoint tests associated with this DTC using the
relay lamp, glove box lamp , RH/LH manufacturer approved diagnostic system. Refer to the electrical
footwell lamps, JAG Sense glove circuit diagrams and check ADRC ECM, roof header console lamp,
box module, RH/LH sunvisor lamps, glove box lamp , RH/LH footwell lamps, JAG Sense glove box
rear dome lamps switched power module, RH/LH sunvisor lamps, rear dome lamps switched power
circuits - short to power, open circuits for short to power, open circuit
circuit
B10FF11 Ignition control ECM and FPDB ignition control Carry out any pinpoint tests associated with this DTC using the
circuit - short to ground manufacturer approved diagnostic system. Refer to the electrical
circuit diagrams and check ECM and FPDB ignition control circuit
for short to ground
B10FF15 Ignition control ECM and FPDB ignition control Carry out any pinpoint tests associated with this DTC using the
circuit - short to power, open circuit manufacturer approved diagnostic system. Refer to the electrical
circuit diagrams and check ECM and FPDB ignition control circuit
for short to power, open circuit
B114011 Engine Crank Engine crank authorisation signal Carry out any pinpoint tests associated with this DTC using the
Authorisation circuit - short to ground manufacturer approved diagnostic system. Refer to the electrical
circuit diagrams and check engine crank authorisation signal
B114015 Engine Crank Engine crank authorisation signal Carry out any pinpoint tests associated with this DTC using the
Authorisation circuit - short to power, open circuit manufacturer approved diagnostic system. Refer to the electrical
circuit diagrams and check engine crank authorisation signal
circuit for short to power, open circuit
B114211 Ignition Status 1 Ignition supply 1 circuits - short to Carry out any pinpoint tests associated with this DTC using the
ground manufacturer approved diagnostic system. Refer to the electrical
circuit diagrams and check all ignition supply 1 circuits for short to
ground
power, open circuit manufacturer approved diagnostic system. Refer to the electrical
power, open circuit
ground manufacturer approved diagnostic system. Refer to the electrical
ground
power, open circuit manufacturer approved diagnostic system. Refer to the electrical
power, open circuit
B123711 Gear Shift Module Transmission shift module wake-up Carry out any pinpoint tests associated with this DTC using the
Early W ake-up control circuit - short to ground manufacturer approved diagnostic system. Refer to the electrical
circuit diagrams and check transmission shift module wake-up
B123E13 Crank Enable OK to crank signal circuit - open Refer to the electrical circuit diagrams and check OK to crank
P001600 Crankshaft Position The relative positions of the CKP Reset the sensor positions
- Camshaft Position and CMP teeth are not correct
Correlation - Bank 1 - Sensors incorrectly aligned on
Sensor A rebuild
P001800 Crankshaft Position The relative positions of the CKP Reset the sensor positions
- Camshaft Position and CMP teeth are not correct
Correlation - Bank 2 - Sensors incorrectly aligned on
Sensor A rebuild
P051212 Starter Request Crank request circuit - short to Refer to the electrical circuit diagrams and check crank request
Circuit power circuit for short to power
P051214 Starter Request Crank request circuit - short to Carry out any pinpoint tests associated with this DTC using the
Circuit ground, open circuit manufacturer approved diagnostic system. Refer to the electrical
circuit diagrams and check crank request circuit for short to
ground, open circuit
P051300 Incorrect Security key invalid Check for CAN network interference/EMC related error.
Immobilizer Key Re-synchronise ID by re-configuring the ECM and instrument
cluster as new modules
P061614 Starter Relay Circuit Starter relay circuit - short to Carry out any pinpoint tests associated with this DTC using the
Low ground, open circuit manufacturer approved diagnostic system. Refer to the electrical
circuit diagrams and check starter relay circuit for short to ground,
open circuit
P061712 Starter Relay Circuit Starter relay circuit - short to power Refer to the electrical circuit diagrams and check starter relay
High circuit for short to power
P081713 Starter Disable Starter relay negative control circuit Refer to the electrical circuit diagrams and check starter relay
Circuit/Open - open circuit negative control circuit for open circuit
P081A11 Starter Disable Starter relay negative control circuit Refer to the electrical circuit diagrams and check starter relay
Circuit Low - short to ground negative control circuit for short to ground
P081B12 Starter Disable Starter relay negative control circuit Refer to the electrical circuit diagrams and check starter relay
Circuit High - short to power negative control circuit for short to power
P085114 Park/Neutral Switch Park/Neutral switch input circuit - Carry out any pinpoint tests associated with this DTC using the
Input Circuit Low low manufacturer approved diagnostic system. Refer to the electrical
circuit diagrams and check Park/Neutral switch input circuit for
short to ground, open circuit
P085212 Park/Neutral Switch Park/Neutral switch input circuit - Carry out any pinpoint tests associated with this DTC using the
Input Circuit High high manufacturer approved diagnostic system. Refer to the electrical
circuit diagrams and check Park/Neutral switch input circuit for
short to power
P125900 Immobilizer to PCM Incorrect ID received from Re-configure the instrument cluster using the manufacturer
Signal Error instrument cluster approved diagnostic system
U016700 Lost Communication Security challenge response timeout Carry out any pinpoint tests associated with this DTC using the
W ith Vehicle manufacturer approved diagnostic system. Refer to the electrical
Immobilizer Control circuit diagrams and check power and ground supplies to vehicle
Module immobilizer module. Carry out the CAN network integrity test
using the manufacturer approved diagnostic system
U042600 Invalid Data Security code mis-match Check CAN network between ECM and instrument cluster. Check
Received From power and grounds to ECM and instrument cluster. Check correct
Vehicle Immobilizer ECM and instrument cluster installed. Re-synchronise ID by
Control Module re-configuring the ECM and instrument cluster as new modules
Starting System - V6 3.0L Petrol - Starter Motor
Removal
5. Remove the starter motor positive cable cover.

Remove the starter motor retaining bolts.
Installation
Tighten to 25 Nm.
5. Tighten to 7 Nm.
Starting System - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8 -
Battery positive terminal integral connector retaining nut 10 - 89
Starting System - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8 - Starting System -
Component Location
Component Location
Starting System - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8 - Starting System -
Overview
Overview
The starter motor is rated as a 1.8 kW and is a Denso level 3-sealed unit. It is an RA type starter motor, which is of the
offset design with the solenoid being directly behind the pinion to give a more positive engagement to the ring gear. The
motor is geared directly to the pinion. Each starter motor is of the pre-engaged type and comprises a series wound motor
and an overrunning clutch. This starter incorporates labyrinth-breathing tubes to help with sealing and drainage.
The starter solenoid is energised by a signal from the ECM (engine control module) when the ignition switch is moved to
the crank position. W hen engine cranking is requested, the ECM checks that a valid key code has been received before
granting the crank request.
The power for starter operation is supplied on a substantial single cable connected direct from the battery positive
terminal. The cable is connected to the solenoid via a copper threaded stud with an anti-rotational device and secured with
a nut.
The starter motor is located on the rear RH (right-hand) side of the engine block. The motor is secured to the block and
protrudes through an aperture to drive the flywheel via a ring gear.
Starting System - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8 - Starting System
For a detailed description of the starting system, refer to the relevant Description and Operation section in the workshop
manual. REFER to:
Starting System (303-06 Starting System - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8, Description and Operation),
vehicle.
Visual Inspection
Battery Fuses
Wiring harness
Starter relay
4. 4. If the concern is not visually evident, verify the symptom and refer to the symptom chart, alternatively, check for
Symptom Chart

The engine does not Gear selector not in P Make sure the gear selector is in the P or N position. Check the
crank (starter motor or N position battery is in fully charged and serviceable condition. Check the
does not turn) Battery starter motor and harness. Check for related DTCs and refer to the
Harness/Connectors relevant DTC Index
Starter motor
Starter relay
Start switch
module (TCM)
(ECM)
Engine seized
The engine does not Starter motor Check the starter motor installation (fasteners tight, starter motor
crank (starter motor installation square to engine, etc). Check the ring gear teeth for damage,
does turn) Starter motor foreign objects, etc.
Ring gear
Engine cranks too Battery Check the battery is in fully charged and serviceable condition.
slowly Harness/Connectors Refer to the electrical circuit diagrams and test the starter motor
Starter motor and starter motor circuits
grade
Engine cranks too fast Low engine Check the engine compressions.
compression REFER to: Engine - 3.0L NA V6 - AJ27/4.2L NA V8 - AJV8/4.2L SC V8
- AJV8 (303-00 Engine System - General Information, Diagnosis and
Testing).
Excessive starter Starter motor Check the starter motor installation (fasteners tight, motor square
motor noise Starter motor to engine, etc). Check the starter motor casing condition. Check the
installation/casing ring gear teeth for damage, foreign objects, etc.
Ring gear
DTC Index
part number 3548-1358-00. Failure to follow this instruction may result in damage to the vehicle.
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, after performing the pinpoint tests, the fault is not present, an intermittent concern
may be the cause. Always check for loose connections and corroded terminals.

B100951 Ignition Faulty instrument cluster Check ignition, power and ground supplies to CJB and
Authorisation Target SID re-synchronisation instrument cluster. Re-synchronize ID by
error following programming re-configuring the instrument cluster as a new
CAN fault module. Check CAN communications between
instrument cluster and tester
B100962 Ignition Low speed CAN fault Check CAN communications between CJB and
Authorisation CJB fault instrument cluster. Check ignition, power and ground
Instrument cluster fault supplies to CJB and instrument cluster. Confirm
Incorrect module installed correct module is installed. Re-synchronise ID by
(CJB/Instrument cluster) re-configuring the instrument cluster as a new
Target SID synchronisation module. Check CAN network for interference/EMC
error following re-programming related issues
B100963 Ignition CJB fault Check Power and Ground supplies to CJB and
Authorisation Low speed CAN fault instrument cluster. Check CAN communications
Instrument cluster fault between CJB and instrument cluster. Check battery is
Low battery voltage <9V in fully charged and serviceable condition, refer to the
battery care manual
B100964 Ignition CJB fault Check power and ground supplies to CJB and
Instrument cluster fault between CJB and instrument cluster
Authorisation Low speed CAN fault communications between RJB and instrument cluster.
Instrument cluster fault Check power and ground supplies to instrument
cluster
B100A62 Fuel Pump Low speed CAN fault Check CAN communications between RJB and
Authorisation RJB fault instrument cluster. Check power and ground supplies
Instrument cluster fault to RJB and instrument cluster. Confirm correct module
Incorrect module installed installed. Re-synchronise ID by re-configuring the RJB
(RJB/Instrument cluster) as a new module. Check CAN network for
W rite target SID interference/EMC related issues
synchronisation error following
re-programming
B100A63 Fuel Pump RJB fault Check power and ground supplies to RJB and
Instrument cluster fault between RJB and instrument cluster. Check battery is
battery care manual
B100D51 Column lock Not programmed Check ignition, power and ground supplies to steering
authorisation column lock and instrument cluster. Re-synchronise ID
by re-configuring the steering column lock as a new
module
authorisation - Steering column lock fault instrument cluster. Check power and ground supplies
signal compare Instrument cluster fault to steering column lock and instrument cluster.
failure Incorrect module installed Confirm the correct modules are installed.
(Steering column Re-synchronize ID by re-configuring the steering
lock/Instrument cluster) column lock as new. Check CAN network for
Target ID synchronisation error interference/EMC related issues
B100D64 Column lock CAN fault Check CAN network to steering column lock. Check
authorisation - Steering column lock fault power and ground supplies to steering column lock
signal plausibility Instrument cluster fault and instrument cluster
failure
B100D87 Column lock CAN fault Carry out any pinpoint tests associated with this DTC
authorisation - Steering column lock fault using the manufacturer approved diagnostic system.
missing message Instrument cluster fault Check CAN network between steering column lock and
Low voltage at steering column instrument cluster. Check power and ground supplies
lock < 8V to steering column lock and instrument cluster
B102611 Steering Column Steering column lock power Carry out any pinpoint tests associated with this DTC
Lock circuit - short to ground using the manufacturer approved diagnostic system.
Refer to the electrical circuit diagrams and check
steering column lock power circuit for short to ground
B102612 Steering Column Steering column lock ground Refer to the electrical circuit diagrams and check
Lock circuit - short to power steering column lock ground circuit for short to power
B102615 Steering Column Steering column lock power Carry out any pinpoint tests associated with this DTC
Lock circuit - short to power, open using the manufacturer approved diagnostic system.
circuit Refer to the electrical circuit diagrams and check
steering column lock power circuit for short to power,
open circuit
B102B67 Passive Key CJB fault Check power and ground supplies to CJB and RKE
Low speed CAN fault module. Check CAN communications between CJB and
Remote Keyless Entry (RKE) RKE module. Re-synchronise ID by re-configuring the
module fault RKE module as a new module
W rite target SID
re-programming
B102B87 Passive Key CJB fault Check power and ground supplies to CJB, RKE module
Low speed CAN fault and receiver. Check CAN communications between CJB
RKE module fault and instrument cluster. Check key fob battery. Confirm
Key fob battery low/battery vehicle surroundings, move vehicle. Check CAN
contact issue network for interference/EMC related issues.
Interference from other RF Disconnect battery, then re-connect - confirm
signal operation by re-programming keys. Check serial circuit
EMC/noise between receiver and RKE module. Confirm spare key
Receiver fault works. Refer to the electrical circuit diagrams and test
Receiver not programmed circuits to all 3 antennas. Check whereabouts of key
correctly
module)
Key fault
Confirm placement of key
within vehicle
B108A11 Start Button Start/Stop switch analogue Refer to the electrical circuit diagrams and check
input circuits 1 or 2 - short to Start/Stop switch analogue input circuits 1 and 2 for
ground short to ground
power short to power
B108A23 Start Button Start/Stop switch digital input Carry out any pinpoint test associated with this DTC
signal circuit - stuck low using the manufacturer approved diagnostic system.
Start/Stop switch digital input signal circuit for short
to ground
B10E511 PCM Wake-up ECM wake-up signal circuit - Refer to the electrical circuit diagrams and check ECM
Signal short to ground wake-up signal circuit for short to ground
B10F111 Key In Switch Keyless vehicle module, key IN Carry out any pinpoint tests associated with this DTC
status circuit - short to ground using the manufacturer approved diagnostic system.
keyless vehicle module, key IN status circuit for short
to ground
B10FA93 Delayed Power Off ADRC ECM, roof header console Carry out any pinpoint tests associated with this DTC
relay lamp, glove box lamp , RH/LH using the manufacturer approved diagnostic system.
footwell lamps, JAG Sense Refer to the electrical circuit diagrams and check ADRC
glove box module, RH/LH ECM, roof header console lamp, glove box lamp ,
sunvisor lamps, rear dome RH/LH footwell lamps, JAG Sense glove box module,
lamps switched power circuits - RH/LH sunvisor lamps, rear dome lamps switched
short to power, open circuit power circuits for short to power, open circuit
B10FF11 Ignition control ECM and FPDB ignition control Carry out any pinpoint tests associated with this DTC
circuit - short to ground using the manufacturer approved diagnostic system.
Refer to the electrical circuit diagrams and check ECM
and FPDB ignition control circuit for short to ground
circuit - short to power, open using the manufacturer approved diagnostic system.
circuit Refer to the electrical circuit diagrams and check ECM
and FPDB ignition control circuit for short to power,
open circuit
B114011 Engine Crank Engine crank authorisation Carry out any pinpoint tests associated with this DTC
Authorisation signal circuit - short to ground using the manufacturer approved diagnostic system.
engine crank authorisation signal circuit for short to
ground
Authorisation signal circuit - short to power, using the manufacturer approved diagnostic system.
open circuit Refer to the electrical circuit diagrams and check
power, open circuit
B114211 Ignition Status 1 Ignition supply 1 circuits - short Carry out any pinpoint tests associated with this DTC
to ground using the manufacturer approved diagnostic system.
Refer to the electrical circuit diagrams and check all
ignition supply 1 circuits for short to ground
to power, open circuit using the manufacturer approved diagnostic system.
ignition supply 1 circuits for short to power, open
circuit
to ground using the manufacturer approved diagnostic system.
to power, open circuit using the manufacturer approved diagnostic system.
ignition supply 2 circuits for short to power, open
circuit
B123711 Gear Shift Module Transmission shift module Carry out any pinpoint tests associated with this DTC
Early W ake-up wake-up control circuit - short using the manufacturer approved diagnostic system.
to ground Refer to the electrical circuit diagrams and check
transmission shift module wake-up control circuit for
short to ground
B123E13 Crank Enable OK to crank signal circuit - open Refer to the electrical circuit diagrams and check OK
circuit to crank signal circuit for open circuit
P001600 Crankshaft Position The relative positions of the Reset the sensor positions
- Camshaft CKP and CMP teeth are not
Position correct
Correlation - Bank - Sensors incorrectly aligned
1 Sensor A on rebuild
P001800 Crankshaft Position The relative positions of the Reset the sensor positions
- Camshaft CKP and CMP teeth are not
Position correct
Correlation - Bank - Sensors incorrectly aligned
2 Sensor A on rebuild
P051212 Starter Request Crank request circuit - short to Refer to the electrical circuit diagrams and check crank
Circuit power request circuit for short to power
P051214 Starter Request Crank request circuit - short to Carry out any pinpoint tests associated with this DTC
Circuit ground, open circuit using the manufacturer approved diagnostic system.
Refer to the electrical circuit diagrams and check crank
request circuit for short to ground, open circuit
P051300 Incorrect Security key invalid Check for CAN network interference/EMC related error.
Immobilizer Key Re-synchronise ID by re-configuring the ECM and
instrument cluster as new modules
P061614 Starter Relay Starter relay circuit - short to Carry out any pinpoint tests associated with this DTC
Circuit Low ground, open circuit using the manufacturer approved diagnostic system.
starter relay circuit for short to ground, open circuit
P061712 Starter Relay Starter relay circuit - short to Refer to the electrical circuit diagrams and check
Circuit High power starter relay circuit for short to power
P081713 Starter Disable Starter relay negative control Refer to the electrical circuit diagrams and check
Circuit/Open circuit - open circuit starter relay negative control circuit for open circuit
P081A11 Starter Disable Starter relay negative control Refer to the electrical circuit diagrams and check
Circuit Low circuit - short to ground starter relay negative control circuit for short to
ground
P081B12 Starter Disable Starter relay negative control Refer to the electrical circuit diagrams and check
Circuit High circuit - short to power starter relay negative control circuit for short to power
P085114 Park/Neutral Park/Neutral switch input circuit Carry out any pinpoint tests associated with this DTC
Switch Input - low using the manufacturer approved diagnostic system.
Circuit Low Refer to the electrical circuit diagrams and check
Park/Neutral switch input circuit for short to ground,
open circuit
P085212 Park/Neutral Park/Neutral switch input circuit Carry out any pinpoint tests associated with this DTC
Switch Input - high using the manufacturer approved diagnostic system.
Circuit High Refer to the electrical circuit diagrams and check
Park/Neutral switch input circuit for short to power
P125900 Immobilizer to PCM Incorrect ID received from Re-configure the instrument cluster using the
Signal Error instrument cluster manufacturer approved diagnostic system
U016700 Lost Security challenge response Carry out any pinpoint tests associated with this DTC
Communication timeout using the manufacturer approved diagnostic system.
W ith Vehicle Refer to the electrical circuit diagrams and check
Immobilizer power and ground supplies to vehicle immobilizer
Control Module module. Carry out the CAN network integrity test
U042600 Invalid Data Security code mis-match Check CAN network between ECM and instrument
Received From cluster. Check power and grounds to ECM and
Vehicle instrument cluster. Check correct ECM and instrument
Immobilizer cluster installed. Re-synchronise ID by re-configuring
Control Module the ECM and instrument cluster as new modules
Starting System - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8 - Starter Motor
Removal
Procedures).
5. Remove the starter motor positive cable cover.

Remove the starter motor retaining bolts.
Remove the starter motor.
Installation
6. Tighten to 7 Nm.
Engine Ignition - V6 3.0L Petrol -
Item Specification
Firing order 1-4-2-5-3-6
Spark plug gap 1.3-1.45mm (0.051-0.057in)
Spark plug type AGSF22FSM
High temperature nickel anti-seize lubricant F6AZ-9L494-AA (Spark plug thread) ESE-M12A4-A
Spark plugs 15 11 -
Ignition coil-on-plug retaining bolts 6 - 53
Engine Ignition - V6 3.0L Petrol - Engine Ignition - Component Location
ItemDescription
2 Ignition coil
Comments:
6 Off
Engine Ignition - V6 3.0L Petrol - Engine Ignition - Overview
OVERVIEW
The 3.0L V6 engine ignition system has a single iridium tipped spark plug per cylinder, with each spark plug powered by an on-plug ignition
coil. The ignition coils are directly driven by the ECM.
Power for the ignition coils is supplied from the main relay and a fuse in the BJB. A capacitor is connected in parallel with the power
supplies to the ignition coils to suppress RFI (radio frequency interference).
Engine Ignition - V6 3.0L Petrol - Engine Ignition - System Operation and Component
Description
Control Diagram
NOTE: A = Hardwired; D = High speed CAN (controller area network) bus; N = Medium speed CAN bus
ItemDescription
1 Battery
4 MS CAN bus to other vehicle systems
6 Ignition coils
8 Start control module and start/stop switch
System Operation
Engine Ignition
Each ignition coil contains a power stage to switch the current in the primary circuit. The ECM controls the switching with a signal to the
power stage. The ECM monitors operation of the ignition coils using a feedback signal from each of the power stages. If a fault is detected
the ECM stores an appropriate fault code.
Power for the ignition coils is supplied from the main relay and a fuse in the BJB. A capacitor is connected in parallel with the power
supplies to the ignition coils to suppress RFI (radio frequency interference).
The ECM varies the dwell time of the ignition coils depending on battery voltage and engine speed, to ensure a constant energy level is
produced in the secondary coil each time the power stage is switched. This ensures a good spark is always produced by the spark plug
without excessive primary current flow, thus avoiding overheating or damage to the ignition coils.
The ECM calculates the ignition timing for individual cylinders from:
Engine speed
Camshaft position
Engine load
Engine temperature
The knock control function
The shift control function
The idle speed control function.
Ignition Coils
The engine is fitted with eight plug-top coils that are controlled directly by the ECM. This means that the ECM, at the point where sufficient
charge has built up, switches the primary circuit of each coil and a spark is produced in the spark plug. The positive supply to the coil is fed
from a common fuse. Each coil contains a power stage to trigger the primary current. The ECM sends a signal to each of the coils power
stage to trigger the power stage switching. Each bank has a feedback signal that is connected to each power stage. If the coil power stage
has a failure the feedback signal is not sent, causing the ECM to store a fault code appropriate to the failure.
The ECM calculates the dwell time depending on battery voltage and engine speed to ensure constant secondary energy. This ensures
sufficient secondary (spark) energy is always available, without excessive primary current flow thus avoiding overheating or damage to the
coils.
The individual cylinder spark timing is calculated from a variety of inputs:
Engine speed and load

Engine temperature
Knock control
Transmission shift control
Idle speed control.
Engine Ignition - V6 3.0L Petrol - Engine Ignition
For a detailed description of the ignition system, refer to the relevant Description and Operation sections in the workshop manual. REFER
to:
Engine Ignition (303-07A Engine Ignition - V6 3.0L Petrol, Description and Operation),
Engine Ignition (303-07B Engine Ignition - V8 4.2L Petrol/V8 S/C 4.2L Petrol, Description and Operation),
Engine Ignition (303-07B Engine Ignition - V8 4.2L Petrol/V8 S/C 4.2L Petrol, Description and Operation),
Engine Ignition (303-07B Engine Ignition - V8 4.2L Petrol/V8 S/C 4.2L Petrol, Description and Operation).
Visual Inspection
Engine oil level Fuses
Cooling system coolant level Wiring harness
Fuel level Loose or corroded electrical connectors
Fuel contamination/grade/quality Ignition coils
Sensor(s)
step.
4. 4. If the cause is not visually evident, refer to the Symptom Chart below, alternatively, check for Diagnostic Trouble Codes (DTCs)
and refer to the DTC Index.
Symptom Chart

Engine cranks, but does not fire Engine breather system Ensure the engine breather system is free from restriction and is
disconnected/restricted correctly installed. Check for ignition system, fuel system and
Ignition system electronic engine control DTCs and refer to the relevant DTC Index
Fuel system
Engine cranks and fires, but will Evaporative emissions purge Check for evaporative emissions, fuel system and ignition system
not start valve related DTCs and refer to the relevant DTC Index
Fuel pump
Spark plugs
HT short to ground (tracking)
check rubber boots for
cracks/damage
Ignition system
Difficult cold start Engine coolant level/anti- Check the engine coolant level and condition. Ensure the battery is
freeze content in a fully charged and serviceable condition. Check for electronic
Battery engine controls, engine emissions, fuel system and evaporative
Electronic engine controls emissions system related DTCs and refer to the relevant DTC Index
Exhaust Gas Recirculation
Fuel pump
Purge valve
Difficult hot start Injector leak Check for injector leak, install new injector as required. Check for
Electronic engine control electronic engine controls, evaporative emissions, fuel system,
Purge valve ignition system and engine emission system related DTCs and refer
Fuel pump to the relevant DTC Index
Ignition system
Difficult to start after hot soak Injector leak Check for injector leak, install new injector as required. Check for
(vehicle standing, engine off, Electronic engine control electronic engine controls, evaporative emissions, fuel system,
after engine has reached Purge valve ignition system and engine emission system related DTCs and refer
operating temperature) Fuel pump to the relevant DTC Index
Ignition system
disconnected/restricted correctly installed. Check for electronic engine control, ignition
ECM relay system and fuel system related DTCs and refer to the relevant DTC
Electronic engine control Index. Check for blockage in air filter element and air intake system.
Ignition system Check for air leakage in air intake system
Air intake system restricted
Air leakage
Fuel lines
Engine hesitates/poor Fuel pressure, fuel pump, fuel Check for fuel system related DTCs and refer to the relevant DTC
acceleration lines Index. Check for injector leak, install new injector as required. Check
Injector leak for air leakage in air intake system. Ensure accelerator pedal is free
Air leakage from restriction. Check for electronic engine controls, ignition, engine
Electronic engine control emission system and transmission related DTCs and refer to the
Restricted accelerator pedal
Ignition system
Engine backfires Fuel pump/lines Check for fuel system failures. Check for air leakage in intake air
Air leakage system. Check for electronic engine controls, ignition system and
Electronic engine controls VCT system related DTCs and refer to the relevant DTC Index
Ignition system
timing (VCT) hub
Engine surges Fuel pump/lines Check for fuel system failures. Check for electronic engine controls,
Electronic engine controls throttle system and ignition system related DTCs and refer to the
Ignition system
Engine detonates/knocks Fuel pump/lines Check for fuel system failures. Check for air leakage in intake air
Air leakage system. Check for electronic engine controls and VCT system related
Electronic engine controls DTCs and refer to the relevant DTC Index
Sticking VCT hub
No throttle response Electronic engine controls Check for electronic engine controls and throttle system related DTCs
Throttle motor and refer to the relevant DTC Index
disconnected/restricted correctly installed. Check for electronic engine controls, transmission
Electronic engine control and traction control related DTCs and refer to the related DTC Index.
Transmission malfunction Check for air leakage in intake air system
Traction control event
Air leakage
DTC Index
3548-1358-00.
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: If DTCs are recorded and, after the pinpoint tests have been carried out, the fault is not present, an intermittent concern may be
the cause. Always check for loose connections and corroded terminals.

P035100 Ignition Coil A Ignition module/coil circuits - Carry out any pinpoint tests associated with this DTC using the
Primary/Secondary short to ground, power, high manufacturer approved diagnostic system. Refer to the electrical
Circuit resistance circuit diagrams and check ignition module/coil circuits for short to
ground, power, high resistance
P035200 Ignition Coil B Ignition module/coil circuits - Carry out any pinpoint tests associated with this DTC using the
P035300 Ignition Coil C Ignition module/coil circuits - Carry out any pinpoint tests associated with this DTC using the
P035400 Ignition Coil D Ignition module/coil circuits - Carry out any pinpoint tests associated with this DTC using the
P035500 Ignition Coil E Ignition module/coil circuits - Carry out any pinpoint tests associated with this DTC using the
P035600 Ignition Coil F Ignition module/coil circuits - Carry out any pinpoint tests associated with this DTC using the
P035700 Ignition Coil G Ignition module/coil circuits - Carry out any pinpoint tests associated with this DTC using the
P035800 Ignition Coil H Ignition module/coil circuits - Carry out any pinpoint tests associated with this DTC using the
P131500 Persistent Misfire ECM to ignition coil primary Check for cylinder mis-fire, ignition and injector DTCs and refer to
circuit fault (cylinder misfire the DTC Index. Check for fuel system failure. Check and install
detected DTC also flagged) spark plug as required. Carry out cylinder compression tests
Fuel injector circuit fault(s)
(injector DTCs also flagged)
Fuel delivery pressure low
Spark plug failure/fouled
/incorrect gap
Cylinder compression low
P131600 Misfire Rate Exceeds Misfire rate exceeds emissions Check for individual cylinder misfire DTCs and refer to DTC Index in
Emissions thresholds this section
P136700 Ignition Spare Ignition module/coil monitoring Refer to the electrical circuit diagrams and check ignition
circuit 1 - short to ground, short module/coil monitoring circuit 1 for short to ground, short to
to power, high resistance power, high resistance
P136800 Ignition Spare Ignition module/coil monitoring Refer to the electrical circuit diagrams and check ignition
circuit 2 - short to ground, short module/coil monitoring circuit 2 for short to ground, short to
to power, high resistance power, high resistance
Pinpoint Tests
PINPOINT TEST A : CHECK SPARK PLUG

NOTE: W hen installing new spark plugs, only spark plugs to the recommended specification must be used.
CONDITIONS
A1: CHECK SPARK PLUG
NOTE: Some spark plug types cannot be regapped and must be replaced.
1 Remove the suspect spark plug(s).
REFER to: Ignition Coil-On-Plug LH (303-07A Engine Ignition - V6 3.0L Petrol, Removal and Installation) /
Ignition Coil-On-Plug RH (303-07A Engine Ignition - V6 3.0L Petrol, Removal and Installation).
2 Visually inspect the spark plug for cracks, damage, carbon buildup or wet fouling, check the condition of the ground
electrode, the center electrode tip and the spark plug HT contact and confirm that the spark plug gap is correctly set
using a wire gauge taking care not to cause damage to the center or ground electrode tips.
REFER to: Specifications (303-07A Engine Ignition - V6 3.0L Petrol, Specifications).
Is the spark plug condition good, and the spark plug gap correct ?
Yes
Check ignition coil and circuits. See possible sources list for misfire.
No
Install a new spark plug(s) as required.
REFER to: Specifications (303-07A Engine Ignition - V6 3.0L Petrol, Specifications) /
Ignition Coil-On-Plug LH (303-07A Engine Ignition - V6 3.0L Petrol, Removal and Installation) /
Ignition Coil-On-Plug RH (303-07A Engine Ignition - V6 3.0L Petrol, Removal and Installation).
. CLEAR the DTC. TEST the system for normal operation.
Engine Ignition - V6 3.0L Petrol - Ignition Coil-On-Plug LH
Removal
1. Disconnect the ignition coil-on-plug electrical connector.
Installation
Tighten to 6 Nm.
Engine Ignition - V6 3.0L Petrol - Ignition Coil-On-Plug RH
Removal
For additional information, refer to: Intake Manifold (303-01B Engine -
V6 3.0L Petrol, Removal and Installation).
Installation
Tighten to 6 Nm.
Engine Ignition - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8 -
Item Specification
Firing order 1-5-4-2-6-3-7-8
Spark plug type - Vehicles with supercharger NGK-IFR-5N10
Spark plug type - Vehicles without supercharger NGK-IFR-5N10
Spark plugs 27 18 -
Ignition coil-on-plug retaining bolts 5 - 44
Engine Ignition - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8 - Engine Ignition -
Component Location
ItemDescription
2 Ignition coil
3 Spark plug
Overview
OVERVIEW
The 4.2L V8 Normally Aspirated and Supercharged engine ignition systems have a single iridium tipped spark plug per
cylinder, with each spark plug powered by an on-plug ignition coil. The ignition coils are directly driven by the BJB (battery
junction box).
Power for the ignition coils is supplied from the main relay and a fuse in the BJB. A capacitor is connected in parallel with
the power supplies to the ignition coils to suppress RFI (radio frequency interference).
Each ignition coil contains a power stage to switch the current in the primary circuit. The ECM (engine control module)
controls the switching with a signal to the power stage. The ECM monitors operation of the ignition coils using a feedback
signal from each of the power stages. If a fault is detected the ECM stores an appropriate fault code.
The ECM varies the dwell time of the ignition coils depending on battery voltage and engine speed, to ensure a constant
energy level is produced in the secondary coil each time the power stage is switched. This ensures a good spark is always
produced by the spark plug without excessive primary current flow, thus avoiding overheating or damage to the ignition
coils.
Engine speed
Camshaft position
Engine load
Engine temperature
On automatic transmission models, the shift control function
Control Diagram
NOTE: A = Hardwired; D = High speed CAN (controller area network) bus; N = Medium speed CAN bus
ItemDescription
1 Battery
4 MS CAN bus to other vehicle systems
6 Ignition coils
8 Start control module and start/stop switch
System Operation
Engine Ignition
Each ignition coil contains a power stage to switch the current in the primary circuit. The ECM controls the switching with a
signal to the power stage. The ECM monitors operation of the ignition coils using a feedback signal from each of the power
stages. If a fault is detected the ECM stores an appropriate fault code.
Power for the ignition coils is supplied from the main relay and a fuse in the BJB. A capacitor is connected in parallel with
the power supplies to the ignition coils to suppress RFI (radio frequency interference).
The ECM varies the dwell time of the ignition coils depending on battery voltage and engine speed, to ensure a constant
energy level is produced in the secondary coil each time the power stage is switched. This ensures a good spark is always
produced by the spark plug without excessive primary current flow, thus avoiding overheating or damage to the ignition
coils.
Engine speed
Camshaft position
Engine load
Engine temperature
The shift control function
Ignition Coils
The engine is fitted with eight plug-top coils that are controlled directly by the ECM. This means that the ECM, at the point
where sufficient charge has built up, switches the primary circuit of each coil and a spark is produced in the spark plug. The
positive supply to the coil is fed from a common fuse. Each coil contains a power stage to trigger the primary current. The
ECM sends a signal to each of the coils power stage to trigger the power stage switching. Each bank has a feedback signal
that is connected to each power stage. If the coil power stage has a failure the feedback signal is not sent, causing the
ECM to store a fault code appropriate to the failure.
The ECM calculates the dwell time depending on battery voltage and engine speed to ensure constant secondary energy.
This ensures sufficient secondary (spark) energy is always available, without excessive primary current flow thus avoiding
overheating or damage to the coils.

Engine temperature
Knock control
Transmission shift control
Idle speed control.
Engine Ignition - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8 - Engine Ignition
For a detailed description of the ignition system, refer to the relevant Description and Operation sections in the workshop
manual. REFER to: (303-07 Engine Ignition - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8)
Engine Ignition (Description and Operation),

Engine Ignition (Description and Operation),
Engine Ignition (Description and Operation).
vehicle.
Visual Inspection
Cooling system coolant level W iring harness
Fuel level Loose or corroded electrical connectors
Fuel contamination/grade/quality Ignition coils
Sensor(s)
4. 4. If the cause is not visually evident, refer to the Symptom Chart below, alternatively, check for Diagnostic Trouble
Codes (DTCs) and refer to the DTC Index.
Symptom Chart

Engine cranks, but does not Engine breather system Ensure the engine breather system is free from
fire disconnected/restricted restriction and is correctly installed. Check for ignition
Ignition system system, fuel system and electronic engine control DTCs
Engine cranks and fires, but Evaporative emissions purge Check for evaporative emissions, fuel system and
will not start valve ignition system related DTCs and refer to the relevant
Fuel pump DTC Index
Spark plugs
HT short to ground
(tracking) check rubber
boots for cracks/damage
Ignition system
Difficult cold start Engine coolant level/anti- Check the engine coolant level and condition. Ensure the
freeze content battery is in a fully charged and serviceable condition.
Battery Check for electronic engine controls, engine emissions,
Electronic engine controls fuel system and evaporative emissions system related
Exhaust Gas Recirculation DTCs and refer to the relevant DTC Index
Fuel pump
Purge valve
Difficult hot start Injector leak Check for injector leak, install new injector as required.
Electronic engine control Check for electronic engine controls, evaporative
Purge valve emissions, fuel system, ignition system and engine
Fuel pump emission system related DTCs and refer to the relevant
Ignition system DTC Index
Difficult to start after hot Injector leak Check for injector leak, install new injector as required.
soak (vehicle standing, Electronic engine control Check for electronic engine controls, evaporative
engine off, after engine has Purge valve emissions, fuel system, ignition system and engine
reached operating Fuel pump emission system related DTCs and refer to the relevant
temperature) Ignition system DTC Index
ECM relay engine control, ignition system and fuel system related
Electronic engine control DTCs and refer to the relevant DTC Index. Check for
Ignition system blockage in air filter element and air intake system.
Air intake system restricted Check for air leakage in air intake system
Air leakage
Fuel lines
Engine hesitates/poor Fuel pressure, fuel pump, Check for fuel system related DTCs and refer to the
acceleration fuel lines relevant DTC Index. Check for injector leak, install new
Injector leak injector as required. Check for air leakage in air intake
Air leakage system. Ensure accelerator pedal is free from restriction.
Electronic engine control Check for electronic engine controls, ignition, engine
Throttle motor emission system and transmission related DTCs and
Restricted accelerator pedal refer to the relevant DTC Index
Ignition system
Engine backfires Fuel pump/lines Check for fuel system failures. Check for air leakage in
Air leakage intake air system. Check for electronic engine controls,
Electronic engine controls ignition system and VCT system related DTCs and refer
Ignition system to the relevant DTC Index
timing (VCT) hub
Engine surges Fuel pump/lines Check for fuel system failures. Check for electronic
Electronic engine controls engine controls, throttle system and ignition system
Ignition system
Engine detonates/knocks Fuel pump/lines Check for fuel system failures. Check for air leakage in
Air leakage intake air system. Check for electronic engine controls
Electronic engine controls and VCT system related DTCs and refer to the relevant
Sticking VCT hub DTC Index
No throttle response Electronic engine controls Check for electronic engine controls and throttle system
Electronic engine control engine controls, transmission and traction control
Transmission malfunction related DTCs and refer to the related DTC Index. Check
Traction control event for air leakage in intake air system
Air leakage
DTC Index
NOTE: If DTCs are recorded and, after the pinpoint tests have been carried out, the fault is not present, an intermittent
concern may be the cause. Always check for loose connections and corroded terminals.

P035100 Ignition Coil A Ignition module/coil circuits Carry out any pinpoint tests associated with this DTC
Primary/Secondary - short to ground, power, using the manufacturer approved diagnostic system.
Circuit high resistance Refer to the electrical circuit diagrams and check
ignition module/coil circuits for short to ground, power,
high resistance
P035200 Ignition Coil B Ignition module/coil circuits Carry out any pinpoint tests associated with this DTC
high resistance
P035300 Ignition Coil C Ignition module/coil circuits Carry out any pinpoint tests associated with this DTC
high resistance
P035400 Ignition Coil D Ignition module/coil circuits Carry out any pinpoint tests associated with this DTC
high resistance
P035500 Ignition Coil E Ignition module/coil circuits Carry out any pinpoint tests associated with this DTC
high resistance
P035600 Ignition Coil F Ignition module/coil circuits Carry out any pinpoint tests associated with this DTC
high resistance
P035700 Ignition Coil G Ignition module/coil circuits Carry out any pinpoint tests associated with this DTC
high resistance
P035800 Ignition Coil H Ignition module/coil circuits Carry out any pinpoint tests associated with this DTC
high resistance
P131500 Persistent Misfire ECM to ignition coil primary Check for cylinder mis-fire, ignition and injector DTCs
circuit fault (cylinder misfire and refer to the DTC Index. Check for fuel system
detected DTC also flagged) failure. Check and install spark plug as required. Carry
Fuel injector circuit fault(s) out cylinder compression tests
/incorrect gap
P131600 Misfire Rate Exceeds Misfire rate exceeds Check for individual cylinder misfire DTCs and refer to
Emissions emissions thresholds DTC Index in this section
P136700 Ignition Spare Ignition module/coil Refer to the electrical circuit diagrams and check
monitoring circuit 1 - short ignition module/coil monitoring circuit 1 for short to
to ground, short to power, ground, short to power, high resistance
high resistance
monitoring circuit 2 - short ignition module/coil monitoring circuit 2 for short to
to ground, short to power, ground, short to power, high resistance
high resistance
Pinpoint Tests
PINPOINT TEST A : CHECK SPARK PLUG

NOTE: W hen installing new spark plugs, only spark plugs to the recommended specification must be used.
CONDITIONS
A1: CHECK SPARK PLUG
NOTE: Some spark plug types cannot be regapped and must be replaced.
1 Remove the suspect spark plug(s).
REFER to: Ignition Coil-On-Plug - 4.2L NA V8 - AJV8 (303-07 Engine Ignition - 4.2L NA V8 - AJV8/4.2L
SC V8 - AJV8, Removal and Installation) /
Ignition Coil-On-Plug - 4.2L SC V8 - AJV8 (303-07 Engine Ignition - 4.2L NA V8 - AJV8/4.2L SC V8 -
2 Visually inspect the spark plug for cracks, damage, carbon buildup or wet fouling, check the condition
of the ground electrode, the center electrode tip and the spark plug HT contact and confirm that the
spark plug gap is correctly set using a wire gauge taking care not to cause damage to the center or
ground electrode tips.
REFER to: Specifications (303-07 Engine Ignition - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8,
Specifications).
Is the spark plug condition good, and the spark plug gap correct ?
Yes
Check ignition coil and circuits. See possible sources list for misfire.
No
Install a new spark plug(s) as required.
REFER to: Specifications (303-07 Engine Ignition - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8,
Specifications) /
Ignition Coil-On-Plug - 4.2L NA V8 - AJV8 (303-07 Engine Ignition - 4.2L NA V8 - AJV8/4.2L SC V8 -
AJV8, Removal and Installation) /
Ignition Coil-On-Plug - 4.2L SC V8 - AJV8 (303-07 Engine Ignition - 4.2L NA V8 - AJV8/4.2L SC V8 -
. CLEAR the DTC. TEST the system for normal operation.
Engine Ignition - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8 - Ignition Coil-On-
Plug4.2L NA V8 - AJV8
Removal
Installation).
2. Remove the ignition coil-on-plug cover.
Remove the bolt.
Installation
Engine Ignition - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8 - Ignition Coil-On-
Plug4.2L SC V8 - AJV8
Removal
For additional information, refer to: Engine Cover - 4.2L SC V8
Installation).
2. Detach the PCV valve from the RH valve cover

Remove the ignition coil-on-plug cover.

Disconnect the ignition coil-on-plug electrical connector.

Remove the ignition coil-on-plug.
Remove the bolt.
Installation
Install the ignition coil-on-plug.
2. Connect and secure the electrical connector.

3. Install the ignition coil-on-plug cover.
Position and secure the clips.
4. Install the PCV valve.

For additional information, refer to: Engine Cover - 4.2L SC V8
Installation).
Glow Plug System -
Glow plug 10 - 89
Glow Plug System - Glow Plug System - Component Location
COMPONENT LOCATION
ItemDescription
1 Glow plug module
2 Glow plugs
3 Glow plug warning lamp
Glow Plug System - Glow Plug System - Overview
OVERVIEW
The glow plug system has a glow plug installed in the inlet side of each cylinder. The glow plugs heat the combustion chambers before and
during cranking, to aid cold starting, and after the engine starts to reduce emissions and engine noise when idling with a cold engine.
The glow plugs are connected for each bank by a common harness which is connected into the main engine harness. The harness for each
bank connects into a connector block which attaches to each of the glow plugs for that bank. The glow plugs are connected directly to the
glow plug module which is controlled by glow plug software contained within the ECM (engine control module).
Each glow plug is a tubular heating element which contains a spiral filament encased in magnesium oxide powder. At the tip of the tubular
heating element is the heater coil. Behind the heater coil, and connected in series, is a control coil. The control coil regulates the current to
the heater coil to safeguard against overheating.
Glow Plug System - Glow Plug System - System Operation and Component Description
Control Diagram
NOTE: A = Hardwired; D = HS CAN (controller area network)
ItemDescription
1 Battery
2 Glow plug module
3 Glow plug (6 off)
5 Engine Control Module (ECM)
6 Engine Junction Box (EJB) - (100A Midi-Fuse)
7 Battery Junction Box (BJB) - (250A Megafuse)
System Operation
System Operation
There are three phases of glow plug heating:
Pre heating
Crank heating
Post heating
The ECM (engine control module) determines the heating times from the ECT (engine coolant temperature). The lower the ECT, the longer
the heating times.
When the ignition is switched to power mode 9 (engine crank), the ECM calculates any required heating times and, if heating is required,
energizes the glow plug relay in the BJB (battery junction box). The glow plug relay supplies an ignition power supply to the glow plug
module. The glow plug module is controlled by the ECM which determines the pre-heat time required. The module then supplies power to
each of the glow plugs for the required time.
When pre-heating is required, the ECM also sends a message to the instrument cluster, on the high speed CAN, to request illumination of
the glow plug indicator. The glow plug indicator remains illuminated for the duration of the pre heating phase, or until the ignition is
switched to crank, whichever occurs first. If required, the ECM keeps the glow plug module energized during cranking and for the duration of
any post heating phase.
The ECM monitors the drive circuit of the glow plug module, via a direct diagnostic connection with the module, for plausibility of operation,
continuity, and short and open circuits. If a fault is detected, the glow plug module passes the fault information to the ECM, which stores a
related fault code and permanently illuminates the glow plug indicator while the ignition is in power mode 9.
Pre Heating
Pre-heat is the length of time the glow plugs operate prior to engine cranking. The ECM controls the pre-heat time based on ECT sensor
output and battery voltage. If the ECT sensor fails, the ECM will use the IAT (intake air temperature) sensor value as a default value. The
pre-heat duration is extended if the coolant temperature is low and the battery is not fully charged.
The ECM receives the corresponding temperature signal from the ECT sensor.
The pre heating period is dependent on the temperature signal (low temperature = longer pre heating period).
The driver is informed that pre heating is in operation by the glow plug indicator light in the instrument cluster coming on. The pre heating
times become longer as the coolant temperature falls.
The BARO (barometric pressure) also has an influence on activation and deactivation of the glow plugs in the event of large altitude
differences.
Crank Heating
Crank heating is carried out at every start where the coolant temperature is below the predefined threshold of 20 C. Crank heating begins
if the engine speed exceeds 42 rpm for longer than 50ms, or the starter is active for longer than 4 sec. If the coolant temperature sensor is
defective, a default temperature of 0 C is used.
Post Heating
Post heat is the length of time the glow plugs operate after the engine starts. The ECM controls the post heating time based on ECT sensor
output. The post heat phase reduces engine noise, improves idle quality and reduces hydrocarbon emissions.
Preheating is followed by the post heating phase once the engine has started. The post heating phase depends upon how the vehicle is
driven.
In addition to ECT, BARO and engine speed, the injected fuel quantity is significant in this context. For example, if the injected fuel
quantity is 70 mg per piston stroke and the coolant temperature is below 20 C, post heating is performed at engine speeds between 1100
and 3500 rpm.
In the case of greater injection quantities and considerably lower engine temperatures, the post heating phase is also activated depending
on the engine speed. At 14 mg per piston stroke and an ECT of below 0 C, for example, post heating is performed at engine speeds
between 1100 and 1500 rpm.
Glow Plug
The ceramic sheathed element glow plugs are made from a heat-resistant, electrically conductive ceramic material. The ceramic sheathed-
element glow plugs outer layer is heated directly and is self regulating. The self regulation allows the resistance of the sheathed element
to automatically increase as the heat increases preventing the glow plug from overheating. In addition, during the heating process and
under the control of the glow plug relay, the glow plugs can be operated above their nominal voltages. This permits heat-up speeds of
1000C per second. The sheathed-element glow plugs reach a maximum glow temperature of 1300C and can hold a temperature of 1150C
for several minutes after the first-start glow or at intervening times.
The glow plug is a tubular heating element that protrudes into the combustion chamber of the engine. The heating element contains a
spiral filament encased in magnesium oxide powder. At the tip of the tubular heating element is the heater coil. Behind the heater coil is a
control coil. The control coil is connected in series and regulates the heater coil to ensure that it does not overheat.
Each cylinder bank has a separate harness connecting the three glow plugs. The harness connects into the engine wiring harness and each
harness has a connector block which attaches to each of the glow plugs for that bank.
The glow plug module receives a battery voltage feed via a 250A megafuse in the BJB and a 100A midi-fuse in the EJB (engine junction
box). Operation of the glow plug module is controlled by the ECM, which also controls the illumination of the glow plug indicator in the
instrument cluster.
The system has been designed as a low-voltage glow system. At 7 volts, the nominal voltage of the sheathed-element glow plugs is
significantly lower than the 12 volts of the main electrical circuit. The electronic glow plug module matches the voltage to the sheathed-
element glow plugs and controls their glow temperature precisely to the specific requirements of the engine. This produces the optimum
glow temperature even when the main circuit voltage is interrupted during engine starting. The lower power consumption of the ceramic
glow plugs and their time-staggered activation reduce to a minimum the peak load on the main circuit during the cold start and immediate
post-start periods.
In the event of glow plug failure, the engine may be difficult to start and excessive smoke emissions may be observed after starting.
Glow Plug Module

The glow plug module is located in the RH (right-hand) side of the engine compartment. The module is attached to the power steering
reservoir bracket with a bolt and nut.
Two connectors are used on the module. One connector receives the power supplies from the battery via the BJB and EJB and also provides
for the connections to/from the ECM. The second connector supplies the outputs to the glow plugs.
Glow Plug System - Glow Plug System
For a detailed description of the glow plug system, refer to the relevant Description and Operation sections in the workshop manual. REFER
to: (303-07C Glow Plug System)
Glow Plug System (Description and Operation),

Glow Plug System (Description and Operation),
Glow Plug System (Description and Operation).
2. 2. Visually inspect for obvious signs of damage.
Visual Inspection
Electrical
Fuse(s)
Glow plug relay
Engine management control relay
W iring harness
Electrical connector(s)
Glow plug(s)
step.
4. 4. If the cause is not visually evident, check for Diagnostic Trouble Codes (DTCs) and refer to the DTC Index.
DTC Index
3548-1358-00.
NOTE: If the control module or a 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 programme 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 an
up-to-date calibration certificate. W hen testing resistance always take the resistance of the DMM leads into account.

P038072 Glow Plug/Heater Circuit Glowplug relay circuits - Refer to the electrical circuit diagrams and check glowplug relay
A short to ground, power, circuits for short to ground, power, open circuit. Check battery voltage.
open circuit Check and install a new relay as required
Glowplug relay failure
P038073 Glow Plug/Heater Circuit Glowplug relay circuits - Refer to the electrical circuit diagrams and check glowplug relay
A short to ground, power, circuits for short to ground, power, open circuit. Check battery voltage.
open circuit Check and install a new relay as required
Glowplug relay failure
P038311 Glow Plug Control Glowplug relay control Refer to the electrical circuit diagrams and check glowplug relay
Module Control Circuit circuit - short to ground control circuit for short to ground. Check and install a new relay as
Low Glowplug relay failure required
P038412 Glow Plug Control Glowplug relay control Refer to the electrical circuit diagrams and check glowplug relay
Module Control Circuit circuit - short to power control circuit for short to power. Check and install a new relay as
High Glowplug relay failure required
P067013 Glow Plug Control Glow plug relay control Refer to the electrical circuit diagrams and check glow plug relay
Module Control circuit - open circuit control circuit for open circuit. Check and install a new relay as
Circuit/Open Glow plug relay failure required
Engine Emission Control - TDV6 2.7L Diesel -
Exhaust gas recirculation (EGR) valve to cylinder head retaining bolts 10 89
EGR valve to EGR cooler retaining bolts 10 89
EGR valve tube to exhaust manifold retaining bolts 10 89
EGR valve cooler mounting bracket retaining bolt 10 89
EGR valve outlet tube to EGR valve retaining bolts 10 89
EGR valve outlet tube to timing cover retaining bolt 5 44
Fuel filter mounting bracket retaining M8 bolt 25 18
Fuel filter mounting bracket retaining M6 bolt 10 89
Engine Emission Control - TDV6 2.7L Diesel - Engine Emission Control - Component
Location
EGR COMPONENT LOCATION
ItemDescription
1 Electric throttle
2 EGR (exhaust gas recirculation) to electric throttle tube
3 EGR cooler
4 EGR modulator valve
5 EGR modulator solenoid valve
6 EGR coolant hoses
7 EGR modulator/ cooler assembly
CRANKCASE VENTILATION COMPONENT LOCATION
ItemDescription
1 Scavenger pipe
2 Scavenger pipe
3 Crankcase breather connection
4 Crankcase gas to air intake tube
5 Crankcase oil return valve
6 Oil return tube
7 Oil separator
Engine Emission Control - TDV6 2.7L Diesel - Engine Emission Control - Overview
OVERVIEW
The combined EGR (exhaust gas recirculation) modulator and cooler is located under each cylinder bank, between the exhaust manifold and
the cylinder head. The cooler side of the EGR is connected to the vehicle cooling system, via hoses. The inlet exhaust side is connected
directly into the exhaust manifolds on each side. A flow regulating, wax thermostat is fitted to the coolant outlet of the EGR cooler. The
purpose of the thermostat is to promote faster engine warm-up, improve cabin heater performance and assist the emissions to comply with
the requirements of EU4 regulations. The exhaust gas passes through the cooler and is expelled via the actuator and a metal pipe into the
throttle housing. The EGR modulator is a solenoid operated valve which is controlled by the ECM (engine control module) . The ECM uses the
EGR modulator to control the amount of exhaust gas being recirculated in order to reduce exhaust emissions and combustion noise. EGR is
enabled when the engine is at normal operating temperature and under cruising conditions.
The crankcase ventilation system ensures that all gasses emitted from the crankcase during engine running are separated from any oil
particles. Crankcase gasses are drawn into the oil separator unit from the crankcase and the cylinder head covers (both banks) where the
gas and oil are separated. The gas is returned to the inlet side of the air induction system prior to the turbo charger. The oil is drained
down to the sump via an oil return valve locate at the rear of the cylinder block.
Engine Emission Control - TDV6 2.7L Diesel - Engine Emission Control - System
System Operation
The EGR (exhaust gas recirculation) system comprises: EGR modulator x 2 EGR cooler x 2 Associated connecting pipes The combined EGR
modulator and cooler is located between the V of the cylinder banks. The cooler side of the EGR is connected to the vehicle cooling system,
via hoses. The inlet exhaust side is connected to the exhaust manifolds on each side via a metal pipe. The exhaust gas passes through the
cooler and is expelled via the actuator and a metal pipe into the throttle housing. The EGR modulator is a solenoid operated valve which is
controlled by the ECM (engine control module). The ECM uses the EGR modulator to control the amount of exhaust gas being recirculated in
order to reduce exhaust emissions and combustion noise. The EGR is enabled when the engine is at normal operating temperature and
under cruising conditions.
The crankcase ventilation system on the engine ensures that all gasses emitted from the crankcase during engine running are separated
from any oil particles.
EGR Valve and Cooler
ItemDescription
1 EGR modulator
2 EGR cooler
The combined EGR modulator and cooler is located under each cylinder bank, between the exhaust manifold and the cylinder head. The
cooler side of the EGR is connected to the vehicle cooling system, via hoses. The inlet exhaust side is connected directly into the exhaust
manifolds on each side. The exhaust gas passes through the cooler and is expelled via the actuator and a metal pipe into the throttle
housing. The EGR modulator is a solenoid operated valve which is controlled by the ECM. The ECM uses the EGR modulator to control the
amount of exhaust gas being recirculated in order to reduce exhaust emissions and combustion noise. The EGR is enabled when the engine
is at normal operating temperature and under cruising conditions.
A flow regulating, wax thermostat is fitted to the coolant outlet of the EGR cooler. The purpose of the thermostat is to promote faster
engine warm-up, improve cabin heater performance and assist the emissions to comply with the requirements of EU4 regulations. The
thermostat is closed when cold, starts to open at 75C (167F) and is fully open at normal operating temperatures. The thermostat has a
small bleed hole which allows a small amount of leakage when cold.
The EGR modulator receives a 12V supply from the main relay. The ground for the solenoid is via the ECM and is controlled using a PWM
(pulse width modulation) signal. The PWM duty signal of the solenoid ground is varied to determine the precise amount of exhaust gas
delivered to the cylinders.
The modulators are operated through their full range at each engine start-up, to clear any carbon deposits that may have built up whilst the
engine was running
In the event of a failure of the EGR modulator, the EGR function will become inoperative. The ECM can monitor the EGR modulator solenoid
for short circuits and store fault codes in the event of failure. The modulator can also be activated for testing using the recommended
Jaguar diagnostic tool.
Crankcase Ventilation
Crankcase gasses are drawn into the oil separator unit from the crankcase and the cylinder head covers (both banks) where the gas and oil
are separated. The gas is returned to the intake side of the air induction system prior to the turbo charger. The oil is drained down to the
sump via an oil return valve located at the rear of the cylinder block.
Engine Emission Control - TDV6 2.7L Diesel - Engine Emission Control
For a detailed description of the diesel engine emission control system, refer to the relevant Description and Operation sections in the
workshop manual. REFER to: (303-08A Engine Emission Control - TDV6 2.7L Diesel)
Engine Emission Control (Description and Operation),

Engine Emission Control (Description and Operation).
Visual Inspection
EGR valve Wiring harness
EGR pipes/hoses Electrical connector(s)
Vacuum system Fuses(s)
Engine breather system
step.
Symptom Chart

Poor performance, excessive Incorrect EGR flow Check EGR valve for correct operation. Check for related DTCs and
smoke emission refer to the relevant DTC Index
Excessive engine Engine breather system Check engine breather system for blockage/restriction. Check for
blow-by/crankcase pressure blocked/restricted excessive engine wear.
Excessive engine wear REFER to: Engine - TDV6 2.7L Diesel (303-00 Engine System -
General Information, Diagnosis and Testing).
DTC Index
3548-1358-00.
module/component.

P040121 Exhaust Gas EGR control NOTE: This DTC may log if the engine temperature is more than 98C and the
Recirculation Flow deviation ambient temperature is between 5 - 15C.
Insufficient Detected below
minimum Carry out PW M test on EGR control valve. Set ignition status to 'ON', engine 'OFF'.
threshold Check and record 'EGR valve position bank 0' and 'EGR valve position bank 1'
Engine datalogger signals, and command 'EGR valve 0 command' and 'EGR valve 1
cooling command' to 100% then 0%. Value of the signal should be approximately 95%
system fault maximum and 5% minimum, If PW M test is passed check engine cooling system
EGR valve functions correctly. Check correct thermostat is installed. if not, suspect the EGR
control actuators, check and install new actuators as required
system fault
P040222 Exhaust Gas EGR control Set ignition status to 'ON', engine 'OFF'. Check and record 'EGR valve position bank
Recirculation Flow deviation 0' and 'EGR valve position bank 1' datalogger signals, and command 'EGR valve 0
Excessive Detected above command' and 'EGR valve 1 command' to 100% then 0%. Value of the signal
maximum should be approximately 95% maximum and 5% minimum, if not, suspect the EGR
threshold actuators, check and install new actuators as required
P040300 Exhaust Gas EGR actuator Carry out any pinpoint tests associated with this DTC using the manufacturer
Recirculation A Control A valve approved diagnostic system. Refer to electrical circuit diagrams and check EGR valve
Circuit circuits - circuits for short to ground, power, open circuit. Start engine and allow to idle, check
short to and record 'EGR valve 0 command' and 'EGR valve position 0' datalogger signals.
ground, Turn the ignition status to 'OFF' and check the EGR cleaning cycle is performed, the
power, open 'EGR valve 0 command' should cycle from 0% to 100% approximately 6 times. Set
circuit ignition status to 'ON' engine 'OFF' and command 'EGR valve 0 command' to 0%,
EGR actuator check and record 'EGR valve position 0' datalogger signal. Value of signal should be
failure between 0-20%. Command 'EGR valve 0 command' to 100%, check and record 'EGR
valve position 0' datalogger signal. Value of signal should be between 80-100%.
Check and install a new EGR valve as required, refer to the new module/component
Recirculation A Control A circuits - approved diagnostic system. Refer to electrical circuit diagrams and check EGR valve
Circuit short to circuits for short to ground, power, open circuit. Start engine and allow to idle, check
ground, and record 'EGR valve 0 command' and 'EGR valve position 0' datalogger signals.
power, open Turn the ignition status to 'OFF' and check the EGR cleaning cycle is performed, the
circuit 'EGR valve 0 command' should cycle from 0% to 100% approximately 6 times. Set
EGR actuator ignition status to 'ON' engine 'OFF' and command 'EGR valve 0 command' to 0%,
failure check and record 'EGR valve position 0' datalogger signal. Value of signal should be
between 0-20%. Command 'EGR valve 0 command' to 100%, check and record 'EGR
Check and install a new EGR valve as required, refer to the new module/component
Recirculation Sensor A A circuits - approved diagnostic system. Refer to the electrical circuit diagrams and check the EGR
Circuit Low short to actuator A circuit for short to ground. Set ignition status to 'ON' engine 'OFF', check
ground and record 'EGR valve position 0' datalogger signal, and command 'EGR valve 0
EGR actuator command' to 0% then to 99%. Value of signal should be between 0-15% and
failure 85-99%. Check and install a new EGR valve as required
Recirculation Sensor A A circuits - approved diagnostic system. Refer to the electrical circuit diagrams and check the EGR
Circuit High short to actuator A circuit for short to power. Set ignition status to 'ON' engine 'OFF', check
power and record 'EGR valve position 0' datalogger signal, and command 'EGR valve 0
EGR actuator command' to 0% then to 99%. Value of signal should be between 0-15% and
failure 85-99%. Check and install a new EGR valve as required
P040721 Exhaust Gas EGR throttle Carry out any pinpoint tests associated with this DTC using the manufacturer
Recirculation Sensor B TPS1 circuit - approved diagnostic system. Refer to the electrical circuit diagrams and check EGR
Circuit Low short to throttle TPS1 circuit for short to ground, open circuit. Check and install a new EGR
ground, open throttle as required
circuit
EGR throttle
failure
Recirculation Sensor B TPS1 circuit - approved diagnostic system. Refer to the electrical circuit diagrams and check EGR
Circuit High short to throttle TPS1 circuit for short to power. Check and install a new EGR throttle as
power required
EGR throttle
failure
P045A00 Exhaust Gas EGR actuator Carry out any pinpoint tests associated with this DTC using the manufacturer
Recirculation B Control B valve approved diagnostic system. Refer to electrical circuit diagrams and check EGR valve
Circuit circuits - circuits for short to ground, power, open circuit. Start engine and allow to idle, check
short to and record 'EGR valve 1 command' and 'EGR valve position 1' datalogger signals.
ground, Turn the ignition status to 'OFF' and check the EGR cleaning cycle is performed, the
power, open 'EGR valve 1 command' should cycle from 0% to 100% approximately 6 times. Set
circuit ignition status to 'ON' engine 'OFF' and command 'EGR valve 1 command' to 0%,
EGR actuator check and record 'EGR valve position 1' datalogger signal. Value of signal should be
failure between 0-20%. Command 'EGR valve 1 command' to 100%, check and record 'EGR
ECM failure valve position 1' datalogger signal. Value of signal should be between 80-100%.
Check and install a new EGR valve/ECM as required, refer to the new
module/component installation note at the top of the DTC Index
Recirculation B Control B circuits - approved diagnostic system. Refer to electrical circuit diagrams and check EGR valve
Circuit short to circuits for short to ground, power, open circuit. Start engine and allow to idle, check
ground, and record 'EGR valve 1 command' and 'EGR valve position 1' datalogger signals.
power, open Turn the ignition status to 'OFF' and check the EGR cleaning cycle is performed, the
circuit 'EGR valve 1 command' should cycle from 0% to 100% approximately 6 times. Set
EGR actuator ignition status to 'ON' engine 'OFF' and command 'EGR valve 1 command' to 0%,
failure check and record 'EGR valve position 1' datalogger signal. Value of signal should be
ECM failure between 0-20%. Command 'EGR valve 1 command' to 100%, check and record 'EGR
Check and install a new EGR valve/ECM as required, refer to the new
P045C00 Exhaust Gas EGR valve Carry out any pinpoint tests associated with this DTC using the manufacturer
Recirculation B Control control approved diagnostic system. Refer to the electrical circuit diagrams and check intake
Circuit Low minimum air temperature, ambient pressure, manifold absolute pressure, mass air flow, boost
deviation pressure and EGR actuators/sensors and circuits for short to ground, power, open
circuit. Start engine and allow to idle, check and record 'EGR valve 1 controller
deviation' datalogger signal, approximately every 30 seconds quickly apply and
release throttle pedal. Value of signal should not exceed either +12% or -7%. Check
for sticking EGR valve, check and install a new EGR valve as required
P045D00 Exhaust Gas EGR valve Carry out any pinpoint tests associated with this DTC using the manufacturer
Recirculation B Control control approved diagnostic system. Refer to the electrical circuit diagrams and check intake
Circuit High maximum air temperature, ambient pressure, manifold absolute pressure, mass air flow, boost
circuit. Start engine and allow to idle, check and record 'EGR valve 1 controller
Recirculation Throttle TPA+ circuit - approved diagnostic system. Refer to the electrical circuit diagrams and check EGR
Control Circuit A Open open circuit throttle TPA+ circuit for open circuit. Check and install a new EGR throttle as required,
EGR throttle refer to the new module/component installation note at the top of the DTC Index
failure
P048819 Exhaust Gas Circuit current Carry out any pinpoint tests associated with this DTC using the manufacturer
Recirculation Throttle above approved diagnostic system. Set ignition status to 'ON' engine 'OFF', check and record
Control Circuit A threshold 'EGR throttle position' datalogger signal, then command 'EGR throttle command' to
Range/Performance 100%. Value of signal should be between 85-99%, if not install new EGR throttle.
Command 'EGR throttle command' to 0%, value of signal should be between 0-20%,
if not install new EGR throttle. Manually close and open the EGR throttle and check
the feedback voltage and resistance. Voltage should range between 0.20-4.80 volts,
resistance should range between 300-2500 Ohms, if this is not the case install a new
EGR throttle. If EGR throttle has been replaced and the DTC remains, suspect the
ECM, check and install a new ECM as required, refer to the new module/component
P048821 Exhaust Gas Signal Carry out any pinpoint tests associated with this DTC using the manufacturer
Recirculation Throttle Amplitude < approved diagnostic system. Refer to the electrical circuit diagrams and check EGR
Control Circuit A minimum throttle circuits for short, open circuit. Set ignition status to 'ON' engine 'OFF', check
Range/Performance and record 'Measured throttle position' datalogger signal, command 'EGR throttle
command' to 0%. If value of signal is not between 0-20% install a new EGR throttle
P048822 Exhaust Gas Signal Carry out any pinpoint tests associated with this DTC using the manufacturer
Recirculation Throttle Amplitude > approved diagnostic system. Refer to the electrical circuit diagrams and check EGR
Control Circuit A maximum throttle circuits for short, open circuit. Set ignition status to 'ON' engine 'OFF', check
Range/Performance and record 'Measured throttle position' datalogger signal, command 'EGR throttle
command' to 100%. If value of signal is not between 70-99% install a new EGR
throttle
P048900 Exhaust Gas EGR valve Carry out any pinpoint tests associated with this DTC using the manufacturer
Recirculation A Control control approved diagnostic system. Refer to the electrical circuit diagrams and check intake
Circuit Low minimum air temperature, ambient pressure, manifold absolute pressure, mass air flow, boost
circuit. Start engine and allow to idle, check and record EGR valve 0 controller
P049000 Exhaust Gas EGR valve Carry out any pinpoint tests associated with this DTC using the manufacturer
Recirculation A Control control approved diagnostic system. Refer to the electrical circuit diagrams and check intake
Circuit High maximum air temperature, ambient pressure, manifold absolute pressure, mass air flow, boost
circuit. Start engine and allow to idle, check and record EGR valve 0 controller
P133521 EGR Position Sensor A EGR valve Refer to the electrical circuit diagrams and check sensor connector and circuits for
Minimum/Maximum adaption short, open circuit. Set ignition status to 'ON' engine 'OFF', check and record 'EGR
Stop Performance bank 1 valve position bank 0' datalogger signal and command 'EGR valve 0 command' to
bottom limit 0%. If value of signal is between 0-15% clear DTC and re-test, if not suspect the EGR
check valve bank 1, check and install a new valve as required
P133522 EGR Position Sensor A EGR valve Refer to the electrical circuit diagrams and check sensor connector and circuits for
Stop Performance bank 1 top valve position bank 0' datalogger signal and command 'EGR valve 0 command' to
limit check 0%. If value of signal is between 0-15% clear DTC and re-test, if not suspect the EGR
valve bank 1, check and install a new valve as required
Recirculation Sensor C bank 2 approved diagnostic system. Refer to the electrical circuit diagrams and check the EGR
Circuit Low circuits - actuator bank 2 circuits for short to ground. Set ignition status to 'ON' engine 'OFF',
short to check and record 'EGR valve position bank 1' datalogger signal, and command 'EGR
ground valve 1 command' to 0% then to 99%. Value of signal should be between 0-15% and
EGR actuator 85-99%. Check and install a new EGR valve as required
failure
P140B22 Exhaust Gas EGR actuator Carry out any pinpoint tests associated with this DTC using the manufacturer
Recirculation Sensor C bank 2 approved diagnostic system. Refer to the electrical circuit diagrams and check the EGR
Circuit High circuits - actuator bank 2 circuits for short to power. Set ignition status to 'ON' engine 'OFF',
short to check and record 'EGR valve position bank 1' datalogger signal, and command 'EGR
power valve 1 command' to 0% then to 99%. Value of signal should be between 0-15% and
EGR actuator 85-99%. Check and install a new EGR valve as required
failure
P140E21 EGR Position Sensor C EGR valve Refer to the electrical circuit diagrams and check sensor connector and circuits for
Stop Performance bank 2 valve position bank 1' datalogger signal, and command 'EGR valve 1 command' to
bottom limit 0%. If value of signal is between 0-15% clear DTC and re-test, if not suspect the EGR
check valve bank 2, check and install a new valve as required
P140E22 EGR Position Sensor C EGR valve Refer to the electrical circuit diagrams and check sensor connector and circuits for
Stop Performance bank 2 top valve position bank 1' datalogger signal and command 'EGR valve 1 command' to
limit check 0%. If value of signal is between 0-15% clear DTC and re-test, if not suspect the EGR
valve bank 2, check and install a new valve as required
P141A27 Exhaust Gas EGR valve Refer to the electrical circuit diagrams and check EGR valve signal circuits for short,
Recirculation Sensor A bank 1 - open circuit. Start engine and run to normal operating temperature, check and record
Circuit sensor signal 'EGR valve position bank 0' datalogger signal. If after approximately 5 seconds the
Intermittent/Erratic not plausible signal value has increased by more than 80%/10ms, suspect the EGR valve bank 1,
check and install a new EGR valve as required
P141B1C Exhaust Gas EGR throttle Carry out any pinpoint tests associated with this DTC using the manufacturer
Recirculation Sensor B position approved diagnostic system. Refer to the electrical circuit diagrams and check throttle
Circuit sensor signal position sensor circuits for short, open circuit. Start engine and run to normal
Intermittent/Erratic not plausible operating temperature, check and record 'EGR valve position bank 0' datalogger
signal, then slowly increase engine speed to 3000 rev/min. If signal value has
increased by more than 80%/10ms, suspect the EGR throttle bank 1, check and install
a new EGR throttle as required
P141C27 Exhaust Gas EGR valve Refer to the electrical circuit diagrams and check EGR valve signal circuits for short,
Recirculation Sensor C bank 2 - open circuit. Start engine and run to normal operating temperature, check and record
Circuit sensor signal 'EGR valve position bank 1' datalogger signal. If after approximately 5 seconds the
Intermittent/Erratic not plausible signal value has increased by more than 80%/10ms, suspect the EGR valve bank 2,
check and install a new EGR valve as required
Recirculation Throttle position approved diagnostic system. Refer to the electrical circuit diagrams and check EGR
Control Circuit A Low control throttle circuits for short to ground, power, open circuit. Set ignition status to 'ON'
deviation engine 'OFF', check and record 'Throttle controller deviation' and 'EGR throttle
below position' datalogger signals. Check EGR throttle is open, then command 'EGR
minimum throttle command' closed. Value of signal 'EGR throttle position' should increase
threshold above 90%, and 'Throttle controller deviation' value should not exceed either MAX
+5% of MIN -15%. If the values of these signals are outside of the parameters, check
for sticking EGR throttle, install a new EGR throttle as required
Recirculation Throttle position approved diagnostic system. Refer to the electrical circuit diagrams and check EGR
Control Circuit A High control throttle circuits for short to ground, power, open circuit. Set ignition status to 'ON'
deviation engine 'OFF', check and record 'Throttle controller deviation' and 'EGR throttle
above position' datalogger signals. Check EGR throttle is open, then command 'EGR
maximum throttle command' closed. Value of signal 'EGR throttle position' should increase
threshold above 90%, and 'Throttle controller deviation' value should not exceed either MAX
+5% of MIN -15%. If the values of these signals are outside of the parameters, check
for sticking EGR throttle, install a new EGR throttle as required
Engine Emission Control - TDV6 2.7L Diesel - Crankcase Vent Oil Separator
Removal
5. Disconnect the port deactivation vacuum hose.
6. Disconnect the crankcase vent hoses.

7. CAUTIONS:
Discard the seals.
Make sure that all openings are sealed.
Release and remove the crankcase vent oil separator.
Installation
1. CAUTION: Install the new seals.

Engine Emission Control - TDV6 2.7L Diesel - Exhaust Gas Recirculation (EGR) Valve
Outlet Tube
Removal
Detach the exhaust gas recirculation (EGR) valve outlet tube.
Detach the EGR valve outlet tube.
Release the engine wiring harness.
Remove the Torx screw.
NOTE: Discard the gasket.
Remove the EGR valve outlet tube.
Remove the 2 bolts.
Installation
Loosely install the EGR valve outlet tube.
Do not fully close the retaining clamp at this stage.

Loosely install the EGR valve outlet tube bolts.
Loosely install the bolt.
Fully close the EGR valve outlet tube retaining clamp.
Tighten to 10 Nm.
Tighten to 5 Nm.

Published: 06-Oct-2011
Engine Emission Control - TDV6 2.7L Diesel - Exhaust Gas Recirculation (EGR) Valve LH
Removal
WARNING: Since injury such as scalding could be caused by escaping steam or coolant, make sure the vehicle cooling system is cool
prior to carrying out this procedure.

5. Clamp the coolant hoses in the locations shown to minimise coolant

loss.
8. Remove the EGR valve retaining bolt and coolant hose bracket.
Displace the catalytic converter heatshield downwards to access

the bolt.

Installation
2. Loosely install the EGR valve.

3. Install the bracket.
Displace the catalytic converter heatshield downwards to access

the bolt.
4. Connect the EGR valve inlet tube.
Tighten to 10 Nm.
Tighten to 10 Nm.
Tighten to 27 Nm.

Fill the cooling system to the upper level mark of the coolant expansion
tank.
Remove the coolant expansion tank bleed screw.

Tighten to 3 Nm.

Increase engine speed to 2000rpm and cycle between this and idle
for 60 seconds.
14. Check and top up the cooling system as required.

Engine Emission Control - TDV6 2.7L Diesel - Exhaust Gas Recirculation (EGR) Valve
RH
Removal
WARNING: Since injury such as scalding could be caused by escaping steam or coolant, make sure the vehicle cooling system is cool
prior to carrying out this procedure.

4. Reposition the engine junction box (EJB).
Remove the two bolts.
Remove the nut.

6. Clamp the coolant hoses in the locations shown to minimise coolant
loss.

Installation
2. Loosely install the EGR valve.
3. Connect the EGR valve inlet tube.

Tighten to 10 Nm.
6. Remove the coolant hose clamps.

8. Secure the EJB.
Tighten to 10 Nm.

Fill the cooling system to the upper level mark of the coolant expansion
tank.
Remove the coolant expansion tank bleed screw.

Tighten to 3 Nm.

Increase engine speed to 2000rpm and cycle between this and idle
for 60 seconds.
Check and top up the cooling system as required.

Engine Emission Control - V6 3.0L Petrol -
Secondary air injection (AIR) control valve to exhaust manifold tube retaining nuts 35 26 -
AIR control valve to exhaust manifold tube to exhaust manifold adaptor 35 26 -
Exhaust manifold blanking plug 35 26 -
AIR control valve bracket retaining bolt 8 - 71
AIR control valve bracket retaining nut 8 - 71
AIR pump bracket bolts and nuts 9 - 80
AIR pump to bracket nuts 8 - 71
AIR vacuum reservoir retaining bolt 5 - 44
Engine Emission Control - V6 3.0L Petrol - Engine Emission Control - Component
Location
ItemDescription
1 AIR (secondary air injection) vacuum reservoir
2 Full load breather
3 PCV (positive crankcase ventilation) valve
4 AIR pump
5 AIR switching valve
6 AIR control valve
Engine Emission Control - V6 3.0L Petrol - Engine Emission Control - Overview
OVERVIEW
The engine emission control system on the 3.0L engine comprise:
Crankcase ventilation system

AIR (secondary air injection) system
The crankcase ventilation system consists of two hoses, connected between the left-hand valve cover and the intake manifold and the
right-hand valve cover and the air cleaner outlet pipe and a PCV (positive crankcase ventilation) valve located on the top on the LH
(left-hand) engine cam cover. The PCV system recycles crankcase gases back through the engine where they mix with incoming air/fuel
charge and help to reduce hydrocarbon emissions.
The AIR system comprises the following components:
AIR pump
AIR switching valve
AIR control valve
AIR vacuum reservoir
AIR pump relay
AIR pressure sensor (North American specification vehicles only)
Engine Emission Control - V6 3.0L Petrol - Engine Emission Control - System Operation
System Operation
CRANKCASE VENTILATION SYSTEM
The crank system recycles crankcase gases back through the engine where they mix with incoming air/fuel charge and help to reduce
hydrocarbon emissions. The PCV (positive crankcase ventilation) system consists of two hoses, connected between the left-hand valve cover
and the intake manifold and the right-hand valve cover and the air cleaner outlet pipe. The LH (left-hand) hose has a PCV valve at the
engine cover end.
The PCV valve regulates the amount of ventilation air and crankcase gas supplied to the intake manifold and also prevents backfiring into
the crankcase.
SECONDARY AIR INJECTION SYSTEM

The AIR (secondary air injection) pump is used to provide a supply of air into the exhaust manifolds during the cold start period of the
engine. The AIR cycle lasts for up to 65 seconds. The hot unburnt fuel particles leaving the combustion chamber mix with the air injected
into the exhaust manifolds and immediately combust.
This subsequent combustion of the unburnt and partially burnt carbon monoxide (CO)CO (carbon monoxide) and hydrocarbon (HC)HC
(hydrocarbon) particles help to reduce the emission of these pollutants from the exhaust system. The additional heat generated in the
exhaust manifold also provides rapid heating of the exhaust system catalytic converters. The additional oxygen which is delivered to the
catalytic converters also generates an exothermic reaction which causes the catalytic converters to reach their optimum operating
temperature and 'light off' quickly.
The catalytic converters only start to provide effective treatment of emission pollutants when they reach an operating temperature of
approximately 250C (482F) and need to be between temperatures of 400C (752F) and 800C (1472F) for optimum efficiency.
Consequently, the heat produced by the AIR 'afterburning' reduces the time delay before the catalysts reach an efficient operating
temperature.
POSOTIVE CRANKCASE VENTILATION VALVE
The PCV valve is a spring loaded valve that opens when the engine is under full load. Once open the valve allows crankcase gasses to flow
to the intake manifold. The PCV valve prevents reverse flow into the crankcase.
SECONDARY AIR INJECTION PUMP
The AIR pump is fitted on rubber mountings to help prevent noise which is generated by AIR pump operation. The AIR pump is powered
from the vehicle battery by a dedicated relay and supplies approximately 10 to 15 kg/hr (22 to 33 lb/hr) of air when the engine is at idle
speed and the ambient temperature is below 20C (68F).
Air is drawn into the AIR pump through vents in its front cover and is then passed through a foam filter. The air is delivered to the exhaust
manifold on each side of the engine through a combination of plastic pipes and stainless steel tubes.
One second after the AIR pump is energised, the ECM switches on the AIR switching valve, which opens to allow vacuum from the AIR
vacuum reservoir to be applied to the vacuum operated AIR control valve. W hen the vacuum is applied to the AIR control valve, it opens to
allow the air from the AIR pump through to the exhaust manifolds.
When the ECM switches off the AIR switching valve, the vacuum supply to the AIR control valve is cut-off and the valve closes to prevent
further air being injected into the exhaust manifolds. With an approximate five second delay after as the AIR switching valve is closed, the
ECM removes power from the AIR pump relay, and this in turn stops the AIR pump from operating.
SECONDARY AIR INJECTION SWITCHING VALVE
The ECM switches on the AIR switching valve with a one second delay after initiating AIR pump operation. When the AIR switching valve is
open, a steady vacuum supply is allowed through to open the vacuum operated AIR control valve. When the ECM switches off the AIR
switching valve, the valve closes and immediately shuts off the vacuum supply to the AIR control valve. The pump continues to operate for
a further five seconds for system diagnostic purposes.
When the AIR switching valve is switched off, the vacuum supply line opens to atmosphere, and this causes the AIR switching valve to
close automatically to prevent any further injection of air.
SECONDARY AIR INJECTION CONTROL VALVE
The injected air from the AIR pump is controlled by the AIR control valve. This allows the correct amount of air to be injected directly into
the exhaust manifolds. The AIR control valve prevents exhaust gasses from blowing back into the AIR pump. Vacuum to the AIR switching
valve is provided from the intake manifold vacuum by the AIR vacuum reservoir. A small bore vacuum hose provides the vacuum route
between the AIR vacuum reservoir and AIR switching valve. A further small bore vacuum hose is used to connect the AIR switching valve to
the AIR control valve.
The AIR control valve is assisted in operation by a vacuum source from the AIR vacuum reservoir located in the right-hand side of the
engine bay. This assistance allows the actuation of the AIR control valve independently from the intake manifold vacuum levels available.
When the pressure in the exhaust system is higher than in the AIR system, the AIR control valve closes the circuit, and this protects the
AIR system from exhaust gasses blowing back into the AIR system.
Vacuum to the AIR switching valve is provided from the intake manifold vacuum by the AIR vacuum reservoir. A small bore vacuum hose
provides the vacuum route between the AIR vacuum reservoir and AIR switching valve. A further small bore vacuum hose is used to connect
the AIR switching valve to the AIR control valve.
SECONDARY AIR INJECTION RESERVOIR

The AIR vacuum reservoir is included in the vacuum supply line between the intake manifold and the AIR switching valve. The AIR vacuum
reservoir contains a one-way valve to stop vacuum leaking back towards the intake manifold side.
The AIR vacuum reservoir holds a constant vacuum so that the AIR control valve opens as soon as the AIR switching valve is switched on.
SECONDARY AIR INJECTION PRESSURE SENSOR
The AIR system is monitored by measuring the system pressure by using the AIR pressure sensor at several instances during its cycle of
operation.
The AIR system pressure is measured before operation of the AIR pump. The AIR pump is then switched on and with a one second delay,
the AIR switching valve is opened. After a stabilizing period, the system pressure is measured again, this time by taking the average of a
one second duration of readings, and normalising for variations in battery voltage and atmospheric pressure. If the system pressure
measured at this time has not risen enough with respect to the initial AIR pressure reading then a failure will be flagged.
A second pressure measurement is made after the requirement for AIR into the exhaust system has expired, but continuing on from the
same period of AIR pump operation, i.e. the pump is left running, against a closed AIR switching valve. Again this pressure measurement is
the average of a one second duration of readings normalised for variations in battery voltage and atmospheric pressure. If the system
pressure measured at this time has not risen enough or has risen too much with respect to the system pressure during normal operation of
AIR then a failure will be flagged.
A final pressure reading is taken after the AIR system has been switched off to ensure the system shuts down.
Engine Emission Control - V6 3.0L Petrol - Engine Emission Control
For a detailed description of the Engine Emission Control system, refer to the relevant Description and Operation sections in the workshop
manual. REFER to: (303-08B Engine Emission Control - V6 3.0L Petrol)

Visual Inspection
Engine breather hoses Fuses
Cyclone separator Wiring harness
Exhaust gas recirculation (EGR) pipes (check for cracks) Loose or corroded electrical connectors
EGR valve Sensor(s)
Secondary air injection (AIR) pump Stepper motor(s)
Secondary air injection (AIR) valve Secondary air injection (AIR) pump
Secondary air injection (AIR) valve
step.
4. 4. If the cause is not visually evident, verify the customer concern and refer to the Symptom Chart below, alternatively, check for
Symptom Chart

Engine cranks, but does not Engine breather system Ensure the engine breather system is free from restriction and is
fire disconnected/restricted correctly installed
Difficult to start cold Exhaust gas recirculation (EGR) Check for related DTCs and refer to the relevant DTC Index
valve stuck open
disconnected/restricted correctly installed
Engine stops/stalls EGR valve stuck open Check for related DTCs and refer to the relevant DTC Index
Poor idle quality EGR valve stuck open Check for related DTCs and refer to the relevant DTC Index
Engine hesitates/poor EGR valve stuck open Check for related DTCs and refer to the relevant DTC Index
acceleration
disconnected/restricted correctly installed
Excessive fuel consumption, EGR valve stuck open Check for related DTCs and refer to the relevant DTC Index. Ensure
black smoke, emissions EGR system not operating the engine breather system is free from restriction and is correctly
Engine breather system restricted installed
Loud 'ticking' noise with EGR pipes cracked Inspect the EGR pipes, paying particular attention to the ribbed
engine running sections. Replace as required
Engine oil leaks Engine breather system restricted Ensure the engine breather system is free from restriction and is
correctly installed
DTC Index
3548-1358-00.
module/component.
NOTE: If DTCs are recorded and, after the pinpoint tests have been carried out, the fault is not present, an intermittent concern may be
DTC Description Possible Causes Action

P040100 Exhaust Gas Recirculation Flow EGR valve/pipe Check for correct installation of the EGR valve and pipe. Check for
Insufficient Detected incorrectly installed or blockage in EGR valve and pipe. Check for stuck EGR valve. Check
loose and install a new EGR valve as required
EGR pipe blocked
EGR valve stuck closed,
blocked
EGR valve failure
P041100 Secondary Air Injection Low airflow being Check AIR pump, vacuum solenoid and AIR control valve hardware.
Incorrect Upstream Flow delivered from secondary Refer to the electrical circuit diagrams and check AIR pump and
Detected air injection (AIR) pump vacuum solenoid power supply circuits. Check stuck/partially stuck
vacuum solenoid. Check for loose/split vacuum pipe from solenoid
to AIR control valve. Check for loose/split AIR pump outlet pipe
P041300 Secondary Air Injection AIR vacuum solenoid Refer to the electrical circuit diagrams and check AIR vacuum
Switching Valve A Circuit Open control circuit high solenoid control circuit for short to power
P041400 Secondary Air Injection AIR vacuum solenoid Refer to the electrical circuit diagrams and check AIR vacuum
Switching Valve A Circuit control circuit low solenoid control circuit for short to ground, high resistance
Shorted
P048900 Exhaust Gas Recirculation EGR valve power supply Carry out any pinpoint tests associated with this DTC using the
Control Circuit Low circuit - short to ground, manufacturer approved diagnostic system. Refer to the electrical
high resistance circuit diagrams and check EGR valve power supply circuit for short
to ground, high resistance
P049000 Exhaust Gas Recirculation EGR valve control circuit Carry out any pinpoint tests associated with this DTC using the
Control Circuit High - short to power manufacturer approved diagnostic system. Refer to the electrical
circuit diagrams and check EGR valve control circuit for short to
power
P049100 Secondary Air Injection System Low airflow being Check (Bank 1) AIR system pipe for blockage. Check for loose/split
Insufficient Flow (Bank 1) delivered to secondary AIR pump outlet pipe
air injection (AIR)
system (Bank 1)
P049200 Secondary Air Injection System Low airflow being Check (Bank 2) AIR system pipe for blockage. Check for loose/split
Insufficient Flow (Bank 2) delivered to secondary AIR pump outlet pipe
air injection (AIR)
system (Bank 2)
P243100 Secondary Air Injection System Secondary air injection Carry out any pinpoint tests associated with this DTC using the
Air Flow/Pressure Sensor system leaks manufacturer approved diagnostic system. Refer to the electrical
Circuit Range/Performance Secondary air injection circuit diagrams and check secondary air injection system circuits
Bank 1 pump for short, open circuit. Check the integrity of the secondary air
Secondary air injection injection system
valve
Air Flow/Pressure Sensor manifold absolute manufacturer approved diagnostic system. Refer to the electrical
Circuit Low Bank 1 pressure sensor circuit - circuit diagrams and check secondary air injection manifold
short to ground, high absolute pressure sensor circuit for short to ground, high
resistance resistance
Air Flow/Pressure Sensor manifold pressure (MAP) manufacturer approved diagnostic system. Refer to the electrical
Circuit High Bank 1 sensor circuit - short to circuit diagrams and check secondary air injection manifold
power pressure (MAP) sensor circuit for short to power
Pump Stuck On Bank 1 pump control circuit - manufacturer approved diagnostic system. Refer to the electrical
short to ground circuit diagrams and check secondary air injection pump control
Pump Stuck Off Bank 1 pump control circuit - manufacturer approved diagnostic system. Refer to the electrical
short to power circuit diagrams and check secondary air injection pump control
circuit for short to power
Engine Emission Control - V6 3.0L Petrol - Secondary Air Injection (AIR) Control Valve
Removal
1. Remove the secondary air injection (AIR) control valve to exhaust
manifold right-hand tube.
Control Valve to Exhaust Manifold Tube RH (303-08B Engine Emission
Control - V6 3.0L Petrol, Removal and Installation).
3. Disconnect the AIR switching valve electrical connector.
4. Disconnect the AIR switching valve vacuum hoses.
5. Detach the AIR wiring harness.
6. Disconnect the AIR control valve vacuum hose.

7. NOTE: Note the position of the timing marks on the AIR control valve
and the AIR supply hose.
Disconnect the AIR supply hose.
8. Remove the AIR control valve and bracket assembly.
Installation
Tighten to 8 Nm.
If required, carry out a short drive cycle.

Short Drive Cycle Self-Test (303-14C, General Procedures).
to Exhaust Manifold Tube LH
Removal

2. NOTE: Note the position of the timing mark on the secondary air
injection (AIR) control valve to exhaust manifold left-hand tube. The
timing mark indicates the correct end of the AIR control valve to exhaust
manifold left-hand tube that should be connected to the AIR control valve
to exhaust manifold right-hand tube.
Disconnect the secondary air injection (AIR) control valve to exhaust

manifold left-hand tube.

Installation).
4. Remove the AIR control valve to exhaust manifold left-hand tube from
the left-hand exhaust manifold.
Installation
Tighten to 35 Nm.
2. NOTE: Make sure that the timing mark on the AIR control valve to
exhaust manifold left-hand tube is correctly aligned.
Tighten to 35 Nm.
to Exhaust Manifold Tube RH
Removal

4. Disconnect the secondary air injection (AIR) control valve to exhuast
manifold right-hand tube from the right-hand exhaust manifold.
5. Disconnect the AIR control valve to exhaust manifold left-hand tube.
6. Disconnect the AIR control valve to exhaust manifold right-hand tube.

Installation).
8. Remove the AIR control valve to exhaust manifold right-hand tube.
Installation
Tighten to 8 Nm.
Engine Emission Control - V6 3.0L Petrol - Secondary Air Injection (AIR) Pump
Removal


3. Disconnect the secondary air injection (AIR) pump electrical connector.
4. Disconnect the AIR pump hose.
5. Remove the AIR pump and bracket assembly.

access only.
Remove the 3 nuts.
Remove the AIR pump and bracket assembly.
Installation
Tighten to 8 Nm.
2. Tighten to 9 Nm.
3. Tighten to 8 Nm.

Engine Emission Control - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8 -
Exhaust gas recirculation (EGR) valve to intake manifold retaining bolts 10 7 -
EGR valve tube to EGR valve retaining bolts 21 15 -
Exhaust manifold to EGR valve tube retaining nuts 21 15 -
Secondary air injection (AIR) control valve to exhaust manifold tube retaining nuts 35 26 -
AIR control valve to exhaust manifold tube to exhaust manifold adaptor 35 26 -
AIR control valve retaining bolts 25 18 -
AIR pump retaining nuts 9 - 80
AIR pump retaining bolt 9 - 80
AIR vacuum reservoir retaining bolts 5 - 44
Engine Emission Control - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8 - Engine
Emission Control - Component Location
NATURALLY ASPIRATED ENGINE
ItemDescription
1 AIR (secondary air injection) vacuum reservoir
2 PCV (positive crankcase ventilation) valve
4 Gas transfer pipe
6 AIR pump
7 AIR control valve
SUPERCHARGED ENGINE
ItemDescription
1 PCV valve
2 AIR vacuum reservoir
3 EGR valve
4 Gas transfer pipe
7 AIR pump
8 AIR control valve
Emission Control - Overview
OVERVIEW
The engine emission control system on the 4.2L engines (Supercharged and NA) comprise:
Crankcase ventilation system

AIR (secondary air injection) system
The crankcase ventilation system consists of two hoses, connected between the left-hand valve cover and the intake
manifold and the right-hand valve cover and the air cleaner outlet pipe and a PCV (positive crankcase ventilation) valve
located on the top on the LH (left-hand) engine cam cover. The PCV system recycles crankcase gases back through the
engine where they mix with incoming air/fuel charge and help to reduce hydrocarbon emissions.
The AIR system comprises the following components:
AIR pump
AIR switching valve
AIR control valve
AIR vacuum reservoir
AIR pump relay
AIR pressure sensor (North American specification vehicles only)
Emission Control - System Operation and Component Description
System Operation
CRANKCASE VENTILATION
The engine is ventilated through a part load and a full load breather. The part load breather is a flexible composite hose
connected between the PCV (positive crankcase ventilation) valve mounted above the oil separator in the RH (right-hand)
bank camshaft cover and the induction elbow.
SECONDARY AIR INJECTION

AIR (secondary air injection) is fitted to the vehicle to reduce exhaust emissions to meet European Union (EU) Stage 4 and
Federal Petrol Emission standards. The AIR system comprises:
AIR pump
AIR valve
Associated pipes
AIR pressure sensor (NAS only)
The AIR pump is used to provide a supply of air into the exhaust manifolds during the cold start period of the engine. The
AIR cycle lasts for up to 65 seconds. The hot unburnt fuel particles leaving the combustion chamber mix with the air
injected into the exhaust manifolds and immediately combust.
This subsequent combustion of the unburnt and partially burnt CO (carbon monoxide) and HC (hydrocarbon) particles help
to reduce the emission of these pollutants from the exhaust system. The additional heat generated in the exhaust
manifold also provides rapid heating of the exhaust system catalytic converters. The additional oxygen which is delivered
to the catalytic converters also generates an exothermic reaction which causes the catalytic converters to reach their
optimum operating temperature and 'light off' quickly.
The catalytic converters only start to provide effective treatment of emission pollutants when they reach an operating
temperature of approximately 250C (482F) and need to be between temperatures of 400C (752F) and 800C (1472F)
for optimum efficiency. Consequently, the heat produced by the AIR 'afterburning' reduces the time delay before the
catalysts reach an efficient operating temperature.
EGR SYSTEM
The EGR (exhaust gas recirculation) system comprises of an EGR valve and exhaust manifold to EGR valve tube. The EGR
system allows a measured quantity of exhaust gas to be directed back to the intake manifold. The exhaust gas is
introduced to the incoming charge air in the intake manifold, where it mixes with the air/fuel mixture and lowers the peak
gas temperature, reducing NOX (oxides of nitrogen) exhaust emissions. The gas is drawn through the exhaust manifold to
EGR valve tube from the exhaust to the inlet manifold through the EGR valve. The EGR valve is electrically operated and is
controlled through an input from the ECM (engine control module).
The ECM monitors the operation of the EGR system from inputs from the MAP (manifold absolute pressure) sensor and can
detect high or low flow through the valve as a result of changes to the pressure readings.
High or low flow outside the expected range results in the setting of a DTC (diagnostic trouble code).
On vehicles without a supercharger the MAP sensor is mounted on the rear of intake manifold. On vehicles with a
supercharger the MAP sensor is mounted on the rear of the throttle body elbow.)
POSITIVE CRANKCASE VENTILATION VALVE
The PCV valve is a spring loaded valve that opens when the engine is under full load. Once open the valve allows
crankcase gasses to flow to the intake manifold. The PCV valve also prevents reverse flow into the crankcase.
SECONDARY AIR INJECTION PUMP

The AIR pump is fitted on rubber mountings to help prevent noise which is generated by AIR pump operation. The AIR
pump is powered from the vehicle battery by a dedicated relay and supplies approximately 10 to 15 kg/hr (22 to 33 lb/hr)
of air when the engine is at idle speed and the ambient temperature is below 20C (68F).
Air is drawn into the AIR pump through vents in its front cover and is then passed through a foam filter. The air is
delivered to the exhaust manifold on each side of the engine through a combination of plastic pipes and stainless steel
tubes.
One second after the AIR pump is energized, the ECM switches on the AIR switching valve, which opens to allow vacuum
from the AIR vacuum reservoir to be applied to the vacuum operated AIR control valve. W hen the vacuum is applied to the
AIR control valve, it opens to allow the air from the AIR pump through to the exhaust manifolds.
When the ECM switches off the AIR switching valve, the vacuum supply to the AIR control valve is cut-off and the valve
closes to prevent further air being injected into the exhaust manifolds. W ith an approximate five second delay after as the
AIR switching valve is closed, the ECM removes power from the AIR pump relay, and this in turn stops the AIR pump from
operating.
SECONDARY AIR INJECTION SWITCHING VALVE
The ECM switches on the AIR switching valve with a one second delay after initiating AIR pump operation. When the AIR
switching valve is open, a steady vacuum supply is allowed through to open the vacuum operated AIR control valve. When
the ECM switches off the AIR switching valve, the valve closes and immediately shuts off the vacuum supply to the AIR
control valve. The pump continues to operate for a further five seconds for system diagnostic purposes.
When the AIR switching valve is switched off, the vacuum supply line opens to atmosphere, and this causes the AIR
switching valve to close automatically to prevent any further injection of air.
SECONDARY AIR INJECTION CONTROL VALVE

The injected air from the AIR pump is controlled by the AIR control valve. This allows the correct amount of air to be
injected directly into the exhaust manifolds. The AIR control valve prevents exhaust gasses from blowing back into the AIR
pump. Vacuum to the AIR switching valve is provided from the intake manifold vacuum by the AIR vacuum reservoir. A
small bore vacuum hose provides the vacuum route between the AIR vacuum reservoir and AIR switching valve. A further
small bore vacuum hose is used to connect the AIR switching valve to the AIR control valve.
The AIR control valve is assisted in operation by a vacuum source from the AIR vacuum reservoir located in the right-hand
side of the engine bay. This assistance allows the actuation of the AIR control valve independently from the intake
manifold vacuum levels available.
When the pressure in the exhaust system is higher than in the AIR system, the AIR control valve closes the circuit, and
this protects the AIR system from exhaust gasses blowing back into the AIR system.
Vacuum to the AIR switching valve is provided from the intake manifold vacuum by the AIR vacuum reservoir. A small bore
vacuum hose provides the vacuum route between the AIR vacuum reservoir and AIR switching valve. A further small bore
vacuum hose is used to connect the AIR switching valve to the AIR control valve.
SECONDARY AIR INJECTION RESERVOIR
The AIR vacuum reservoir is included in the vacuum supply line between the intake manifold and the AIR switching valve.
The AIR vacuum reservoir contains a one-way valve to stop vacuum leaking back towards the intake manifold side.
The AIR vacuum reservoir holds a constant vacuum so that the AIR control valve opens as soon as the AIR switching valve
is switched on.
SECONDARY AIR INJECTION PRESSURE SENSOR (NAS only)

The AIR system is monitored by measuring the system pressure by using the AIR pressure sensor at several instances
during its cycle of operation.
The AIR system pressure is measured before operation of the AIR pump. The AIR pump is then switched on and with a one
second delay, the AIR switching valve is opened. After a stabilizing period, the system pressure is measured again, this
time by taking the average of a one second duration of readings, and normalizing for variations in battery voltage and
atmospheric pressure. If the system pressure measured at this time has not risen enough with respect to the initial AIR
pressure reading then a failure will be flagged.
A second pressure measurement is made after the requirement for AIR into the exhaust system has expired, but
continuing on from the same period of AIR pump operation, i.e. the pump is left running, against a closed AIR switching
valve. Again this pressure measurement is the average of a one second duration of readings normalized for variations in
battery voltage and atmospheric pressure. If the system pressure measured at this time has not risen enough or has risen
too much with respect to the system pressure during normal operation of AIR then a failure will be flagged.
A final pressure reading is taken after the AIR system has been switched off to ensure the system shuts down.
EGR VALVE
The EGRvalve is a 4 pole 60 point stepper motor with an integral cooler unit which is mounted on the side of the induction
elbow. The EGR valve receives four 12 Volt signals from the ECM. The EGR valve is cooled by the return coolant flow from
the electric throttle. The EGR valve is connected to the LH (left-hand) exhaust manifold via the gas transfer pipe.
Emission Control
For a detailed description of the Engine Emission Control system, refer to the relevant Description and Operation sections
in the workshop manual. REFER to: (303-08 Engine Emission Control - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8)

vehicle.
Visual Inspection
Engine breather hoses Fuses
Cyclone separator Wiring harness
Exhaust gas recirculation (EGR) pipes (check for cracks) Loose or corroded electrical connectors
EGR valve Sensor(s)
Secondary air injection (AIR) pump Stepper motor(s)
Secondary air injection (AIR) valve Secondary air injection (AIR) pump
Secondary air injection (AIR) valve
4. 4. If the cause is not visually evident, verify the customer concern and refer to the Symptom Chart below,
Symptom Chart

Engine cranks, but does Engine breather system Ensure the engine breather system is free from
not fire disconnected/restricted restriction and is correctly installed
Difficult to start cold Exhaust gas recirculation (EGR) Check for related DTCs and refer to the relevant DTC
valve stuck open Index
Engine stalls soon after Breather system Ensure the engine breather system is free from
start disconnected/restricted restriction and is correctly installed
Engine stops/stalls EGR valve stuck open Check for related DTCs and refer to the relevant DTC
Index
Poor idle quality EGR valve stuck open Check for related DTCs and refer to the relevant DTC
Index
Engine hesitates/poor EGR valve stuck open Check for related DTCs and refer to the relevant DTC
acceleration Index
disconnected/restricted restriction and is correctly installed
Excessive fuel EGR valve stuck open Check for related DTCs and refer to the relevant DTC
consumption, black smoke, EGR system not operating Index. Ensure the engine breather system is free from
emissions Engine breather system restriction and is correctly installed
restricted
Loud 'ticking' noise with EGR pipes cracked Inspect the EGR pipes, paying particular attention to
engine running the ribbed sections. Replace as required
Engine oil leaks Engine breather system Ensure the engine breather system is free from
restricted restriction and is correctly installed
DTC Index
NOTE: If DTCs are recorded and, after the pinpoint tests have been carried out, the fault is not present, an intermittent
concern may be the cause. Always check for loose connections and corroded terminals.

P040100 Exhaust Gas Recirculation EGR valve/pipe Check for correct installation of the EGR valve and pipe.
Flow Insufficient Detected incorrectly installed Check for blockage in EGR valve and pipe. Check for
or loose stuck EGR valve. Check and install a new EGR valve as
EGR pipe blocked required
EGR valve stuck
closed, blocked
EGR valve failure
P041100 Secondary Air Injection Low airflow being Check AIR pump, vacuum solenoid and AIR control
Incorrect Upstream Flow delivered from valve hardware. Refer to the electrical circuit diagrams
Detected secondary air and check AIR pump and vacuum solenoid power supply
injection (AIR) pump circuits. Check stuck/partially stuck vacuum solenoid.
Check for loose/split vacuum pipe from solenoid to AIR
control valve. Check for loose/split AIR pump outlet
pipe
P041300 Secondary Air Injection AIR vacuum solenoid Refer to the electrical circuit diagrams and check AIR
Switching Valve A Circuit control circuit high vacuum solenoid control circuit for short to power
Open
P041400 Secondary Air Injection AIR vacuum solenoid Refer to the electrical circuit diagrams and check AIR
Switching Valve A Circuit control circuit low vacuum solenoid control circuit for short to ground, high
Shorted resistance
P048900 Exhaust Gas Recirculation EGR valve power Carry out any pinpoint tests associated with this DTC
Control Circuit Low supply circuit - short using the manufacturer approved diagnostic system.
to ground, high Refer to the electrical circuit diagrams and check EGR
resistance valve power supply circuit for short to ground, high
resistance
P049000 Exhaust Gas Recirculation EGR valve control Carry out any pinpoint tests associated with this DTC
Control Circuit High circuit - short to using the manufacturer approved diagnostic system.
power Refer to the electrical circuit diagrams and check EGR
valve control circuit for short to power
P049100 Secondary Air Injection Low airflow being Check (Bank 1) AIR system pipe for blockage. Check for
System Insufficient Flow delivered to loose/split AIR pump outlet pipe
(Bank 1) secondary air
injection (AIR)
system (Bank 1)
P049200 Secondary Air Injection Low airflow being Check (Bank 2) AIR system pipe for blockage. Check for
System Insufficient Flow delivered to loose/split AIR pump outlet pipe
(Bank 2) secondary air
injection (AIR)
system (Bank 2)
P243100 Secondary Air Injection Secondary air Carry out any pinpoint tests associated with this DTC
System Air Flow/Pressure injection system using the manufacturer approved diagnostic system.
Sensor Circuit leaks Refer to the electrical circuit diagrams and check
Range/Performance Bank 1 Secondary air secondary air injection system circuits for short, open
injection pump circuit. Check the integrity of the secondary air
Secondary air injection system
injection valve
System Air Flow/Pressure injection manifold using the manufacturer approved diagnostic system.
Sensor Circuit Low Bank 1 absolute pressure Refer to the electrical circuit diagrams and check
sensor circuit - short secondary air injection manifold absolute pressure
to ground, high sensor circuit for short to ground, high resistance
resistance
System Air Flow/Pressure injection manifold using the manufacturer approved diagnostic system.
Sensor Circuit High Bank 1 pressure (MAP) Refer to the electrical circuit diagrams and check
sensor circuit - short secondary air injection manifold pressure (MAP) sensor
to power circuit for short to power
System Pump Stuck On Bank injection pump using the manufacturer approved diagnostic system.
1 control circuit - short Refer to the electrical circuit diagrams and check
to ground secondary air injection pump control circuit for short to
ground
System Pump Stuck Off injection pump using the manufacturer approved diagnostic system.
Bank 1 control circuit - short Refer to the electrical circuit diagrams and check
to power secondary air injection pump control circuit for short to
power
Engine Emission Control - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8 - Exhaust
Gas Recirculation (EGR) Valve4.2L NA V8 - AJV8
Removal
Procedures).
Installation).
4. WARNING: Since injury such as scalding could be

caused by escaping steam or coolant, allow the vehicle cooling
system to cool prior to carrying out this procedure.

contamination.
Disconnect the 2 EGR valve coolant hoses.
Clamp the EGR coolant hoses to minimize coolant loss.
5. Release the EGR valve to exhaust manifold pipe.
Remove the 2 nuts.

6. Release the EGR valve from the throttle body elbow.
Remove the 2 bolts.
Remove the 2 bolts.
Installation
1. Attach the EGR valve to the EGR valve pipe.
2. Attach the EGR valve to the throttle body elbow.

3. Attach the EGR valve to exhaust manifold pipe.
Tighten the nuts to 25 Nm (18 lb.ft).

Installation).
Battery, Mounting and Cables, Specifications).
8. Check and top-up the coolant.

For additional information, refer to: Powertrain Control Module
(PCM) Long Drive Cycle Self-Test (303-14C, General
Procedures).
Gas Recirculation (EGR) Valve4.2L SC V8 - AJV8
Removal


stands.
3. Refer to: Cooling System Draining, Filling and Bleeding (303-03A

Engine Cooling - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8, General
Procedures).
4. Refer to: Secondary Bulkhead Panel RH - 2.7L V6 - TdV6/3.0L NA V6

- AJ27/4.2L NA V8 - AJV8/4.2L SC V8 - AJV8 (501-02 Front End Body
5. Refer to: Throttle Body (303-04B Fuel Charging and Controls - 4.2L

coolant.
7.

coolant.
9.
10.
11.
12. 12. CAUTION: Discard the bolts.
Torque: 10 Nm
13. 13. CAUTION: Discard the nuts.
Torque: 21 Nm
Torque: 21 Nm
Installation
2. 2. NOTE: For NAS vehicles only.

Manifold to Exhaust Gas Recirculation (EGR) Valve Tube4.2L NA V8 - AJV8
Removal
Procedures).
Installation).
For additional information, refer to: Intake Manifold (303-01A
4. Remove the exhaust gas recirculation (EGR) valve inlet
tube.
Installation

Manifold to Exhaust Gas Recirculation (EGR) Valve Tube4.2L SC V8 - AJV8
Removal

2. Refer to: Exhaust Gas Recirculation (EGR) Valve - 4.2L SC V8 - AJV8

(303-08 Engine Emission Control - 4.2L NA V8 - AJV8/4.2L SC V8 -
Torque: 21 Nm
Installation

Engine Emission Control - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8 - Secondary
Air Injection (AIR) Control Valve to Exhaust Manifold Tube
Removal

2. Refer to: Secondary Air Injection (AIR) Control Valve - 4.2L SC V8 -

AJV8 (303-08 Engine Emission Control - 4.2L NA V8 - AJV8/4.2L SC
V8 - AJV8, Removal and Installation).
6.
7.
8.
9. Torque: 8 Nm
10.
stands.

12. Torque: 8 Nm
13. Torque: 8 Nm
14.
15. Torque: 8 Nm
16. Torque: 8 Nm
17.
18. Torque: 8 Nm
19. Torque: 35 Nm
20. Torque: 35 Nm
Installation

Air Injection (AIR) Control Valve4.2L NA V8 - AJV8
Removal
Procedures).
Installation).
3. Release the AIR tube from the AIR control valve.
Remove the 2 bolts.
4. Release the AIR control valve.
5. Remove the AIR control valve.
Release the clip and disconnect the hose.
Installation
2. Attach the AIR control valve hose.
3. Tighten to 25 Nm

(PCM) Short Drive Cycle Self-Test (303-14C, General
Procedures).
Air Injection (AIR) Control Valve4.2L SC V8 - AJV8
Removal


stands.
3. Refer to: Air Cleaner Outlet Pipe (303-12, Removal and Installation).
4. Refer to: Cooling System Draining, Filling and Bleeding (303-03A

Engine Cooling - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8, General
Procedures).
5.
6.
7. Torque: 35 Nm
8. Torque: 25 Nm
9.
Installation

Air Injection (AIR) Pump
Removal


3. Disconnect the secondary air injection (AIR) pump electrical
connector.
4. Disconnect the AIR pump hose.
5. Remove the AIR pump and bracket assembly.

Remove the 3 nuts.
Tighten to 8 Nm.
Installation
Tighten to 8 Nm.
2. Tighten to 9 Nm.
3. Tighten to 8 Nm.

Procedures).
Air Injection Manifold Absolute Pressure Sensor
Removal
1. Remove the secondary air injection manifold absolute
pressure sensor.
Disconnect the hose.
Installation
Tighten to 5 Nm.

Procedures).
Intake Air Distribution and Filtering - TDV6 2.7L Diesel -
Air cleaner retaining bolt 8 - 71
Intake Air Distribution and Filtering - TDV6 2.7L Diesel - Intake Air Distribution and
Filtering - Component Location
ItemDescription
1 RH (right-hand) intake manifold
2 RH port deactivation actuator
3 Electric throttle body
4 Charge air temperature sensor
5 LH (left-hand) intake manifold
7 LH turbo
8 LH turbo to charge air cooler pipe
9 Air cleaner to turbo pipe
10 Turbo to charge air cleaner 'T' piece
11 Air cleaner box
12 MAF (mass air flow)/IAT (intake air temperature) sensors
13 Dirty air intake
14 Charge air cooler
15 Charge air cooler to throttle pipe
16 RH turbo to charge air cooler pipe
17 RH exhaust manifold
18 RH Turbo
Filtering - Overview
Authoring Template
OVERVIEW
The intake air distribution system comprises:
Twin MAF (mass air flow)/IAT (intake air temperature)

Charge air temperature sensor
Air cleaner and air cleaner housing
Charge air cooler
Twin turbochargers
Intake port deactivation system
Air is drawn in from the vehicle exterior via the intake duct, at the front of the engine to the air cleaner box. The air passes through the air
cleaner and exits the air cleaner housing via 2 ports. The clean air then passes through two MAF/IAT sensors and is drawn down to the
turbochargers. The turbochargers force the air up to the charge air cooler via a T piece and out to the electric throttle, where it then flows
into the respective intake air manifolds and down to the cylinder heads.
Filtering - System Operation and Component Description
System Operation
Filtering
For a detailed description of the diesel engine air intake distribution and filtering system, refer to the relevant Description and Operation
sections in the workshop manual. REFER to: (303-12A Intake Air Distribution and Filtering - TDV6 2.7L Diesel)
Intake Air Distribution and Filtering (Description and Operation),

Intake Air Distribution and Filtering (Description and Operation),
Intake Air Distribution and Filtering (Description and Operation).
Visual Inspection
Hoses and ducts (damage/connections) Mass Air Flow (MAF) sensor
Air cleaner element (contaminated/blocked) Secondary Air Injection (AIR), Manifold Absolute Pressure (MAP) sensors
Restricted air intake Throttle body
Seals and gaskets Harness (security/damage)
Connections (security/damage)
step.
Symptom Chart

Vehicle does not Restricted/blocked air intake Ensure the air intake system is free from blockage and is correctly
start/hard starting/poor Restricted/blocked air cleaner installed. Install a new air cleaner element as required.
performance element REFER to: Air Cleaner Element (303-12A Intake Air Distribution and
Filtering - TDV6 2.7L Diesel, Removal and Installation).
Excessive intake noise Intake pipe Check for correct installation and integrity of air intake system. Check for
disconnected/damaged after the correct installation and integrity of the air cleaner assembly. REFER to:
air cleaner (303-12A Intake Air Distribution and Filtering - TDV6 2.7L Diesel)
Air cleaner assembly incorrectly Air Cleaner (Removal and Installation),
assembled/damaged Air Cleaner Element (Removal and Installation).
DTC Index
3548-1358-00.
module/component.

P007C16 Charge Air Cooler Circuit voltage below Carry out any pinpoint tests associated with this DTC using the manufacturer
Temperature Sensor threshold approved diagnostic system. Refer to the electrical circuit diagrams and check
Circuit Low charge air cooler temperature sensor signal circuit for short to ground. Check
and install a new sensor as required
P007D17 Charge Air Cooler Circuit voltage above Refer to the electrical circuit diagrams and check charge air cooler
Temperature Sensor threshold temperature sensor signal circuit for short to power. Check and install a new
Circuit High sensor as required
P007E27 Charge Air Cooler Signal rate of change Carry out any pinpoint tests associated with this DTC using the manufacturer
Temperature Sensor above threshold approved diagnostic system. Refer to the electrical circuit diagrams and check
Intermittent/Erratic charge air cooler temperature sensor circuits for poor connections. Check and
P010036 Mass or Volume Air MAF sensor A signal Carry out any pinpoint tests associated with this DTC using the manufacturer
Flow A Circuit circuit - signal approved diagnostic system. Check for additional DTCs and refer to relevant
frequency too low DTC Index. Refer to the electrical circuit diagrams and check MAF sensor A
signal circuit for short to ground, power, open circuit. Check 'Frequential
mass air flow A' datalogger signal, if reading outside of parameters 40-50
kg/h, install a new MAF sensor and re-test
P010116 Mass or Volume Air Circuit voltage below Carry out any pinpoint tests associated with this DTC using the manufacturer
Flow Sensor A/B threshold approved diagnostic system. Check for additional DTCs and refer to relevant
Correlation DTC Index. Refer to the electrical circuit diagrams and check MAF sensor A
mass air flow A' datalogger signal , if reading is below 40 kg/h, install a new
MAF sensor and re-test
P010117 Mass or Volume Air Circuit voltage above Carry out any pinpoint tests associated with this DTC using the manufacturer
Flow Sensor A/B threshold approved diagnostic system. Check for additional DTCs and refer to relevant
Correlation DTC Index. Refer to the electrical circuit diagrams and check MAF sensor A
mass air flow A' datalogger signal, if reading is above 50 kg/h, install a new
MAF sensor and re-test
P010221 Mass or Volume Air Signal amplitude < Carry out any pinpoint tests associated with this DTC using the manufacturer
Flow A Circuit Low minimum approved diagnostic system. Check low pressure air intake system for leaks
and integrity. Refer to the electrical circuit diagrams and check MAF sensor A
signal circuit for short to ground, power, open circuit. Check for sticking EGR
valve
P010322 Mass or Volume Air Signal amplitude > Carry out any pinpoint tests associated with this DTC using the manufacturer
Flow A Circuit High maximum approved diagnostic system. Check high pressure air intake system for leaks
and integrity. Check for signs of water ingress around air cleaner, intake and
MAF sensor. Refer to the electrical circuit diagrams and check MAF sensor A
signal circuit for short to ground, power, open circuit
P010438 Mass or Volume Air Signal frequency Carry out any pinpoint tests associated with this DTC using the manufacturer
Flow A Circuit incorrect approved diagnostic system. Refer to the electrical circuit diagrams and check
Intermittent/Erratic MAF sensor A signal circuit for short to ground, power, open circuit. W ith
engine at idle speed check and record 'Frequential mass air flow A'
datalogger signal, increase engine speed to 2,000 rpm then check and record
signal. If value changed by more than 110 kg/h, install a new MAF sensor and
re-test
P010A36 Mass or Volume Air Signal frequency too Carry out any pinpoint tests associated with this DTC using the manufacturer
Flow B Circuit low approved diagnostic system. Check for additional DTCs and refer to the
relevant DTC Index. Refer to the electrical circuit diagrams and check MAF
sensor B signal circuit for short to ground, power, open circuit. Check
'Frequential mass air flow B' using datalogger, if reading outside of
parameters 40-50 kg/h, install a new MAF sensor and re-test
P010C21 Mass or Volume Air Signal amplitude < Carry out any pinpoint tests associated with this DTC using the manufacturer
Flow B Circuit Low minimum approved diagnostic system. Check low pressure air intake system for leaks
and integrity. Refer to the electrical circuit diagrams and check MAF sensor B
signal circuit for short to ground, power, open circuit. Check for sticking EGR
valve
P010D22 Mass or Volume Air Signal amplitude > Carry out any pinpoint tests associated with this DTC using the manufacturer
Flow B Circuit High maximum approved diagnostic system. Check high pressure air intake system for leaks
and integrity. Check for signs of water ingress around air cleaner, intake and
MAF sensor. Refer to the electrical circuit diagrams and check MAF sensor B
signal circuit for short to ground, power, open circuit
P010E38 Mass or Volume Air Signal frequency Carry out any pinpoint tests associated with this DTC using the manufacturer
Flow B Circuit incorrect approved diagnostic system. Refer to the electrical circuit diagrams and check
Intermittent/Erratic MAF sensor B signal circuit for short to ground, power, open circuit. W ith
engine at idle speed check and record 'Frequential mass air flow B', increase
engine speed to 2,000 rpm then check and record signal. If value changed by
more than 110 kg/h, install a new MAF sensor and re-test
P010F62 Mass or Volume Air Signal compare failure Check for additional DTCs and refer to the relevant DTC Index. Check for air
Flow Sensor A/B leaks between each MAF sensor and turbocharger inlet. Check for correct
Correlation operation of turbochargers and EGR actuators
P011216 Intake Air Circuit voltage above Carry out any pinpoint tests associated with this DTC using the manufacturer
Temperature Sensor 1 threshold approved diagnostic system. Refer to the electrical circuit diagrams and check
Circuit Low Input Intake air IAT sensor signal circuit for short to ground. Check and install a new sensor
temperature sensor as required
failure
P011317 Intake Air Circuit voltage below Carry out any pinpoint tests associated with this DTC using the manufacturer
Temperature Sensor 1 threshold approved diagnostic system. Refer to the electrical circuit diagrams and check
Circuit High Input Intake air IAT sensor signal circuit for short to power. Check and install a new sensor as
temperature sensor required
failure
P011427 Intake Air Signal rate of change Carry out any pinpoint tests associated with this DTC using the manufacturer
Temperature Sensor 1 above threshold approved diagnostic system. Refer to electrical circuit diagrams and check IAT
Intermittent/Erratic sensor signal circuit for short, open circuit and poor connections. Run engine
to normal operating temperature, check and record 'Intake air temperature'
datalogger signal, after approximately 10 minutes check and record 'Intake
air temperature' signal. If value of signal has increased by more than
P219900 Intake Air Intake Air Refer to the electrical circuit diagrams and check IAT and ACT sensor circuits
Temperature 1/2 Temperature (IAT) or for short to ground, power, open circuit. Check and install a new IAT/ACT
Correlation Air Charge sensor as required
Temperature (ACT)
sensor circuits - short
to ground, power,
open circuit
IAT/ACT sensor
failure
P219921 Intake Air Off-set between Refer to the electrical circuit diagrams and check IAT and ACT sensor circuits
Temperature 1/2 Intake Air for short to ground, power, open circuit. Check and record 'Intake air
Correlation Temperature (IAT) temperature', 'Boost air temperature 0' and 'Boost air temperature 1'
and Air Charge datalogger signals. If value of 'Boost air temperature 0' and 'Boost air
Temperature (ACT) temperature 1' signals are similar, install a new IAT sensor as required. The
sensors 'Boost air temperature 1' temperature should be approximately 15C from
the ambient temperature, after the engine has been running and 'Intake air
temperature' which should have an operating range of approximately +40C
to -30C. Install a new Boost air temperature bank 1 sensor or IAT sensor as
required
P219922 Intake Air Off-set between Refer to the electrical circuit diagrams and check IAT and ACT sensor circuits
Temperature 1/2 Intake Air for short to ground, power, open circuit. Check and record 'Intake air
Correlation Temperature (IAT) temperature', 'Boost air temperature 0' and 'Boost air temperature 1'
and Air Charge datalogger signals. If value of 'Boost air temperature 0' and 'Boost air
Temperature (ACT) temperature 1' signals are similar, install a new IAT sensor as required. The
sensors 'Boost air temperature 1' temperature should be approximately 15C from
the ambient temperature, after the engine has been running and 'Intake air
temperature' which should have an operating range of approximately +40C
to -30C. Install a new Boost air temperature bank 1 sensor or IAT sensor as
required
Intake Air Distribution and Filtering - TDV6 2.7L Diesel - Air Cleaner
Special Tool(s)
303-397
Removal
Release the mass air flow (MAF) sensors wiring harness.
Disconnect the 2 MAF sensor electrical connectors.
Using special tool 303-397, detach the MAF sensor outlet pipes.
Release the upper MAF sensor outlet pipe.
Release the lower MAF sensor outlet pipe.

Disconnect the port deactivation vacuum hose.
5. Release the air intake scoop.
Remove the bolt.
Release from the locating grommet.

access only.
Remove the air intake scoop.
Installation
Tighten to 8 Nm.
Intake Air Distribution and Filtering - TDV6 2.7L Diesel - Air Cleaner Element
Removal
1.
2. TORQUE: 8 Nm
3.
Installation
Intake Air Distribution and Filtering - TDV6 2.7L Diesel - Charge Air Cooler
Removal
CAUTION: Engine coolant will damage the paint finished surfaces. If spilt, immediately remove the coolant and clean the area with
water.


Procedures).
4. Disconnect the coolant top hose from the radiator.
5. Remove the air intake elbow pipe.
6. Detach the charge air cooler intake elbow.

9. Remove the radiator upper mountings.
10. Remove the right-hand A/C condensor retaining bolt.
11. Remove the left-hand A/C condensor retaining stud.

12. Tie the A/C condenser forwards, clear of the radiator.
13. With assistance, remove the radiator assembly.
14. Remove the foam insulation pads.
15. Remove the charge air cooler from the radiator.
1. Remove the charge air cooler retaining bolts.
Installation
Tighten to 7 Nm.
2. Tighten to 7 Nm.
3. Tighten to 7 Nm.
4. Tighten to 7 Nm.
5. Tighten to 7 Nm.
Intake Air Distribution and Filtering - V6 3.0L Petrol -
Air cleaner 8 71
Intake Air Distribution and Filtering - V6 3.0L Petrol - Intake Air Distribution and
Filtering - Component Location
ItemDescription
1 Air cleaner box
2 Dirty air intake
3 Clean air duct
4 Electric throttle
5 Air intake manifold
6 MAP (manifold absolute pressure) sensor
7 Vacuum take off
8 IMT (intake manifold tuning) valve
9 IMT valve
10 MAF (mass air flow) sensor
Filtering - Overview
OVERVIEW
The air induction system comprises:
Dirty air intake duct

Air cleaner and housing
IMT (intake manifold tuning) valves
Air intake manifold
Associated clean air ducts
MAP (manifold absolute pressure)
Electric throttle
Dirty air is drawn through the air intake mounted at the front LH (left-hand) side of the engine compartment and routed into the base of the
air cleaner box. The air cleaner is a replaceable paper filter element which is accessed by removing the top of the air cleaner box. The air is
drawn through the air cleaner out of the air cleaner box past the MAF (mass air flow) along a tube to the electirc throttle. From the electric
throttel the clean air is drawn to the intake manifold. The intake manifold is one unit which is divided into two separate halves. Each half
supplies clean air to one bank of cylinders. Two IMT valves control the airways between the two halves of the intake manifolds.
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 (engine control module) to optimize torque across the engine's speed and load range. The upper IMT valve opens between 4,100
and 6,150 rpm while the lower IMT valve opens between 3,900 and 6,150 rpm.
Filtering - System Operation and Component Description
System Operation
Refer to: Intake Air Distribution and Filtering (303-12B Intake Air Distribution and Filtering - V6 3.0L Petrol, Description and Operation).
Filtering
For a detailed description of the Intake Air Distribution and Filtering system, refer to the relevant Description and Operation sections in the
Intake Air Distribution and Filtering (303-12B Intake Air Distribution and Filtering - V6 3.0L Petrol, Description and Operation),
Intake Air Distribution and Filtering (303-12C Intake Air Distribution and Filtering - V8 4.2L Petrol, Description and Operation),
Intake Air Distribution and Filtering (303-12D Intake Air Distribution and Filtering - V8 S/C 4.2L Petrol, Description and Operation),
Intake Air Distribution and Filtering (303-12D Intake Air Distribution and Filtering - V8 S/C 4.2L Petrol, Description and Operation),
Intake Air Distribution and Filtering (303-12D Intake Air Distribution and Filtering - V8 S/C 4.2L Petrol, Description and Operation).
Visual Inspection
Air cleaner element (contaminated/blocked) Secondary Air Injection (AIR) Manifold Absolute Pressure (MAP) sensor
step.
Symptom Chart

Vehicle does not start/hard Restricted/blocked air intake Ensure the air intake system is free from blockage and is correctly
starting/poor performance Restricted/blocked air cleaner installed. Install a new air cleaner element as necessary. REFER to:
element Air Cleaner Element (303-12B, Removal and Installation),
Air Cleaner Element (303-12C, Removal and Installation),
Air Cleaner Element (303-12D, Removal and Installation).
Excessive intake noise Intake pipe disconnected/damaged Check for correct installation and integrity of air intake system.
after the air cleaner Check for correct installation and integrity of the air cleaner
Air cleaner assembly incorrectly assembly. REFER to:
assembled/damaged Air Cleaner (303-12B, Removal and Installation),
Air Cleaner (303-12C, Removal and Installation),
Air Cleaner LH (303-12D, Removal and Installation),
Air Cleaner RH (303-12D, Removal and Installation).
DTC Index
3548-1358-00.
module/component.
first five digits of the seven digit code listed to identify the fault (the last two digits give additional information read by the manufacturer-
NOTE: If DTCs are logged and, after performing the pinpoint tests, a fault is not present, an intermittent concern may be the cause.

P009623 Intake Air Temperature Charge air cooler air Refer to the electrical circuit diagrams and check charge air cooler air
Sensor 2 Circuit temperature sensor temperature sensor circuit for short to ground, high resistance
Range/Performance circuit - signal stuck low
Sensor 2 Circuit temperature sensor temperature sensor circuit for short to power
Range/Performance circuit - signal stuck
high
Sensor 2 Circuit temperature sensor temperature sensor circuit for short, open circuit. Check and install a new
Range/Performance circuit - signal invalid sensor as required
Charge air cooler air
temperature sensor
failure
P009700 Intake Air Temperature No sub type information Carry out any pinpoint tests associated with this DTC using the
Sensor 2 Circuit Low manufacturer approved diagnostic system. Refer to the electrical circuit
diagrams and check charge air cooler air temperature sensor circuit for
P009800 Intake Air Temperature No sub type information Carry out any pinpoint tests associated with this DTC using the
Sensor 2 Circuit High manufacturer approved diagnostic system. Refer to the electrical circuit
diagrams and check charge air cooler air temperature sensor circuit for
short to power
P010100 Mass or Volume Air Flow Blocked air cleaner Check air cleaner element is free from restriction. Check for leak from air
A Circuit element intake system, rectify as required. Ensure the engine breather system is
Range/Performance Leakage from air intake correctly installed and in serviceable condition. Carry out any pinpoint
system tests associated with this DTC using the manufacturer approved
Engine breather leak diagnostic system. Refer to the electrical circuit diagrams and check MAF
MAF sensor sensing sensor circuit for intermittent short to ground, high resistance. Check and
circuit - high resistance, install a new MAF sensor as required
intermittent short to
ground
MAF sensor supply
circuit - high resistance
MAF sensor failure
P010200 Mass or Volume Air Flow MAF sensor circuits - Carry out any pinpoint tests associated with this DTC using the
A Circuit Low short to ground, high manufacturer approved diagnostic system. Refer to the electrical circuit
resistance diagrams and check MAF sensor circuits for short to power ground, high
MAF sensor ground resistance. Check and install a new MAF sensor as required
MAF sensor failure
P010300 Mass or Volume Air Flow MAF sensor circuits - Carry out any pinpoint tests associated with this DTC using the
A Circuit High short to power manufacturer approved diagnostic system. Refer to the electrical circuit
MAF sensor ground diagrams and check MAF sensor circuits for short to power, ground, high
circuit - high resistance resistance. Check and install a new MAF sensor as required
MAF sensor failure
P010B00 Mass or Volume Air Flow No sub type information Carry out any pinpoint tests associated with this DTC using the
B Circuit manufacturer approved diagnostic system. Refer to the electrical circuit
Range/Performance diagrams and check MAF sensor circuits for short, open circuit
P010C00 Mass or Volume Air Flow MAF sensor circuits - Carry out any pinpoint tests associated with this DTC using the
B Circuit Low short to ground, high manufacturer approved diagnostic system. Refer to the electrical circuit
resistance diagrams and check MAF sensor circuits for short to ground, high
MAF sensor ground resistance. Check and install a new MAF sensor as required
MAF sensor failure
P010D00 Mass or Volume Air Flow MAF sensor circuits - Carry out any pinpoint tests associated with this DTC using the
B Circuit High short to power manufacturer approved diagnostic system. Refer to the electrical circuit
MAF sensor ground diagrams and check MAF sensor circuits for short to power, ground, high
circuit - high resistance resistance. Check and install a new MAF sensor as required
MAF sensor failure
P010F00 Mass or Volume Air Flow Blocked Air cleaner in 1 Carry out any pinpoint tests associated with this DTC using the
Sensor A/B Correlation bank manufacturer approved diagnostic system. Check for any P0101 or P010B
Leakage from intake air DTCs. Check air cleaner is free from restriction. Check for any leaks in the
system intake air system and all joints. Check engine breather system is correctly
Engine breather leak installed and in a serviceable condition. Check flow diffusors are not
Flow Diffusor blocking obstructing MAF sensors. Check and install new MAF sensors as required
MAF sensor
Failure of A bank MAF
sensor
Failure of B bank MAF
sensor
P011123 Intake Air Temperature IAT sensor sensing Carry out any pinpoint tests associated with this DTC using the
Sensor 1 Circuit circuit - high resistance manufacturer approved diagnostic system. Refer to the electrical circuit
Range/Performance IAT sensor failure diagrams and check IAT sensor circuits for short, open circuit, high
resistance. Check and install a new MAF sensor as required
Sensor 1 Circuit Low circuit - high resistance, manufacturer approved diagnostic system. Refer to the electrical circuit
disconnected diagrams and check IAT sensor circuits for short, open circuit, high
IAT sensor failure resistance, disconnected connector. Check and install a new MAF sensor
as required
Sensor 1 Circuit High circuit - short to ground, manufacturer approved diagnostic system. Refer to the electrical circuit
short to power diagrams and check IAT sensor circuits for short, open circuit, high
IAT sensor failure resistance. Check and install a new MAF sensor as required
P050600 Idle Air Control System Air intake restriction Ensure the air intake system is free from restriction. Check the FEAD belt
RPM Lower Than Front End Accessory and components for failure
Expected Drive (FEAD) overload
(defective/seized
component)
P050624 Idle Air Control System Air intake restriction Ensure the air intake system is free from restriction. Check the FEAD belt
RPM Lower Than Front End Accessory and components for failure
(defective/seized
component)
P050700 Idle Air Control System Intake air leak between Check for leakage and correct installation of air intake system. Check for
RPM Higher Than MAF sensor and engine leakage and correct installation of engine crankcase breather system
Expected Engine crankcase
breather leak
P050723 Idle Air Control System Intake air leak between Check for leakage and correct installation of air intake system. Check for
RPM Higher Than MAF sensor and engine leakage and correct installation of engine crankcase breather system
Expected Engine crankcase
breather leak
Intake Air Distribution and Filtering - V6 3.0L Petrol - Air Cleaner
Removal
1.
2.
3.
4. Torque: 8 Nm
5. 5. NOTE: Do not disassemble further if the component is removed for
access only.
6.
7.
Installation

Intake Air Distribution and Filtering - V6 3.0L Petrol - Air Cleaner Outlet Pipe
Removal
1.
2.
Installation

Intake Air Distribution and Filtering - V6 3.0L Petrol - Air Cleaner Element
Removal
1.
2.
3.
4.
Installation

Intake Air Distribution and Filtering - 4.2L NA V8 - AJV8 -
Supercharger outlet pipe retaining nuts 9 - 80
Supercharger outlet pipe retaining bolts 9 - 80
Supercharger retaining bolts 24 18 -
Air intake elbow retaining bolts 24 18 -
Air intake elbow lower bracket retaining bolts 20 15 -
Exhaust gas recirculation (EGR) valve retaining bolts 10 7 -
Exhaust manifold to EGR valve tube retaining bolts 21 15 -
Throttle body intake hose retaining clip 10 7 -
Intake Air Distribution and Filtering - 4.2L NA V8 - AJV8 - Intake Air
Distribution and Filtering - Component Location
ItemDescription
1 Dirty air intake
2 Intake manifold
4 Clean air pipe
5 Electric throttle
7 Air cleaner box
Distribution and Filtering - Overview
Authoring Template
OVERVIEW
The 4.2 Liter NA V8 engine air intake and distribution system comprises:
Air cleaner
Air cleaner box
Air Intake manifold
Electronic throttle
The air cleaner box is located in front of the LH (left-hand) front wheel, inside the engine compartment and contains a
replaceable paper filter element.
Dirty air is drawn through the air intake which is located behind the radiator grill on the LH side and into the air filter box
past the paper filter element. Clean air is then passed over the MAF (mass air flow) sensor located in the ducting directly
behind the air filter box, through the electric throttle and up to the air intake manifold where it is distributed to the
individual cylinders.
The intake manifold is located on top of the engine between the two engine banks. The manifold is manufactured from a
composite material with metal insert fixings. The intake manifold comprises a central chamber with eight tracts leading to
the inlet ports on the engine.
Distribution and Filtering - System Operation and Component Description
System Operation
Refer to: Intake Air Distribution and Filtering (303-12A Intake Air Distribution and Filtering - 4.2L NA V8 - AJV8, Description
and Operation).
Distribution and Filtering
For a detailed description of the Intake Air Distribution and Filtering system, refer to the relevant Description and
Operation sections in the workshop manual. REFER to:
Intake Air Distribution and Filtering (303-12A Intake Air Distribution and Filtering - 4.2L NA V8 - AJV8, Description
and Operation),
and Operation),
and Operation),
Intake Air Distribution and Filtering (303-12B Intake Air Distribution and Filtering - 4.2L SC V8 - AJV8, Description and
Operation),
Operation),
Operation).
vehicle.
Visual Inspection
Air cleaner element Secondary Air Injection (AIR) Manifold Absolute Pressure (MAP)
(contaminated/blocked) sensor
Symptom Chart

Vehicle does not Restricted/blocked air intake Ensure the air intake system is free from blockage and is
start/hard starting/poor Restricted/blocked air cleaner correctly installed. Install a new air cleaner element as
performance element necessary. REFER to:
Air Cleaner Element (303-12A Intake Air
Distribution and Filtering - 4.2L NA V8 - AJV8,
Removal and Installation),
Air Cleaner Element (303-12D, Removal and
Installation).
Excessive intake noise Intake pipe Check for correct installation and integrity of air intake
disconnected/damaged after the system. Check for correct installation and integrity of
air cleaner the air cleaner assembly. REFER to:
Air cleaner assembly incorrectly Air Cleaner (303-12A Intake Air Distribution and
assembled/damaged Filtering - 4.2L NA V8 - AJV8, Removal and
Installation),
Air Cleaner LH (303-12D, Removal and
Installation),
Air Cleaner RH (303-12D, Removal and
Installation).
DTC Index
NOTE: If DTCs are logged and, after performing the pinpoint tests, a fault is not present, an intermittent concern may be

P009623 Intake Air Temperature Charge air cooler air Refer to the electrical circuit diagrams and check charge air
Sensor 2 Circuit temperature sensor cooler air temperature sensor circuit for short to ground,
Range/Performance circuit - signal stuck high resistance
low
Sensor 2 Circuit temperature sensor cooler air temperature sensor circuit for short to power
Range/Performance circuit - signal stuck
high
Sensor 2 Circuit temperature sensor cooler air temperature sensor circuit for short, open circuit.
Range/Performance circuit - signal invalid Check and install a new sensor as required
Charge air cooler air
temperature sensor
failure
P009700 Intake Air Temperature No sub type Carry out any pinpoint tests associated with this DTC using
Sensor 2 Circuit Low information the manufacturer approved diagnostic system. Refer to the
electrical circuit diagrams and check charge air cooler air
temperature sensor circuit for short to ground, high
resistance
P009800 Intake Air Temperature No sub type Carry out any pinpoint tests associated with this DTC using
Sensor 2 Circuit High information the manufacturer approved diagnostic system. Refer to the
electrical circuit diagrams and check charge air cooler air
temperature sensor circuit for short to power
P010100 Mass or Volume Air Blocked air cleaner Check air cleaner element is free from restriction. Check for
Flow A Circuit element leak from air intake system, rectify as required. Ensure the
Range/Performance Leakage from air engine breather system is correctly installed and in
intake system serviceable condition. Carry out any pinpoint tests
Engine breather leak associated with this DTC using the manufacturer approved
MAF sensor sensing diagnostic system. Refer to the electrical circuit diagrams
circuit - high and check MAF sensor circuit for intermittent short to
resistance, ground, high resistance. Check and install a new MAF
intermittent short to sensor as required
ground
MAF sensor supply
circuit - high
resistance
MAF sensor failure
P010200 Mass or Volume Air MAF sensor circuits - Carry out any pinpoint tests associated with this DTC using
Flow A Circuit Low short to ground, high the manufacturer approved diagnostic system. Refer to the
resistance electrical circuit diagrams and check MAF sensor circuits for
MAF sensor ground short to power ground, high resistance. Check and install a
circuit - high new MAF sensor as required
resistance
MAF sensor failure
P010300 Mass or Volume Air MAF sensor circuits - Carry out any pinpoint tests associated with this DTC using
Flow A Circuit High short to power the manufacturer approved diagnostic system. Refer to the
MAF sensor ground electrical circuit diagrams and check MAF sensor circuits for
circuit - high short to power, ground, high resistance. Check and install a
resistance new MAF sensor as required
MAF sensor failure
P010B00 Mass or Volume Air No sub type Carry out any pinpoint tests associated with this DTC using
Flow B Circuit information the manufacturer approved diagnostic system. Refer to the
Range/Performance electrical circuit diagrams and check MAF sensor circuits for
short, open circuit
P010C00 Mass or Volume Air MAF sensor circuits - Carry out any pinpoint tests associated with this DTC using
Flow B Circuit Low short to ground, high the manufacturer approved diagnostic system. Refer to the
resistance electrical circuit diagrams and check MAF sensor circuits for
MAF sensor ground short to ground, high resistance. Check and install a new
circuit - high MAF sensor as required
resistance
MAF sensor failure
P010D00 Mass or Volume Air MAF sensor circuits - Carry out any pinpoint tests associated with this DTC using
Flow B Circuit High short to power the manufacturer approved diagnostic system. Refer to the
MAF sensor ground electrical circuit diagrams and check MAF sensor circuits for
circuit - high short to power, ground, high resistance. Check and install a
resistance new MAF sensor as required
MAF sensor failure
P010F00 Mass or Volume Air Blocked Air cleaner in Carry out any pinpoint tests associated with this DTC using
Flow Sensor A/B 1 bank the manufacturer approved diagnostic system. Check for
Correlation Leakage from intake any P0101 or P010B DTCs. Check air cleaner is free from
air system restriction. Check for any leaks in the intake air system and
Engine breather leak all joints. Check engine breather system is correctly
Flow Diffusor blocking installed and in a serviceable condition. Check flow
MAF sensor diffusors are not obstructing MAF sensors. Check and install
Failure of A bank MAF new MAF sensors as required
sensor
Failure of B bank MAF
sensor
P011123 Intake Air Temperature IAT sensor sensing Carry out any pinpoint tests associated with this DTC using
Sensor 1 Circuit circuit - high the manufacturer approved diagnostic system. Refer to the
Range/Performance resistance electrical circuit diagrams and check IAT sensor circuits for
IAT sensor failure short, open circuit, high resistance. Check and install a new
MAF sensor as required
Sensor 1 Circuit Low circuit - high the manufacturer approved diagnostic system. Refer to the
resistance, electrical circuit diagrams and check IAT sensor circuits for
disconnected short, open circuit, high resistance, disconnected connector.
IAT sensor failure Check and install a new MAF sensor as required
Sensor 1 Circuit High circuit - short to the manufacturer approved diagnostic system. Refer to the
ground, short to power electrical circuit diagrams and check IAT sensor circuits for
P050600 Idle Air Control System Air intake restriction Ensure the air intake system is free from restriction. Check
RPM Lower Than Front End Accessory the FEAD belt and components for failure
(defective/seized
component)
P050624 Idle Air Control System Air intake restriction Ensure the air intake system is free from restriction. Check
RPM Lower Than Front End Accessory the FEAD belt and components for failure
(defective/seized
component)
P050700 Idle Air Control System Intake air leak Check for leakage and correct installation of air intake
RPM Higher Than between MAF sensor system. Check for leakage and correct installation of engine
Expected and engine crankcase breather system
Engine crankcase
breather leak
P050723 Idle Air Control System Intake air leak Check for leakage and correct installation of air intake
RPM Higher Than between MAF sensor system. Check for leakage and correct installation of engine
Expected and engine crankcase breather system
Engine crankcase
breather leak
Intake Air Distribution and Filtering - 4.2L NA V8 - AJV8 - Air Cleaner
Removal
1.
2.
3.
4. Torque: 8 Nm

6.
7.
Installation

Intake Air Distribution and Filtering - 4.2L NA V8 - AJV8 - Air Cleaner Outlet
Pipe
Removal
1. Refer to: Engine Cover - 4.2L NA V8 - AJV8 (501-05 Interior Trim and
2.
3.
Installation

Intake Air Distribution and Filtering - 4.2L NA V8 - AJV8 - Air Cleaner
Element
Removal
1.
2.
3.
4.
Installation

Intake Air Distribution and Filtering - 4.2L SC V8 - AJV8 -
Supercharger outlet pipe retaining nuts 9 - 80
Supercharger outlet pipe retaining bolts 9 - 80
Supercharger retaining bolts 24 18 -
Air intake elbow retaining bolts 24 18 -
Air intake elbow lower bracket retaining bolts 20 15 -
Exhaust gas recirculation (EGR) valve retaining bolts 10 7 -
Exhaust manifold to EGR valve tube retaining bolts 21 15 -
Throttle body intake hose retaining clip 10 7 -
Intake Air Distribution and Filtering - 4.2L SC V8 - AJV8 - Intake Air
Distribution and Filtering - Component Location
ItemDescription
1 RH (right-hand)MAF (mass air flow) sensor
2 Clean air Y piece
3 LH (left-hand) intercooler
4 LH air cleaner box
5 LH intercooler
6 Electric throttle
7 Clean air duct
8 LHMAF sensor
9 RH dirty air intake
10 LH dirty air intake
11 LH air cleaner box
Distribution and Filtering - Overview
OVERVIEW
The engine air intake and distribution system comprises:
Two air cleaner boxes

Two air intakes
Electric throttle
A supercharger
Two MAF (mass air flow) sensors
Two supercharger charge air coolers
Air is supplied to the supercharger via the 2 air cleaners, air cleaner outlet pipes, throttle body intake pipe, throttle body
and induction elbow. The supercharger delivers pressurized air to two separate charge air cooler units mounted onto the
cylinder bank it supplies. Pressurized cooled air is fed from the charge air coolers directly into each inlet port. The
supercharger is attached to the three mounting bosses between the two cylinder heads. The supercharger has a filled for
life internal lubrication system. The supercharger is positively aligned with the drive belt by a doweled mounting bracket.
A MAF sensor is fitted at the outlet of each air cleaner box. The sensor provides an input to the ECM (engine control
module). The intake elbow directs the metered airflow from the throttle body outlet (underside of the throttle body) into
the intake of the supercharger.
A supercharger by-pass valve assembly is located between the supercharger outlet and the induction elbow. A butterfly
valve inside the assembly is opened by a diaphragm actuator operated by vacuum feed from the elbow. At closed or
partially open throttle positions, the butterfly valve opens, allowing the airflow from the two charge air cooler inlets to be
directed back to the supercharger inlet. This action inhibits the supercharging effect and reduces engine torque.
Progressive opening of the throttle causes the by-pass valve to gradually close.
Each cylinder bank is fitted with a charge air cooler which supplies pressurized air to the four cylinders. The inlet ports to
the two charge air coolers are connected to the supercharger via the supercharger outlet pipe consisting of adjustable
metal ducts with bonded rubber seals. The charge air coolers are water cooled via a radiator and water pump.
Distribution and Filtering - System Operation and Component Description
System Operation
Refer to: Intake Air Distribution and Filtering (303-12B Intake Air Distribution and Filtering - 4.2L SC V8 - AJV8, Description
and Operation).
Distribution and Filtering

REFER to: Intake Air Distribution and Filtering (303-12A Intake Air Distribution and Filtering - 4.2L NA V8 - AJV8, Diagnosis
and Testing).
Intake Air Distribution and Filtering - 4.2L SC V8 - AJV8 - Air Cleaner LH
Removal
1.
2.
3.
4. Torque: 8 Nm

6. 6. NOTE: Some variation in the illustrations may occur,

but the essential information is always correct.
7. 7. NOTE: Some variation in the illustrations
may occur, but the essential information is
always correct.
Installation

Intake Air Distribution and Filtering - 4.2L SC V8 - AJV8 - Air Cleaner RH
Removal
1.
2.
3.
4.
Torque: 8 Nm

NOTE: Some variation in the illustrations may occur,

NOTE: LH shown, RH similar.


7. 7. NOTE: Some variation in the illustrations
may occur, but the essential information is
always correct.
Installation

Intake Air Distribution and Filtering - 4.2L SC V8 - AJV8 - Air Cleaner
Element
Removal
1. 1. NOTE: Left-hand shown, right-hand similar.

Installation

Intake Air Distribution and Filtering - 4.2L SC V8 - AJV8 - Air Cleaner Outlet
Pipe
Removal
2.
3. Torque: 6 Nm
Installation

Intake Air Distribution and Filtering - 4.2L SC V8 - AJV8 - Charge Air Cooler
Removal

2. Refer to: Supercharger (303-12B Intake Air Distribution and Filtering

- 4.2L SC V8 - AJV8, Removal and Installation).
3.
4.
5. Torque: 10 Nm
6. Torque: 13 Nm
7. Torque: 10 Nm
8. Torque: 13 Nm
Installation

Intake Air Distribution and Filtering - 4.2L SC V8 - AJV8 - Supercharger
Removal

2. Refer to: Cooling System Draining, Filling and Bleeding (303-03

Engine Cooling - 3.0L, General Procedures).
3. Refer to: Cowl Vent Screen (501-02 Front End Body Panels, Removal
and Installation).
4. Refer to: Supercharger Outlet Pipe (303-12B Intake Air Distribution

5. Refer to: Exhaust Manifold to Exhaust Gas Recirculation (EGR) Valve

Tube - 4.2L NA V8 - AJV8 (303-08 Engine Emission Control - 4.2L NA
6. Torque: 25 Nm
7.
8.
9.
10.
11. Torque: 10 Nm
12.
Rotate the drive belt tensioner clockwise. Use a
1/2 inch square drive bar to rotate the drive belt
tensioner.
13.
14.
15.
16.
17.
18. Torque: 8 Nm
19. Torque: 25 Nm
20. Torque: 25 Nm
21. Torque: 25 Nm
22.
23. Torque: 25 Nm
Installation

Intake Air Distribution and Filtering - 4.2L SC V8 - AJV8 - Supercharger
Outlet Pipe
Removal
3.
4.
5.
6.
7. Torque: 9 Nm
8. Torque: 9 Nm
9. Torque: 8 Nm
Installation

Evaporative Emissions - V6 3.0L Petrol -
Evaporative emission canister carrier bolts 10 7 -
Evaporative Emissions - V6 3.0L Petrol - Evaporative Emissions - Component Location
ItemDescription
1 Fuel feed line
2 Charcoal cannister purge line
3 Fuel filter
4 Purge valve
5 Fuel filler cap
6 Fuel pump
7 Filler neck
8 Fuel pump driver module
9 Charcoal cannister
Evaporative Emissions - V6 3.0L Petrol - Evaporative Emissions - Overview
OVERVIEW
The EVAP (evaporative emission) control system reduces the level of hydrocarbons released into the atmosphere by fuel vapor venting from
the fuel tank. The system comprises a charcoal canister, purge valve and interconnecting vent pipes and hoses. The vent pipes are
connected to the system components using quick release connectors.
Fuel vapor is generated by the fuel in the tank and the amount of vapor produced increases as the fuel heats up. Fuel vapor can flow freely
to the charcoal canister via the tank venting system. The venting system consists of roll over valves and a liquid vapor separator mounted
internally in the tank and then externally via a breather line. The breather line allows the fuel vapor to flow to the charcoal canister via a 'Y'
piece mounted on the filler pipe.
On all vehicles the fuel vapor is restricted in its path to the charcoal canister but can flow freely during the refueling operation to
atmosphere, via the filler opening.
The vapor passes into the charcoal canister where it is absorbed and stored by the charcoal. Because there is a limit to the amount of vapor
the canister can contain, the fuel vapor is purged from the canister when the engine is running and burned in the engine.
Evaporative Emissions - V6 3.0L Petrol - Evaporative Emissions - System Operation
System Operation
The atmospheric pressure at the air intake vent of the system is higher than the inlet manifold pressure under all throttled engine running
conditions. It is this pressure differential across the system that causes the air to flow through the air intake, through the purge system,
and in to the engine.
The ECM (engine control module) waits until the engine is running above 40C (104F) coolant temperature with closed loop fuel operational
before the purging process is activated. Under these conditions the engine should be running smoothly with no warm up enrichment. The
purge valve duty (and flow) is initially ramped slowly because the vapor concentration is unknown (a sudden increase in purge could cause
unstable engine running or cause it to stall due to an extremely "rich" air/fuel mixture.). The concentration is then determined from the
amount of adjustment that the closed loop fueling is required to make to achieve the target Air Fuel Ratio (AFR). Once the concentration
has been determined, the purge flow can be increased rapidly and the injected fuel can be proactively adjusted to compensate for the
known purge vapor and the target AFR control is maintained.
When the purging process is active, fresh air is drawn into the charcoal canister via the vent hose connection and the spider trap.
Charcoal Cannister
The charcoal canister is located in a central position, forward of the spare wheel. It is attached at the rear with two bolts which screw into
the spare wheel carrier. At the front, the canister has two lugs which locate in the parking brake module support bracket.
The canister has a capacity of 1400cc (85.4 in3).
The canister has three ports which allow for the attachment of the atmospheric vent hose, the purge hose and the tank vent hose.
The canister contains a bed of activated charcoal or carbon. The charcoal is produced using special manufacturing techniques to treat the
charcoal with oxygen. The oxygen treatment opens up millions of pores between the carbon atoms resulting in a highly porous charcoal with
a very large effective surface area which is capable of absorbing large quantities of fuel vapor. Once treated the charcoal is known as
'activated' carbon or charcoal.
Purge Valve
The purge valve is located LH (left-hand) side of the engine, on a bracket which is attached to the cylinder block. The purge hose is routed
from the purge valve, along the left hand side of the air intake manifold, to the elbow assembly which locates the electric throttle. The
purge valve is controlled by the ECM and is operated when engine operating conditions are correct to allow purging of the charcoal canister.
The purge valve is a solenoid operated valve which is closed when de-energized.
The purge hose is connected, at the right hand rear of the engine, with a quick release coupling to the purge line which runs parallel with
the fuel feed line along the top of the fuel tank to the charcoal canister.
The purge hose continues from the purge valve and is routed to a connection on the air intake elbow assembly. The hose is connected to
the elbow with a quick release connector.
The purge valve is PWM (pulse width modulation) at 10Hz by the ECM. At this high frequency, the pulses of purge gas flow into the inlet
manifold in an almost a continuous flow. The valve operates between 7% and 100% duty or mark space ratio (% open time).
Evaporative Emissions - V6 3.0L Petrol - Evaporative Emissions
For a detailed description of the evaporative emission system and operation, refer to the relevant Description and Operation section of the
workshop manual. REFER to: Evaporative Emissions (303-13 Evaporative Emissions - V8 5.0L Petrol/V8 S/C 5.0L Petrol, Description and
Operation).
confirmation of a fault and may also cause additional faults in the vehicle being checked and/or the donor vehicle.
Visual Inspection
Fuel filler cap and seal Fuses
Fuel filler neck Connectors
DMTL fresh air filter (restriction, etc) Harness
Fuel tank (leaks, damage, etc) Purge valve
Fuel lines and joints, etc Diagnostic module fuel tank leak (DMTL) pump
Carbon canister
Purge valve
Diagnostic module fuel tank leak (DMTL) pump module
step.
4. 4. If the cause is not visually evident, verify the symptom and refer to the Symptom Chart, alternatively check for Diagnostic Trouble
Codes (DTCs) and refer to the DTC Index.
5. 5. Where K-Line, Vacutec or other proprietary smoke test equipment is available, it should be utilized to assist with Evaporative
Emissions System leak diagnosis.
Symptom Chart

Difficulty in filling fuel tank Restriction in the vapour line between the fuel tank and the Check for restrictions/damage, etc (see
carbon canister outlet/atmospheric port visual inspection)
Fuel smell System leak Check for leaks, check the purge valve
Purge valve inoperative operation
'Check Fuel Filler Cap' Fuel filler cap missing/not tightened after refuelling Check the fuel filler cap and seal
displayed on Message Center
DTC Index
For a list of Diagnostic Trouble Codes (DTCs) that could be logged on this vehicle, please refer to Section 100-00.
Evaporative Leak OBD Fault Rectification Guide

Determine Which DTC Has Been Stored
Using the manufacturer approved diagnostic system, choose diagnostic session, then choose the following symptom paths :
Powertrain/engine system/fuel vapour and odor, Powertrain/engine system/fuel tank, Electrical/instruments/warning
lamps/engine malfunction lamp/lamp illuminated, Powertrain/engine system/engine performance/fuel consumption high
NOTE: This guide covers DTCs that relate to evaporative leak monitoring, as listed in the table below
DTC Description
P0442-00 DMTL small leak
P0447-00 DMTL COV electrical low (open)
P0448-00 DMTL COV electrical high
P0455-00 DMTL rough leak
P2401-00 DMTL pump electrical low (open)
P2402-00 DMTL pump electrical high
P2404-2F DMTL noise fault
P2404-29 DMTL reference leak
P2405-00 DMTL reference current low
P2406-00 DMTL reference current high
P2450-00 DMTL COV stuck open
P2451-00 DMTL COV stuck closed
P240B-00 DMTL heater electrical low (open)
P240C-00 DMTL heater electrical high
Attempt To Replicate The Fault Using The "Fuel Leak Check" Forced Test
1. 1. Record any DTCs that has been logged
2. 2. Using the manufacturer approved diagnostic system, in the Recommendations tab run the Fuel Leak Check forced test
3. 3. For the test to run the fuel level must be between 15% and 85%
4. 4. During this procedure the engine must be off
5. 5. The possible responses from the test and the associated DTCs are listed below
6. 6. If again no fault is found it could suggest that the failure mode is a borderline condition (refer to section 3) or that it was caused
by incorrect fitment of the fuel cap or the fuel filler neck is at fault therefore it is important not disturb the fuel cap
7. 7. Disconnect purge pipe from the purge valve, observe the condition of connection (the seating and condition of the "O" ring) and
then reconnect. Using the manufacturer approved diagnostic system, run Purge Valve Self Test (to clean the purge valve) then
run the Fuel Leak Check
8. 8. If the test failed, a smoke test is required to determine the cause of the leak
NOTE: P240B & P240C are not included in the Fuel Leak Check forced test (these monitors run at every ignition on and complete within
30 seconds)
Response Description ID Equivalent DTC

Function running: Reference leak measurement 1
Function running: Rough leak measurement 2
Function running: Small leak measurement 3
Function running: 2nd ref leak measurement 4
Function running: COV Cleaning 5
Function aborted due to conditions: Vbatt conditions not correct (too high/ low) 11
Function aborted due to conditions: Variation Ref. I (reference current) too high 12 P2404-29
Function aborted due to conditions: DMTL electrical fault 13 P0447, P0448
Function aborted due to conditions: Maximum diagnostic time exceeded 14
Function aborted due to conditions: Crash detected 15
Function aborted due to conditions: Refuel detected 20
Function aborted due to conditions: Filler cap opened 21
Function aborted due to conditions: Engine start 23
Function aborted due to conditions: Noisy current measurement 24 P2404-2F
Function aborted due to conditions: Ambient temp outside range 26
Function aborted due to conditions: Ambient pressure outside range 27
Function aborted due to conditions: Other conditions 29
Function complete - Tight system, fault free 30
Function complete - Fine leak detected 31 P0442
Function complete - Rough leak detected 32 P0455
Function complete - Module error 33 P2401, P2402, P2450, P2451, P2405, P2406, P2404-29
Function complete - Medium leak detected 34 P0442, P0455
Read The "Ranking values" To Determine How Far Away The Result Is From The Failure Threshold
9. 9. When the Fuel Leak Check forced test has completed the test results (known as ranking values) will be displayed
10. 10. These should be compared against the limits shown in the table below
11. 11. If the test result is borderline then there is a risk that a failure will occur at a later date (during customer usage of the vehicle)
12. 12. To avoid this the vehicle should be carefully checked for any small leaks
Ranking Value Normal Result For Tight System Leak Failure Condition
Rough Leak (40 thou+) 0 > = 50 >= 128
Small Leak (20 thou+) 0 > = 60 >= 128
TRACE THE ROOT CAUSE OF THE FAULT
The list below provides some suggested actions to help trace the root cause of the fault
Each action should be followed up with a Fuel Leak Check forced test (and ranking value check) in order to determine if any improvement
has been made
DTC Fault Description Fault Rectification Actions after smoke test

P0442-00 DMTL small leak 1. Inspect / refit filler cap after smoke test (inspect filler neck for correct fitment to pocket so that
filer neck protrudes)
2. Run engine at idle; Using the manufacturer approved diagnostic system, run Purge Valve Self
Test (to clean the purge valve)
3. Check that the DMTL module wiring connector has been installed correctly and that the seals
around the connector body and individual wires are in good condition
4. Check all fuel system connections are correctly installed and secure
5. Visually inspect purge canister, purge pipes, fuel tank and filler neck for any obvious damage
6. Try isolating the purge valve by fitting a blanking plug to the purge pipe
7. Carry out a smoke test
8. Replace the DMTL module
P0447-00 DMTL COV electrical 1. Check fuse

low (open) 2. Check that fuse fits tightly into the fuse holder
3. Check that the DMTL module wiring connector has been fitted correctly
4. Check wiring harness continuity between DMTL module and ECU connectors
5. Replace DMTL module
P0448-00 DMTL COV electrical 1. Check wiring

high 2. Replace DMTL module
P0455-00 DMTL rough leak 1. Inspect / refit filler cap after smoke test (inspect filler neck for correct fitment to pocket so that
filer neck protrudes)
2. Run engine at idle; Using the manufacturer approved diagnostic system, run "Purge Valve Self
Test" (to help clean the purge valve)
3. Check that the DMTL module wiring connector has been installed correctly and that the seals
around the connector body and individual wires are in good condition (surprisingly, this is a potential
leakage path!)
4. Check all fuel system connections are correctly installed and secure
DTC Fault Description Fault Rectification Actions after smoke test
5. Visually inspect purge canister, purge pipes, fuel tank and filler neck for any obvious damage
6. Try isolating the purge valve by fitting a blanking plug to the purge pipe
7. Carry out a smoke test
P2401-00 DMTL pump electrical 1. Check fuse

low (open) 2. Check that fuse fits correctly into the fuse holder
P2402-00 DMTL pump electrical 1. Check wiring

high 2. Replace DMTL module
P2404-2F DMTL noise fault Replace DMTL module
P2404-29 DMTL reference leak Replace DMTL module
P2405-00 DMTL reference Replace DMTL module

current low
P2406-00 DMTL reference 1. Check for any blockages in the DMTL ventilation pipe & filter
current high 2. Replace DMTL module
P2450-00 DMTL COV stuck Replace DMTL module

open
P2451-00 DMTL COV stuck Replace DMTL module
close
P240B-00 DMTL heater 1. Check fuse
electrical low (open) 2. Check that fuse fits tightly into the fuse holder
P240C-00 DMTL heater 1. Check wiring

electrical high 2. Replace DMTL module
Pre and 10MY Denso/Bosch PCM Systems

CAUTION: The Maximum pressure of the EVAP system is 0.07 bar do not exceed
NOTE: Apart from the purge valve connection, it is recommended to smoke test the EVAP system without disturbing any joints associated
with the system, this will determine the leak more accurately and quickly
1. Remove rear wheel arch liner to access fuel filler neck

2. On the fuel filler neck the DMTL filter will be visible as shown in picture. Unclip filter housing from fuel filler neck to gain better
access to DMTL filter
3. Remove carefully the top of filter to expose filter and remove
4. Attach rubber adapter to tip of smoke machine nozzle to ensure tight seal to filter housing. Disconnect the purge pipe from purge
valve; this will be an escape point for the smoke to exit
5. Allow tester to complete self-test and green READY light to turn ON 2. For best Tester performance; completely unwind Testers
supply hose
6. Press Smoke on control panel to fill EVAP system with smoke vapour. The control panel Smoke light will light indicating smoke
production. The smoke setting is on a 15 minute timer. Pressing the Smoke button again turns Tester off. It is normal for the flow
meter ball, while in the smoke mode, not to be as steady as when it is in the Test mode. Note: The pressure gauge is active only
after smoke cycle is complete
7. Continue introducing smoke into the EVAP System until the flow meters ball stops descending and this assures the system test
pressure is met and smoke will appear from the purge pipe, then close off purge pipe with special tool (Test Adapter Hose/EVAP Port
310-142)
CAUTION: On some vehicles, the DMTL filter can not be removed, in these instances fill the system through the purge valve and
smoke will appear from the filter
Pre 10MY Vehicles
On pre 10MY DMTL systems, Using the manufacturer approved diagnostic system, select Measurement application session then select the
Recommendations tab which will give you access to Datalogger. Then select Engine systems then select the Output state control
data-logger signal Engine output 1 diagnostic module tank leakage -change over valve active which will close the system. Then
select Engine output 1 diagnostic module tank leakage pump active this will pressurize the EVAP system
10MY vehicles
On 10MY vehicles a smoke test application is available so therefore only smoke fill the system and then run the application
8. Follow the EVAP system path with the halogen light provided and looks for the smoke exiting the leak(s) or use the UV light
provided and look for the dye deposited at the exact location of the leak(s)
9. Repair the leak(s) and perform the Fuel Leak Check application again or smoke test to verify repair, as well as to make sure
there are no additional leaks in the EVAP system
The UltraTraceUV smoke solutions dye feature is especially helpful when the leak is in an area that is not readily visible, as on the top of
the fuel tank or behind a panel. Once you gain access to the area of the leak, wear the yellow UV glasses and shine the UV light provided
to identify the exact location of the leak(s). Smoke exiting a very small leak is even easier to see with lower pressure. If you encounter
smoke leaking out of an area but find it difficult to pinpoint exactly where the source of the leak is; try reducing the pressure in the system
being tested by turning the Tester OFF and allow the pressure to dissipate. The longer a particular leak is allowed to leak, the more
fluorescent dye material will be deposited at that leak. W ith some vapour system leaks, the leak may only present itself under vacuum and
not under pressure. If equipment permits, test the system in both states. Purge valve faults [P0441, P0444, P0458 and P0459] should all
inhibit DMTL leak test and therefore need to be resolved prior to any DMTL issues. For this reason, when smoke testing the vapour system,
it should be sufficient to enter the system at the connection up stream of the purge valve. If no leak is found then testing the remainder of
the system up to the purge valve is recommended
NOTE: It may be possible to search for small leaks using a gas analyzer and looking for HC (hydro carbon) spikes. This should enable
leaks to be detected in areas of the vapor system that our out of sight of the technician. The solenoid should be deactivated after five
minutes to prevent potential damage. Check that connector and individual terminals are sealed correctly
Phase-One (quantifying the leak)
1. Connect the tester supply hose to vehicle EVAP system. > Refer to appropriate vehicle application
2. Determine if the vehicles EVAP system you are testing is governed by a .020 (0.5 mm) or .040 (1 mm) acceptable leak standard.
Press the appropriate calibration standard on the testers control panel and observe the position of the flow meter ball. > This
function automatically turns off in 10 seconds
3. Position the flow meter's pointer flag so that it aligns with the measurement observed in step 2 above. > This sets PASS / FAIL
mark
4. Close vehicles EVAP Vent Solenoid. > Refer to appropriate vehicle application
5. Press TEST on control panel and fill EVAP system. > This introduces 5-minutes of nitrogen gas
6. Look for flow meter ball to stop descending indicating that the vehicle system is full. > Fill time 1-4 minutes depending on system
volume
7. Compare flow meter ball reading to pointer flag. > ABOVE flag = FAIL (go to Phase-Two). > BELOW flag = PASS (test complete)
Testing With Pressure and Vacuum Decay
In addition to quantifying the leak with the Phase-One flow test, the Tester allows you the flexibility of testing the vehicles EVAP system
by using either Pressure Decay or Vacuum Decay methods. Below are instructions for performing both decay tests
Pressure-Decay Test
NOTE: The Pressure Decay test is best performed immediately after the Phase-one flow test, since the system has already built up
pressure
At the completion of the Phase-one flow test, the EVAP system is fully pressurized, since the Phase-one test uses pressure to perform its
flow test. Testing pressure decay with the Vacutec 522B-J/LR is very simple. All you need to do is the following:
1. Allow tester to complete self-test and green READY light to turn ON

2. Connect Tester supply hose to vehicle EVAP system
3. Close vehicles EVAP Vent solenoid > Refer to appropriate vehicle application
4. Press VACUUM switch on the tester control panel
- NOTE: The vacuum switch is on a 30-second timer, which should be sufficient time to draw the appropriate vacuum from the
EVAP system. Press VACUUM switch again if additional time is required
5. After vacuum timer turns off, observe the vacuum gauge for any decay (loss of vacuum) indicating a leak in the EVAP system
NOTE: Disconnect the Tester from the vehicle after the Vacuum Decay Test. The fuel pressure in the vehicles fuel tank is constantly
changing due to the vehicles fuel volatility and that could cause the Testers pressure gauge to exceed its maximum reading limits
Evaporative Emissions - V6 3.0L Petrol - Evaporative Emission Canister
Special Tool(s)
HTJ1200-2
Removal

2. Remove the left-hand shock absorber and spring assembly.
For additional information, refer to: Shock Absorber and Spring Assembly
(204-02 Rear Suspension, Removal and Installation).
3. CAUTION: The brake caliper must be supported at all times.

Detach the left-hand rear brake caliper and anchor plate.
Remove and discard the brake caliper anchor plate retaining bolts.

NOTE: Mark the brake disc position in relation to the hub.
Remove the left-hand brake disc.

Using a suitable tie strap, secure the left-hand brake caliper to the
upper arm.
6. Disconnect the left-hand rear wheel speed sensor electrical connector.
7. Disconnect the headlamp levelling sensor.
8. Remove the front muffler.

For additional information, refer to: Front Muffler (309-00A Exhaust
System - TDV6 2.7L Diesel, Removal and Installation).
9. W ARNING: Rotate the special tool height adjustment valve slowly.

Failure to follow this instruction may result in personal injury.
Install the special tool to support the left-hand side of the rear
subframe.
10. Remove the rear subframe left-hand reinforcement plate retaining

bolts.
11. Remove and discard the rear subframe left-hand rear retaining bolt.
12. Remove the rear subframe left-hand reinforcement plate.
Remove and discard the rear subframe left-hand front retaining

bolt.
13. W ARNING: Rotate the special tool height adjustment valve

slowly. Failure to follow this instruction may result in personal injury.
CAUTIONS:
Make sure the rear subframe weight is evenly supported on the

special tool. Failure to follow this instruction may result in damage to the
vehicle.
Make sure when lowering the rear subframe damage does not occur
to the surrounding components. Failure to follow this instruction may
Using the special tool, lower the left-hand side of the rear subframe to a
maximum of 152mm.
14. NOTE: Non federal market vehicles only.
NOTE: Rear subframe shown removed for clarity.
Remove the fuel pump driver module.
Disconnect the electrical connection.
Remove 1 screw.
15. NOTE: Non federal market vehicles only.
NOTE: Rear subframe shown removed for clarity.
Remove the evaporative emissions canister.
Disconnect the 2 quick release connectors.
Remove the 2 nuts.
16. NOTE: Rear subframe shown removed for clarity.
NOTE: Federal market vehicles only.
Disconnect the evaporative emission canister vent solenoid vapor hose.
Disconnect the evaporative emission canister vent solenoid electrical

connector.
Disconnect the evaporative emission canister vapor pipes.

Detach the evaporative emission canister.
20. NOTE: Federal market vehicles only.
Remove the evaporative emission canister.
Installation
Tighten to 7 Nm.
2. NOTE: Install new rear subframe retaining bolts.
Loosely install the rear subframe left-hand front retaining bolt.
Install the rear subframe left-hand reinforcement plate.
3. NOTE: Install new rear subframe retaining bolts.
Install the rear subframe left-hand rear retaining bolt.
Tighten to 125 Nm.

4. Install the rear subframe left-hand reinforcement plate retaining bolts.
Tighten to 47 Nm.
5. Tighten the rear subframe left-hand front retaining bolt.
Tighten to 125 Nm.

NOTE: Remove and discard the securing tie strap.
NOTE: Install new brake caliper anchor plate retaining bolts.
Install the left-hand brake caliper and anchor plate.

Evaporative Emissions - V6 3.0L Petrol - Evaporative Emission Canister Purge Valve
Removal
1. Disconnect the evaporative emission canister purge valve hose.
2. Detach the evaporative emission canister purge valve hose.
3. Disconnect the evaporative emission canister purge valve electrical

connector.
4. Remove the evaporative emission canister purge valve and bracket

assembly.
Detach the wiring harness from the bracket.
Detach the vacuum hose retaining clip from the stud.
Remove the retaining nut and bolt.

5. Remove the evaporative emission canister purge valve.
Disconnect the evaporative emission canister purge valve hose.
Installation
Tighten to 10 Nm.
Evaporative Emissions - V6 3.0L Petrol - Evaporative Emission Canister Vent Solenoid
Removal
W ARNINGS:
Do not carry or operate cellular phones when working on or near any fuel related components. Highly flammable vapours are always
present and may ignite. Failure to follow these instructions may result in personal injury.
CAUTION: Make sure the working surfaces are thoroughly clean to avoid contamination of the sensitive components.

2. Disconnect the evaporative emission canister vent solenoid vapor hose.
3. Disconnect the evaporative emission canister vent solenoid electrical

connector.
4. Remove the evaporative emission canister vent solenoid.
Remove and discard the evaporative emission canister vent

solenoid O-ring seal.
Installation
Tighten to 6 Nm.
Evaporative Emissions - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8 -
Evaporative emission canister carrier bolts 10 7 -
Evaporative Emissions - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8 - Evaporative
Emissions - Component Location
Naturally Aspirated
ItemDescription
1 Purge valve
2 Fuel delivery pipe
3 Fuel pump
4 Fuel filler
5 Tank leakage detection filter
7 Tank leakage detection pump
8 Fuel tank
9 Purge pipe
10 Fuel Filter
Naturally Aspirated
ItemDescription
1 Purge valve
2 Fuel delivery pipe
3 Fuel pump
4 Fuel filler
5 Tank leakage detection filter
8 Fuel tank
9 Purge pipe
10 Fuel Filter
Emissions - Overview
OVERVIEW
The EVAP (evaporative emission) control system reduces the level of hydrocarbons released into the atmosphere by fuel
vapor venting from the fuel tank. The system comprises a charcoal canister, purge valve and interconnecting vent pipes
and hoses. The vent pipes are connected to the system components using quick release connectors.
Fuel vapor is generated by the fuel in the tank and the amount of vapor produced increases as the fuel heats up. Fuel
vapor can flow freely to the charcoal canister via the tank venting system. The venting system consists of roll over valves
and a liquid vapor separator mounted internally in the tank and then externally via a breather line. The breather line
allows the fuel vapor to flow to the charcoal canister via a 'Y' piece mounted on the filler pipe.
On NAS vehicles the vapor generated in the fuel tank during refueling flows without restriction to the charcoal canister.
On all vehicles except NAS, the vapor is restricted in its path to the charcoal canister but can flow freely during the
refueling operation to atmosphere, via the filler opening.
The vapor passes into the charcoal canister where it is absorbed and stored by the charcoal. Because there is a limit to the
amount of vapor the canister can contain, the fuel vapor is purged from the canister when the engine is running and
burned in the engine.
All NAS vehicles have a fuel tank leakage monitoring system. This is a legislative requirement. The fuel tank leakage
monitoring system periodically checks the EVAP system and the fuel tank for leaks when the ignition is switched off. The
fuel tank leakage monitoring system comprises the previously described components of the EVAP system with the addition
of a fuel tank leakage monitoring pump and a fuel tank leakage monitoring filter.
Emissions - System Operation and Component Description
System Operation
The atmospheric pressure at the air intake vent of the system is higher than the inlet manifold pressure under all throttled
engine running conditions. It is this pressure differential across the system that causes the air to flow through the air
intake, through the purge system, and in to the engine.
The ECM (engine control module) waits until the engine is running above 40C (104F) coolant temperature with closed
loop fuel operational before the purging process is activated. Under these conditions the engine should be running
smoothly with no warm up enrichment. The purge valve duty (and flow) is initially ramped slowly because the vapor
concentration is unknown (a sudden increase in purge could cause unstable engine running or cause it to stall due to an
extremely "rich" air/fuel mixture.). The concentration is then determined from the amount of adjustment that the closed
loop fueling is required to make to achieve the target Air Fuel Ratio (AFR). Once the concentration has been determined,
the purge flow can be increased rapidly and the injected fuel can be proactively adjusted to compensate for the known
purge vapor and the target AFR control is maintained.
When the purging process is active, fresh air is drawn into the charcoal canister via the tank leakage detection valve
atmospheric vent connection and its filter on NAS vehicles or, via the vent hose connection and the spider trap on non NAS
vehicles.
Tank Leakage Detection

The tank leakage detection system is a legislative requirement for NAS vehicles. The tank leakage detection system
periodically checks the EVAP (evaporative emission) system and the fuel tank for leaks when the ignition is switched off.
The tank leakage detection system comprises the previously described components of the EVAP system with the following
additional components; a tank leakage detection pump and a tank leakage detection filter.
To check the fuel tank and the EVAP system for leaks, the ECM operates the tank leakage detection pump and monitors
the current draw. Initially, the ECM establishes a reference current by pumping air through the reference orifice and back to
atmosphere. Once the reference current is determined, the ECM closes the normally open valve which seals the EVAP
system. The purge valve remains de-energized and is therefore closed. The output from the air pump is diverted from the
reference orifice and into the EVAP system.
When the normally open valve is closed, the load on the air pump falls to zero. Providing there are no leaks, the air pump
will begin to pressurize the EVAP system and the load and current draw in the pump increases. By monitoring the rate and
level of the current increase, the ECM can determine if there is a leak in the EVAP system.
During normal vehicle operation, 15 seconds after the engine has started, the ECM energizes the heating element in the
pump to prevent condensation formation and possible incorrect readings. The heater remains energized until either the
engine and ignition are off (if no tank leakage detection test is running) or until after the tank leakage detection test is
completed.
Leaks are classified as:
Minor - equivalent to a hole diameter of 0.5 to 1.0 mm (0.02 to 0.04 in)

Major - equivalent to hole diameter of 1.0 mm (0.04 in) or greater.
The ECM performs a check for major leaks each time the ignition is switched off, providing the following conditions are
met:
The vehicle speed is zero

The engine speed is zero
The pressure altitude (70 kPa (10.15 lbf/in2) derived from engine load calculations) is below 3047 m (10000 feet)
The ambient temperature is between 0 and 40C (32 and 104F)
The charcoal canister load factor is 2.5 or less (where the load factor is a measure, between -1 and +30, of the fuel
vapor stored in the charcoal canister. Where -1 is 0% fuel vapor, 0 is stoichiometric fuel vapor level and +30 is
100% saturated with fuel vapor.
The fuel tank level is valid and between 15 and 85% of nominal capacity
The engine running time during the previous cycle was more than 10 minutes
The battery voltage is between 10 and 15 volts
The last engine off time was more than 180 minutes
No errors are detected with the EVAP components, the ambient air temperature and the fuel level.
NOTE: A leak test can be performed using the Jaguar approved diagnostic system. This overrides the above conditions
and is useful for checking correct system and component operation.
The ECM performs a check for minor leaks after every 2nd major leak check or after refueling is detected.
When the leak check is complete, the ECM stops the tank leakage detection pump and opens (de-energizes) the normally
open valve.
If the fuel filler cap is opened or refueling is detected during the leak check, by a sudden drop in the current draw or a rise
in the fuel level, the ECM aborts the leak check.
If a leak is detected during the check, the ECM stores an appropriate fault code in its memory. If a leak is detected on two
consecutive checks, the ECM illuminates the MIL (malfunction indicator lamp) in the instrument cluster on the next drive
cycle.
The duration of a leak check can be between 60 and 600 seconds depending on the results and fuel tank level.
Tank Leakage Detection Pump
The tank leakage detection pump is connected to the atmospheric vent of the charcoal canister and incorporates a PTC
(positive temperature coefficient) heating element, a normally open valve and a reference orifice.
The tank leakage detection filter protects the pump from dust being drawn into the system when the pump is being
operated. The filter is located on the fuel filler head and is connected to the tank leakage detection pump by a hose.
The tank leakage detection pump is only operated when the ignition is switched off and is controlled by the ECM. The ECM
also monitors the electric air pump operation and the normally open valve for faults The tank leakage detection test is
performed after the engine has stopped following a 10 minute run, providing that the vehicle fuel tank is between 15 and
85 percent full, the ambient temperature is above 0C (32F) and less than 40C (104F) and the vehicle was not started
for at least 3hrs prior to this run.
The tank leakage detection pump is driven to pressurize the fuel tank and the current is measured with the change-over
valve in different states.
A comparison of the current draw in each state indicates the degree of any leak, and the ECM then sets the appropriate
DTC (diagnostic trouble code).
Charcoal Cannister
The charcoal canister is located in a central position, forward of the spare wheel. It is attached at the rear with two bolts
which screw into the spare wheel carrier. At the front, the canister has two lugs which locate in the parking brake module
support bracket.
The canister on ROW vehicles has a capacity of 1400cc (85.4 in3). The canister on NAS vehicles has a capacity of 3000cc
(183 in3).
The canister has three ports which allow for the attachment of the atmospheric vent hose, the purge hose and the tank
vent hose. On NAS vehicles the atmospheric vent hose connection allows for the attachment of the tank leakage detection
pump.
The canister contains a bed of activated charcoal or carbon. The charcoal is produced using special manufacturing
techniques to treat the charcoal with oxygen. The oxygen treatment opens up millions of pores between the carbon atoms
resulting in a highly porous charcoal with a very large effective surface area which is capable of absorbing large quantities
of fuel vapor. Once treated the charcoal is known as 'activated' carbon or charcoal. The charcoal canister on NAS vehicles
uses a higher grade charcoal to meet the requirements of LEV2 emission regulations.
Purge Valve
The purge valve is located RH (right-hand) side of the engine, on a bracket which is attached to the water pump. The
purge hose is routed from the purge valve to the electric throttle. The purge valve is controlled by the ECM and is operated
when engine operating conditions are correct to allow purging of the charcoal canister. The purge valve is a solenoid
operated valve which is closed when de-energized.
The purge hose is connected, at the front RH side of the engine, with a quick release coupling to the purge line which runs
parallel with the fuel feed line along the top of the fuel tank to the charcoal canister.
The purge hose continues from the purge valve and is routed to a connection on the air intake elbow assembly. The hose
is connected to the elbow with a quick release connector.
The purge valve is PWM (pulse width modulation) at 10Hz by the ECM. At this high frequency, the pulses of purge gas flow
into the inlet manifold in an almost a continuous flow. The valve operates between 7% and 100% duty or mark space ratio
(% open time).
On NAS vehicles the system does not include a pressure test point. Pressure testing of the purge valve hose is achieved
by disconnecting the purge valve joint on the underside of the vehicle, forward of the fuel tank and connecting a special
tool to allow the system to be pressure tested. The test performs a pressure test on the purge hose connection forward of
the fuel tank back to the charcoal canister. The special tool is then connected to the purge hose connection forward of the
fuel tank to perform a pressure test on the purge hose to the purge valve.
Emissions
For a detailed description of the Evaporative Emissions system, refer to the relevant Description and Operation sections in
the workshop manual. REFER to: (303-13 Evaporative Emissions - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8)
Evaporative Emissions (Description and Operation),

Evaporative Emissions (Description and Operation),
Evaporative Emissions (Description and Operation).
vehicle.
Visual Inspection
Fuel filler cap and seal Fuses
Fuel filler neck Connectors
Diagnostic Monitoring of Tank Leakage (DMTL) fresh air filter (restriction, etc) Harnesses
Fuel tank (leaks, damage, etc) Purge valve
Fuel lines and joints, etc DMTL pump
Carbon canister
Purge valve
DMTL pump module
4. 4. If the cause is not visually evident, and there are clear symptoms, refer to the Symptom Chart below,
alternatively, check for Diagnostic Trouble Codes (DTCs) then proceed to the DTC Index.
5. NOTE: On all vehicles equipped with Diagnostic Monitor Tank Leakage (DMTL), there is a requirement to blank off
the ventilation port (large diameter stub pipe) of the DMTL module, to prevent mis-diagnosis when carrying out a
smoke test.
5. Where K-Line, Vacutec or other proprietary smoke test equipment is available, it should be utilised to assist with
Evaporative Emissions System leak diagnosis.
Symptom Chart

Difficulty in filling fuel Restriction in the vapour line between the fuel tank Check for restrictions/damage, etc
tank and the carbon canister outlet/atmospheric port (see visual inspection)
Fuel smell System leak Check for leaks, check the purge
Purge valve inoperative valve operation
'Check Fuel Filler Cap' Fuel filler cap missing/not tightened after refuelling Check the fuel filler cap and seal
displayed on Message
Center
DTC Index
CAUTION: W hen probing connectors to take measurements in the course of the diagnostic tests, use the adaptor kit,
NOTE: If the module or a component is suspect and the vehicle remains under the manufacturer warranty, refer to the
the installation of a new module/component.

P044100 Evaporative Emission Purge valve - Refer to the electrical circuit diagrams and check
System Incorrect Purge range/performance EVAP purge valve control circuit for short, open
Flow circuit
P044200 Evaporative Emission No sub type information Check EVAP system for leak using appropriate
System Leak Detected smoke/leak tester
(small leak)
P044700 Evaporative Emission DMTL COV circuit - short Carry out any pinpoint tests associated with this
System Vent Control Circuit to ground DTC using the manufacturer approved diagnostic
Open system. Refer to the electrical circuit diagrams and
check DMTL COV circuit for short to ground
System Vent Control Circuit to power DTC using the manufacturer approved diagnostic
Shorted system. Refer to the electrical circuit diagrams and
check DMTL COV circuit for short to power
P045600 Evaporative Emission DMTL system has Check EVAP system for leak using appropriate
System Leak Detected detected a leak smoke/leak tester
(very small leak)
P045800 Evaporative Emission EVAP canister purge valve Carry out any pinpoint tests associated with this
System Purge Control Valve control circuit - short to DTC using the manufacturer approved diagnostic
Circuit Low ground, high resistance system. Refer to the electrical circuit diagrams and
EVAP canister purge valve check EVAP canister purge valve control circuit for
failure short to ground, high resistance. Check and install a
new EVAP canister purge valve as required
Circuit High power system. Refer to the electrical circuit diagrams and
check EVAP canister purge valve control circuit for
short to power
P240100 Evaporative Emission DMTL pump circuit - short Carry out any pinpoint tests associated with this
System Leak Detection to ground DTC using the manufacturer approved diagnostic
Pump Control Circuit Low system. Refer to the electrical circuit diagrams and
check DMTL pump circuit for short to ground
System Leak Detection to power DTC using the manufacturer approved diagnostic
Pump Control Circuit High system. Refer to the electrical circuit diagrams and
check DMTL pump circuit for short to power
P240429 Evaporative Emission DMTL reference leak Check integrity of evaporative emissions system,
System Leak Detection DMTL pump circuit - short i.e. blocked/leaking. Refer to the electrical circuit
Pump Sense Circuit to ground, power, high diagrams and check DMTL pump circuit for short to
Range/Performance resistance ground, power, high resistance
DMTL pipework
blocked/leaking
P24042F Evaporative Emission DMTL reference leak Check integrity of evaporative emissions system,
System Leak Detection DMTL pump circuit - short i.e. blocked/leaking. Refer to the electrical circuit
DMTL pipework
blocked/leaking
P240500 Evaporative Emission DMTL pump circuit - short Refer to the electrical circuit diagrams and check
System Leak Detection to ground, power, high DMTL pump circuit for short to ground, power, high
Pump Sense Circuit Low resistance resistance
Pump Sense Circuit High resistance resistance
P240B00 Evaporative Emission DMTL heater control Carry out any pinpoint tests associated with this
System Leak Detection circuit low DTC using the manufacturer approved diagnostic
Pump Heater Circuit Low system. Refer to the electrical circuit diagrams and
check DMTL heater control circuit for short to
P240C00 Evaporative Emission DMTL heater control Carry out any pinpoint tests associated with this
System Leak Detection circuit high DTC using the manufacturer approved diagnostic
Pump Heater Circuit High system. Refer to the electrical circuit diagrams and
check DMTL heater control circuit for short to power
P245000 Evaporative Emission DMTL system circuit - Carry out any pinpoint tests associated with this
Control System Switching short to ground, power, DTC using the manufacturer approved diagnostic
Valve Performance/Stuck high resistance system. Refer to the electrical circuit diagrams and
Open check DMTL system circuit for short to ground,
power, high resistance. Check for stuck valve
Valve Stuck Closed high resistance system. Refer to the electrical circuit diagrams and
check DMTL system circuit for short to ground,
Emission Canister
Removal
WARNING: Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related
personal injury.


2. Remove the rear differential.
For additional information, refer to: Axle Assembly (205-02,

NOTE: Sub-frame shown removed for clarity.
Disconnect the evaporative emissions canister.
Disconnect the 3 lines.
Disconnect the 2 electrical connectors.
4. Remove the fuel pump driver module.
Remove the clip.
5. NOTE: Sub-frame shown removed for clarity.
Remove the evaporative emissions canister.
Remove the 3 nuts.
Installation
1. Install the evaporative emissions canister.
Torque: 10 Nm (7 lb.ft)
2. Install the fuel pump driver module.

3. Connect the evaporative emissions canister.
4. Install the rear differential.
For additional information, refer to: Axle Assembly (205-02,
Emission Canister Purge Valve4.2L NA V8 - AJV8
Removal
Installation).
2. Release the 2 electrical connectors.

contamination.
Disconnect the evaporative emission canister purge valve

outlet line at the throttle body elbow.

contamination.
Disconnect the evaporative emission canister purge valve

inlet line.
5. Remove the evaporative emission canister purge valve
assembly.
Remove the 2 nuts.

Remove the evaporative emission canister purge valve.
Remove the bolt.
Installation
1. NOTE: Make sure that this component is installed to the
Install the evaporative emission canister purge valve.
2. Install the evaporative emission canister purge valve

assembly.
Tighten the nuts to 10 Nm.
3. Connect the evaporative emission canister purge valve lines.

4. Secure the electrical connectors.
Install the engine cover.
Emission Canister Purge Valve4.2L SC V8 - AJV8
Removal

2. Refer to: Throttle Body (303-04B Fuel Charging and Controls - 4.2L
3.
4.
5.
6. Torque: 10 Nm
Installation

Electronic Engine Controls - TDV6 2.7L Diesel -
Camshaft position CMP (camshaft position) sensor retaining bolt 10 - 89
Crankshaft position CKP (crankshaft position) sensor retaining bolt 5 - 44
RHD (right-hand drive)ECM (engine control module) Bracket to Dash Panel Retaining Nuts 7 - 62
RHDECM to Bracket retaining nuts 7 - 62
LHD (left-hand drive)ECM Bracket to Dash Panel retaining Nuts 7 - 62
LHDECM to Bracket Retaining Bolts 7 - 62
Engine oil pressure EOP (engine oil pressure) sensor 15 11 -
Knock sensor Left-Hand retaining bolt 20 15 -
Knock Sensor Right-Hand retaining bolt 20 15 -
Manifold absolute pressure MAP (manifold absolute pressure) sensor 3 - 26
Mass air flow MAF (mass air flow) sensor retaining screws 2 - 18
Electronic Engine Controls - TDV6 2.7L Diesel - Electronic Engine Controls - Component
Location
COMPONENT LOCATION SHEET 1 OF 3
ItemDescription
2 ABS (anti-lock brake system) control module
4 Brake pedal switch
5 APP (accelerator pedal position) sensor
ItemDescription
1 KS (knock sensor)
2 Fuel pump
3 Fuel pressure sensor
5 ECT (engine coolant temperature) sensor
ItemDescription
1 Boost temperature sensor
3 Glow plugs
4 Injectors
5 Turbo vane controller
6 CKP (crankshaft position) sensor
7 CMP (camshaft position) sensorRCM (restraints control module)BPP (brake pedal position)
9 MAF (mass air flow)/IAT (intake air temperature) sensor
Electronic Engine Controls - TDV6 2.7L Diesel - Electronic Engine Controls - Overview
OVERVIEW
The V6 Diesel engine has an engine management system controlled by an ECM (engine control module) and is able to monitor, adapt and
precisely control the fuel injection. The ECM uses multiple sensor inputs and precision control of actuators to achieve optimum performance
during all driving conditions.
The ECM controls fuel delivery to all 6 cylinders via a Common Rail (CR) injection system. The CR system uses a fuel rail to accumulate
highly pressurized fuel and feed the 6, electronically controlled injectors. The fuel rail is located in close proximity to the injectors, which
assists in maintaining full system pressure at each injector at all times.
BJB (battery junction box)ABS (anti-lock brake system)IAT (intake air temperature)AJB (auxiliary junction box)APP (accelerator pedal
position)KS (knock sensor)ECT (engine coolant temperature)MAF (mass air flow)
The ECM uses the drive by wire principle for acceleration control. There are no control cables or physical connections between the accelerator
pedal and the engine. Accelerator pedal demand is communicated to the ECM by two potentiometers located in a throttle position sensor.
The ECM uses the two signals to determine the position, rate of movement and direction of movement of the pedal. The ECM then uses this
data, along with other engine information from other sensors, to achieve the optimum engine response.
The ECM processes information from the following input sources:
CKP (crankshaft position) sensor

CMP (camshaft position) sensor
Manifold air temperature and pressure
Coolant temperature
Oil temperature
Inlet air flow and temperature
Fuel rail temperature
KS (1 per cylinder bank)
The ECM outputs controlling signals to the following sensors and actuators:
Fuel injectors
Cooling fan control
Electronic Throttle
Electronic vane controlled turbo
Port deactivation
Fuel pressure control valve
Fuel volume control valve
Electronic EGR (exhaust gas recirculation)
Glow plugs.
Electronic Engine Controls - TDV6 2.7L Diesel - Electronic Engine Controls - System
Control Diagram
NOTE: A = Hardwired; D = High speed CAN (controller area network); O = LIN bus
Control diagram Sheet 1 of 2
ItemDescription
1 Battery
3 CMP (camshaft position) sensor
8 EOP (engine oil pressure) sensor
10 Boost pressure sensor
11 RCM (restraints control module)
12 BPP (brake pedal position) switch
13 KS (knock sensor)
Control diagram Sheet 2 of 2
ItemDescription
1 Glow plugs
2 Electric cooling fan
3 Vacuum control valve
6 Start switch
8 Start control module
9 Smart key
11 RCM
12 Turbo vane controller
14 Generator
16 Clock spring
17 ECM
19 Injectors
System Operation
DIESEL PARTICULATE FILTER (DPF) CONTROL
Vehicles are fitted with a Diesel Particulate Filter (DPF) which collects the particulate matter produced during the combustion process and
reduces the particulates entering the atmosphere.
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 is controlled by the ECM and 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 itself be
damaged or destroyed.
The exhaust gas and DPF temperatures are controlled by the DPF software located in the ECM. The DPF software monitors the load status of
the DPF based on driving style, distance travelled and signals from a differential pressure sensor and temperature sensors located before
and after the DPF in the exhaust system. When the particulate loading of the DPF reaches predetermined levels, the DPF is actively
regenerated by adjusting, in conjunction with the ECM, various engine control functions such as:
fuel injection
intake air throttle
EGR
turbocharger boost pressure control.
The regeneration process is possible because of the flexibility of the common-rail fuel injection engine which provides precise control of fuel
flow, fuel pressure and injection timing which are essential requirements to promote the efficient regeneration process.
The ECM contains the DPF software which controls and monitors the DPF and the regeneration process. The software is broken down into
three separate modules; a DPF supervisor module, a DPF fuel management module and a DPF air management module, which interact with
each other to provide precise DPF control.
These three 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.
The DPF co-ordinator module reacts to a regeneration request from the supervisor module by initiating and controlling the following DPF re
generation requests:
EGR cut-off
Turbocharger boost pressure control
Engine load increase
Control of air pressure and temperature in the intake manifold
Fuel injection control.
When the supervisor module issues a regeneration request, the co-ordinator module requests EGR cut-off and a regeneration specific
turbocharger boost pressure control. It then waits for a feedback signal from the EGR system confirming that the EGR valve is closed.
NOTE: The EGR valve is open at idle to allow reduced NO. EGR is not used during part load due to intake manifold contamination.
When the EGR valve is closed, the co-ordinator module initiates requests to increase engine load by controlling the intake air temperature
and pressure.
Once confirmation is received that intake conditions are controlled or a calibration time has expired, the co-ordinator module then changes
to a state awaiting an accelerator pedal release manoeuvre from the driver. If this occurs or a calibration time has expired, the co-ordinator
module generates a request to control fuel injections to increase exhaust gas temperature.
The DPF air management module controls the following functions:
EGR control
Intake air temperature and pressure 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 and temperature. This control is
required to achieve the correct in-cylinder conditions for stable and robust combustion of the post injected fuel.
Restricting the air intake during DPF regeneration has the following functions:
Increase in engine load

Slower combustion
Reduction in the mass of air taken in
A reduction in the speed of the exhaust gases and therefore an increase in the time for which the gases are in the catalytic
converter.
The module controls the intake air temperature by actuating the EGR throttle and by adjustment of the turbocharger boost pressure control.
Engine Control Module
The ECM is located in the plenum area attached to the bulkhead. The ECM is always on the opposite side to the hand of drive.
Inputs
The ECM has the following inputs:
Engine Coolant Temperature

MAF (2 off)
Stop lamp switch (via ABS module on CAN) and hardwired to the ECM
IAT (intake air temperature)
Throttle Pedal Position 1
Throttle Pedal Position 2
Electronic throttle Position
Engine speed and position sensor (CKP)
CMP sensor
Engine Oil Temperature
Speed Control Switches (resistive ladders)
Vehicle Speed (via CAN )
Generator Monitor
RCM
MAP (manifold absolute pressure)
KS (4 off)
Fuel temperature and pressure
Water in fuel sensor
Boost air temperature
Park/neutral switch
Outputs
The ECM outputs to the following:
Throttle actuator
Fuel injectors (6 off)
EGR Valves
Electric cooling fan
Fuel pump relay
Starter relay
Air conditioning condenser fan module
EMS Main relay
Electric fan control
Generator control
Glow plugs
Active engine mounts
Port deactivation control solenoid valve
The ECM connected to the vehicle harnesses via three connectors. The ECM contains data processors and memory microchips. The output
signals to the actuators are in the form of ground paths provided by driver circuits within the ECM. The ECM driver circuits produce heat
during normal operation and dissipate this heat via the casing. Some sensors receive a regulated voltage supplied by the ECM. This avoids
incorrect signals caused by voltage drop during cranking.
The ECM performs self diagnostic routines and stores fault codes in its memory. These fault codes and diagnostics can be accessed using
the Jaguar approved diagnostic system. If the ECM is to be replaced, the new ECM is supplied 'blank' and must be configured to the vehicle
using the Jaguar approved diagnostic system. A 'flash' EEPROM (electrically erasable programmable read only memory) allows the ECM to be
externally configured, using the Jaguar approved diagnostic system, with market specific or new tune information. The current engine tune
data can be accessed and read using the Jaguar approved diagnostic system.
When a new ECM is fitted, it must also be synchronized to the immobilization control module using the Jaguar approved diagnostic system.
ECM's cannot be 'swapped' between vehicles.
The ECM is connected to the engine sensors which allow it to monitor the engine operating conditions. The ECM processes these signals and
decides the actions necessary to maintain optimum engine performance in terms of driveability, fuel efficiency and exhaust emissions. The
memory of the ECM is programmed with instructions for how to control the engine, this known as the strategy. The memory also contains
data in the form of maps which the ECM uses as a basis for fueling and emission control. By comparing the information from the sensors to
the to the data in the maps, the ECM is able to calculate the various output requirements. The ECM contains an adaptive strategy which
updates the system when components vary due to production tolerances or ageing.
The ECM receives a vehicle speed signal on a CAN bus connection from the ABS Module. Vehicle speed is an important input to the ECM
strategies. The ABS derives the speed signal from the ABS wheel speed sensors. The frequency of this signal changes according to road
speed. The ECM uses this signal to determine the following:
How much to reduce engine torque during gear changes.

When to permit speed control operation.
To control the operation of the speed control system.
Implementation of the idle strategy when the vehicle is stationary.
Camshaft Position Sensor (CMP)
The CMP is located on the front face of the left hand cylinder head. The sensor tip protrudes through the face to pick up on the reluctor
behind the camshaft pulley. The CMP is a Hall effect type sensor
The ECM uses the CMP sensor signal to determine if the piston in No. 1 cylinder is at injection TDC (top dead center) or exhaust TDC. Once
this has been established, the ECM can then operate the correct injector to inject fuel into the cylinder when the piston is at injection TDC.
The CMP sensor is a Hall effect sensor which used by the ECM at engine start-up to synchronize the ECM with the CKP sensor signal. The
ECM does this by using the CMP sensor signal to identify number one cylinder to ensure the correct injector timing. Once the ECM has
established the injector timing, the CMP sensor signal is no longer used.
The CMP sensor receives a 5V supply from the ECM. Two further connections to the ECM provide ground and signal output.
If a fault occurs, an error is registered in the ECM. Two types of failure can occur; camshaft signal frequency too high or total failure of the
camshaft signal. The error recorded by the ECM can also relate to a total failure of the crankshaft signal or crankshaft signal dynamically
implausible. Both components should be checked to determine the cause of the fault.
If a fault occurs with the CMP sensor when the engine is running, the engine will continue to run but the ECM will deactivate boost pressure
control. Once the engine is switched off, the engine will crank but will not restart while the fault is present.
Crankshaft Position Sensor (CKP)
The CKP sensor is located at the rear of the engine block on the left hand side. The sensor tip is aligned with a magnetic trigger which is
attached to the crankshaft. The reluctor is a press fit on the end of the crankshaft. The trigger wheel must be carefully aligned to the
crankshaft to ensure correct timing. The sensor produces a square wave signal, the frequency of which is proportional to engine speed.
The ECM monitors the CKP sensor signal and can detect engine over-speed. The ECM counteracts engine over-speed by gradually fading out
speed synchronized functions. The CKP is a Hall effect sensor. The sensor measures the magnetic field variation induced by the magnetized
trigger wheel.
The trigger wheel has two missing teeth representing 6 of crankshaft rotation. The two missing teeth provide a reference point for the
angular position of the crankshaft.
When the space with the two missing teeth pass the sensor tip, a gap in the signal is produced which the ECM uses to determine the
crankshaft position. The air gap between the sensor tip and the ring is important to ensure correct signals are output to the ECM. The
recommended air gap between the CKP and the trigger wheel is 0.4 mm- 1.5 mm.
The ECM uses the signal from the CKP sensor for the following functions:
Synchronisation.
Determine fuel injection timing.
Enable the fuel pump relay circuit (after the priming period).
Produce an engine speed signal which is broadcast on the CAN bus for use by other systems.
Mass Air Flow/Intake Air Temperature (MAF/IAT) Sensor
The MAF/IAT sensor is located on the inlet air duct directly after the air filter box. The sensor combines the two functions of a MAF sensor
and an IAT sensor in one unit. The sensor is housed in a plastic molding which is connected between the intake manifold and the air intake
pipe.
The MAF sensor works on the hot film principle. Two sensing elements are contained within a film. One element is maintained at ambient
(air intake) temperature, e.g. 25Celsius (77F). The other element is heated to 200Celsius (392F) above the ambient temperature, e.g.
225Celsius (437F). Intake air entering the engine passes through the MAF sensor and has a cooling effect on the film. The ECM monitors
the current required to maintain the 200Celsius (392F) differential between the two elements and uses the differential to provide a
precise, non-linear, signal which equates to the volume of air being drawn into the engine.
The MAF sensor output is a digital signal proportional to the mass of the incoming air. The ECM uses this data, in conjunction with signals
from other sensors and information from stored fueling maps, to determine the precise fuel quantity to be injected into the cylinders. The
signal is also used as a feedback signal for the EGR system.
The IAT sensor incorporates a NTC (negative temperature coefficient) thermistor in a voltage divider circuit. The NTC thermistor works on
the principle of decreasing resistance in the sensor as the temperature of the intake air increases. As the thermistor allows more current to
pass to ground, the voltage sensed by the ECM decreases. The change in voltage is proportional to the temperature change of the intake
air. Using the voltage output from the IAT sensor, the ECM can correct the fueling map for intake air temperature. The correction is an
important requirement because hot air contains less oxygen than cold air for any given volume.
The MAF sensor receives a 12V supply from the BJB and a ground connection via the ECM. Two further connections to the ECM provide a MAF
signal and IAT signal.
The IAT sensor receives a 5V reference voltage from the ECM and shares a ground with the MAF sensor. The signal output from the IAT
sensor is calculated by the ECM by monitoring changes in the supplied reference voltage to the IAT sensor voltage divider circuit.
The ECM checks the calculated air mass against the engine speed. If the calculated air mass is not plausible, the ECM uses a default air
mass figure which is derived from the average engine speed compared to a stored characteristic map. The air mass value will be corrected
using values for boost pressure, atmospheric pressure and air temperature.
If the MAF sensor fails the ECM implements the default strategy based on engine speed. In the event of a MAF sensor signal failure, the
following symptoms may be observed:
EGR system off

Delayed engine response
Reduced engine performance.
If the IAT sensor fails the ECM uses a default intake air temperature of 40Celsius (104F). In the event of an IAT sensor failure, any of the
following symptoms may be observed:
Under fueling, resulting in reduced engine performance.
Engine Coolant Temperature sensor
The ECT is located in the top hose at the coolant manifold junction. The ECT sensor provides the ECM and the instrument cluster with
engine coolant temperature status.
The ECM uses the temperature information for the following functions:
Fueling calculations
Limit engine operation if engine coolant temperature becomes too high
Cooling fan operation
Glow plug activation time.
The instrument cluster uses the temperature information for temperature gauge operation. The engine coolant temperature signal is also
transmitted on the CAN bus by the instrument cluster for use by other systems.
The ECM/ECT sensor circuit consists of an internal voltage divider circuit which incorporates an NTC thermistor. As the coolant temperature
rises the resistance through the sensor decreases and vice versa. The output from the sensor is the change in voltage as the thermistor
allows more current to pass to earth relative to the temperature of the coolant.
The ECM compares the signal voltage to stored values and adjusts fuel delivery to ensure optimum driveability at all times. The engine will
require more fuel when it is cold to overcome fuel condensing on the cold metal surfaces inside the combustion chamber. To achieve a richer
air/fuel ratio, the ECM extends the injector opening time. As the engine warms up the air/fuel ratio is leaned off.
The input to the sensor is a 5V reference voltage supplied from the voltage divider circuit within the ECM. The ground from the sensor is
also connected to the ECM which measures the returned current and calculates a resistance figure for the sensor which relates to the
coolant temperature.
The following table shows engine coolant temperature values and the corresponding sensor resistance and voltage values.
Coolant Temperature Sensor Response

Temperature (Degrees Celsius) Resistance (Kohms) Voltage (Volts)
-40 925 4.54
-30 496 4.46
-20 277 4.34
-10 160 4.15
0 96 3.88
10 59 3.52
20 37 3.09
30 24 2.62
40 16 2.15
50 11 1.72
60 7.5 1.34
70 5.6 1.04
80 3.8 0.79
90 2.9 0.64
100 2.08 0.49
110 1.56 0.38
120 1.19 0.29
130 0.918 0.22
140 0.673 0.17
150 0.563 0.14
If the ECT sensor fails, the following symptoms may be observed:
Difficult cold start (under extreme conditions).

Engine performance compromised.
Temperature gauge inoperative or inaccurate reading.
In the event of ECT sensor signal failure, the ECM applies a default value of 80Celsius (176F) coolant temperature for fueling purposes.
The ECM will also permanently operate the cooling fan at all times when the ignition is switched on, to protect the engine from overheating.
Engine Oil Temperature Sensor
The oil temperature sensor is located in the engine sump. The temperature sensor is a NTC type which operates in the -30 Degrees Celsius
to +150 Degrees Celsius temperature range.
Oil Temperature Sensor Response

Temperature Degrees Celsius Resistance Ohms
60 620
90 255
120 117
150 60
Fuel Rail Temperature Sensor

The fuel rail temperature sensor is located on the LP return line.
The sensor is an NTC sensor which is connected to the ECM by two wires. The ECM fuel temperature sensor circuit consists of an internal
voltage divider circuit which incorporates an NTC thermistor. As the fuel temperature rises the resistance through the sensor decreases. The
output from the sensor is the change in voltage as the thermistor allows more current to pass to earth relative to the temperature of the
fuel.
The ECM monitors the fuel temperature constantly. If the fuel temperature exceeds 130Celsius (185F), the ECM invokes an engine 'derate'
strategy. This reduces the amount of fuel delivered to the injectors in order to allow the fuel to cool. W hen this occurs, the driver may
notice a loss of performance.
Further fuel cooling is available by a bi-metallic valve diverting fuel through the fuel cooler when the fuel reaches a predetermined
temperature.
The wires to the fuel sensor are monitored by the ECM for short and open circuit. The ECM also monitors the 5V supply. If a failure occurs a
fault is recorded in the ECM memory and the ECM uses a default fuel pressure value.
If the ECM registers an 'out of range' deviation between the pressure signal from the sensor and the pre-programmed 'set point' a fault is
stored in the ECM memory. Depending on the extent of the deviation, the ECM will reduce the injection quantity, stop the engine
immediately or prevent further engine starting.
Brake Light Switch
The brake switch is located on the brake pedal and is operated by the brake pedal. The switch has a normally open circuit switch which
closes the circuit when the driver has applied the brakes. The switch is connected directly to the ECM and the ECM also receives a brake
light signal on the CAN bus from the ABS control module.
The ECM uses the brake signal for the following:
To limit fuelling during braking (only when adaptive speed control is active)
To inhibit/cancel Speed control if the brakes are applied.
In the event of a brake switch failure, the following symptoms may be observed:
Speed control inactive

Increased fuel consumption.
Glow Plugs
Three glow plugs are located in each of the cylinder heads, on the inlet side. The glow plugs and the glow plug relay are a vital part of the
engine starting strategy. The glow plugs heat the air inside the cylinder during cold starts to assist combustion. The use of glow plugs helps
reduce the amount of additional fuel required on start-up, and consequently reduces the emission of black smoke. The use of glow plugs
also reduces the amount of injection advance required, which reduces engine noise, particularly when idling with a cold engine.
There are three phases of glow plug activity:
Pre-heat
During crank
Post heat
The main part of the glow plug is a tubular heating element which protrudes into the combustion chamber of the engine. The heating
element contains a spiral filament encased in magnesium oxide powder. At the tip of the tubular heating element is the heater coil. Behind
the heater coil, and connected in series, is a control coil. The control coil regulates the heater coil to ensure that it does not overheat.
Pre-heat is the length of time the glow plugs operate prior to engine cranking. The ECM controls the pre-heat time based on ECT sensor
output and battery voltage. If the ECT sensor fails, the ECM will use the fuel temperature sensor value as a default value. The pre-heat
duration is extended if the coolant temperature is low and the battery is not fully charged.
Post heat is the length of time the glow plugs operate after the engine starts. The ECM controls the post heating time based on ECT sensor
output. The post heat phase reduces engine noise, improves idle quality and reduces hydrocarbon emissions.
At ECTs below 0 degrrees celcius instrument cluster displays 'COLD START IN PROGRESS' in the message center. The glow-lamp is activated
separately from the glow-plugs, so is not illuminated during or after start. The plugs can still be ON when the lamp is off in these two
phases.
In the event of glow plug failure, the engine may be difficult to start.
Boost Air Temperature Sensor
The is boost air temperature sensor is located in the rear of the intake chamber immediately preceding the electric throttle. The sensor is
used to measure the intake air temperature from the turbo in order to calculate the required amount of fueling.
Boost Pressure Control

The Boost Pressure (BP) sensor is located post turbo after the eclectic throttle valve. The sensor provides a voltage signal to the ECM
relative to the intake manifold pressure. The BP sensor has a three pin connector which is connected to the ECM and provides a 5V reference
supply from the ECM, a signal input to the ECM and a ground for the sensor.
The BP sensor uses diaphragm transducer to measure pressure. The ECM uses the BP sensor signal for the following functions:
Maintain manifold boost pressure.

Reduce exhaust smoke emissions when driving at high altitude.
Control of the EGR system.
If the BP sensor fails, the ECM uses a default pressure of 1013 mbar (14 lbf/in). In the event of a BP sensor failure, the following
symptoms may be observed:
Altitude compensation inoperative (black smoke emitted from the exhaust).

Active boost control inoperative.
Boost control is achieved by the use of a direct drive electric actuator. The actuator is attached to the side of the turbo unit and is
connected with the control mechanism via a linkage. The electric actuator works on the torque motor principal and has integrated control
module.
The electric actuator moves the control vanes through an 60 degree stroke and has the capability to learn its own maximum stroke
positions. The electric actuator is controlled via PWM (pulse width modulation) signals from the ECM.
If the ECM detects a fault with the Boost Pressure (BP) sensor, it uses an open loop boost control based on engine speed and airflow as a
default value.
Knock Sensors
The TDV6 EMS has two knock sensors located in the V of the engine, one per cylinder bank. The sensors are connected to the ECM via a
twisted pair.
The knock sensors produce a voltage signal in proportion to the amount of mechanical vibration generated at each ignition point. Each
sensor monitors the related cylinder bank.
The knock sensors incorporate a piezo-ceramic crystal. This crystal produces a voltage whenever an outside force tries to deflect it, (i.e.
exerts a mechanical load on it). W hen the engine is running, the compression waves in the material of the cylinder block, caused by the
combustion of the fuel/air mixture within the cylinders, deflect the crystal and produce an output voltage signal. The signals are supplied to
the ECM, which compares them with `mapped' signals stored in memory. From this, the ECM can determine when detonation occurs on
individual cylinders. When detonation is detected, the ECM retards the ignition timing on that cylinder for a number of engine cycles, then
gradually returns it to the original setting.
Care must be taken at all times to avoid damaging the knock sensors, but particularly during removal and fitting procedures. The
recommendations regarding torque and surface preparation must be adhered to. The torque applied to the sensor and the quality of the
surface preparation both have an influence over the transfer of mechanical noise from the cylinder block to the crystal.
The ECM uses the signals supplied by the knock sensors, in conjunction with the signal it receives from the camshaft sensor, to determine
the optimum ignition point for each cylinder. The ignition point is set according to preprogrammed ignition maps stored within the ECM. If
the only fuel available is of poor quality, or the customer switches to a lower grade of fuel after using a high grade for a period of time, the
engine may suffer slight pre-ignition for a short period. This amount of pre-ignition will not damage the engine. This situation will be
evident while the ECM learns and then modifies its internal mapping to compensate for the variation in fuel quality. This feature is called
adaption. The ECM has the capability of adapting its fuel and ignition control outputs in response to several sensor inputs.
The ECM will cancel closed loop control of the ignition system if the signal received from either knock sensor becomes implausible. In these
circumstances the ECM will default to a safe ignition map. This measure ensures the engine will not become damaged if low quality fuel is
used. The MIL (malfunction indicator lamp) will not illuminate, although the driver may notice that the engine 'pinks' in some driving
conditions and displays a drop in performance and smoothness.
When a knock sensor fault is stored, the ECM will also store details of the engine speed, engine load and the coolant temperature.
Fuel Rail Pressure Control Valve

ItemDescription
1 Fuel volume control valve
2 High pressure fuel pump
3 Fuel rail pressure control valve
The fuel rail pressure control valve is incorporated into the high pressure fuel pump. The control valve regulates the fuel pressure within the
fuel rail and is controlled by the ECM. The control valve is a PW M controlled solenoid valve.
When the solenoid is de-energized, an internal spring holds an internal valve closed. At fuel pressure of 100 bar (1450 lbf/in) or higher, the
force of the spring is overcome, opening the valve and allowing fuel pressure to decay into the fuel return pipe. W hen the pressure in the
fuel rail decays to approximately 100 bar (1450 lbf/in) or less, the spring force overcomes the fuel pressure and closes the valve. W hen the
ECM energizes the solenoid, the valve is closed allowing the fuel pressure to build. The pressure in the fuel rail in this condition can reach
approximately 1600 bar.
The ECM controls the fuel rail pressure by operating the control valve solenoid using a PWM signal. By varying the duty cycle of the PWM
signal, the ECM can accurately control the fuel rail pressure and hence the pressure delivered to the injectors according to engine load. This
is achieved by the control valve allowing a greater or lesser volume of fuel to pass from the high pressure side of the pump to the
un-pressurized fuel return line, regulating the pressure on the high pressure side.
The fuel rail pressure control valve receives a PWM signal from the ECM of between 0 and 12V. The ECM controls the operation of the control
valve using the following information to determine the required fuel pressure:
Fuel rail pressure

Engine load
Accelerator pedal position
Engine temperature
Engine speed.
In the event of a total failure of the fuel rail pressure control valve, the engine will not start.
In the event of a partial failure of the fuel rail pressure control valve, the ECM will activate the solenoid with the minimum duty cycle which
results in the injection quantity being limited.
Fuel Volume Control Valve

The fuel rail volume control valve is incorporated into the high pressure fuel pump. The VCV spills unwanted fuel back to the tank (or LP
system) or forwards it to the PCV. This avoids unused fuel being pressurized by the HP stage of the pump, only to be spilt back to LP by the
PCV wasting energy and heating the fuel.
Injectors
There are six electronic fuel injectors located in a central position between the four valves of each cylinder. The ECM divides the injectors
into two banks of three with cylinders 1 to 3 being designated bank A and cylinders 4 to 6 designated bank B, with injector numbers 1 and 4
at the front of the engine.
Each injector is supplied with pressurized fuel from the fuel rail and delivers finely atomized fuel directly into the combustion chambers.
Each injector is individually controlled by the ECM which operates each injector in the firing order and controls the injector opening period
via PW M signals. Each injector receives a 120V supply from the ECM and, using programmed injection/timing maps and sensor signals,
determines the precise pilot and main injector timing for each cylinder. If battery voltage falls to between 6 and 9V, fuel injector operation
is restricted, affecting emissions, engine speed range and idle speed. In the event of a failure of a fuel injector, the following symptoms
may be observed:
Engine misfire
Idle irregular
Reduced engine performance
Reduced fuel economy
Difficult starting
Increased smoke emissions.
The ECM monitors the wires for each injector for short circuit and open circuit, each injector and the transient current within the ECM. If a
defect is found, an error is registered in the ECM for the injector in question.
EGR System
The EGR system comprises:
EGR modulator x 2
EGR cooler x 2
Associated connecting pipes
EGR Modulator and Cooler
The combined EGR modulator and cooler is located under each cylinder bank, between the exhaust manifold and the cylinder head. The
cooler side of the EGR is connected to the vehicle cooling system via hoses. The inlet exhaust side is connected directly into the exhaust
manifolds on each side. The exhaust gas passes through the cooler and is expelled via the actuator and a metal pipe into the throttle
housing. The EGR modulator is a solenoid operated valve which is controlled by the ECM. The ECM uses the EGR modulator to control the
amount of exhaust gas being re-circulated in order to reduce exhaust emissions and combustion noise.
The EGR modulator is controlled by an H bridge driver to control the precise amount of exhaust gas delivered to the cylinders.
The modulators are operated through their full range at each engine shut down, to clear any carbon deposits that may have built up whilst
the engine was running
In the event of a failure of the EGR modulator, the EGR function will become inoperative. The ECM can monitor the EGR modulator solenoid
for short circuits and store fault codes in the event of failure. The modulator can also be activated for testing using the Jaguar
recommended diagnostic equipment.
Accelerator Pedal Position Sensor (APP)
The APP is incorporated into the pedal assembly. The sensor is a twin track rotary potentiometer type.
The APP sensor is located in plastic housing which is integral with the throttle pedal. The housing is injection molded and provides location
for the APP sensor. The sensor is mounted externally on the housing and is secured with two Torx screws. The external body of the sensor
has a six pin connector which accepts a connector on the vehicle wiring harness.
The sensor has a spigot which protrudes into the housing and provides the pivot point for the pedal mechanism. The spigot has a slot which
allows for a pin, which is attached to the sensor potentiometers, to rotate through approximately 90, which relates to pedal movement.
The pedal is connected via a link to a drum, which engages with the sensor pin, changing the linear movement of the pedal into rotary
movement of the drum. The drum has two steel cables attached to it. The cables are secured to two tension springs which are secured in
the opposite end of the housing. The springs provide 'feel' on the pedal movement and require an effort from the driver similar to that of a
cable controlled throttle. A detente mechanism is located at the forward end of the housing and is operated by a ball located on the drum.
At near maximum throttle pedal movement, the ball contacts the detente mechanism. A spring in the mechanism is compressed and gives
the driver the feeling of depressing a 'kickdown' switch when full pedal travel is achieved.
Electronic Throttle
The electric throttle body is located in the inlet tract prior to where the inlet splits to divert air flow into the two separate air intake
manifolds. The electric throttle controls the volume of air allowed into the inlet manifold by means of a DC motor which controls a flap in
the body of the throttle. This is done in response to inputs from the engine management system.
Just after the throttle flap the tubes from the EGR valves/coolers are joined into the assembly.
Central Junction Box
The CJB initiates the power up and power down routines within the ECM. When the ignition is turned on 12V is applied to the Ignition Sense
input. The ECM then starts its power up routines and turns on the ECM main relay; the main power to the ECM and it's associated system
components. W hen the ignition is turned OFF the ECM will maintain its powered up state for up to 60 seconds while it initiates its power
down routine and on completion will turn off the ECM main relay.
Generator
The generator has a multifunction voltage regulator for use in a 14V charging system with 612 zener diode bridge rectifiers.
The ECM monitors the load on the electrical system via PW M signal and adjusts the generator output to match the required load. The ECM
also monitors the battery temperature to determine the generator regulator set point. This characteristic is necessary to protect the
battery; at low temperatures battery charge acceptance is very poor so the voltage needs to be high to maximize any rechargeability, but at
high temperatures the charge voltage must be restricted to prevent excessive gassing of the battery with consequent water loss.
The generator has a smart charge capability that will reduce the electrical load on the generator reducing torque requirements, this is
implemented to utilize the engine torque for other purposes. This is achieved by monitoring three signals to the ECM:
Generator sense (A sense), measures the battery voltage at the CJB.

Generator communication (Alt Com) communicates desired generator voltage set point from ECM to generator.
Generator monitor (Alt Mon) communicates the extent of generator current draw to ECM. This signal also transmits faults to the ECM
which will then sends a message to the instrument cluster on the CAN bus to illuminate the charge warning lamp.
DPF Temperature Sensors

Three temperature sensors are used in the DPF system. One is located before the catalytic convertor, the second sensor is after the
catalytic converter and the third sensor is located before the DPF.
The sensors measure the temperature of exhaust gas exiting the turbocharger, before it passes through the DPF and after it has passed
through the DPF and provides the information required by the ECM to calculate the DPF temperature. The information is used, in conjunction
with other data, to estimate the amount of accumulated particulate and to control the DPF temperature.
The sensors are Negative Temperature Co-efficient (NTC) type resistors, which measure the temperature of the exhaust gases. The
resistance, and subsequently the voltage at the sensor will decrease as the exhaust gas temperature increases.
In the event of a fault in a temperature sensor, the ECM uses a substitute value of 350C (1202F).
Differential Pressure Sensor

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 conduction with other data, to calculate the accumulated amount of trapped particulates.
By measuring the pressure difference between the DPF inlet and outlet air flow and the DPF temperature, the DPF software can determine if
the DPF is becoming blocked and requires regeneration.
A DPF is recognized as overloaded if the differential pressure under certain operating conditions exceeds the overload limit calculated by the
ECM. The DPF software may start regeneration attempts but be unable to complete them. These attempts are counted by the ECM and, if
the maximum number of regeneration attempts is reached, a fault entry is recorded in the ECM at the next ignition on cycle.
The DPF software performs the following checks using the DPF differential pressure sensor:
Plausibility check
Diesel particulate filter efficiency
Diesel particulate filter overloaded
Diesel particulate filter clogged
Monitoring of the maximum regeneration attempts in the lower load range.
Electronic Engine Controls - TDV6 2.7L Diesel - Electronic Engine Controls
For a detailed description of the 2.7L Diesel electronic engine controls, refer to the relevant Description and Operation section in the
workshop manual. REFER to: (303-14 Electronic Engine Controls - 2.7L Diesel)

Visual Inspection
Fuel level Electrical connector(s)
Fuel contamination Sensor(s)
Fuel leaks Engine control module (ECM)
Front End Accessory Drive (FEAD) belt Transmission control module (TCM)
step.
4. 4. If the cause is not visually evident refer to the Symptom Chart, alternatively, check for Diagnostic Trouble Codes (DTCs) and refer
to the DTC Index.
Symptom Chart
and Procedure manual (section B1.2), or determine if any prior approval programme is in operation, prior to the installation of a new
module/component.
Symptom Possible source Action

Engine cranks, Low/contaminated fuel Check the fuel level/condition. Check the integrity of the air intake system and for
but does not Air leakage correct installation. Check the fuel pump module operation, check the fuel system low
start Fuel system low pressure pressure circuit for leaks/damage. Check the fuel filter, check the FVCV and FPCV. Check
circuit fault the fuel injection pump. Check the CKP sensor and circuits. Refer to the new
Fuel pump module fault module/component installation note at the top of the Symptom Chart if an ECM is
Blocked fuel filter suspect
(FVCV)
blocked/contaminated
(FPCV)
Fuel injection pump failure
Crankshaft position (CKP)
sensor
ECM fault
Difficult to start Glow plug system fault Check the glow plugs and circuits. Check the fuel level/condition. Check the integrity of
(very cold conditions) the air intake system and for correct installation. Check the fuel pump module
Low/contaminated fuel operation, check the fuel system low pressure circuit for leaks/damage. Check the fuel
Air leakage filter, FVCV and FPCV. Check the EGR system
Fuel pump module fault
Fuel system low pressure
circuit fault
Blocked fuel filter
(FVCV)
(FPCV)
Exhaust gas recirculation
(EGR) valve(s) fault
Rough idle Air ingress Check the integrity of the air intake system and for correct installation. Check the fuel
Low/contaminated fuel level/condition. Check the fuel system low pressure circuit for leaks/damage. Check the
Fuel system low pressure fuel filter, FVCV and FPCV. Check the EGR system
circuit fault
Blocked fuel filter
(FVCV)
(FPCV)
Symptom Possible source Action
Lack of power Air intake system fault Check the integrity of the air intake system and for correct installation. Check for a
when Diesel particulate filter blocked DPF or catalytic converter, install new components as required. Check the fuel
accelerating (DPF) blocked/restricted pressure. Check the EGR system. Check the VGT actuators
Restricted exhaust system
Low fuel pressure
Variable geometry
turbocharger (VGT) actuator
fault
Engine Low/contaminated fuel Check the fuel level/condition. Check the fuel system low pressure circuit for
stops/stalls Air ingress leaks/damage. Check for fuel system leaks, FVCV and FPCV. Check the EGR system
Fuel system low pressure
circuit fault
(FVCV)
(FPCV)
High pressure fuel leak
Engine judders Low/contaminated fuel Check the fuel level/condition. Check the fuel system low pressure circuit for
Air ingress leaks/damage. Check for fuel system leaks, FVCV and FPCV. Check the fuel injection
Fuel system low pressure pump
circuit fault
Fuel metering valve
(FVCV)
(FPCV)
Fuel injection pump fault
Excessive fuel Fuel system low pressure Check the fuel system low pressure circuit for leaks/damage. Check the FVCV and FPCV.
consumption circuit fault Check the fuel temperature sensor, fuel injection pump, etc for leaks. Check for injector
Fuel volume control valve DTCs. Check the EGR system
(FVCV)
(FPCV)
leak
Injector(s) failure
DTC index
3548-1358-00.
module/component.

B10A231 Crash Input RCM PWM signal circuit - Refer to the electrical circuit diagrams and check RCM PWM signal
no signal circuit for short, open circuit
B10A236 Crash Input Signal frequency too low Check RCM for related DTCs and refer to the relevant DTC Index
B10A237 Crash Input Signal frequency too high Check RCM for related DTCs and refer to the relevant DTC Index
B10A239 Crash Input Incorrect has too few Check RCM for related DTCs and refer to the relevant DTC Index
pulses
B10A23A Crash Input Incorrect has too many Check RCM for related DTCs and refer to the relevant DTC Index
pulses
B11D901 Battery Voltage General electrical failure Carry out any pinpoint tests associated with this DTC using the
manufacturer approved diagnostic system. Check battery is in fully
charged and serviceable condition, refer to the battery care manual
B11DB01 Battery Monitoring Module Battery monitoring Disconnect vehicle battery, re-connect after 60 seconds, clear DTC
system hardware fault and retest. If DTC remains install a new battery monitoring module
B11DB87 Battery Monitoring Module Battery monitoring If additional DTCs B108783, B108786, B108787 are logged, suspect
module connector the RJB. Check and install a new RJB as required, refer to the new
dis-connected/poor module/component installation note at the top of the DTC Index. If
connection additional DTCs B108783, B108786, B108787 are NOT logged, check
Battery monitoring for good/clean contact at battery monitoring module connector,
module to RJB LIN circuit refer to electrical circuit diagrams and check battery monitoring
- open circuit module to RJB LIN circuit and battery monitoring module to battery
Battery monitoring positive monitor circuit for open circuit. Clear DTC and repeat
module to battery automated diagnostic procedure using manufacturer approved
positive monitor circuit - diagnostic system. If DTC remains suspect the battery monitoring
open circuit module, check and install a new battery monitoring module as
Battery monitoring required, refer to the new module/component installation note at
module/RJB failure the top of the DTC Index
B120668 Crash Occurred ECU has detected the Check RCM and RJB for related DTCs and refer to the relevant DTC
vehicle has crashed - Index
Event information DTC
only
P000113 Fuel Volume Regulator Fuel volume regulator Refer to the electrical circuit diagrams and check fuel volume
Control Circuit/Open control circuit - open regulator control circuit for open circuit. Check resistance across fuel
circuit regulator control valve is between 1.5 and 15 Ohms, install a new
Fuel volume regulator valve as required
Control Circuit control circuit - short to manufacturer approved diagnostic system. Refer to the electrical
Range/Performance ground, power, high circuit diagrams and check fuel volume regulator control circuit for
resistance short to ground, power, high resistance. Check and install new fuel
Fuel volume regulator volume regulator control valve/ECM as required, refer to the new
ECM failure
Control Circuit Low control circuit - short to regulator control circuit for short to ground. Check resistance across
ground fuel regulator control valve is between 1.5 and 15 Ohms, install a
Fuel volume regulator new valve as required
above threshold diagrams and check fuel volume regulator control valve circuit for
Fuel volume regulator short, open circuit. Check resistance across fuel regulator control
control valve failure valve is between 1.5 and 15 Ohms, install a new valve as required
Control Circuit High control circuit - short to regulator control circuit for short to ground, power, open circuit.
ground, power, high Check resistance across fuel regulator control valve is between 1.5
resistance and 15 Ohms, install a new valve as required
Control Exceeded Learning minimum manufacturer approved diagnostic system. Refer to the electrical
Limit circuit diagrams and check fuel volume regulator control circuit for
short to ground, power, open circuit
Control Exceeded Learning maximum manufacturer approved diagnostic system. Refer to the electrical
Limit circuit diagrams and check fuel volume regulator control circuit for
short to ground, power, open circuit
P004711 Turbocharger/Supercharger Turbocharger boost Carry out any pinpoint tests associated with this DTC using the
Boost Control Solenoid A control solenoid A circuit - manufacturer approved diagnostic system. Refer to the electrical
Circuit Low short to ground circuit diagrams and check turbocharger boost control solenoid A
Turbocharger boost circuit for short to ground. Suspect the turbocharger boost control
control solenoid A failure solenoid A, check and install a new turbocharger as required, refer
to the new module/component installation note at the top of the
DTC Index
P004812 Turbocharger/Supercharger Turbocharger boost Carry out any pinpoint tests associated with this DTC using the
Boost Control Solenoid A control solenoid A circuit - manufacturer approved diagnostic system. Refer to the electrical
Circuit High short to power circuit diagrams and check turbocharger boost control solenoid A
Turbocharger boost circuit for short to power. Suspect the turbocharger boost control
control solenoid A failure solenoid A, check and install a new turbocharger as required, refer
to the new module/component installation note at the top of the
DTC Index
P004C00 Turbocharger/Supercharger Turbocharger boost Refer to the electrical circuit diagrams and check turbocharger boost
Boost Control Solenoid B control solenoid B circuit - control solenoid B circuit for short to ground. Suspect the
Circuit Low short to ground turbocharger boost control solenoid B, check and install a new
Turbocharger boost turbocharger as required, refer to the new module/component
control solenoid B failure installation note at the top of the DTC Index
Electronic Engine Controls - TDV6 2.7L Diesel - Camshaft Position (CMP) Sensor
Removal

2. Remove the LH exhaust gas recirculation (EGR) valve.
Valve LH (303-08A Engine Emission Control - TDV6 2.7L Diesel, Removal
and Installation).
3. Disconnect the camshaft position (CMP) sensor electrical conector.
Installation
1. NOTE: Only turn the engine in the normal direction of rotation.
NOTE: Timing belt left hand cover shown removed for clarity.
Turn the engine until one of the three webs on the back of the camshaft
pulley is visible through the CMP sensor housing.
2. CAUTION: The CMP sensor tip must rest on one of the three webs
on the back of the camshaft pulley. Incorrect installation may result in the
CMP sensor being damaged.
NOTE: Timing belt left hand cover shown removed for clarity.
Install the CMP sensor until the tip of the sensor touches the back of
the camshaft pulley.
3. Install the CMP sensor retaining bolt.
Tighten to 10 Nm.
4. Connect the CMP sensor electrical connector.
5. Install the LH EGR valve.

Valve LH (303-08A Engine Emission Control - TDV6 2.7L Diesel, Removal
and Installation).
Electronic Engine Controls - TDV6 2.7L Diesel - Crankshaft Position (CKP) Sensor
Removal


Installation).


connector.
10. Remove the CKP sensor blanking cover.
11. NOTE: The CKP sensor retaining bolt should not be removed from the
CKP sensor.
Fully loosen the CKP sensor retaining bolt.

Installation
1. CAUTION: Install the CKP sensor correctly into the housing.

Failure to follow this instruction may result in damage to the CKP sensor.
2. Tighten to 5 Nm.
Electronic Engine Controls - TDV6 2.7L Diesel - Crankshaft Position (CKP) Sensor Ring
Special Tool(s)
Installer - Crankshaft Position (CKP) Sensor
Ring
303-1130
Removal


For additional information, refer to: Flexplate (303-01A Engine - TDV6
5. Remove the CKP sensor blanking cover.
6. NOTE: The CKP sensor retaining bolt should not be removed from the
CKP sensor.
Fully loosen the CKP sensor retaining bolt.

8. Remove and discard the CKP sensor ring.
Installation
1. Install a new CKP sensor ring to the special tool.
Make sure that the CKP sensor ring is aligned correctly with the
special tool pip and that both mating surfaces are fully seated.
Align the special tool alignment peg to the timing hole on the
crankshaft.
3. Install a new CKP sensor ring.
Tighten the special tool nut, to install the CKP sensor ring to the
crankshaft.
4. Loosen the special tool nut.
6. CAUTION: Install the CKP sensor correctly into the housing.

Failure to follow this instruction may result in damage to the CKP sensor.
Install the CKP sensor.
Tighten to 5 Nm.
7. Install the CKP sensor blanking cover


For additional information, refer to: Flexplate (303-01A Engine - TDV6
Electronic Engine Controls - TDV6 2.7L Diesel - Engine Control Module (ECM)
Removal
All vehicles

For additional information, refer to: Secondary Bulkhead Panel LH - V8

All vehicles
Remove the pedestrian protection actuator.

Release the pedestrian protection actuator bracket.
Reposition the pedestrian protection actuator bracket.
Remove the engine control module (ECM) cover.

Disconnect the 3 electrical connectors from the engine control module

(ECM).
Remove the ECM.
Installation
Tighten to 10 Nm.
2. Tighten to 6 Nm.
4. Tighten to 8 Nm.
Electronic Engine Controls - TDV6 2.7L Diesel - Engine Coolant Temperature (ECT)
Sensor
Removal
CAUTION: Since injury such as scalding could be caused by escaping steam or coolant, make sure the vehicle cooling system is cool
prior to carrying out this procedure

3. CAUTIONS:
Be prepared to collect escaping fluids.
The seal is to be reused unless damaged.
Remove the engine coolant temperature (ECT) sensor.
Lift the tang and rotate the ECT sensor anti-clockwise.
Installation

2. Fill the cooling system, keeping coolant to the upper level mark of the
expansion tank.
Electronic Engine Controls - TDV6 2.7L Diesel - Engine Oil Pressure (EOP) Sensor
Removal
2. Disconnect the engine oil pressure (EOP) sensor electrical connector.
3. Remove the EOP sensor.
Installation
Tighten to 15 Nm.
Electronic Engine Controls - TDV6 2.7L Diesel - Fuel Rail Pressure (FRP) Sensor
General Equipment
Pneumatic vacuum gun
Removal
W ARNINGS:
The spilling of fuel is unavoidable during this operation. Ensure that all necessary precautions are taken to prevent fire and explosion.
Do not carry out any repairs to the fuel system with the engine running. The fuel pressure within the system can be as high as 1650
bar (23,931 lb-sq-in). 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.
Do not remove the fuel rail pressure sensor from the fuel injection diverter rail.
1. NOTE: If a new fuel rail pressure sensor is to be installed, a new fuel

injection diverter rail and fuel rail pressure sensor must be installed as an
assembly.


7. Disconnect the low pressure fuel inlet and return lines.
Install suitable blanking caps to the fuel lines and unions.
Detach the high-pressure fuel supply lines.
Loosen the high-pressure fuel supply lines.

11. Remove and discard the high-pressure fuel supply lines.
Remove and discard the high-pressure fuel diverter rail supply line.
13. Remove the fuel line retaining nut.
Release the fuel charging wiring harness.
15. Reposition the fuel line.

16. Remove the FRP and fuel injection diverter rail assembly.
Remove the 2 studs.
Installation
1. WARNINGS:


injury.

CAUTIONS:

system.
diverter rail.
Install the FRP and fuel injection diverter rail assembly.
Install the two retaining studs, but do not fully tighten at this
stage.
2. Attach the fuel line.
3. Connect the FRP sensor electrical connector.
4. Install the fuel line retaining nut.
Tighten to 7 Nm.
Tighten the fuel injection diverter rail retaining studs to 23 Nm.




Install the new high-pressure fuel rail supply line.




Attach the high-pressure fuel supply lines.
Tighten to 10 Nm.
Tighten to 7 Nm.
9. Attach the low-pressure fuel line.


16. Bleed the fuel system.
Electronic Engine Controls - TDV6 2.7L Diesel - Fuel Temperature Sensor
Removal
WARNING: This procedure involves fuel handling. Be prepared for fuel spillage at all times and always observe fuel handling
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 install blanking plugs to any open orifices or lines. Failure to
follow this instruction may result in foreign matter ingress to the fuel injection system.
1. WARNINGS:

injury.
CAUTION: 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.

Installation).
5. Disconnect the fuel return line from the fuel cooler.

Release the engine wiring harness from the fuel supply manifolds.
Release and reposition the wiring harness.
7. Disconnect the engine oil pressure (EOP) switch electrical connector.
Remove and discard the fuel injector leak off pipe retaining clips.
Disconnect the fuel injector leak off pipe.

9. Remove the fuel injector leak off pipe.
Clean any spilt fuel from the engine.
Installation
1. CAUTIONS:
Install new fuel injector leak off pipe retaining clips.
material.

Electronic Engine Controls - TDV6 2.7L Diesel - Knock Sensor (KS) LH
Removal
1. Remove the crankcase vent oil separator.

For additional information, refer to: Crankcase Vent Oil Separator
(303-08A Engine Emission Control - TDV6 2.7L Diesel, Removal and
Installation).
2. W ARNING: Be prepared to collect escaping oil.
Remove the engine oil filter.
Loosen the element cover 4 complete turns to allow engine oil to

drain from the filter cover.
Remove element cover.
3. Disconnect the knock sensors (KS) electrical connector.
4. Disconnect the LH glow plug wiring harness electrical connector.

removal.
Remove the LH knock sensor (KS).
Installation
1. CAUTIONS:
material.
Make sure that the cable is correctly routed.
NOTE: Make sure that this component is installed to the noted removal
position.
Tighten to 20 Nm.
Tighten to 25 Nm.

Electronic Engine Controls - TDV6 2.7L Diesel - Knock Sensor (KS) RH
Removal
1. Remove the crankcase vent oil separator.
2. W ARNING: Be prepared to collect escaping oil.
Remove the engine oil filter.
Loosen the element cover 4 complete turns to allow engine oil to

drain from the filter cover.
Remove element cover.
3. Disconnect the knock sensor (KS) electrical connectors.
4. Disconnect the glow plug electrical connectors.

removal.
Remove the knock sensor (KS).
Installation
1. CAUTIONS:
material.
Make sure that the cable is correctly routed.
NOTE: Make sure that this component is installed to the noted removal
position.
Tighten to 20 Nm.
Tighten to 25 Nm.

Electronic Engine Controls - TDV6 2.7L Diesel - Intake Air Temperature (IAT) Sensor
Removal
1. Refer to: Engine Cover - TDV6 2.7L Diesel (501-05 Interior Trim and Ornamentation,
2.
3.
Installation

Electronic Engine Controls - TDV6 2.7L Diesel - Manifold Absolute Pressure (MAP)
Sensor
Removal
2. Disconnect the manifold absolute pressure (MAP) sensor electrical
connector.
3. Remove the MAP sensor.
Installation
Tighten to 3 Nm.
Electronic Engine Controls - TDV6 2.7L Diesel - Mass Air Flow (MAF) Sensor
Removal
NOTE: This procedure is showing the lower mass air flow (MAF) sensor removal and installation. The upper MAF sensor removal and
installation is similar.

2. Remove the mass air flow (MAF) sensor.
Installation
foreign material.
Tighten to 2 Nm.
Electronic Engine Controls - TDV6 2.7L Diesel - Oil Temperature Sensor
Removal


4. Disconnect the oil temperature sensor electrical connector.
5. Remove the engine oil temperature sensor.
Installation
foreign material.
Install is the reverse of removal.
Tighten to 24 Nm.
Electronic Engine Controls - V6 3.0L Petrol -
Camshaft position (CMP) sensor retaining bolt 7 - 62
Heated oxygen sensor (H02S) 40 30 -
Catalyst monitor sensor 40 30
Crankshaft position (CKP) sensor retaing bolt 7 - 62
Knock sensor retaining bolt 25 18 -
Variable camshaft timing oil control solenoid 10 7 -
Intake manifold tuning valve 10 7 -
Engine coolant temperature (ECT) sensor 17 13 -
Manifold absolute pressure (MAP) sensor 10 7 -
Lubricants, fluids, sealers and adhesives
Sealant W SK-M4G-328-A3
Electronic Engine Controls - V6 3.0L Petrol - Electronic Engine Controls - Component
Location
ItemDescription
1 Electric throttle
2 VCT (variable camshaft timing) solenoid
3 KS (knock sensor)
4 Fuel rail pressure sensor
5 EOP (engine oil pressure) sensor
6 Engine oil temperature sensor
8 CKP (crankshaft position)
ItemDescription
3 IMT valve
4 KS
Electronic Engine Controls - V6 3.0L Petrol - Electronic Engine Controls - Overview
OVERVIEW
The V6 3 Liter engine is controlled by an ECM (engine control module) manufactured by DENSO. The Engine Management System (EMS)
controls the following:
Engine fueling
Ignition timing
Closed loop fueling
Knock control
Idle speed control
Emission control
On Board Diagnostic
Interface with the immobilization system
Speed control
The ECM controls the engine fueling by providing sequential fuel injection to all cylinders. Ignition is controlled by a direct ignition system,
provided by six plug top coils. The ECM is able to detect and correct for ignition knock on each cylinder and adjust the ignition timing for
each cylinder to achieve optimum performance.
The ECM uses a torque-based strategy to generate the torque required by the driver and other vehicle control modules. The EMS uses
various sensors to determine the torque required from the engine. The EMS also interfaces with other vehicle electronic control modules's,
via the CAN (controller area network) bus, to obtain additional information (e.g. road speed from the ABS (anti-lock brake system) control
module). The EMS processes these signals and decides how much torque to generate. Torque is then generated by using various actuators
to supply air, fuel and spark to the engine (electronic throttle, injectors, coils, etc.).
The EMS comprises the following inputs:

MAF sensor
Knock sensors
Fuel rail temperature sensor
ECT (engine coolant temperature) sensor
Engine oil temperature sensor
MAP (manifold absolute pressure) sensor
Electric throttle feedback sensor
AIR (secondary air injection)MAP sensor
APP (accelerator pedal position) sensor
Tank leakage detection system (NAS only)
Cooling fan speed feedback
Oxygen sensors
Brake switch
Speed control cancel/suspend switch
Automatic speed limiter switch
Crank request signal
IAT (intake air temperature) sensor
External air temperature sensor
The EMS comprises the following outputs:
Fuel injectors
Ignition coils
Engine cooling fan
Electric throttle
Electric fuel pump driver module
VCT (variable camshaft timing) solenoids
Purge valve
EGR (exhaust gas recirculation) valve
AIR pump
Starter relay control
Electronic Engine Controls - V6 3.0L Petrol - Electronic Engine Controls - System
Control Diagram
NOTE: A = Hardwired, D = High speed CAN (controller area network) bus, N = Medium speed CAN bus, O = LIN (local interconnect
network) bus
CONTROL DIAGRAM SHEET 1 OF 3
ItemDescription
1 Battery
2 Keyless vehicle module
4 KS (knock sensor)
12 EOP (engine oil pressure) switch
13 Exterior air temperature sensor
17 Start/stop switch
ItemDescription
1 FPDM (fuel pump driver module)
2 Generator
3 O2S (oxygen sensor) upstream
4 O2S downstream
5 Electric throttle
6 Purge valve
11 AIR (secondary air injection) pump
12 ECM
13 Injectors
14 Plug top coils
ItemDescription
2 Diagnostic socket
3 Steering column lock
4 Electronic parking brake module
8 Clock spring
12 Adaptive front lighting module
13 Start/ stop switch
14 ECM
15 Pedestrian protection system control module
System Operation
provided by six plug top coils. The ECM is able to detect and correct for ignition knock on each cylinder and adjust the ignition timing for
The ECM uses a torque-based strategy to generate the torque required by the driver and other vehicle control modules. The ECM uses
via the CAN bus, to obtain additional information (e.g. road speed from the ABS control module). The EMS processes these signals and
decides how much torque to generate. Torque is then generated by using various actuators to supply air, fuel and spark to the engine
(electronic throttle, injectors, coils, etc.).
System Inputs
The EMS has the following inputs:
RCM
Park/neutral switch
Ignition coil feedback
MAF
Engine speed
Camshaft position
Driver demand
Brake pedal position switch
Speed control switches
Generator load
HO2S (heated oxygen sensor) pre catalyst
HO2S post catalyst
Throttle position
Cooling fan speed
Ignition switch
Knock sensors
MAP
ECT (engine coolant temperature)
Engine oil temperature
EOP
Fuel pressure
Fuel temperature
System Outputs
The EMS has the following outputs:
Throttle Actuator
Brake vacuum pump relay
Ignition coils
Oxygen sensor heaters
Fuel injectors
Purge Valve
Engine Cooling Fan
Fuel pump relay
Starter Relay
ECM Main Relay
Generator Control
Fuel tank leakage detection
ECM Adaptions
The ECM has the ability to adapt the values it uses to control certain outputs. This capability ensures the EMS can meet emissions
legislation and improve the refinement of the engine throughout its operating range.
The components which have adaptions associated with them are:
The APP sensor

The oxygen sensors
The MAF/IAT (intake air temperature) sensor
The CKP sensor
The Electric throttle body.
Oxygen Sensors and MAF/AT Sensor

There are several adaptive maps associated with the fueling strategy. Within the fueling strategy the ECM calculates short-term adaptions
and long term adaptions. The ECM will monitor the deterioration of the oxygen sensors over a period of time. It will also monitor the current
correction associated with the sensors.
The ECM will store a fault code in circumstances where an adaption is forced to exceed its operating parameters. At the same time, the ECM
will record the engine speed, engine load and intake air temperature.
Crankshaft Position Sensor

The characteristics of the signal supplied by the CKP sensor is learnt by the ECM . This enables the ECM to set an adaption and support the
engine misfire detection function. Due to the small variation between different flywheels and different CKP sensors, the adaption must be
reset if either component is renewed, or removed and refitted. It is also necessary to reset the flywheel adaption if the ECM is renewed or
replaced. The ECM supports four flywheel adaptions for the CKP sensor. Each adaption relates to a specific engine speed range. The engine
speed ranges are detailed in the table below:
Adaptions Engine Speed, rev/min

1 1800 - 3000
2 3001 - 3800
3 3801 - 4600
4 4601 - 5400
Misfire Detection
Legislation requires that the ECM must be able to detect the presence of an engine misfire. It must be able to detect misfires at two
separate levels. The first level is a misfire that could lead to the vehicle emissions exceeding 1.5 times the Federal Test Procedure (FTP)
requirements for the engine. The second level is a misfire that may cause catalyst damage.
The ECM sensor monitors the number of misfire occurrences within two engine speed ranges. If the ECM detects more than a predetermined
number of misfire occurrences within either of these two ranges, over two consecutive journeys, the ECM will record a fault code and details
of the engine speed, engine load and engine coolant temperature. In addition, the ECM monitors the number of misfire occurrences that
happen in a 'window' of 200 engine revolutions. The misfire occurrences are assigned a weighting according to their likely impact on the
catalysts. If the number of misfires exceeds a certain value, the ECM stores catalyst-damaging fault codes, along with the engine speed,
engine load and engine coolant temperature.
The signal from the CKP indicates how fast the poles on the flywheel are passing the sensor tip. A sine wave is generated each time a pole
passes the sensor tip. The ECM can detect variations in flywheel speed by monitoring the sine wave signal supplied by the CKP sensor.
By assessing this signal, the ECM can detect the presence of an engine misfire. At this time, the ECM will assess the amount of variation in
the signal received from the CKP and assigns a roughness value to it. This roughness value can be viewed within the real time monitoring
feature, using a Land Rover approved diagnostic system. The ECM will evaluate the signal against a number of factors and will decide
whether to count the occurrence or ignore it. The ECM can assign a roughness and misfire signal for each cylinder, (i.e. identify which
cylinder is misfiring).
Diagnostics
The ECM stores faults as DTC (diagnostic trouble code), referred to as 'P' codes. The 'P' codes are defined by OBD (on-board diagnostic)
legislation and, together with their associated environmental and freeze frame data, can be read using a third party scan tool or a Land
Rover approved diagnostic system. A Land Rover approved diagnostic system can also read real time data from each sensor, the adaptive
values currently being employed and the current fueling, ignition and idle settings.
The ECM is located in the engine bay attached to the bulkhead. On LHD (left-hand drive) vehicles the ECM is located on the RH (right-hand)
side of the compartment behind the BJB. On RHD (right-hand drive) vehicles the ECM is located on the LH (left-hand) side of the engine
compartment.
provided by eight plug top coils. The ECM is able to detect and correct for ignition knock on each cylinder and adjust the ignition timing for
The ECM uses a torque-based strategy to generate the torque required by the driver and other vehicle control modules. The EMS uses
via the CAN bus, to obtain additional information (e.g. road speed from the ABS control module). The EMS processes these signals and
decides how much torque to generate. Torque is then generated by using various actuators to supply air, fuel and spark to the engine
(electronic throttle, injectors, coils, etc.).
The crankshaft position sensor is mounted at the rear underside of the engine near the transmission bell housing. Connection between the
sensor and the harness is via a link harness and a two-way connector. Both wires go directly to the ECM. The sensor produces the signal
which enables the ECM to determine the angle of the crankshaft, and the engine rpm. From this, the point of ignition, fuel injection, etc. is
calculated. If the signal wires are reversed a 3 advance in timing will occur, as the electronics within the ECM uses the falling edge of the
signal waveform as its reference/timing point for each tooth.
The reluctor is pressed into the flywheel and has a "tooth" pattern based on 36 teeth at 10 intervals and approximately 5 wide: one of
the teeth is removed to provide a hardware reference mark which is 60 degrees BTDC (before top dead center) No.1 cylinder. Because of the
crankshaft sensor's orientation, the target wheel uses windows machined into the face, rather than actual teeth.
The sensor operates by generating an output voltage caused by the change in magnetic field that occurs as the windows pass in front of the
sensor. The output voltage varies with the speed of the windows passing the sensor, the higher the engine speed, the higher the output
voltage. Note that the output is also dependent on the air gap between the sensor and the teeth (the larger the gap, the weaker the
signal, the lower the output voltage). The ECM transmits the engine speed to other vehicle control modules on CAN.

Two sensors are located at the rear of the engine, in the cylinder head (one per bank), above the rear cylinders. This is a Variable Reluctor
Sensor (VRS) producing four pulses for every two engine revolutions. The sensing element is positioned between 0 and 2mm from the side
of the cam gear wheel.
The variable cam intake is parked in the retarded position and can advance up to 48 degrees.
The camshaft timing wheel is a sintered component which has four teeth on it to enable the EMS to detect cylinder identification. The signal
is used for:
Variable intake cam timing

Cylinder recognition
Enabling sequential fuel injection
Knock control
Cylinder identification for diagnostic purposes.
Failure symptoms include:
Ignition timing reverting to the base mapping, with no cylinder correction.

Active knock control is disabled, along with its diagnostic (safe ignition map-loss of performance).
Quick cam/crank synchronisation on start disabled.
Variable cam timing is disabled
Engine coolant Temperature Sensor
The sensor is located at the front of the engine in the water pipe below the throttle body. The ECT sensor is a thermistor used to monitor
the engine coolant temperature. The ECT sensor is vital to the correct running of the engine as a richer mixture is required at lower block
temperatures for good quality starts and smooth running, leaning off as the temperature rises to maintain emissions and performance.
The sensor has an operating temperature range of -40 Degrees Celsius to 119 Degrees Celsius. W hen a defective coolant sensor is
detected, the ECM uses the oil temperature sensor value.PTC (positive temperature coefficient)
Tank Leakage Detection-NAS ONLY

The tank leakage detection system periodically checks the evaporative system and the fuel tank for leaks when the ignition is switched off.
The tank leakage detection pump is connected to the atmospheric vent of the charcoal cannister and incorporates a PTC heating element a
normally open valve and a reference orifice. The tank leakage detection pump is only operated when the ignition is switched off and is
controlled by the ECM. The ECM also monitors the electric air pump operation and the normally open valve for faults. To check the fuel tank
and EVAP system for leaks the ECM operates the tank leakage detection pump and monitors the current draw. This is compared to a
referenced figure established from the current draw when air is pumped through the reference orifice.
Purge Valve
The purge valve is located at the rear of the engine on a bracket which is attached to the transmission bell housing. The purge valve is a
solenoid operated valve which is closed when de-energized. The purge valve is controlled by a 10Hz PW M (pulse width modulation) signal
from the ECM. W hen the engine operating conditions are correct, the ECM opens the purge valve which causes fuel vapor and fresh air to be
drawn through the charcoal cannister. The fresh air is drawn through the charcoal cannister via the tank leakage detection pump fresh air
vent.NTC (negative temperature coefficient)
Oil temperature is monitored through a temperature sensor mounted in the oil system. This component is a NTC. The sensor is mounted
next to the oil pressure sensor at the front of the engine and locates into the oil filter bracket.

The fuel rail temperature sensor measures the temperature of the fuel in the fuel rail. This input is then used to deliver the correct quantity
of fuel to the engine. Operating Range -40 Degrees Celsius to 150 Degrees Celsius. The fuel rail temperature sensor is fitted on the rear of
the right hand bank (bank A) fuel rail.
Mass Air Flow/Intake Air Temperature Sensor (MAF/IAT)
The air flow meter is located in the clean air duct immediately after the air filter box.
The air mass flow is determined by the cooling effect of intake air passing over a hot film element contained within the device. The higher
the air flow the greater the cooling effect and the lower the electrical resistance of the hot film element. The ECM then uses this signal
from the Mass Air Flow meter to calculate the air mass flowing into the engine.
The measured air mass flow is used in determining the fuel quantity to be injected in order to maintain the stoichiometric air/fuel mixture
required for correct operation of the engine and exhaust catalysts. Should the device fail there is a software backup strategy that will be
evoked once a fault has been diagnosed.
The following symptoms may be observed if the sensor fails:
During driving the engine RPM might dip, before recovering.

Difficulty in starting or start-stall.
Poor throttle response/engine performance.
Lambda control and idle speed control halted.
Emissions incorrect.
AFM signal offset
The IAT sensor is integrated into the MAF sensor. It is a temperature dependent resistor (thermistor), i.e. the resistance of the sensor
varies with temperature. This thermistor is a NTC type element meaning that the sensor resistance decreases as the sensor temperature
increases. The sensor forms part of a voltage divider chain with an additional resistor in the ECM. The voltage from this sensor changes as
the sensor resistance changes, thus relating the air temperature to the voltage measured by the ECM.
The ECM stores a 25 Degrees Celsius default value for air temperature in the event of a sensor failure.
Manifold Absolute Pressure Sensor (MAP)
The MAP sensor provides a voltage proportional to the absolute pressure in the intake manifold. This signal allows the load on the engine to
be calculated and used within the internal calculations of the ECM. The sensor is located on the rear of the air intake manifold.
The output signal from the MAP sensor, together with the CKP and IAT sensors, is used by the ECM to calculate the amount of air induced
into the cylinders. This enables the ECM to determine ignition timing and fuel injection duration values.
The MAP sensor receives a 5V supply voltage from the ECM and provides an analogue signal to ECM, which relates to the absolute manifold
pressure and allows the ECM to calculate engine load. The ECM provides a ground for the sensor.
If the MAP signal is missing, the ECM will substitute a default manifold pressure reading based on crankshaft speed and throttle angle. The
engine will continue to run with reduced drivability and increased emissions, although this may not be immediately apparent to the driver.
The ECM will store fault codes which can be retrieved using the recommended Jaguar diagnostic tool.
Knock Sensors
The EMS has two knock sensors located in the V of the engine, one per cylinder bank. The sensors are connected to the ECM via a twisted
pair of wires.
The knock sensors produce a voltage signal in proportion to the amount of mechanical vibration generated at each ignition point. Each
sensor monitors the related cylinder bank.
The knock sensors incorporate a piezo-ceramic crystal. This crystal produces a voltage whenever an outside force tries to deflect it, (i.e.
exerts a mechanical load on it). W hen the engine is running, the compression waves in the material of the cylinder block, caused by the
combustion of the fuel/air mixture within the cylinders, deflect the crystal and produce an output voltage signal. The signals are supplied to
the ECM, which compares them with `mapped' signals stored in memory. From this, the ECM can determine when detonation occurs on
individual cylinders. When detonation is detected, the ECM retards the ignition timing on that cylinder for a number of engine cycles, then
gradually returns it to the original setting.
Care must be taken at all times to avoid damaging the knock sensors, but particularly during removal and fitting procedures. The
recommendations regarding torque and surface preparation must be adhered to. The torque applied to the sensor and the quality of the
surface preparation both have an influence over the transfer of mechanical noise from the cylinder block to the crystal.
The ECM uses the signals supplied by the knock sensors, in conjunction with the signal it receives from the camshaft sensor, to determine
the optimum ignition point for each cylinder. The ignition point is set according to preprogrammed ignition maps stored within the ECM. The
ECM is programmed to use ignition maps for 98 RON premium specification fuel. It will also function on 91 RON regular specification fuel
and learn new adaptions. If the only fuel available is of poor quality, or the customer switches to a lower grade of fuel after using a high
grade for a period of time, the engine may suffer slight pre-ignition for a short period. This amount of pre-ignition will not damage the
engine. This situation will be evident while the ECM learns and then modifies its internal mapping to compensate for the variation in fuel
quality. This feature is called adaption. The ECM has the capability of adapting its fuel and ignition control outputs in response to several
sensor inputs.
The ECM will cancel closed loop control of the ignition system if the signal received from either knock sensor becomes implausible. In these
circumstances the ECM will default to a safe ignition map. This measure ensures the engine will not become damaged if low quality fuel is
used. The MIL (malfunction indicator lamp) lamp will not illuminate, although the driver may notice that the engine 'pinks' in some driving
conditions and displays a drop in performance and smoothness.
When a knock sensor fault is stored, the ECM will also store details of the engine speed, engine load and the coolant temperature.
Electric Throttle
The V6 EMS incorporates an electric throttle control system. The electronic throttle body is located on the air intake manifold in the engine
compartment. The system comprises three main components:
Electronic throttle control valve

APP
ECM
When the accelerator pedal is depressed the APP sensor provides a change in the monitored signals. The ECM compares this against an
electronic map and moves the electronic throttle valve via a PWM control signal which is in proportion to the APP angle signal. The system
is required to:
Regulate the calculated intake air load based on the accelerator pedal sensor input signals and programmed mapping.
Monitor the drivers input request for cruise control operation.
Automatically position the electronic throttle for accurate cruise control.
Perform all dynamic stability control throttle control interventions.
Monitor and carry out maximum engine and road speed cut out.
A software strategy within the ECM enables the throttle position to be calibrated each ignition cycle. When the ignition is turned OFF, the
ECM performs a self test and calibration routine on the electronic throttle by closing the throttle fully. The power is then removed and the
ECM checks that the throttle returns to the reference position under the pressure from the spring.
The APP sensor is located in a plastic housing which is integral with the throttle pedal. The housing is injection molded and provides
location for the APP sensor. The sensor is mounted externally on the housing and is secured with two Torx screws. The external body of the
sensor has a six pin connector which accepts a connector on the vehicle wiring harness.
The sensor has a spigot which protrudes into the housing and provides the pivot point for the pedal mechanism. The spigot has a slot which
allows for a pin, which is attached to the sensor potentiometers, to rotate through approximately 90 degrees , which relates to pedal
movement. The pedal is connected via a link to a drum, which engages with the sensor pin, changing the linear movement of the pedal into
rotary movement of the drum. The drum has two steel cables attached to it. The cables are secured to two tension springs which are
secured in the opposite end of the housing. The springs provide 'feel' on the pedal movement and require an effort from the driver similar to
that of a cable controlled throttle. A detente mechanism is located at the forward end of the housing and is operated by a ball located on
the drum. At near maximum throttle pedal movement, the ball contacts the detente mechanism. A spring in the mechanism is compressed
and gives the driver the feeling of depressing a 'kickdown' switch when full pedal travel is achieved.
The APP sensor signals are checked for range and plausibility. Two separate reference voltages are supplied to the pedal. Should one sensor
fail, the other is used as a 'limphome' input. In limp home mode due to an APP signal failure the ECM will limit the maximum engine speed
to 2000 rpm.
APP Sensor Output Graph

ItemDescription
A Voltage
B APP sensor angle
C Kick down angle
The APP sensor has two potentiometer tracks which each receive a 5V input voltage from the ECM. Track 1 provides an output of 0.5V with
the pedal at rest and 2.0V at 100% full throttle. Track 2 provides an output of 0.5V with the pedal at rest and 4.5V at 100% full throttle.
The signals from the two tracks are used by the ECM to determine fueling for engine operation and also by the ECM and the TCM to initiate
a kickdown request for the automatic transmission.
The ECM monitors the outputs from each of the potentiometer tracks and can determine the position, rate of change and direction of
movement of the throttle pedal. The 'closed throttle' position signal is used by the ECM to initiate idle speed control and also overrun fuel
cut-off.
Oxygen Sensors
There are four oxygen sensors located in the exhaust system. Two upstream before the catalytic converter (HO2S) and two down stream
after the catalytic converter (O2S). The sensor monitors the level of oxygen in the exhaust gases and is used to control the fuel/air mixture.
Positioning a sensor in the stream of exhaust gasses from each bank enables the ECM to control the fueling on each bank independently of
the other, allowing much closer control of the air/fuel ratio and catalyst conversion efficiency.
The oxygen sensors need to operate at high temperatures in order to function correctly. To achieve the high temperatures required, the
sensors are fitted with heater elements that are controlled by a PW M signal from the ECM. The heater elements are operated immediately
following engine start and also during low load conditions when the temperature of the exhaust gases is insufficient to maintain the
required sensor temperatures. A non-functioning heater delays the sensors readiness for closed loop control and influences emissions. The
PWM duty cycle is carefully controlled to prevent thermal shock to cold sensors.
HO2S sensors also known as Linear or "W ide Band" sensors produces a constant voltage, with a variable current that is proportional to the
oxygen content. This allows closed loop fueling control to a target lambda, i.e. during engine warm up (after the sensor has reached
operating temperature and is ready for operation). This improves emission control.
The O2S sensor uses Zirconium technology that produces an output voltage dependant upon the ratio of exhaust gas oxygen to the ambient
oxygen. The device contains a Galvanic cell surrounded by a gas permeable ceramic, the voltage of which depends upon the level of O2
(oxygen) defusing through. Nominal output voltage of the device for l =1 is 300 to 500m volts. As the fuel mixture becomes richer (l<1) the
voltage tends towards 900m volts and as it becomes leaner (l>1) the voltage tends towards 0 volts. Maximum tip temperature is 1,000
Degrees Celsius for a maximum of 100 hours.
Sensors age with mileage, increasing their response time to switch from rich to lean and lean to rich. This increase in response time
influences the ECM closed loop control and leads to progressively increased emissions. Measuring the period of rich to lean and lean to rich
switching monitors the response rate of the upstream sensors.
Diagnosis of electrical faults is continually monitored in both the upstream and downstream sensors. This is achieved by checking the signal
against maximum and minimum threshold, for open and short circuit conditions.
Oxygen sensors must be treated with the utmost care before and during the fitting process. The sensors have ceramic material within them
that can easily crack if dropped/banged or over-torqued. The sensors must be torqued to the required figure, (40-50Nm), with a calibrated
torque wrench. Care should be taken not to contaminate the sensor tip when anti-seize compound is used on the thread. Heated sensor
signal pins are tinned and universal are gold plated. Mixing up sensors could contaminate the connectors and affect system performance.
Failure Modes
Mechanical fitting & integrity of the sensor.

Sensor open circuit/disconnected.
Short circuit to vehicle supply or ground.
Lambda ratio outside operating band.
Crossed sensors bank A & B.
Contamination from leaded fuel or other sources.
Change in sensor characteristic.
Harness damage.
Air leak into exhaust system.
Failure Symptoms
Default to Open Loop fueling for the particular cylinder bank

High CO (carbon monoxide) reading.
Strong smell of HO2S till default condition.
Excess Emissions.
It is possible to fit front and rear sensors in their opposite location. However the harness connections are of different gender and color to
ensure that the sensors cannot be incorrectly connected. In addition to this the upstream sensors have two holes in the shroud, whereas
the down stream sensors have four holes in the shroud for the gas to pass through.
Generator
The Generator has a power control module voltage regulator for use in a 14V charging system with 612 zener diode bridge rectifiers.
The ECM monitors the load on the electrical system via PW M signal and adjusts the generator output to match the required load. The ECM
also monitors the battery temperature to determine the generator regulator set point. This characteristic is necessary to protect the
battery; at low temperatures battery charge acceptance is very poor so the voltage needs to be high to maximize any rechargeability, but at
high temperatures the charge voltage must be restricted to prevent excessive gassing of the battery with consequent water loss.
The Generator has a smart charge capability that will reduce the electrical load on the Generator reducing torque requirements, this is
implemented to utilize the engine torque for other purposes. This is achieved by monitoring three signals to the ECM:
Generator sense (A sense), measures the battery voltage at the CJB (central junction box).
Generator communication (Alt Com) communicates desired Generator voltage set point from ECM to Generator.
Generator monitor (Alt Mon) communicates the extent of Generator current draw to ECM. This signal also transmits faults to the ECM
which will then sends a message to the instrument pack on the CAN bus to illuminate the charge warning lamp.
Fuel Injectors
The engine has 6 fuel injectors (one per cylinder), each injector is directly driven by the ECM. The injectors are fed by a common fuel rail as
part of a returnless fuel system. The fuel rail pressure is regulated to 4.5 bar by a fuel pressure regulator which is integral to the fuel pump
module, within the fuel tank. The injectors can be checked by resistance checks. There is a fuel pressure test Schrader valve attached to the
fuel rail on the front LH side for fuel pressure testing purposes. The ECM monitors the output power stages of the injector drivers for
electrical faults.
The injectors have a resistance of 13.8 Ohms 0.7 Ohms @ 20 Degrees Celsius.
Ignition Coils
The engine is fitted with six plug-top coils that are driven directly by the ECM. This means that the ECM, at the point where sufficient
charge has built up, switches the primary circuit of each coil and a spark is produced in the spark plug. The positive supply to the coil is fed
from a common fuse. Each coil contains a power stage to trigger the primary current. The ECM sends a signal to each of the coils power
stage to trigger the power stage switching. Each bank has a feedback signal that is connected to each power stage. If the coil power stage
has a failure the feedback signal is not sent, causing the ECM to store a fault code appropriate to the failure.
The ECM calculates the dwell time depending on battery voltage and engine speed to ensure constant secondary energy. This ensures
sufficient secondary (spark) energy is always available, without excessive primary current flow thus avoiding overheating or damage to the
coils.

Engine temperature
Knock control
Auto gearbox shift control
Idle speed control.

The fuel rail pressure sensor is located on top of the fuel rail adjacent to the fuel inlet. The fuel rail pressure sensor measures the pressure
of the fuel in the fuel rail. This input is then used by the fuel pump control module to control the amount of fuel delivered to the fuel rail.
The FPDM is located on the RH side of the charcoal canister on top of the fuel tank. The fuel pump control module receives a power supply
via the fuel pump relay in the auxiliary fuse box.
The ECM sends a PWM signal to the FPDM, the duty cycle of the signal determines the duty cycle of the pump. The ECM sets a target fuel
pressure based on engine load. The target fuel pressure is maintained by using feedback from the fuel rail pressure sensor which is used to
control the fuel pump via a closed loop PW M signal. The PWM signal to the pump represents half the ON time of the pump. If the ECM
transmits a 50% on time the fuel pump control module drives the pump at 100%. If the ECM transmits a 5% ON time the fuel pump control
module drives the pump at 10%. The fuel pump control module will only turn the fuel pump ON if it receives a valid signal between 4% and
50%. When the ECM requires the fuel pump to be turned OFF the ECM transmits a duty cycle signal of 75%.
The status of the FPDM is monitored by the ECM. Any errors can be retrieved from the ECM. The fuel pump control module cannot be
interrogated for diagnostic purposes.
The ECM controls the FPDM in response to inputs from the fuel rail pressure sensor, MAP and the MAF/IAT sensor.
Variable Valve Timing (VVT)

Variable valve timing is used on the V6 engine to enhance low and high speed engine performance and idle speed quality.
For each intake camshaft the VVT (variable valve timing) system comprises:
VVT unit
Valve timing solenoid
The VVT system alters the phase of the intake valves relative to the fixed timing of the exhaust valves, to alter:
The mass of air flow to the cylinders.

The engine torque response.
Emissions.
The VVT unit uses a vane type device to control the camshaft angle. The system operates over a range of 48 degrees and is advanced or
retarded to its optimum position within this range.
The VVT system is controlled by the ECM based on engine load and speed along with engine oil temperature to calculate the appropriate
camshaft position.
The VVT system provides the following advantages:
Reduced engine emissions and improved fuel consumption which in turn improves the engines internal EGR (exhaust gas
recirculation) effect over a wider operating range.
Enhanced full load torque characteristics.
Improved fuel economy through optimized torque over the engine speed range.
Variable Valve Timing Unit

ItemDescription
1 Vane housing
2 Vane shaft
3 Retard chamber
4 Rotation direction
5 Advance chamber oil channel
6 Stopper pin
7 Intake camshaft
8 Retard chamber oil channel
9 Advance chamber
The VVT unit is a hydraulic actuator mounted on the end of the intake camshaft. The unit advances or retards the camshaft timing to alter
the camshaft to crankshaft phase. The ECM controls the VVT timing unit via an oil control solenoid. The oil control solenoid routes oil
pressure to the advance or retard chambers either side of the vanes within the VVT unit.
The VVT unit is driven by the primary drive chain and rotates relative to the exhaust camshaft. When the ECM requests a retard in camshaft
timing the oil control solenoid is energized which moves the shuttle valve in the solenoid to the relevant position allowing oil pressure to
flow out of the advance chambers in the VVT unit whilst simultaneously allowing oil pressure into the retard chambers.
The ECM controls the advancing and retarding of the VVT unit based on engine load and speed. The ECM sends an energize signal to the oil
control solenoid until the desired VVT position is achieved. When the desired VVT position is reached, the energizing signal is reduced to
hold the oil control solenoid position and consequently desired VVT position. This function is under closed loop control and the ECM can
sense any variance in shuttle valve oil pressure via the camshaft position sensor and can adjust the energizing signal to maintain the
shuttle valve hold position.
operation can be affected by engine oil temperature and properties. At very low oil temperatures the movement of the VVT mechanism will
be slow due to the high viscosity of the oil. W hile at high oil temperatures the low oil viscosity may impair the VVT operation at low oil
pressures. The oil pump has the capacity to cope with these variations in oil pressure while an oil temperature sensor is monitored by the
ECM to provide oil temperature feedback. At extremely high oil temperatures the ECM may limit the amount of VVT advance in order to
prevent the engine from stalling when returning to idle speed.
VVT does not operate when engine oil pressure is below 1.25 bar. This is because there is insufficient pressure to release the VVT units
internal stopper pin. This occurs when the engine is shut down and the VVT unit has returned to the retarded position. The stopper pin locks
the VVT unit to the camshaft to ensure camshaft stability during the next start up.
Valve Timing Solenoid

The valve timing solenoid controls the position of the shuttle valve in the bush carrier. A plunger on the solenoid extends when the solenoid
is energized and retracts when the solenoid is de-energized.
When the valve timing solenoids are de-energized, the coil springs in the bush carriers position the shuttle valves to connect the valve
timing units to drain. In the valve timing units, the return springs hold the ring pistons and gears in the retarded position. When the valve
timing solenoids are energized by the ECM, the solenoid plungers position the shuttle valves to direct engine oil to the valve timing units.
In the valve timing units, the oil pressure overcomes the force of the return springs and moves the gears and ring pistons to the advanced
position. System response times are 1.0 second maximum for advancing and 0.7 second maximum for retarding. While the valve timing is in
the retarded mode, the ECM produces a periodic lubrication pulse. This momentarily energizes the valve timing solenoids to allow a spurt of
oil into the valve timing units. The lubrication pulse occurs once every 5 minutes.
Electronic Engine Controls - V6 3.0L Petrol - Electronic Engine Controls
For a detailed description of the 3.0L petrol electronic engine controls, refer to the relevant Description and Operation section in the
workshop manual. REFER to: (303-14B Electronic Engine Controls - V6 3.0L Petrol)

Visual Inspection
Engine oil level and condition Fuses
Cooling system coolant level W iring harness
Fuel contamination/grade/quality Sensor(s)
Throttle body Engine Control Module (ECM)
Front End Accessory Drive (FEAD) belt Transmission Control Module (TCM)
Air cleaner condition
step.
Symptom Chart

Engine non-start
Engine does not crank Security system/Immobilizer Check that the security system is disarmed
engaged Read DTCs and refer to DTC Index in this section for
Engine in shut-down mode ECM relay tests
ECM relay Ensure the battery is in fully charged and serviceable
Battery condition
Starting system For starting system tests.
Engine seized REFER to: Starting System (303-06B Starting System -
V6 3.0L Petrol, Diagnosis and Testing).
For engine system tests.
REFER to: Engine (303-01B Engine - V6 3.0L Petrol,
Engine cranks, but does not fire Engine breather system Ensure the engine breather system is free from
Ignition system For ignition system tests.
Fuel system REFER to: Engine Ignition (303-07A Engine Ignition -
Electronic engine controls V6 3.0L Petrol, Diagnosis and Testing).
For fuel system tests.
REFER to: Fuel Tank and Lines (310-01B Fuel Tank and
Lines - V6 3.0L Petrol, Diagnosis and Testing).
Read DTCs and refer to DTC Index in this section for
electronic engine control tests
Engine cranks and fires, but will not Evaporative emissions purge For purge valve tests.
start valve REFER to: Evaporative Emissions - 3.0L (303-13
Fuel pump Evaporative Emissions - 3.0L, Diagnosis and Testing).
Spark plugs For fuel system tests.
Ignition coil failure(s) REFER to: Fuel Tank and Lines (310-01B Fuel Tank and
For ignition system tests.
REFER to: Engine Ignition (303-07A Engine Ignition -
Difficult to start
Difficult cold start Check engine coolant Check the engine coolant level and condition.
level/anti-freeze content REFER to: Specifications (303-03B Engine Cooling - V6
Battery 3.0L Petrol, Specifications).
Electronic engine controls Ensure the battery is in a fully charged and serviceable
Exhaust gas recirculation (EGR) condition
valve stuck open Read DTCs and refer to DTC Index in this section for
Fuel pump electronic engine control tests
Evaporative emissions purge For EGR valve tests.
valve REFER to: Engine Emission Control (303-08B Engine
Emission Control - V6 3.0L Petrol, Diagnosis and
Testing).
For purge valve tests.
REFER to: Evaporative Emissions - 3.0L (303-13
Evaporative Emissions - 3.0L, Diagnosis and Testing).
Difficult hot start Injector leak Carry out injector leak tests, check and install new
Electronic engine controls injectors as required.
Evaporative emissions purge REFER to: Fuel Injectors (303-04C Fuel Charging and
valve Controls - V6 3.0L Petrol, Removal and Installation).
Fuel pump Read DTCs and refer to DTC Index in this section for
Ignition system electronic engine control tests
EGR valve stuck open For purge valve tests.
For EGR valve tests.
REFER to: Engine Emission Control (303-08B Engine
Testing).
Difficult to start after hot soak Injector leak Carry out injector leak tests, check and install new
(vehicle standing, engine off, after Electronic engine controls injectors as required.
engine has reached operating Evaporative emissions purge REFER to: Fuel Injectors (303-04C Fuel Charging and
temperature) valve Controls - V6 3.0L Petrol, Removal and Installation).
Fuel pump Read DTCs and refer to DTC Index in this section for
Ignition system electronic engine control tests
EGR valve stuck open For purge valve tests.
REFER to: Engine Emission Control (303-08B Engine
Testing).
Engine cranks too fast/slow Compressions high/low Carry out cylinder compression tests
Battery Ensure battery is in a fully charged and serviceable
Starting system condition
For starting system tests.
REFER to: Starting System (303-06B Starting System -
Engine stalls
ECM relay Read DTCs and refer to DTC Index in this section for
Electronic engine controls ECM relay tests
Ignition system Read DTCs and refer to DTC Index in this section for
Air intake system restricted electronic engine control tests
Air leakage For ignition system tests.
Fuel lines REFER to: Engine Ignition (303-07A Engine Ignition -
Check for blockage in air cleaner element and air
intake system
Check for leakage in air intake system
Engine stalls on overrun ECM relay Read DTCs and refer to DTC Index in this section for
Throttle position (TP) sensors ECM relay and TP sensor tests
Engine stalls at steady speed ECM relay Read DTCs and refer to DTC Index in this section for
CKP sensor ECM relay, CKP, and TP sensor tests
TP sensors
Engine stalls with speed control ECM relay Read DTCs and refer to DTC Index in this section for
enabled ECM relay tests
Engine stalls when manoeuvring ECM relay Read DTCs and refer to DTC Index in this section for
DTC Index TP sensors ECM relay, and TP sensor tests
Additional engine loads (power Check for excessive loads being placed on the engine
steering, air conditioning, etc) from power steering, air conditioning systems etc.
Transmission
CAUTION: W hen probing connectors to take malfunction
measurements in the course of the For transmission
pinpoint system
tests, use tests. kit, part number
the adaptor
3548-1358-00. CAN malfunction REFER to: Diagnostic Strategy (307-01 Automatic
Transmission/Transaxle - V8 4.2L Petrol/V8 S/C 4.2L
Petrol/V6 3.0L warranty,
NOTE: If the module or a component is suspect and the vehicle remains under the Manufacturers Petrol/TDV6 2.7L
refer Diesel,
to the Diagnosis
Warranty and
Policy
and Procedure manual (section B1.2), or determine if any prior approval programme isTesting).
in operation, prior to the Check and installation of a
new module/component. For CAN network tests.
REFER to: Communications Network (418-00 Module
NOTE: Generic scan tools may not read the codes listed, or may read only five digit Communications
codes. Match theNetwork, Diagnosis
five digits from theand
scanTesting).
tool to the

B10A231 Crash Input No signal Refer to the electrical circuit diagrams and check RCM PWM signal circuit
for short, open circuit
B11DB01 Battery Monitoring Battery monitoring system Disconnect vehicle battery, re-connect after 60 seconds, clear DTC and
Module hardware fault retest. If DTC remains Check and install a new battery monitoring
module
B11DB87 Battery Monitoring Battery monitoring module If additional DTCs B108783, B108786, B108787 are logged, suspect the
Module connector RJB. Check and Check and install a new RJB as required, refer to the
dis-connected/poor new module/component Check and installation note at the top of the
connection DTC Index. If additional DTCs B108783, B108786, B108787 are NOT
Battery monitoring module logged, check for good/clean contact at battery monitoring module
to RJB LIN circuit - open connector, refer to electrical circuit diagrams and check battery
circuit monitoring module to RJB LIN circuit and battery monitoring module to
Battery monitoring module battery positive monitor circuit for open circuit. Clear DTC and repeat
to battery positive monitor automated diagnostic procedure using manufacturer approved diagnostic
circuit - open circuit system. If DTC remains suspect the battery monitoring module, check
Battery monitoring and Check and install a new battery monitoring module as required,
module/RJB failure refer to the new module/component Check and installation note at the
top of the DTC Index
B120668 Crash Occurred ECM has detected the Check RCM for related DTCs and refer to the relevant DTC Index
vehicle has crashed - event
information DTC only
C003100 Left Front Wheel Invalid data received from Check ABS module for related DTCs and refer to relevant DTC Index
Speed Sensor ABS - left front wheel
speed signal
C003400 Right Front Wheel Invalid data received from Check ABS module for related DTCs and refer to relevant DTC Index
Speed Sensor ABS - right front wheel
speed signal
C003700 Left Rear W heel Speed Invalid data received from Check ABS module for related DTCs and refer to relevant DTC Index
Sensor ABS - left rear wheel speed
signal
C003A00 Right Rear W heel Invalid data received from Check ABS module for related DTCs and refer to relevant DTC Index
Speed Sensor ABS - right rear wheel
speed signal
P001100 Intake (A) Camshaft Variable Camshaft Timing Carry out any pinpoint tests associated with this DTC using the
Position Timing - (VCT) circuit fault manufacturer approved diagnostic system. Refer to the electrical circuit
Over-Advanced (Bank Valve timing incorrectly set diagrams and check VCT circuits for short, open circuit. Check the valve
1) Timing chain has slipped timing
Over-Retarded (Bank Valve timing incorrectly set diagrams and check VCT circuits for short, open circuit. Check the valve
P001600 Crankshaft Position - The relative positions of Reset the sensor positions
Camshaft Position the CKP and CMP teeth are
Correlation - Bank 1 not correct
Sensor A - Sensors incorrectly
aligned on rebuild
P001800 Crankshaft Position - The relative positions of Reset the sensor positions
Camshaft Position the CKP and CMP teeth are
Correlation - Bank 2 not correct
Sensor A - Sensors incorrectly
aligned on rebuild
Over-Advanced (Bank Valve timing incorrectly set diagrams and check VCT circuits for short, open circuit. Check the valve
Over-Retarded (Bank Valve timing incorrectly set diagrams and check VCT circuits for short, open circuit. Check the valve
P002672 Intake Valve Control VCT solenoid fault Carry out any pinpoint tests associated with this DTC using the
Solenoid Circuit Oil contamination manufacturer approved diagnostic system. Refer to the electrical circuit
Range/Performance VCT oil flow fault diagrams and check VCT circuits for short, open circuit. Check the oil
(Bank 1) VCT/Camshaft mechanical condition and flow. Check for mechanical failure of components
failure
P002677 Intake Valve Control VCT solenoid fault Carry out any pinpoint tests associated with this DTC using the
Solenoid Circuit Oil contamination manufacturer approved diagnostic system. Refer to the electrical circuit
Range/Performance VCT oil flow fault diagrams and check VCT circuits for short, open circuit. Check the oil
(Bank 1) VCT/Camshaft mechanical condition and flow. Check for mechanical failure of components
failure
Electronic Engine Controls - V6 3.0L Petrol - Camshaft Position (CMP) Sensor LH
Removal

For additional information, refer to: Air Cleaner Outlet Pipe (303-12B
Intake Air Distribution and Filtering - V6 3.0L Petrol, Removal and
Installation).
3. TORQUE: 12 Nm
4. CAUTION: A new O-ring seal is to be installed.
TORQUE: 7 Nm
Installation
Electronic Engine Controls - V6 3.0L Petrol - Camshaft Position (CMP) Sensor RH
Removal
NOTE: Some illustrations may show the engine removed for clarity.

3. TORQUE: 7 Nm
Installation
Electronic Engine Controls - V6 3.0L Petrol - Catalyst Monitor Sensor
General Equipment
Snap-on tool S6176
Removal
For additional information, refer to Section 100-02 Jacking and Lifting.
2. Disconnect the catalyst monitor sensor.
3. CAUTION: Make sure the wiring harness is not twisted or damaged

on removal. Failure to follow this instruction may result in damage to the
vehicle.
Using the Snap-on tool S6176, remove the catalyst monitor sensor.
Installation
1. CAUTION: Make sure the wiring harness is not twisted or damaged

on installation. Failure to follow this instruction may result in damage to
the vehicle.
Tighten to 45 Nm.
Electronic Engine Controls - V6 3.0L Petrol - Crankshaft Position (CKP) Sensor
Removal

Installation).
Installation
Tighten to 10 Nm.
Electronic Engine Controls - V6 3.0L Petrol - Engine Control Module (ECM)
Removal
All vehicles

For additional information, refer to: Secondary Bulkhead Panel LH - V8

All vehicles
Remove the pedestrian protection actuator.

Release the pedestrian protection actuator bracket.
Reposition the pedestrian protection actuator bracket.
Remove the engine control module (ECM) cover.

Remove the ECM.
Installation
Tighten to 10 Nm.
2. Tighten to 6 Nm.
4. Tighten to 8 Nm.
Electronic Engine Controls - V6 3.0L Petrol - Engine Coolant Temperature (ECT) Sensor
Removal

2. Refer to: Cooling System Draining, Filling and Bleeding (303-03C Engine Cooling - V8
4.2L Petrol/V8 S/C 4.2L Petrol, General Procedures).
3. Refer to: Air Cleaner Outlet Pipe (303-12B Intake Air Distribution and Filtering - V6
Installation

Electronic Engine Controls - V6 3.0L Petrol - Fuel Temperature Sensor
Removal
2. Refer to: Fuel System Pressure Release - V8 4.2L Petrol/V8 S/C 4.2L Petrol/V6 3.0L
Petrol (310-00 Fuel System - General Information, General Procedures).
3. Refer to: Air Cleaner Outlet Pipe (303-12B Intake Air Distribution and Filtering - V6
4.
5.
Installation

Electronic Engine Controls - V6 3.0L Petrol - Heated Oxygen Sensor (HO2S)
General Equipment
Snap-on tool S6176
Removal

removal.
Disconnect the heated oxygen sensor (HO2S) electrical connector.
Release the harness from the two clips.
4. CAUTION: Make sure that the wiring harness is not twisted or

damaged on removal. Failure to follow this instruction may result in
Using the Snap-on tool S6176, remove the HO2S.
Installation
1. CAUTION: Make sure that the wiring harness is not twisted or
damaged on installation. Failure to follow this instruction may result in
NOTE: Apply lubricant meeting specification ESE-M12A4-A (Never-Seez

Pure Nickel Special) to the thread of the HO2S.
NOTE: Care must be taken not to contaminate the sensitive areas of the
HO2S.
Tighten to 45 Nm.

Electronic Engine Controls - V6 3.0L Petrol - Intake Manifold Tuning (IMT) Valve LH
Removal
2. Disconnect the intake manifold tuning (IMT) valve electrical connector.
3. Remove the IMT valve.
Installation
Tighten to 10 Nm.
Electronic Engine Controls - V6 3.0L Petrol - Knock Sensor (KS) LH
Removal
For additional information, refer to: Fuel Injection Supply Manifold
(303-04C Fuel Charging and Controls - V6 3.0L Petrol, Removal and
Installation).
3. Detach the knock sensor (KS) electrical harness from the clip.
4. Disconnect the KS electrical connector.
5. Remove the KS.
Installation
Tighten to 25 Nm
Electronic Engine Controls - V6 3.0L Petrol - Knock Sensor (KS) RH
Removal

Installation).
3. Release the knock sensor (KS) electrical harness from the engine
cylinder block.
4. Disconnect the KS electrical connector.
5. Remove the KS.
Installation
Tighten to 25 Nm.
Electronic Engine Controls - V6 3.0L Petrol - Manifold Absolute Pressure (MAP) Sensor
Removal
NOTE: Some illustrations may show the engine removed for clarity.
1. TORQUE: 3 Nm
Installation
Electronic Engine Controls - V6 3.0L Petrol - Mass Air Flow (MAF) Sensor
Removal
TORQUE: 1.2 Nm
Installation

Electronic Engine Controls - V6 3.0L Petrol - Oil Temperature Sensor
Removal
5. Remove the oil temperature sensor.
Installation
1. NOTE: If the oil temperature sensor is to be re-used apply a small bead
of sealant meeting Jaguar specification on the first three threads of the oil
temperature sensor.
Tighten to 15 Nm.
Electronic Engine Controls - V6 3.0L Petrol - Variable Camshaft Timing (VCT) Oil
Control Solenoid
Removal
2. Remove the variable camshaft timing (VCT) oil control solenoid.
Installation
Tighten to 10 Nm.

Electronic Engine Controls - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8 -
Camshaft position (CMP) sensor retaining bolt 7 - 62
Heated oxygen sensor (H02S) 40 30 -
Catalyst monitor sensor 40 30
Crankshaft position (CKP) sensor retaing bolt 7 - 62
Knock sensor retaining bolt 25 18 -
Fuel temperature sensor 7 - 62
Intake air temperature (IAT) sensor 35 26 -
Engine coolant temperature (ECT) sensor 17 13 -
Manifold absolute pressure (MAP) sensor 10 7 -
Lubricants, fluids, sealers and adhesives
Sealant WSK-M4G-328-A3
Electronic Engine Controls - Component Location
ItemDescription
1 KS (knock sensor)s
2 MAPT (manifold absolute pressure and temperature)sensor
4 Fuel rail temperature sensor
5 Electric throttle
7 CMP sensor
8 CKP (crankshaft position)
11 Engine oil pressure sensor
12 VCT solenoid
Naturally Aspirated
ItemDescription
1 Electric throttle
2 KSs
4 CMP sensor
5 MAP sensor
6 CMP sensor
7 CKP sensor
8 VCT solenoid
10 Engine oil pressure sensor
11 ECT sensor
12 VCT solenoid
Electronic Engine Controls - Overview
Overview
The V8 4.2 Liter naturally aspirated and supercharged engines are controlled by an ECM (engine control module)
manufactured by DENSO. The Engine Management System (EMS) controls the following:
Engine fueling
Ignition timing
Closed loop fueling
Knock control
Idle speed control
Emission control
OBD (on-board diagnostic)
Interface with the immobilization system
Speed control
The ECM controls the engine fueling by providing sequential fuel injection to all cylinders. Ignition is controlled by a direct
ignition system, provided by eight plug top coils. The ECM is able to detect and correct for ignition knock on each cylinder
and adjust the ignition timing for each cylinder to achieve optimum performance.
The ECM uses a torque-based strategy to generate the torque required by the driver and other vehicle control modules.
The EMS uses various sensors to determine the torque required from the engine. The EMS also interfaces with other vehicle
electronic control modules's, via the CAN (controller area network) bus, to obtain additional information (e.g. road speed
from the ABS (anti-lock brake system) control module). The EMS processes these signals and decides how much torque to
generate. Torque is then generated by using various actuators to supply air, fuel and spark to the engine (electronic
throttle, injectors, coils, etc.).
The EMS comprises the following inputs:

MAF (mass air flow) sensor
Knock sensors
Fuel rail temperature sensor
ECT (engine coolant temperature) sensor
Engine oil temperature sensor
MAP (manifold absolute pressure) sensor
Electric throttle feedback sensor
AIR (secondary air injection)/MAP sensor
APP (accelerator pedal position) sensor
Fuel tank leakage monitoring (NAS only)
Cooling fan speed feedback
HO2S (heated oxygen sensor)
Brake switch
Speed control cancel/suspend switch
Automatic speed limiter switch
Crank request signal
IAT (intake air temperature) sensor
External air temperature sensor
The EMS comprises the following outputs:
Fuel injectors
Ignition coils
Engine cooling fan
Electric throttle
Electric fuel pump driver module
VCT (variable camshaft timing) solenoids
Purge valve
EGR (exhaust gas recirculation) valve
AIR pump
Starter relay control
Electronic Engine Controls - System Operation and Component Description
Control Diagram
NOTE: A = Hardwired, D = High speed CAN (controller area network) bus, N = Medium speed CAN bus, O = LIN (local
interconnect network) bus
ItemDescription
1 FPDM (fuel pump driver module)
2 Generator
3 O2S (oxygen sensor) upstream
4 O2S downstream
5 Electric throttle
6 Purge valve
11 Injectors
12 AIR (secondary air injection) pump
14 Plug top coils
ItemDescription
2 Diagnostic socket
3 Steering column lock
4 EPB (electronic parking brake) module
8 Clock spring
12 Adaptive front lighting module
13 Start/ stop switch
14 ECM
ItemDescription
1 Battery
4 KS (knock sensor)
12 EOP (engine oil pressure) switch
13 Exterior air temperature sensor
16 ECM
17 Start/stop switch
System Operation
ignition system, provided by six plug top coils. The ECM is able to detect and correct for ignition knock on each cylinder
The ECM uses various sensors to determine the torque required from the engine. The EMS also interfaces with other
vehicle electronic control modules's, via the CAN bus, to obtain additional information (e.g. road speed from the ABS
control module). The EMS processes these signals and decides how much torque to generate. Torque is then generated by
using various actuators to supply air, fuel and spark to the engine (electronic throttle, injectors, coils, etc.).
System Inputs
The EMS has the following inputs:
RCM
Park/neutral switch
Ignition coil feedback
MAF
Engine speed
Camshaft position
Driver demand
Brake pedal position switch
Speed control switches
Generator load
HO2S (heated oxygen sensor) pre catalyst
HO2S post catalyst
Throttle position
Cooling fan speed
Ignition switch
Knock sensors
MAP
ECT (engine coolant temperature)
Engine oil temperature
EOP
Fuel pressure
Fuel temperature
System Outputs
The EMS has the following outputs:
Throttle Actuator
Brake vacuum pump relay
Ignition coils
Oxygen sensor heaters
Fuel injectors
Purge Valve
Engine Cooling Fan
Fuel pump relay
Starter Relay
ECM Main Relay
Generator Control
Fuel tank leakage detection
ECM Adaptions
The ECM has the ability to adapt the values it uses to control certain outputs. This capability ensures the EMS can meet
emissions legislation and improve the refinement of the engine throughout its operating range.
The components which have adaptions associated with them are:
The APP sensor

The oxygen sensors
The MAF/IAT (intake air temperature) sensor
The CKP sensor
The Electric throttle body.
Oxygen Sensors and MAF/AT Sensor

There are several adaptive maps associated with the fueling strategy. Within the fueling strategy the ECM calculates
short-term adaptions and long term adaptions. The ECM will monitor the deterioration of the oxygen sensors over a period
of time. It will also monitor the current correction associated with the sensors.
The ECM will store a fault code in circumstances where an adaption is forced to exceed its operating parameters. At the
same time, the ECM will record the engine speed, engine load and intake air temperature.
Crankshaft Position Sensor
The characteristics of the signal supplied by the CKP sensor is learnt by the ECM . This enables the ECM to set an adaption
and support the engine misfire detection function. Due to the small variation between different flywheels and different CKP
sensors, the adaption must be reset if either component is renewed, or removed and refitted. It is also necessary to reset
the flywheel adaption if the ECM is renewed or replaced. The ECM supports four flywheel adaptions for the CKP sensor.
Each adaption relates to a specific engine speed range. The engine speed ranges are detailed in the table below:
Adaptions Engine Speed, rev/min

1 1800 - 3000
2 3001 - 3800
3 3801 - 4600
4 4601 - 5400
Misfire Detection
Legislation requires that the ECM must be able to detect the presence of an engine misfire. It must be able to detect
misfires at two separate levels. The first level is a misfire that could lead to the vehicle emissions exceeding 1.5 times the
Federal Test Procedure (FTP) requirements for the engine. The second level is a misfire that may cause catalyst damage.
The ECM sensor monitors the number of misfire occurrences within two engine speed ranges. If the ECM detects more than
a predetermined number of misfire occurrences within either of these two ranges, over two consecutive journeys, the ECM
will record a fault code and details of the engine speed, engine load and engine coolant temperature. In addition, the ECM
monitors the number of misfire occurrences that happen in a 'window' of 200 engine revolutions. The misfire occurrences
are assigned a weighting according to their likely impact on the catalysts. If the number of misfires exceeds a certain
value, the ECM stores catalyst-damaging fault codes, along with the engine speed, engine load and engine coolant
temperature.
The signal from the CKP indicates how fast the poles on the flywheel are passing the sensor tip. A sine wave is generated
each time a pole passes the sensor tip. The ECM can detect variations in flywheel speed by monitoring the sine wave
signal supplied by the CKP sensor.
By assessing this signal, the ECM can detect the presence of an engine misfire. At this time, the ECM will assess the
amount of variation in the signal received from the CKP and assigns a roughness value to it. This roughness value can be
viewed within the real time monitoring feature, using a Land Rover approved diagnostic system. The ECM will evaluate the
signal against a number of factors and will decide whether to count the occurrence or ignore it. The ECM can assign a
roughness and misfire signal for each cylinder, (i.e. identify which cylinder is misfiring).
Diagnostics
The ECM stores faults as DTC (diagnostic trouble code), referred to as 'P' codes. The 'P' codes are defined by OBD
(on-board diagnostic) legislation and, together with their associated environmental and freeze frame data, can be read
using a third party scan tool or a Land Rover approved diagnostic system. A Land Rover approved diagnostic system can
also read real time data from each sensor, the adaptive values currently being employed and the current fueling, ignition
and idle settings.
The ECM is located in the engine bay attached to the bulkhead. On LHD (left-hand drive) vehicles the ECM is located on
the RH (right-hand) side of the compartment behind the BJB. On RHD (right-hand drive) vehicles the ECM is located on the
LH (left-hand) side of the engine compartment.
ignition system, provided by eight plug top coils. The ECM is able to detect and correct for ignition knock on each cylinder
The EMS uses various sensors to determine the torque required from the engine. The EMS also interfaces with other vehicle
electronic control modules's, via the CAN bus, to obtain additional information (e.g. road speed from the ABS control
module). The EMS processes these signals and decides how much torque to generate. Torque is then generated by using
various actuators to supply air, fuel and spark to the engine (electronic throttle, injectors, coils, etc.).

The crankshaft position sensor is mounted at the rear underside of the engine near the transmission bell housing.
Connection between the sensor and the harness is via a link harness and a two-way connector. Both wires go directly to
the ECM. The sensor produces the signal which enables the ECM to determine the angle of the crankshaft, and the engine
rpm. From this, the point of ignition, fuel injection, etc. is calculated. If the signal wires are reversed a 3 advance in
timing will occur, as the electronics within the ECM uses the falling edge of the signal waveform as its reference/timing
point for each tooth.
The reluctor is pressed into the flywheel and has a "tooth" pattern based on 36 teeth at 10 intervals and approximately
5 wide: one of the teeth is removed to provide a hardware reference mark which is 60 degrees BTDC (before top dead
center) No.1 cylinder. Because of the crankshaft sensor's orientation, the target wheel uses windows machined into the
face, rather than actual teeth.
The sensor operates by generating an output voltage caused by the change in magnetic field that occurs as the windows
pass in front of the sensor. The output voltage varies with the speed of the windows passing the sensor, the higher the
engine speed, the higher the output voltage. Note that the output is also dependent on the air gap between the sensor
and the teeth (the larger the gap, the weaker the signal, the lower the output voltage). The ECM transmits the engine
speed to other vehicle control modules on CAN.
Two sensors are located at the rear of the engine, in the cylinder head (one per bank), above the rear cylinders. This is a
Variable Reluctor Sensor (VRS) producing four pulses for every two engine revolutions. The sensing element is positioned
between 0 and 2mm from the side of the cam gear wheel.
The variable cam intake is parked in the retarded position and can advance up to 48 degrees.
The camshaft timing wheel is a sintered component which has four teeth on it to enable the EMS to detect cylinder
identification. The signal is used for:
Variable intake cam timing

Cylinder recognition
Enabling sequential fuel injection
Knock control
Cylinder identification for diagnostic purposes.
Failure symptoms include:
Ignition timing reverting to the base mapping, with no cylinder correction.

Active knock control is disabled, along with its diagnostic (safe ignition map-loss of performance).
Quick cam/crank synchronisation on start disabled.
Variable cam timing is disabled
Engine coolant Temperature Sensor
The sensor is located at the front of the engine in the water pipe below the throttle body. The ECT sensor is a thermistor
used to monitor the engine coolant temperature. The ECT sensor is vital to the correct running of the engine as a richer
mixture is required at lower block temperatures for good quality starts and smooth running, leaning off as the temperature
rises to maintain emissions and performance.
The sensor has an operating temperature range of -40 Degrees Celsius to 119 Degrees Celsius. W hen a defective coolant
sensor is detected, the ECM uses the oil temperature sensor value.PTC (positive temperature coefficient)
Tank Leakage Detection-NAS ONLY

The tank leakage detection system periodically checks the evaporative system and the fuel tank for leaks when the
ignition is switched off. The tank leakage detection pump is connected to the atmospheric vent of the charcoal cannister
and incorporates a PTC heating element a normally open valve and a reference orifice. The tank leakage detection pump is
only operated when the ignition is switched off and is controlled by the ECM. The ECM also monitors the electric air pump
operation and the normally open valve for faults. To check the fuel tank and EVAP system for leaks the ECM operates the
tank leakage detection pump and monitors the current draw. This is compared to a referenced figure established from the
current draw when air is pumped through the reference orifice.
Purge Valve
The purge valve is located at the rear of the engine on a bracket which is attached to the transmission bell housing. The
purge valve is a solenoid operated valve which is closed when de-energized. The purge valve is controlled by a 10Hz PWM
(pulse width modulation) signal from the ECM. W hen the engine operating conditions are correct, the ECM opens the purge
valve which causes fuel vapor and fresh air to be drawn through the charcoal cannister. The fresh air is drawn through the
charcoal cannister via the tank leakage detection pump fresh air vent.NTC (negative temperature coefficient)
Oil temperature is monitored through a temperature sensor mounted in the oil system. This component is a NTC. The
sensor is mounted next to the oil pressure sensor at the front of the engine and locates into the oil filter bracket.
The fuel rail temperature sensor measures the temperature of the fuel in the fuel rail. This input is then used to deliver
the correct quantity of fuel to the engine. Operating Range -40 Degrees Celsius to 150 Degrees Celsius. The fuel rail
temperature sensor is fitted on the rear of the right hand bank (bank A) fuel rail.
Mass Air Flow/Intake Air Temperature Sensor (MAF/IAT)

The air flow meter is located in the clean air duct immediately after the air filter box.
The air mass flow is determined by the cooling effect of intake air passing over a hot film element contained within the
device. The higher the air flow the greater the cooling effect and the lower the electrical resistance of the hot film
element. The ECM then uses this signal from the Mass Air Flow meter to calculate the air mass flowing into the engine.
The measured air mass flow is used in determining the fuel quantity to be injected in order to maintain the stoichiometric
air/fuel mixture required for correct operation of the engine and exhaust catalysts. Should the device fail there is a
software backup strategy that will be evoked once a fault has been diagnosed.
The following symptoms may be observed if the sensor fails:
During driving the engine RPM might dip, before recovering.

Difficulty in starting or start-stall.
Poor throttle response/engine performance.
Lambda control and idle speed control halted.
Emissions incorrect.
AFM signal offset
The IAT sensor is integrated into the MAF sensor. It is a temperature dependent resistor (thermistor), i.e. the resistance
of the sensor varies with temperature. This thermistor is a NTC type element meaning that the sensor resistance
decreases as the sensor temperature increases. The sensor forms part of a voltage divider chain with an additional resistor
in the ECM. The voltage from this sensor changes as the sensor resistance changes, thus relating the air temperature to
the voltage measured by the ECM.
The ECM stores a 25 Degrees Celsius default value for air temperature in the event of a sensor failure.
Manifold Absolute Pressure Sensor (MAP)
The MAP sensor provides a voltage proportional to the absolute pressure in the intake manifold. This signal allows the
load on the engine to be calculated and used within the internal calculations of the ECM. The sensor is located on the rear
of the air intake manifold.
The output signal from the MAP sensor, together with the CKP and IAT sensors, is used by the ECM to calculate the
amount of air induced into the cylinders. This enables the ECM to determine ignition timing and fuel injection duration
values.
The MAP sensor receives a 5V supply voltage from the ECM and provides an analogue signal to ECM, which relates to the
absolute manifold pressure and allows the ECM to calculate engine load. The ECM provides a ground for the sensor.
If the MAP signal is missing, the ECM will substitute a default manifold pressure reading based on crankshaft speed and
throttle angle. The engine will continue to run with reduced drivability and increased emissions, although this may not be
immediately apparent to the driver. The ECM will store fault codes which can be retrieved using the recommended Jaguar
diagnostic tool.
Knock Sensors
The EMS has two knock sensors located in the V of the engine, one per cylinder bank. The sensors are connected to the
ECM via a twisted pair of wires.
The knock sensors produce a voltage signal in proportion to the amount of mechanical vibration generated at each ignition
point. Each sensor monitors the related cylinder bank.
The knock sensors incorporate a piezo-ceramic crystal. This crystal produces a voltage whenever an outside force tries to
deflect it, (i.e. exerts a mechanical load on it). When the engine is running, the compression waves in the material of the
cylinder block, caused by the combustion of the fuel/air mixture within the cylinders, deflect the crystal and produce an
output voltage signal. The signals are supplied to the ECM, which compares them with `mapped' signals stored in memory.
From this, the ECM can determine when detonation occurs on individual cylinders. When detonation is detected, the ECM
retards the ignition timing on that cylinder for a number of engine cycles, then gradually returns it to the original setting.
Care must be taken at all times to avoid damaging the knock sensors, but particularly during removal and fitting
procedures. The recommendations regarding torque and surface preparation must be adhered to. The torque applied to the
sensor and the quality of the surface preparation both have an influence over the transfer of mechanical noise from the
cylinder block to the crystal.
The ECM uses the signals supplied by the knock sensors, in conjunction with the signal it receives from the camshaft
sensor, to determine the optimum ignition point for each cylinder. The ignition point is set according to preprogrammed
ignition maps stored within the ECM. The ECM is programmed to use ignition maps for 98 RON premium specification fuel.
It will also function on 91 RON regular specification fuel and learn new adaptions. If the only fuel available is of poor
quality, or the customer switches to a lower grade of fuel after using a high grade for a period of time, the engine may
suffer slight pre-ignition for a short period. This amount of pre-ignition will not damage the engine. This situation will be
evident while the ECM learns and then modifies its internal mapping to compensate for the variation in fuel quality. This
feature is called adaption. The ECM has the capability of adapting its fuel and ignition control outputs in response to
several sensor inputs.
The ECM will cancel closed loop control of the ignition system if the signal received from either knock sensor becomes
implausible. In these circumstances the ECM will default to a safe ignition map. This measure ensures the engine will not
become damaged if low quality fuel is used. The MIL (malfunction indicator lamp) lamp will not illuminate, although the
driver may notice that the engine 'pinks' in some driving conditions and displays a drop in performance and smoothness.
When a knock sensor fault is stored, the ECM will also store details of the engine speed, engine load and the coolant
temperature.
Electric Throttle
The V6 EMS incorporates an electric throttle control system. The electronic throttle body is located on the air intake
manifold in the engine compartment. The system comprises three main components:
Electronic throttle control valve

APP
ECM
When the accelerator pedal is depressed the APP sensor provides a change in the monitored signals. The ECM compares
this against an electronic map and moves the electronic throttle valve via a PWM control signal which is in proportion to
the APP angle signal. The system is required to:
Regulate the calculated intake air load based on the accelerator pedal sensor input signals and programmed
mapping.
Monitor the drivers input request for cruise control operation.
Automatically position the electronic throttle for accurate cruise control.
Perform all dynamic stability control throttle control interventions.
Monitor and carry out maximum engine and road speed cut out.
A software strategy within the ECM enables the throttle position to be calibrated each ignition cycle. When the ignition is
turned OFF, the ECM performs a self test and calibration routine on the electronic throttle by closing the throttle fully. The
power is then removed and the ECM checks that the throttle returns to the reference position under the pressure from the
spring.
The APP sensor is located in a plastic housing which is integral with the throttle pedal. The housing is injection molded
and provides location for the APP sensor. The sensor is mounted externally on the housing and is secured with two Torx
screws. The external body of the sensor has a six pin connector which accepts a connector on the vehicle wiring harness.
The sensor has a spigot which protrudes into the housing and provides the pivot point for the pedal mechanism. The
spigot has a slot which allows for a pin, which is attached to the sensor potentiometers, to rotate through approximately
90 degrees , which relates to pedal movement. The pedal is connected via a link to a drum, which engages with the sensor
pin, changing the linear movement of the pedal into rotary movement of the drum. The drum has two steel cables attached
to it. The cables are secured to two tension springs which are secured in the opposite end of the housing. The springs
provide 'feel' on the pedal movement and require an effort from the driver similar to that of a cable controlled throttle. A
detente mechanism is located at the forward end of the housing and is operated by a ball located on the drum. At near
maximum throttle pedal movement, the ball contacts the detente mechanism. A spring in the mechanism is compressed
and gives the driver the feeling of depressing a 'kickdown' switch when full pedal travel is achieved.
The APP sensor signals are checked for range and plausibility. Two separate reference voltages are supplied to the pedal.
Should one sensor fail, the other is used as a 'limphome' input. In limp home mode due to an APP signal failure the ECM
will limit the maximum engine speed to 2000 rpm.
APP Sensor Output Graph

ItemDescription
A Voltage
B APP sensor angle
C Kick down angle
The APP sensor has two potentiometer tracks which each receive a 5V input voltage from the ECM. Track 1 provides an
output of 0.5V with the pedal at rest and 2.0V at 100% full throttle. Track 2 provides an output of 0.5V with the pedal at
rest and 4.5V at 100% full throttle. The signals from the two tracks are used by the ECM to determine fueling for engine
operation and also by the ECM and the TCM to initiate a kickdown request for the automatic transmission.
The ECM monitors the outputs from each of the potentiometer tracks and can determine the position, rate of change and
direction of movement of the throttle pedal. The 'closed throttle' position signal is used by the ECM to initiate idle speed
control and also overrun fuel cut-off.
Oxygen Sensors
There are four oxygen sensors located in the exhaust system. Two upstream before the catalytic converter (HO2S) and two
down stream after the catalytic converter (O2S). The sensor monitors the level of oxygen in the exhaust gases and is used
to control the fuel/air mixture. Positioning a sensor in the stream of exhaust gasses from each bank enables the ECM to
control the fueling on each bank independently of the other, allowing much closer control of the air/fuel ratio and catalyst
conversion efficiency.
The oxygen sensors need to operate at high temperatures in order to function correctly. To achieve the high temperatures
required, the sensors are fitted with heater elements that are controlled by a PWM signal from the ECM. The heater
elements are operated immediately following engine start and also during low load conditions when the temperature of the
exhaust gases is insufficient to maintain the required sensor temperatures. A non-functioning heater delays the sensors
readiness for closed loop control and influences emissions. The PWM duty cycle is carefully controlled to prevent thermal
shock to cold sensors.
HO2S sensors also known as Linear or "W ide Band" sensors produces a constant voltage, with a variable current that is
proportional to the oxygen content. This allows closed loop fueling control to a target lambda, i.e. during engine warm up
(after the sensor has reached operating temperature and is ready for operation). This improves emission control.
The O2S sensor uses Zirconium technology that produces an output voltage dependant upon the ratio of exhaust gas
oxygen to the ambient oxygen. The device contains a Galvanic cell surrounded by a gas permeable ceramic, the voltage of
which depends upon the level of O2 (oxygen) defusing through. Nominal output voltage of the device for l =1 is 300 to
500m volts. As the fuel mixture becomes richer (l<1) the voltage tends towards 900m volts and as it becomes leaner (l>1)
the voltage tends towards 0 volts. Maximum tip temperature is 1,000 Degrees Celsius for a maximum of 100 hours.
Sensors age with mileage, increasing their response time to switch from rich to lean and lean to rich. This increase in
response time influences the ECM closed loop control and leads to progressively increased emissions. Measuring the period
of rich to lean and lean to rich switching monitors the response rate of the upstream sensors.
Diagnosis of electrical faults is continually monitored in both the upstream and downstream sensors. This is achieved by
checking the signal against maximum and minimum threshold, for open and short circuit conditions.
Oxygen sensors must be treated with the utmost care before and during the fitting process. The sensors have ceramic
material within them that can easily crack if dropped/banged or over-torqued. The sensors must be torqued to the required
figure, (40-50Nm), with a calibrated torque wrench. Care should be taken not to contaminate the sensor tip when
anti-seize compound is used on the thread. Heated sensor signal pins are tinned and universal are gold plated. Mixing up
sensors could contaminate the connectors and affect system performance.
Failure Modes
Mechanical fitting & integrity of the sensor.

Sensor open circuit/disconnected.
Short circuit to vehicle supply or ground.
Lambda ratio outside operating band.
Crossed sensors bank A & B.
Contamination from leaded fuel or other sources.
Change in sensor characteristic.
Harness damage.
Air leak into exhaust system.
Failure Symptoms
Default to Open Loop fueling for the particular cylinder bank

High CO (carbon monoxide) reading.
Strong smell of HO2S till default condition.
Excess Emissions.
It is possible to fit front and rear sensors in their opposite location. However the harness connections are of different
gender and color to ensure that the sensors cannot be incorrectly connected. In addition to this the upstream sensors have
two holes in the shroud, whereas the down stream sensors have four holes in the shroud for the gas to pass through.
Generator
The Generator has a power control module voltage regulator for use in a 14V charging system with 612 zener diode
bridge rectifiers.
The ECM monitors the load on the electrical system via PW M signal and adjusts the generator output to match the
required load. The ECM also monitors the battery temperature to determine the generator regulator set point. This
characteristic is necessary to protect the battery; at low temperatures battery charge acceptance is very poor so the
voltage needs to be high to maximize any rechargeability, but at high temperatures the charge voltage must be restricted
to prevent excessive gassing of the battery with consequent water loss.
The Generator has a smart charge capability that will reduce the electrical load on the Generator reducing torque
requirements, this is implemented to utilize the engine torque for other purposes. This is achieved by monitoring three
signals to the ECM:
Generator sense (A sense), measures the battery voltage at the CJB (central junction box).
Generator communication (Alt Com) communicates desired Generator voltage set point from ECM to Generator.
Generator monitor (Alt Mon) communicates the extent of Generator current draw to ECM. This signal also transmits
faults to the ECM which will then sends a message to the instrument pack on the CAN bus to illuminate the charge
warning lamp.
Fuel Injectors
The engine has 6 fuel injectors (one per cylinder), each injector is directly driven by the ECM. The injectors are fed by a
common fuel rail as part of a returnless fuel system. The fuel rail pressure is regulated to 4.5 bar by a fuel pressure
regulator which is integral to the fuel pump module, within the fuel tank. The injectors can be checked by resistance
checks. There is a fuel pressure test Schrader valve attached to the fuel rail on the front LH side for fuel pressure testing
purposes. The ECM monitors the output power stages of the injector drivers for electrical faults.
The injectors have a resistance of 13.8 Ohms 0.7 Ohms @ 20 Degrees Celsius.
Ignition Coils
The engine is fitted with six plug-top coils that are driven directly by the ECM. This means that the ECM, at the point
where sufficient charge has built up, switches the primary circuit of each coil and a spark is produced in the spark plug. The
positive supply to the coil is fed from a common fuse. Each coil contains a power stage to trigger the primary current. The
ECM sends a signal to each of the coils power stage to trigger the power stage switching. Each bank has a feedback signal
that is connected to each power stage. If the coil power stage has a failure the feedback signal is not sent, causing the
ECM to store a fault code appropriate to the failure.
The ECM calculates the dwell time depending on battery voltage and engine speed to ensure constant secondary energy.
This ensures sufficient secondary (spark) energy is always available, without excessive primary current flow thus avoiding
overheating or damage to the coils.
Engine speed and load.

Engine temperature.
Knock control.
Auto gearbox shift control.
Idle speed control.
The fuel rail pressure sensor is located on top of the fuel rail adjacent to the fuel inlet. The fuel rail pressure sensor
measures the pressure of the fuel in the fuel rail. This input is then used by the fuel pump control module to control the
amount of fuel delivered to the fuel rail.

The FPDM is located on the RH side of the charcoal canister on top of the fuel tank. The fuel pump control module receives
a power supply via the fuel pump relay in the auxiliary fuse box.
The ECM sends a PWM signal to the FPDM, the duty cycle of the signal determines the duty cycle of the pump. The ECM
sets a target fuel pressure based on engine load. The target fuel pressure is maintained by using feedback from the fuel
rail pressure sensor which is used to control the fuel pump via a closed loop PWM signal. The PWM signal to the pump
represents half the ON time of the pump. If the ECM transmits a 50% on time the fuel pump control module drives the
pump at 100%. If the ECM transmits a 5% ON time the fuel pump control module drives the pump at 10%. The fuel pump
control module will only turn the fuel pump ON if it receives a valid signal between 4% and 50%. When the ECM requires
the fuel pump to be turned OFF the ECM transmits a duty cycle signal of 75%.
The status of the FPDM is monitored by the ECM. Any errors can be retrieved from the ECM. The fuel pump control module
cannot be interrogated for diagnostic purposes.
The ECM controls the FPDM in response to inputs from the fuel rail pressure sensor, MAP and the MAF/IAT sensor.
Variable Valve Timing (VVT)

Variable valve timing is used on the V6 engine to enhance low and high speed engine performance and idle speed quality.
For each intake camshaft the VVT (variable valve timing) system comprises:
VVT unit
Valve timing solenoid
The VVT system alters the phase of the intake valves relative to the fixed timing of the exhaust valves, to alter:
The mass of air flow to the cylinders.

The engine torque response.
Emissions.
The VVT unit uses a vane type device to control the camshaft angle. The system operates over a range of 48 degrees and
is advanced or retarded to its optimum position within this range.
The VVT system is controlled by the ECM based on engine load and speed along with engine oil temperature to calculate
the appropriate camshaft position.
The VVT system provides the following advantages:
Reduced engine emissions and improved fuel consumption which in turn improves the engines internal EGR effect
over a wider operating range.
Enhanced full load torque characteristics.
Improved fuel economy through optimized torque over the engine speed range.
Variable Valve Timing Unit
ItemDescription
1 Vane housing
2 Vane shaft
3 Retard chamber
4 Rotation direction
5 Advance chamber oil channel
6 Stopper pin
7 Intake camshaft
8 Retard chamber oil channel
9 Advance chamber
The VVT unit is a hydraulic actuator mounted on the end of the intake camshaft. The unit advances or retards the
camshaft timing to alter the camshaft to crankshaft phase. The ECM controls the VVT timing unit via an oil control
solenoid. The oil control solenoid routes oil pressure to the advance or retard chambers either side of the vanes within the
VVT unit.
The VVT unit is driven by the primary drive chain and rotates relative to the exhaust camshaft. When the ECM requests a
retard in camshaft timing the oil control solenoid is energized which moves the shuttle valve in the solenoid to the
relevant position allowing oil pressure to flow out of the advance chambers in the VVT unit whilst simultaneously allowing
oil pressure into the retard chambers.
The ECM controls the advancing and retarding of the VVT unit based on engine load and speed. The ECM sends an energize
signal to the oil control solenoid until the desired VVT position is achieved. W hen the desired VVT position is reached, the
energizing signal is reduced to hold the oil control solenoid position and consequently desired VVT position. This function
is under closed loop control and the ECM can sense any variance in shuttle valve oil pressure via the camshaft position
sensor and can adjust the energizing signal to maintain the shuttle valve hold position.
operation can be affected by engine oil temperature and properties. At very low oil temperatures the movement of the VVT
mechanism will be slow due to the high viscosity of the oil. W hile at high oil temperatures the low oil viscosity may impair
the VVT operation at low oil pressures. The oil pump has the capacity to cope with these variations in oil pressure while an
oil temperature sensor is monitored by the ECM to provide oil temperature feedback. At extremely high oil temperatures
the ECM may limit the amount of VVT advance in order to prevent the engine from stalling when returning to idle speed.
VVT does not operate when engine oil pressure is below 1.25 bar. This is because there is insufficient pressure to release
the VVT units internal stopper pin. This occurs when the engine is shut down and the VVT unit has returned to the
retarded position. The stopper pin locks the VVT unit to the camshaft to ensure camshaft stability during the next start up.
The valve timing solenoid controls the position of the shuttle valve in the bush carrier. A plunger on the solenoid extends
when the solenoid is energized and retracts when the solenoid is de-energized.
When the valve timing solenoids are de-energized, the coil springs in the bush carriers position the shuttle valves to
connect the valve timing units to drain. In the valve timing units, the return springs hold the ring pistons and gears in the
retarded position. When the valve timing solenoids are energized by the ECM, the solenoid plungers position the shuttle
valves to direct engine oil to the valve timing units. In the valve timing units, the oil pressure overcomes the force of the
return springs and moves the gears and ring pistons to the advanced position. System response times are 1.0 second
maximum for advancing and 0.7 second maximum for retarding. W hile the valve timing is in the retarded mode, the ECM
produces a periodic lubrication pulse. This momentarily energizes the valve timing solenoids to allow a spurt of oil into the
valve timing units. The lubrication pulse occurs once every 5 minutes.
For a detailed description of the 4.2L petrol electronic engine controls, refer to the relevant Description and Operation
section in the workshop manual. REFER to: (303-14 Electronic Engine Controls - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8)

vehicle.
Visual Inspection
Engine oil level and condition Fuses
Fuel contamination/grade/quality Sensor(s)
Throttle body Engine Control Module (ECM)
Front End Accessory Drive (FEAD) belt Transmission Control Module (TCM)
Air cleaner condition
Symptom Chart

Engine non-start
Engine does not crank Security system/Immobilizer Check that the security system is disarmed
engaged Read DTCs and refer to DTC Index in this
Engine in shut-down mode section for ECM relay tests
ECM relay Ensure the battery is in fully charged and
Battery serviceable condition
Starting system For starting system tests.
Engine seized REFER to: Starting System (303-06 Starting
System - 4.2L NA V8 - AJV8/4.2L SC V8 -
For engine system tests.
REFER to: Engine (303-01A Engine - 4.2L NA
Engine cranks, but does not fire Engine breather system Ensure the engine breather system is free
disconnected/restricted from restriction and is correctly installed
Ignition system For ignition system tests.
Fuel system REFER to: Engine Ignition (303-07 Engine
Electronic engine controls Ignition - 4.2L NA V8 - AJV8/4.2L SC V8 -
REFER to: Fuel Tank and Lines (310-01 Fuel
Tank and Lines - 4.2L NA V8 - AJV8/4.2L SC
Read DTCs and refer to DTC Index in this
section for electronic engine control tests
Engine cranks and fires, but will Evaporative emissions purge For purge valve tests.
not start valve REFER to: Evaporative Emissions (303-13
Fuel pump Evaporative Emissions - 4.2L NA V8 -
Spark plugs AJV8/4.2L SC V8 - AJV8, Diagnosis and
Ignition coil failure(s) Testing).
REFER to: Engine Ignition (303-07 Engine
Ignition - 4.2L NA V8 - AJV8/4.2L SC V8 -
Difficult to start
Difficult cold start Check engine coolant Check the engine coolant level and condition.
level/anti-freeze content REFER to: Engine Cooling (303-03A Engine
Battery Cooling - 4.2L NA V8 - AJV8/4.2L SC V8 -
Electronic engine controls AJV8, Diagnosis and Testing).
Exhaust gas recirculation Ensure the battery is in a fully charged and
(EGR) valve stuck open serviceable condition
Fuel pump Read DTCs and refer to DTC Index in this
Evaporative emissions purge section for electronic engine control tests
valve For EGR valve tests.
REFER to: Engine Emission Control (303-08
Engine Emission Control - 4.2L NA V8 -
Testing).
REFER to: Evaporative Emissions (303-13
Evaporative Emissions - 4.2L NA V8 -
Testing).
Difficult hot start Injector leak Carry out injector leak tests, check and install
Electronic engine controls new injectors as required.
Evaporative emissions purge REFER to: Fuel Injectors (303-04A Fuel
valve Charging and Controls - 4.2L NA V8 - AJV8,
Fuel pump Removal and Installation).
Ignition system Read DTCs and refer to DTC Index in this
EGR valve stuck open section for electronic engine control tests
Testing).
Testing).
Difficult to start after hot soak Injector leak Carry out injector leak tests, check and install
(vehicle standing, engine off, Electronic engine controls new injectors as required.
after engine has reached Evaporative emissions purge REFER to: Fuel Injectors (303-04A Fuel
operating temperature) valve Charging and Controls - 4.2L NA V8 - AJV8,
EGR valve stuck open section for electronic engine control tests
Testing).
Testing).
Engine cranks too fast/slow Compressions high/low Carry out cylinder compression tests
Battery Ensure battery is in a fully charged and
Starting system serviceable condition
For starting system tests.
REFER to: Starting System (303-06 Starting
System - 4.2L NA V8 - AJV8/4.2L SC V8 -
Engine stalls
Engine stalls soon after start Breather system Ensure the engine breather system is free
disconnected/restricted from restriction and is correctly installed
ECM relay Read DTCs and refer to DTC Index in this
Electronic engine controls section for ECM relay tests
Air intake system restricted section for electronic engine control tests
Air leakage For ignition system tests.
Fuel lines REFER to: Engine Ignition (303-07 Engine
Check for blockage in air cleaner element and
air intake system
Engine stalls on overrun ECM relay Read DTCs and refer to DTC Index in this
Throttle position (TP) section for ECM relay and TP sensor tests
sensors
Engine stalls at steady speed ECM relay Read DTCs and refer to DTC Index in this
CKP sensor section for ECM relay, CKP, and TP sensor
TP sensors tests
Engine stalls with speed control ECM relay Read DTCs and refer to DTC Index in this
enabled section for ECM relay tests
Engine stalls when ECM relay Read DTCs and refer to DTC Index in this
manoeuvring TP sensors section for ECM relay, and TP sensor tests
Additional engine loads Check for excessive loads being placed on the
(power steering, air engine from power steering, air conditioning
conditioning, etc) systems etc.
Transmission malfunction For transmission system tests.
CAN malfunction REFER to: Diagnostic Strategy (307-01
Automatic Transmission/Transaxle - 2.7L V6 -
TdV6/3.0L NA V6 - AJ27/4.2L NA V8 -
Testing).
For CAN network tests.
REFER to: Communications Network (418-00
Module Communications Network, Diagnosis
and Testing).
Poor driveability
Engine hesitates/poor Fuel pressure, fuel pump, For fuel system tests.
acceleration fuel lines REFER to: Fuel Tank and Lines (310-01 Fuel
Injector leak Tank and Lines - 4.2L NA V8 - AJV8/4.2L SC
Air leakage V8 - AJV8, Diagnosis and Testing).
Electronic engine controls Carry out fuel injector leak tests, check and
Ignition system install new injectors as required.
EGR valve stuck REFER to: Fuel Injectors (303-04A Fuel
Transmission malfunction Charging and Controls - 4.2L NA V8 - AJV8,
Restricted pedal travel Removal and Installation).
(carpet, etc) Check for leakage from air intake system
Testing).
For transmission system tests.
REFER to: Diagnostic Strategy (307-01
TdV6/3.0L NA V6 - AJ27/4.2L NA V8 -
Testing).
Ensure accelerator pedal is free from
restriction
Engine backfires Fuel pump, fuel lines For fuel system tests.
Air leakage REFER to: Fuel Tank and Lines (310-01 Fuel
Electronic engine controls Tank and Lines - 4.2L NA V8 - AJV8/4.2L SC
Ignition system V8 - AJV8, Diagnosis and Testing).
Sticking variable camshaft Check for leakage from air intake system
timing (VCT) hub Read DTCs and refer to DTC Index in this
section for VCT system tests
Engine surges Fuel pump, fuel lines For fuel system tests.
Electronic engine controls REFER to: Fuel Tank and Lines (310-01 Fuel
Ignition system Tank and Lines - 4.2L NA V8 - AJV8/4.2L SC
Engine detonates/knocks Electronic engine controls Read DTCs and refer to DTC Index in this
Fuel pump, fuel lines, fuel section for electronic engine control tests
quality For fuel system tests.
Air leakage REFER to: Fuel Tank and Lines (310-01 Fuel
Sticking VCT hub Tank and Lines - 4.2L NA V8 - AJV8/4.2L SC
Check for leakage from air intake system
section for VCT system tests
No throttle response Electronic engine controls Read DTCs and refer to DTC Index in this
Speed control inhibited or Default mode enabled Check message center for default message,
disabled Speed control, brake switch read DTCs and refer to DTC Index
Electronic engine controls For speed control, and brake switch tests.
CAN fault REFER to:
Speed Control (310-03 Speed Control -
4.2L NA V8 - AJV8/4.2L SC V8 - AJV8,
Diagnosis and Testing),
Electronic Engine Controls (303-14
Electronic Engine Controls - 4.2L NA V8 -
Testing).
For CAN network tests.
REFER to: Communications Network (418-00
Module Communications Network, Diagnosis
and Testing).
Poor throttle response Breather system Ensure engine breather system is free from
Electronic engine controls Read DTCs and refer to DTC Index in this
Transmission malfunction section for electronic engine control tests
Traction control event For transmission system tests.
Air leakage REFER to: Diagnostic Strategy (307-01
TdV6/3.0L NA V6 - AJ27/4.2L NA V8 -
Testing).
Engine defaults, warning light Electronic engine controls Read DTCs and refer to DTC Index in this
and messages. Refer to the section for electronic engine control tests
owner handbook
DTC Index

B10A231 Crash Input No signal Refer to the electrical circuit diagrams and check
RCM PWM signal circuit for short, open circuit
B11DB01 Battery Monitoring Module Battery monitoring system Disconnect vehicle battery, re-connect after 60
hardware fault seconds, clear DTC and retest. If DTC remains
Check and install a new battery monitoring
module
B11DB87 Battery Monitoring Module Battery monitoring module If additional DTCs B108783, B108786, B108787
connector are logged, suspect the RJB. Check and Check
dis-connected/poor and install a new RJB as required, refer to the
connection new module/component Check and installation
Battery monitoring module note at the top of the DTC Index. If additional
to RJB LIN circuit - open DTCs B108783, B108786, B108787 are NOT
circuit logged, check for good/clean contact at battery
Battery monitoring module monitoring module connector, refer to electrical
to battery positive monitor circuit diagrams and check battery monitoring
circuit - open circuit module to RJB LIN circuit and battery monitoring
Battery monitoring module to battery positive monitor circuit for
module/RJB failure open circuit. Clear DTC and repeat automated
diagnostic procedure using manufacturer
approved diagnostic system. If DTC remains
suspect the battery monitoring module, check
and Check and install a new battery monitoring
module as required, refer to the new
module/component Check and installation note
at the top of the DTC Index
B120668 Crash Occurred ECM has detected the Check RCM for related DTCs and refer to the
vehicle has crashed - event relevant DTC Index
information DTC only
C003100 Left Front Wheel Speed Invalid data received from Check ABS module for related DTCs and refer to
Sensor ABS - left front wheel speed relevant DTC Index
signal
C003400 Right Front Wheel Speed Invalid data received from Check ABS module for related DTCs and refer to
Sensor ABS - right front wheel relevant DTC Index
speed signal
C003700 Left Rear W heel Speed Invalid data received from Check ABS module for related DTCs and refer to
Sensor ABS - left rear wheel speed relevant DTC Index
signal
C003A00 Right Rear W heel Speed Invalid data received from Check ABS module for related DTCs and refer to
Sensor ABS - right rear wheel speed relevant DTC Index
signal
P001100 Intake (A) Camshaft Variable Camshaft Timing Carry out any pinpoint tests associated with this
Position Timing - (VCT) circuit fault DTC using the manufacturer approved diagnostic
Over-Advanced (Bank 1) Valve timing incorrectly set system. Refer to the electrical circuit diagrams
Timing chain has slipped and check VCT circuits for short, open circuit.
Check the valve timing
Over-Retarded (Bank 1) Valve timing incorrectly set system. Refer to the electrical circuit diagrams
P001600 Crankshaft Position - The relative positions of the Reset the sensor positions
Camshaft Position CKP and CMP teeth are not
Correlation - Bank 1 Sensor correct
A - Sensors incorrectly
aligned on rebuild
P001800 Crankshaft Position - The relative positions of the Reset the sensor positions
Camshaft Position CKP and CMP teeth are not
Correlation - Bank 2 Sensor correct
A - Sensors incorrectly
aligned on rebuild
Over-Advanced (Bank 2) Valve timing incorrectly set system. Refer to the electrical circuit diagrams
Over-Retarded (Bank 2) Valve timing incorrectly set system. Refer to the electrical circuit diagrams
P002672 Intake Valve Control VCT solenoid fault Carry out any pinpoint tests associated with this
Solenoid Circuit Oil contamination DTC using the manufacturer approved diagnostic
Range/Performance (Bank VCT oil flow fault system. Refer to the electrical circuit diagrams
1) VCT/Camshaft mechanical and check VCT circuits for short, open circuit.
failure Check the oil condition and flow. Check for
mechanical failure of components
P002872 Intake Valve Control VCT solenoid fault Refer to the electrical circuit diagrams and check
Solenoid Circuit Oil contamination VCT circuits for short, open circuit. Check the oil
Range/Performance (Bank VCT oil flow fault condition and flow. Check for mechanical failure
2) VCT/Camshaft mechanical of components
failure
P003100 HO2S Heater Control Circuit HO2S heater circuit - circuit Carry out any pinpoint tests associated with this
Low (Bank 1, Sensor 1) fault DTC using the manufacturer approved diagnostic
HO2S heater failure system. Refer to the electrical circuit diagrams
and check HO2S heater circuits for short, open
circuit. Check and install a new HO2S as
required
High (Bank 1, Sensor 1) fault DTC using the manufacturer approved diagnostic
required
P003600 HO2S Heater Control Circuit Catalytic converter monitor Carry out any pinpoint tests associated with this
(Bank 1, Sensor 2) sensor heater circuit - circuit DTC using the manufacturer approved diagnostic
fault system. Refer to the electrical circuit diagrams
Catalytic converter monitor and check Catalytic converter monitor sensor
sensor heater failure heater circuits for short, open circuit. Check and
install new Catalytic converter monitor sensor as
required
Low (Bank 2, Sensor 1) fault DTC using the manufacturer approved diagnostic
required
High (Bank 2, Sensor 1) fault DTC using the manufacturer approved diagnostic
required
P005600 HO2S Heater Control Circuit Catalytic converter monitor Carry out any pinpoint tests associated with this
(Bank 2, Sensor 2) sensor heater circuit - circuit DTC using the manufacturer approved diagnostic
sensor heater failure heater circuits for short, open circuit. Check and
required
P006900 MAP - Barometric Pressure MAP sensor failure Check for MAP sensor related DTCs and refer to
Correlation BARO sensor failure (internal the DTC Index in this section. Check and install
ECM fault) a new ECM. Refer to new module/component
Check and installation Note at top of DTC Index
P007100 Ambient Air Temperature Ambient temperature value Refer to the electrical circuit diagrams and check
Sensor Range/Performance missing from CAN bus ambient air temperature sensor circuits for short
to ground, power, open circuit. Check and Check
and install a new sensor as required
P007200 Ambient Air Temperature Ambient air temperature Carry out any pinpoint tests associated with this
Sensor Circuit Low sensor circuit - short to DTC using the manufacturer approved diagnostic
ground, high resistance system. Refer to the electrical circuit diagrams
and check ambient air temperature sensor
circuits for short to ground, high resistance
P007300 Ambient Air Temperature Ambient air temperature Carry out any pinpoint tests associated with this
Sensor Circuit High sensor circuit - short to DTC using the manufacturer approved diagnostic
power system. Refer to the electrical circuit diagrams
and check ambient air temperature sensor
circuits for short to power
P007514 Intake Valve Control Circuit VCT control solenoid circuit - Refer to the electrical circuit diagrams and check
(Bank 1) short to ground, open circuit VCT control solenoid circuit for short to ground,
open circuit
P007700 Intake Valve Control Circuit VCT control solenoid circuit - Carry out any pinpoint tests associated with this
High (Bank 1) short to power DTC using the manufacturer approved diagnostic
VCT solenoid failure system. Refer to the electrical circuit diagrams
and check VCT circuits for short to power. Check
and install a new VCT control solenoid as
required
P008114 Intake Valve Control Circuit VCT control solenoid circuit - Refer to the electrical circuit diagrams and check
High (Bank 2) short to ground, open circuit VCT control solenoid circuit for short to ground,
open circuit
P008300 Intake Valve Control Circuit VCT control solenoid circuit - Carry out any pinpoint tests associated with this
High (Bank 2) short to power DTC using the manufacturer approved diagnostic
VCT solenoid failure system. Refer to the electrical circuit diagrams
and check VCT circuits for short to power. Check
and install a new VCT control solenoid as
required
P008700 Fuel Rail/System Pressure - Fuel rail pressure (Fuel rail Carry out any pinpoint tests associated with this
Too Low pressure) sensor, sensing DTC using the manufacturer approved diagnostic
circuit - short to ground, system. Refer to the electrical circuit diagrams
open circuit and check Fuel rail pressure sensor circuits for
Fuel rail pressure sensor short to ground, open circuit, high resistance.
supply circuit - high Check and install a new Fuel rail pressure sensor
resistance as required. Check fuel system for failure
failure
Fuel pump failure
P008800 Fuel Rail/System Pressure - Fuel rail pressure sensor Carry out any pinpoint tests associated with this
Too High supply/sensing circuits - DTC using the manufacturer approved diagnostic
short to each other system. Refer to the electrical circuit diagrams
Fuel rail pressure sensor and check Fuel rail pressure sensor circuits for
sensing circuit - short to short to each other, power, open circuit, high
power resistance. Check and install a new Fuel rail
Fuel rail pressure sensor pressure sensor as required. Check fuel system
ground circuit - high for failure
resistance
failure
power
P009623 Intake Air Temperature Charge air cooler air Refer to the electrical circuit diagrams and check
Sensor 2 Circuit temperature sensor circuit - charge air cooler air temperature sensor circuit
Range/Performance signal stuck low for short to ground, high resistance
Range/Performance signal stuck high for short to power
Range/Performance signal invalid for short, open circuit. Check and install a new
Charge air cooler air sensor as required
temperature sensor failure
P009700 Intake Air Temperature No sub type information Carry out any pinpoint tests associated with this
Sensor 2 Circuit Low DTC using the manufacturer approved diagnostic
system. Refer to the electrical circuit diagrams
and check charge air cooler air temperature
sensor circuit for short to ground, high
resistance
P009800 Intake Air Temperature No sub type information Carry out any pinpoint tests associated with this
Sensor 2 Circuit High DTC using the manufacturer approved diagnostic
and check charge air cooler air temperature
sensor circuit for short to power
P00AB23 Intake Air Temperature Charge air cooler air Refer to the electrical circuit diagrams and check
Range/Performance (Bank signal stuck low for short to ground, high resistance
2)
Range/Performance (Bank signal stuck high for short to power
2)
P00AB25 Intake Air Temperature Signal shape/waveform Refer to the electrical circuit diagrams and check
Sensor 1 Circuit failure charge air cooler air temperature sensor circuit
Range/Performance (Bank for short to ground, power, open circuit
2)
Range/Performance (Bank signal invalid for short, open circuit. Check and install a new
2) Charge air cooler air sensor as required
P00AC00 Intake Air Temperature No sub type information Refer to the electrical circuit diagrams and check
Sensor 1 Circuit Low (Bank charge air cooler air temperature sensor circuit
2) for short to ground, high resistance
P00AD00 Intake Air Temperature No sub type information Refer to the electrical circuit diagrams and check
Sensor 1 Circuit High (Bank charge air cooler air temperature sensor circuit
2) for short to power
P010100 Mass or Volume Air Flow A Blocked air cleaner element Check air cleaner element is free from
Circuit Range/Performance Leakage from air intake restriction. Check for leak from air intake
system system, rectify as required. Ensure the engine
Engine breather leak breather system is correctly installed and in
MAF sensor sensing circuit - serviceable condition. Carry out any pinpoint
high resistance, intermittent tests associated with this DTC using the
short to ground manufacturer approved diagnostic system. Refer
MAF sensor supply circuit - to the electrical circuit diagrams and check MAF
high resistance sensor circuit for intermittent short to ground,
MAF sensor failure high resistance. Check and install a new MAF
sensor as required
P010200 Mass or Volume Air Flow A MAF sensor circuits - short Carry out any pinpoint tests associated with this
Circuit Low to ground, high resistance DTC using the manufacturer approved diagnostic
MAF sensor ground circuit - system. Refer to the electrical circuit diagrams
high resistance and check MAF sensor circuits for short to power
MAF sensor failure ground, high resistance. Check and install a new
P010300 Mass or Volume Air Flow A MAF sensor circuits - short Carry out any pinpoint tests associated with this
Circuit High to power DTC using the manufacturer approved diagnostic
high resistance and check MAF sensor circuits for short to power,
P010600 Manifold Absolute Intake manifold air leak Check for correct installation and serviceability
Pressure/BARO Sensor (loose or missing of intake manifold and associated components.
Range/Performance component) Carry out any pinpoint tests associated with this
MAP sensor signal circuit DTC using the manufacturer approved diagnostic
MAP sensor failure and check MAP sensor circuits for short, open
circuit. Check and install a new MAP sensor as
required
P010700 Manifold Absolute MAP sensor circuits - short Carry out any pinpoint tests associated with this
Pressure/BARO Sensor Low to ground, high resistance DTC using the manufacturer approved diagnostic
MAP sensor ground circuits - system. Refer to the electrical circuit diagrams
high resistance and check MAP sensor circuits for short to
MAP sensor failure ground, high resistance. Check and install a new
MAP sensor as required
P010800 Manifold Absolute MAP sensor circuits - short Carry out any pinpoint tests associated with this
Pressure/BARO Sensor High to power DTC using the manufacturer approved diagnostic
MAP sensor power circuits - system. Refer to the electrical circuit diagrams
MAP sensor failure power, high resistance. Check and install a new
MAP sensor as required
P010B00 Mass or Volume Air Flow B No sub type information Carry out any pinpoint tests associated with this
Circuit Range/Performance DTC using the manufacturer approved diagnostic
and check MAF sensor circuits for short, open
circuit
P010C00 Mass or Volume Air Flow B MAF sensor circuits - short Carry out any pinpoint tests associated with this
Circuit Low to ground, high resistance DTC using the manufacturer approved diagnostic
high resistance and check MAF sensor circuits for short to
P010D00 Mass or Volume Air Flow B MAF sensor circuits - short Carry out any pinpoint tests associated with this
Circuit High to power DTC using the manufacturer approved diagnostic
high resistance and check MAF sensor circuits for short to power,
P010F00 Mass or Volume Air Flow Blocked Air cleaner in 1 bank Carry out any pinpoint tests associated with this
Sensor A/B Correlation Leakage from intake air DTC using the manufacturer approved diagnostic
system system. Check for any P0101 or P010B DTCs.
Engine breather leak Check air cleaner is free from restriction. Check
Flow Diffusor blocking MAF for any leaks in the intake air system and all
sensor joints. Check engine breather system is correctly
Failure of A bank MAF sensor installed and in a serviceable condition. Check
Failure of B bank MAF sensor flow diffusors are not obstructing MAF sensors.
Check and install new MAF sensors as required
P011123 Intake Air Temperature IAT sensor sensing circuit - Carry out any pinpoint tests associated with this
Sensor 1 Circuit high resistance DTC using the manufacturer approved diagnostic
Range/Performance IAT sensor failure system. Refer to the electrical circuit diagrams
and check IAT sensor circuits for short, open
circuit, high resistance. Check and install a new
Sensor 1 Circuit Low high resistance, DTC using the manufacturer approved diagnostic
disconnected system. Refer to the electrical circuit diagrams
IAT sensor failure and check IAT sensor circuits for short, open
circuit, high resistance, disconnected connector.
Check and install a new MAF sensor as required
Sensor 1 Circuit High short to ground, short to DTC using the manufacturer approved diagnostic
power system. Refer to the electrical circuit diagrams
IAT sensor failure and check IAT sensor circuits for short, open
P011623 Engine Coolant Low coolant level Fill cooling system to correct level and
Temperature Sensor 1 ECT sensor sensing circuit - specification.
Circuit Range/Performance intermittent high resistance REFER to: Specifications (303-03A Engine
Engine thermostat failure Cooling - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8,
ECT sensor failure Specifications).
Carry out any pinpoint tests associated with this
DTC using the manufacturer approved diagnostic
and check ECT sensor circuits for intermittent
high resistance. Check and install new engine
thermostat as required. Check and install a new
ECT sensor as required
P011700 Engine Coolant ECT sensor sensing circuit - Carry out any pinpoint tests associated with this
Temperature Sensor 1 short to power, high DTC using the manufacturer approved diagnostic
Circuit Low resistance, open circuit, system. Refer to the electrical circuit diagrams
disconnected and check ECT sensor circuits for short to power,
ECT sensor failure high resistance, open circuit, disconnected
connector. Check and install a new ECT sensor
as required
P011800 Engine Coolant Engine overheat Check for cooling fan circuit DTCs and refer to
Temperature Sensor 1 condition/cooling fan failure relevant action specified in DTC Index. Carry out
Circuit High ECT sensor sensing circuit - any pinpoint tests associated with this DTC
short to ground using the manufacturer approved diagnostic
ECT sensor failure system. Refer to the electrical circuit diagrams
and check ECT sensor circuits for short to
ground. Check and install a new ECT sensor as
required
P012100 Throttle/Pedal Position TP sensor sensing circuits TP Carry out any pinpoint tests associated with this
Sensor A Circuit 1 and TP 2 - short to power, DTC using the manufacturer approved diagnostic
Range/Performance high resistance system. Refer to the electrical circuit diagrams
TP sensor failure and check TP sensor sensing circuits TP 1 and TP
2 for short to power, high resistance. Check and
install a new throttle body as required
P012200 Throttle/Pedal Position TP sensor sensing circuit TP Carry out any pinpoint tests associated with this
Sensor A Circuit Low 1 - short to ground, high DTC using the manufacturer approved diagnostic
resistance system. Refer to the electrical circuit diagrams
TP sensor failure and check TP sensor sensing circuit TP 1 for
short to ground, high resistance. Check and
P012300 Throttle/Pedal Position TP sensor sensing circuit TP1 Carry out any pinpoint tests associated with this
Sensor A Circuit High - short to power DTC using the manufacturer approved diagnostic
TP sensor failure system. Refer to the electrical circuit diagrams
and check TP sensor sensing circuit TP 1 for
short to power. Check and install a new throttle
body as required
P012500 Insufficient Coolant Temp Low coolant level Fill cooling system to correct level and
For Closed Loop Fuel ECT sensor sensing circuit - specification.
Control intermittent high resistance REFER to: Specifications (303-03A Engine
and check ECT sensor sensing circuit for
intermittent high resistance. Check and install
new engine thermostat as required. Check and
install a new ECT sensor as required
P012800 Coolant Thermostat Low/contaminated coolant Drain and re-fill cooling system to correct level
(Coolant Temp Below Engine thermostat failure and specification.
Thermostat Regulating Cooling fan circuit(s)/module REFER to: Specifications (303-03A Engine
Temperature) Cooling - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8,
Specifications).
Check and install a new engine thermostat as
required. Refer to the electrical circuit diagrams
and check cooling fan circuits for short, open
circuit. Check for correct operation of cooling
fan, check for DTCs and refer to DTC Index
P01311A O2 Circuit Low Voltage Exhaust gas leakage Carry out any pinpoint tests associated with this
(Bank 1, Sensor 1) H02S variable/constant DTC using the manufacturer approved diagnostic
circuit - circuit fault, system. Check for and rectify any exhaust leak
disconnected between cylinder head and catalytic converter
H02S failure (e.g. manifolds, EGR system etc.). Refer to the
electrical circuit diagrams and check H02S
variable/constant circuit for short, open circuit,
disconnected connector. Check and install a new
HO2S as required
P01321B O2 Circuit High Voltage Exhaust gas leakage Carry out any pinpoint tests associated with this
(Bank 1, Sensor 1) H02S variable/constant DTC using the manufacturer approved diagnostic
circuit - circuit fault, system. Check for and rectify any exhaust leak
disconnected between cylinder head and catalytic converter
H02S failure (e.g. manifolds, EGR system etc.). Refer to the
electrical circuit diagrams and check H02S
variable/constant circuit for short, open circuit,
disconnected connector. Check and install a new
HO2S as required
P013300 O2 Circuit Slow Response Exhaust leak Carry out any pinpoint tests associated with this
(Bank 1, Sensor 1) HO2S to ECM wiring shield DTC using the manufacturer approved diagnostic
high resistance system. Check for and rectify any exhaust leak
Fuel control system fault between cylinder head and catalytic converter
HO2 sensor failure (e.g. manifolds, EGR system etc.). Refer to the
electrical circuit diagrams and check HO2S to
ECM wiring shield for high resistance. Check fuel
control system for failure. Check and install a
new HO2S as required
P013400 O2 Circuit No Activity HO2S slow activation Carry out any pinpoint tests associated with this
Detected (Bank 1, Sensor 1) DTC using the manufacturer approved diagnostic
system
P013700 O2 Circuit Low Voltage Catalytic converter monitor Carry out any pinpoint tests associated with this
(Bank 1, Sensor 2) sensor sensing circuit - short DTC using the manufacturer approved diagnostic
to ground, high resistance, system. Refer to the electrical circuit diagrams
disconnected and check Catalytic converter monitor sensor
Catalytic converter monitor sensing circuit for short to ground, high
sensor failure resistance, disconnected connector. Check and
required
P013800 O2 Circuit High Voltage Catalytic converter monitor Carry out any pinpoint tests associated with this
to power system. Refer to the electrical circuit diagrams
sensor ground braided shield circuits for short to power, and ground braided
- high resistance shield for high resistance. Check and install new
Catalytic converter monitor Catalytic converter monitor sensor as required
sensor failure
P013900 O2 Circuit Slow Response Catalytic converter monitor Carry out any pinpoint tests associated with this
(Bank 1, Sensor 2) sensor tip damaged or DTC using the manufacturer approved diagnostic
blocked system. Check Catalytic converter monitor
sensor tip for damage or blockage, install a new
sensor as required
P014000 O2 Circuit No Activity Catalytic converter monitor Carry out any pinpoint tests associated with this
Detected (Bank 1, Sensor 2) sensing circuit - short to DTC using the manufacturer approved diagnostic
ground, short to power, high system. Refer to the electrical circuit diagrams
resistance, disconnected and check Catalytic converter monitor sensor
Catalytic converter monitor circuits for short to ground, power, high
sensor ground braided shield resistance, disconnected connector and ground
- high resistance braided shield for high resistance. Check and
Catalytic converter monitor install new Catalytic converter monitor sensor as
sensor - mechanical damage required
P014100 O2 Heater Circuit (Bank 1, Catalytic converter monitor Carry out any pinpoint tests associated with this
Sensor 2) sensor heater control circuit DTC using the manufacturer approved diagnostic
- high resistance system. Refer to the electrical circuit diagrams
sensor heater failure heater control circuit for high resistance. Check
and install a new Catalytic converter monitor
sensor as required
P01511A O2 Circuit Low Voltage HO2S sensing circuit - short Carry out any pinpoint tests associated with this
(Bank 2, Sensor 1) to ground, short to power, DTC using the manufacturer approved diagnostic
high resistance system. Refer to the electrical circuit diagrams
HO2S failure and check HO2S sensing circuit for short to
ground, power, high resistance. Check and
install a new HO2S as required
P01521B O2 Circuit High Voltage H02S sensing circuit - short Carry out any pinpoint tests associated with this
(Bank 2, Sensor 1) to ground, short to power, DTC using the manufacturer approved diagnostic
H02S failure and check HO2S sensing circuit for short to
ground, power, high resistance. Check and
P015300 O2 Circuit Slow Response HO2S to ECM wiring shield Carry out any pinpoint tests associated with this
(Bank 2, Sensor 1) high resistance DTC using the manufacturer approved diagnostic
Exhaust leak system. Refer to the electrical circuit diagrams
Fuel control system fault and check HO2S to ECM wiring shield for high
HO2 sensor failure resistance. Check for and rectify any exhaust
leak between cylinder head and catalytic
converter (e.g. manifolds, EGR system etc.).
Check fuel control system for failure. Check and
P015400 O2 Circuit No Activity H02S slow activation Carry out any pinpoint tests associated with this
Detected (Bank 2, Sensor 1) DTC using the manufacturer approved diagnostic
system
P015700 O2 Circuit Low Voltage Catalytic converter monitor Carry out any pinpoint tests associated with this
to ground, high resistance, system. Refer to the electrical circuit diagrams
disconnected and check Catalytic converter monitor sensor
Catalytic converter monitor sensing circuit for short to ground, high
sensor failure resistance, disconnected connector. Check and
install a new Catalytic converter monitor sensor
as required
P015800 O2 Circuit High Voltage Catalytic converter monitor Carry out any pinpoint tests associated with this
to power system. Refer to the electrical circuit diagrams
sensor ground braided shield sensing circuit for short to power, and sensor
- high resistance ground braided shield for high resistance. Check
Catalytic converter monitor and install a new Catalytic converter monitor
sensor failure sensor as required
P015900 O2 Circuit Slow Response Catalytic converter monitor Carry out any pinpoint tests associated with this
(Bank 2, Sensor 2) sensor tip damaged or DTC using the manufacturer approved diagnostic
blocked system. Check Catalytic converter monitor
sensor tip for damage or blockage, install a new
sensor as required
P016000 O2 Circuit No Activity Catalytic converter monitor Carry out any pinpoint tests associated with this
Detected (Bank 2, Sensor 2) sensing circuit - short to DTC using the manufacturer approved diagnostic
resistance, disconnected and check Catalytic converter monitor sensing
Catalytic converter monitor circuit for short to ground, short to power, high
sensor ground braided shield resistance, disconnected connector, and sensor
- high resistance ground braided shield for high resistance. Check
Catalytic converter monitor and install a new Catalytic converter monitor
sensor - mechanical damage sensor as required
P016100 O2 Heater Circuit (Bank 2, Catalytic converter monitor Carry out any pinpoint tests associated with this
Sensor 2) sensor heater control circuit DTC using the manufacturer approved diagnostic
malfunction system. Refer to the electrical circuit diagrams
and check Catalytic converter monitor sensor
heater control circuit for short, open circuit
P017100 System too lean (bank 1) Air intake leak between MAF Check for leak from air intake system. Check for
sensor and cylinder head fuel system blockage/restriction. Check for
Fuel filter, injector, system additional MAF sensor related DTCs and refer to
restriction relevant DTC Index. Check and rectify any
MAF sensor fault (low intake exhaust leak prior to catalytic converter
air flow)
P017200 System Too Rich (Bank 1) Restricted air cleaner Check air cleaner element is free from
Leaking fuel injector(s) restriction. Check for leaking injectors, install
Engine oil contaminated with new injector(s) as required. Check for
fuel (too many cold starts contaminated engine oil, drain and refill engine
with vehicle subsequently oil as required. Check for additional MAF sensor
not getting hot enough for related DTCs and refer to relevant DTC Index
long enough)
intake air flow)
P017400 System Too Lean (Bank 2) Air intake leak between MAF Check for leak from air intake system. Check for
sensor and cylinder head fuel system blockage/restriction. Check for
Fuel filter, injector, system additional MAF sensor related DTCs and refer to
restriction relevant DTC Index. Check and rectify any
MAF sensor fault (low intake exhaust leak prior to catalytic converter
air flow)
P017500 System Too Rich (Bank 2) Restricted air cleaner Check air cleaner element is free from
Leaking fuel injector(s) restriction. Check for leaking injectors, install
Engine oil contaminated with new injector(s) as required. Check for
fuel (too many cold starts contaminated engine oil, drain and refill engine
with vehicle subsequently oil as required. Check for additional MAF sensor
not getting hot enough for related DTCs and refer to relevant DTC Index
long enough)
intake air flow)
P018123 Fuel Temperature Sensor A Fuel temperature sensor Carry out any pinpoint tests associated with this
Circuit Range/Performance sensing circuit - short to DTC using the manufacturer approved diagnostic
resistance and check fuel temperature sensor circuits for
Fuel temperature sensor short to ground, power, high resistance. Check
ground circuit - high and install a new Fuel temperature sensor as
resistance required
failure
resistance required
failure
resistance required
failure
Circuit Low sensing circuit - short to DTC using the manufacturer approved diagnostic
ground system. Refer to the electrical circuit diagrams
Fuel temperature sensor and check fuel temperature sensor circuits for
ground circuit - short circuit short to ground, power, high resistance. Check
Fuel temperature sensor and install a new Fuel temperature sensor as
failure required
Circuit High sensing circuit - short to DTC using the manufacturer approved diagnostic
power, high resistance, system. Refer to the electrical circuit diagrams
disconnected and check fuel temperature sensor circuits for
resistance required
failure
P019100 Fuel Rail Pressure Sensor A Fuel rail pressure sensor Carry out any pinpoint tests associated with this
Circuit Range/Performance stuck DTC using the manufacturer approved diagnostic
system
Circuit Low sensing circuit - short to DTC using the manufacturer approved diagnostic
ground, high resistance, system. Refer to the electrical circuit diagrams
disconnected and check fuel rail pressure sensor circuits for
Fuel rail pressure sensor 5V short to ground, power, high resistance,
supply circuit - high disconnected connector. Check and install a new
resistance Fuel rail pressure sensor as required
failure
Circuit High supply/sensing circuits - DTC using the manufacturer approved diagnostic
short circuit to each other system. Refer to the electrical circuit diagrams
Fuel rail pressure sensor and check fuel rail pressure sensor circuits for
sensing circuit - short to short to ground, power, high resistance,
power disconnected connector. Check and install a new
Fuel rail pressure sensor Fuel rail pressure sensor as required
resistance
failure
P019623 Engine Oil Temperature Engine oil temperature Carry out any pinpoint tests associated with this
Sensor Circuit sensor sensing circuit - DTC using the manufacturer approved diagnostic
Range/Performance intermittent high resistance system. Refer to the electrical circuit diagrams
Engine oil temperature and check engine oil temperature sensor circuits
sensor failure for short to ground, power, high resistance.
Check and install a new engine oil temperature
sensor as required
sensor as required
sensor as required
Sensor Circuit Low sensor sensing circuit - short DTC using the manufacturer approved diagnostic
to ground system. Refer to the electrical circuit diagrams
sensor as required
Sensor Circuit High sensor sensing circuit - short DTC using the manufacturer approved diagnostic
to power, high resistance, system. Refer to the electrical circuit diagrams
disconnected and check engine oil temperature sensor circuits
Engine oil temperature for short to ground, power, high resistance,
sensor failure disconnected connector. Check and install a new
engine oil temperature sensor as required
P020100 Cylinder 1 Injector Circuit / Injector circuit - short to Carry out any pinpoint tests associated with this
Open ground, high resistance, DTC using the manufacturer approved diagnostic
Injector failure and check injector circuits for short to ground,
high resistance, disconnected connector. Check
and install a new injector as required
Sensor/Switch B Circuit Low 2 - short to ground, high DTC using the manufacturer approved diagnostic
TP sensor failure and check TP sensor sensing circuit TP 2 for
short to ground, high resistance. Check and
Sensor/Switch B Circuit High 2- short to power DTC using the manufacturer approved diagnostic
TP sensor failure system. Refer to the electrical circuit diagrams
and check TP sensor sensing circuit TP 2 for
short to power. Check and install a new throttle
body as required
P022700 Throttle/Pedal Position APP sensor circuit APP 1 - Carry out any pinpoint tests associated with this
Sensor/Switch C Circuit Low short to ground, high DTC using the manufacturer approved diagnostic
and check APP sensor circuit APP 1 for short to
ground, high resistance
P022800 Throttle/Pedal Position APP sensor circuit APP 1 - Carry out any pinpoint tests associated with this
Sensor/Switch C Circuit High short to power DTC using the manufacturer approved diagnostic
and check APP sensor circuit APP 1 for short to
power
P023100 Fuel Pump Secondary Circuit No sub type information Refer to the electrical circuit diagrams and check
Low FPDM monitor circuit to ECM for short to ground,
high resistance
P023200 Fuel Pump Secondary Circuit No sub type information Refer to the electrical circuit diagrams and check
High FPDM monitor circuit to ECM for short to power
P023600 Turbocharger/Supercharger Intake manifold air leak Check for correct installation and serviceability
Boost Sensor A Circuit (loose or missing of intake manifold and associated components.
Range/Performance component) Carry out any pinpoint tests associated with this
MAP sensor signal circuit DTC using the manufacturer approved diagnostic
MAP sensor failure and check MAP sensor circuits for short, open
circuit. Check and install a new MAP sensor as
required
P023700 Turbocharger/Supercharger MAP sensor circuits - short Carry out any pinpoint tests associated with this
Boost Sensor A Circuit Low to ground, high resistance DTC using the manufacturer approved diagnostic
MAP sensor ground circuits - system. Refer to the electrical circuit diagrams
MAP sensor failure ground, high resistance. Check and Check and
install a new MAP sensor as required
P023800 Turbocharger/Supercharger MAP sensor circuits - short Carry out any pinpoint tests associated with this
Boost Sensor A Circuit High to power DTC using the manufacturer approved diagnostic
MAP sensor power circuits - system. Refer to the electrical circuit diagrams
MAP sensor failure power, high resistance. Check and Check and
install a new MAP sensor as required
P023800 Turbocharger/Supercharger Turbocharger/supercharger Refer to the electrical circuit diagrams and check
Boost Sensor A Circuit High boost sensor A circuit - short turbocharger/supercharger boost sensor A circuit
to power for short to power
P023B13 Charge Air Cooler Coolant Charge air cooler coolant Refer to the electrical circuit diagrams and check
Pump Control Circuit Low pump control circuit - open charge air cooler coolant pump control circuit for
circuit open circuit
P023C12 Charge Air Cooler Coolant Charge air cooler coolant Refer to the electrical circuit diagrams and check
Pump Control Circuit High pump control circuit - short charge air cooler coolant pump control circuit for
to power short to power
P032700 Knock Sensor 1 Circuit Low Poor sensor contact with the Ensure a good electrical contact with the
(Bank1) cylinder block cylinder block. Carry out any pinpoint tests
KS circuit - short to ground associated with this DTC using the manufacturer
KS failure approved diagnostic system. Refer to the
electrical circuit diagrams and check KS circuits
for short to ground. Check and install a new KS
as required
P032800 Knock Sensor 1 Circuit High Poor sensor contact with the Ensure a good electrical contact with the
(Bank 1) cylinder block cylinder block. Carry out any pinpoint tests
KS circuit - high resistance, associated with this DTC using the manufacturer
short to power approved diagnostic system. Refer to the
KS failure electrical circuit diagrams and check KS circuits
for short to power, high resistance. Check and
install a new KS as required
P033200 Knock Sensor 2 Circuit Low Poor sensor contact with the Ensure a good electrical contact with the
KS circuit - short to ground associated with this DTC using the manufacturer
KS failure approved diagnostic system. Refer to the
electrical circuit diagrams and check KS circuits
for short to ground. Check and install a new KS
as required
P033300 Knock Sensor 2 Circuit High Poor sensor contact with the Ensure a good electrical contact with the
KS circuit - high resistance, associated with this DTC using the manufacturer
short to power approved diagnostic system. Refer to the
KS failure electrical circuit diagrams and check KS circuits
for short to power, high resistance. Check and
install a new KS as required
P033592 Crankshaft Position Sensor CKP sensor circuit - short to Carry out any pinpoint tests associated with this
A Circuit ground, short to power, high DTC using the manufacturer approved diagnostic
resistance, disconnected system. Refer to the electrical circuit diagrams
CKP sensor gap incorrect, and check CKP sensor circuit for short to ground,
foreign matter on sensor short to power, high resistance, disconnected
face, damaged teeth on connector. Check CKP sensor for damage and
rotor check air gap (check at 90 intervals, should be
CKP sensor failure no greater than 4.5mm). Check and install a
new CKP sensor as required
Range/Performance resistance, disconnected system. Refer to the electrical circuit diagrams
P034092 Camshaft Position Sensor A CMP sensor circuit - short to Carry out any pinpoint tests associated with this
Circuit (Bank 1 or single ground, short to power, high DTC using the manufacturer approved diagnostic
sensor) resistance, disconnected system. Refer to the electrical circuit diagrams
CMP sensor gap incorrect, and check CMP sensor circuit for short to ground,
face, damaged rotor connector. Check CMP sensor for correct
CMP sensor failure installation and damage. Check and install a
new CMP sensor as required
Circuit (Bank 1 or single ground, short to power, high DTC using the manufacturer approved diagnostic
sensor) resistance, disconnected system. Refer to the electrical circuit diagrams
Circuit Range/Performance ground, short to power, high DTC using the manufacturer approved diagnostic
(Bank 1 or single sensor) resistance, disconnected system. Refer to the electrical circuit diagrams
Circuit (Bank 2) ground, short to power, high DTC using the manufacturer approved diagnostic
Circuit (Bank 2) ground, short to power, high DTC using the manufacturer approved diagnostic
Circuit Range/Performance ground, short to power, high DTC using the manufacturer approved diagnostic
(Bank 2) resistance, disconnected system. Refer to the electrical circuit diagrams
P035100 Ignition Coil A Ignition module/coil circuits Carry out any pinpoint tests associated with this
Primary/Secondary Circuit - short to ground, power, DTC using the manufacturer approved diagnostic
and check ignition module/coil circuits for short
to ground, power, high resistance
P035200 Ignition Coil B Ignition module/coil circuits Carry out any pinpoint tests associated with this
P035300 Ignition Coil C Ignition module/coil circuits Carry out any pinpoint tests associated with this
P035400 Ignition Coil D Ignition module/coil circuits Carry out any pinpoint tests associated with this
P035500 Ignition Coil E Ignition module/coil circuits Carry out any pinpoint tests associated with this
P035600 Ignition Coil F Ignition module/coil circuits Carry out any pinpoint tests associated with this
P035700 Ignition Coil G Ignition module/coil circuits Carry out any pinpoint tests associated with this
P035800 Ignition Coil H Ignition module/coil circuits Carry out any pinpoint tests associated with this
P040100 Exhaust Gas Recirculation EGR valve/pipe incorrectly Check for correct installation of the EGR valve
Flow Insufficient Detected installed or loose and pipe. Check for blockage in EGR valve and
EGR pipe blocked pipe. Check for stuck EGR valve. Check and
EGR valve stuck closed, install a new EGR valve as required
blocked
EGR valve failure
P041100 Secondary Air Injection Low airflow being delivered Check AIR pump, vacuum solenoid and AIR
Incorrect Upstream Flow from secondary air injection control valve hardware. Refer to the electrical
Detected (AIR) pump circuit diagrams and check AIR pump and
vacuum solenoid power supply circuits. Check
stuck/partially stuck vacuum solenoid. Check for
loose/split vacuum pipe from solenoid to AIR
control valve. Check for loose/split AIR pump
outlet pipe
P041300 Secondary Air Injection AIR vacuum solenoid control Refer to the electrical circuit diagrams and check
Switching Valve A Circuit circuit high AIR vacuum solenoid control circuit for short to
Open power
P041400 Secondary Air Injection AIR vacuum solenoid control Refer to the electrical circuit diagrams and check
Switching Valve A Circuit circuit low AIR vacuum solenoid control circuit for short to
Shorted ground, high resistance
P042000 Catalytic converter System Catalytic converter failure Check for misfire/lean combustion DTCs and
Efficiency Below Threshold due to overheating damage refer to DTC Index in this section. Check the oil
(Bank 1) caused by misfire and/or and fuel condition/level. Check the catalytic
lean combustion converter for damage
Catalytic converter failure
due to poisoning caused by
excessive oil consumption
and/or contaminated fuel
P043000 Catalytic converter System Catalytic converter failure Check for misfire/lean combustion DTCs and
Efficiency Below Threshold due to overheating damage refer to DTC Index in this section. Check the oil
(Bank 2) caused by misfire and/or and fuel condition/level. Check the catalytic
lean combustion converter for damage
Catalytic converter failure
System Incorrect Purge Flow range/performance EVAP purge valve control circuit for short, open
circuit
(small leak)
P044700 Evaporative Emission DMTL COV circuit - short to Carry out any pinpoint tests associated with this
System Vent Control Circuit ground DTC using the manufacturer approved diagnostic
Open system. Refer to the electrical circuit diagrams
and check DMTL COV circuit for short to ground
P044800 Evaporative Emission DMTL COV circuit - short to Carry out any pinpoint tests associated with this
System Vent Control Circuit power DTC using the manufacturer approved diagnostic
Shorted system. Refer to the electrical circuit diagrams
and check DMTL COV circuit for short to power
P045600 Evaporative Emission DMTL system has detected a Check EVAP system for leak using appropriate
System Leak Detected (very leak smoke/leak tester
small leak)
Circuit Low ground, high resistance system. Refer to the electrical circuit diagrams
EVAP canister purge valve and check EVAP canister purge valve control
failure circuit for short to ground, high resistance.
Check and install a new EVAP canister purge
valve as required
Circuit High power system. Refer to the electrical circuit diagrams
and check EVAP canister purge valve control
P046129 Fuel Level Sensor A Circuit Fuel level sensor failure Refer to the electrical circuit diagrams and check
Range/Performance fuel level sensor circuits for short, open circuit,
high resistance
P04612F Fuel Level Sensor A Circuit Fuel level sensor failure Refer to the electrical circuit diagrams and check
Range/Performance fuel level sensor circuits for short, open circuit,
high resistance
Low fuel level sensor circuits for short, open circuit,
high resistance
High fuel level sensor circuits for short, open circuit,
high resistance
P048023 Fan 1 Control Circuit Electric cooling fan control Carry out any pinpoint tests associated with this
circuit - short to ground, DTC using the manufacturer approved diagnostic
and check electric cooling fan control circuit for
P048024 Fan 1 Control Circuit Electric cooling fan control Carry out any pinpoint tests associated with this
circuit - short to power DTC using the manufacturer approved diagnostic
and check electric cooling fan control circuit for
short to power
P048309 Fan Performance Cooling fan difficult to Carry out any pinpoint tests associated with this
turn/obstructed DTC using the manufacturer approved diagnostic
Fan/Motor damaged system. CLEAR any obstruction and Check and
install a new fan as required
P048316 Fan Performance Cooling fan control module Carry out any pinpoint tests associated with this
reports battery voltage less DTC using the manufacturer approved diagnostic
than nine volts system. Check the battery is in fully charged
and serviceable condition. Refer to the electrical
circuit diagrams and check the charging system
and cooling fan circuits for short, open circuit
P048317 Fan Performance Fan control module reports Carry out any pinpoint tests associated with this
battery voltage greater than DTC using the manufacturer approved diagnostic
18 volts system. Refer to the electrical circuit diagrams
and check the charging system and cooling fan
P048900 Exhaust Gas Recirculation EGR valve power supply Carry out any pinpoint tests associated with this
Control Circuit Low circuit - short to ground, DTC using the manufacturer approved diagnostic
and check EGR valve power supply circuit for
P049000 Exhaust Gas Recirculation EGR valve control circuit - Carry out any pinpoint tests associated with this
Control Circuit High short to power DTC using the manufacturer approved diagnostic
and check EGR valve control circuit for short to
power
P049100 Secondary Air Injection Low airflow being delivered Check (Bank 1) AIR system pipe for blockage.
System Insufficient Flow to secondary air injection Check for loose/split AIR pump outlet pipe
(Bank 1) (AIR) system (Bank 1)
P049200 Secondary Air Injection Low airflow being delivered Check (Bank 2) AIR system pipe for blockage.
System Insufficient Flow to secondary air injection Check for loose/split AIR pump outlet pipe
(Bank 2) (AIR) system (Bank 2)
P050082 Vehicle Speed Sensor A Vehicle speed - invalid Check ABS for related DTCs and refer to relevant
signal received over CAN DTC Index
P050162 Vehicle Speed Sensor A Vehicle speed - range Check ABS/TCM for related DTCs and refer to
Range/Performance performance relevant DTC Index
P050400 Brake Switch A / B The brake pressure reading Carry out any pinpoint tests associated with this
Correlation does not agree with the DTC using the manufacturer approved diagnostic
brake light switch value system. Refer to the electrical circuit diagrams
and check brake switch circuits for short, open
circuit, high resistance
P050401 Brake Switch A / B Brake switch high fault: Carry out any pinpoint tests associated with this
Correlation - Brake lights stuck on DTC using the manufacturer approved diagnostic
- Gearshift interlock system. Refer to the electrical circuit diagrams
inoperative and check brake switch circuits for short, open
- Speed control circuit, high resistance
inoperative
Brake switch low fault:
- Brake lights inoperative
- Gearshift stuck in Park
- Reduced engine braking
P050600 Idle Air Control System RPM Air intake restriction Ensure the air intake system is free from
Lower Than Expected Front End Accessory Drive restriction. Check the FEAD belt and components
(FEAD) overload for failure
(defective/seized
component)
P050624 Idle Air Control System RPM Air intake restriction Ensure the air intake system is free from
Lower Than Expected Front End Accessory Drive restriction. Check the FEAD belt and components
(FEAD) overload for failure
(defective/seized
component)
P050700 Idle Air Control System RPM Intake air leak between MAF Check for leakage and correct installation of air
Higher Than Expected sensor and engine intake system. Check for leakage and correct
Engine crankcase breather installation of engine crankcase breather system
leak
P050723 Idle Air Control System RPM Intake air leak between MAF Check for leakage and correct installation of air
Higher Than Expected sensor and engine intake system. Check for leakage and correct
Engine crankcase breather installation of engine crankcase breather system
leak
P050A84 Cold Start Idle Air Control Signal below allowable range Check for leakage and correct installation of air
System Performance intake system. Check for leakage and correct
installation of engine crankcase breather
system. Check for additional related DTCs and
P050A85 Cold Start Idle Air Control Signal above allowable Check for leakage and correct installation of air
System Performance range intake system. Check for leakage and correct
installation of engine crankcase breather
system. Check for additional related DTCs and
P050B84 Cold Start Ignition Timing Sticking throttle Check for additional throttle and torque related
Performance DTCs and refer to the DTC Index
P050B85 Cold Start Ignition Timing Sticking throttle Check for additional throttle and torque related
Performance DTCs and refer to the DTC Index
P051212 Starter Request Circuit Crank request circuit - short Refer to the electrical circuit diagrams and check
to power crank request circuit for short to power
P051214 Starter Request Circuit Crank request circuit - short Carry out any pinpoint tests associated with this
to ground, open circuit DTC using the manufacturer approved diagnostic
and check crank request circuit for short to
P051300 Incorrect Immobilizer Key Security key invalid Check for CAN network interference/EMC related
error. Re-synchronise ID by re-configuring the
ECM and instrument cluster as new modules
P056013 System Voltage ECM power supply circuit - Refer to the electrical circuit diagrams and check
open circuit ECM power supply circuit for open circuit
P056100 System Voltage Unstable System voltage comparison Check for sensor 5 volt supply related DTCs and
refer to DTC Index in this section
P056200 System Voltage Low Sensor 5 volt power supply Carry out any pinpoint tests associated with this
circuit - low input DTC using the manufacturer approved diagnostic
and check sensor 5 volt power supply circuit for
P056300 System Voltage High Sensor 5 volt power supply Carry out any pinpoint tests associated with this
circuit - high input DTC using the manufacturer approved diagnostic
and check sensor 5 volt power supply circuit for
short to power
P057501 Cruise Control Input Circuit General electrical failure Check speed control system for related DTCs
and refer to relevant DTC Index. Carry out CAN
network integrity tests using the manufacturer
P057616 Cruise Control Input Circuit Circuit voltage below Check speed control system for related DTCs
Low threshold and refer to relevant DTC Index. Carry out CAN
P057717 Cruise Control Input Circuit Circuit voltage above Check speed control system for related DTCs
High threshold and refer to relevant DTC Index. Carry out CAN
P057800 Cruise Control Multi- One of speed control Check for stuck speed control switch, install a
Function Input A Circuit switches stuck new switch pack as required
Stuck
P05791C Cruise Control Multi- Speed control switch pack Check and install a new speed control switch
Function Input A Circuit internal failure pack as required
Range/Performance
P059000 Cruise Control Multi- Active speed limiter fault Check for active speed limiter fault, install a
Function Input B Circuit new transmission shift module as required
Stuck
P060143 Internal Control Module Special memory failure Suspect the ECM, check and install a new
Memory Check Sum Error module as required, refer to the new
module/component installation note at top of
DTC Index
P060145 Internal Control Module Program memory failure Suspect the ECM, check and install a new
Memory Check Sum Error module as required, refer to the new
DTC Index
P060442 Internal Control Module General memory failure Suspect the ECM, check and install a new
Random Access Memory module as required, refer to the new
(RAM) Error module/component installation note at top of
DTC Index
DTC Index
P060444 Internal Control Module Data memory failure Suspect the ECM, check and install a new
DTC Index
DTC Index
P060500 Internal Control Module EEPROM/flash checksum Configure the module using the Jaguar approved
Read Only Memory (ROM) error diagnostic system
Error
P060529 Internal Control Module Signal invalid Suspect the ECM, check and install a new
Read Only Memory (ROM) module as required, refer to the new
Error module/component installation note at top of
DTC Index
P060542 Internal Control Module General memory failure Suspect the ECM, check and install a new
DTC Index
DTC Index
P060544 Internal Control Module Data memory failure Suspect the ECM, check and install a new
DTC Index
DTC Index
P060546 Internal Control Module Calibration/parameter Suspect the ECM, check and install a new
Read Only Memory (ROM) memory failure module as required, refer to the new
DTC Index
P060548 Internal Control Module Supervision software failure Suspect the ECM, check and install a new
DTC Index
P060564 Internal Control Module Signal plausibility failure Suspect the ECM, check and install a new
DTC Index
P060600 ECM/PCM Processor No sub type information Suspect the ECM, check and install a new
DTC Index
P060601 ECM/PCM Processor General Electrical Failure Suspect the ECM, check and install a new
DTC Index
P060604 ECM/PCM Processor System Internal Failures Suspect the ECM, check and install a new
DTC Index
P060605 ECM/PCM Processor System Programming Suspect the ECM, check and install a new
Failures module as required, refer to the new
DTC Index
P060641 ECM/PCM Processor General checksum failure Suspect the ECM, check and install a new
DTC Index
P060642 ECM/PCM Processor General memory failure Suspect the ECM, check and install a new
DTC Index
P060643 ECM/PCM Processor Special memory failure Suspect the ECM, check and install a new
DTC Index
P060644 ECM/PCM Processor Data memory failure Suspect the ECM, check and install a new
DTC Index
P060645 ECM/PCM Processor Program memory failure Suspect the ECM, check and install a new
DTC Index
P060646 ECM/PCM Processor Calibration/parameter Suspect the ECM, check and install a new
memory failure module as required, refer to the new
DTC Index
P060647 ECM/PCM Processor W atchdog/safety Suspect the ECM, check and install a new
MicroController failure module as required, refer to the new
DTC Index
P060648 ECM/PCM Processor Supervision software failure Suspect the ECM, check and install a new
DTC Index
P060649 ECM/PCM Processor Internal electronic failure Suspect the ECM, check and install a new
DTC Index
P060700 Control Module Performance No sub type information Suspect the ECM, check and install a new
DTC Index
P060A64 Internal Control Module Signal plausibility failure Clear the DTC and retest. If the DTC resets,
Monitoring Processor suspect the ECM, check and install a new
Performance module as required, refer to new
DTC Index
P060A67 Internal Control Module Signal incorrect after event Clear the DTC and retest. If the DTC resets,
Monitoring Processor suspect the ECM, check and install a new
Performance module as required, refer to new
DTC Index
P060D00 Internal Control Module APS Communication Carry out any pinpoint tests associated with this
Accelerator Pedal Position DTC using the manufacturer approved diagnostic
Performance system. Refer to the electrical circuit diagrams
and check the accelerator pedal position sensor
circuits for short, open circuit, high resistance
P060E62 Internal Control Module Signal compare failure Carry out any pinpoint tests associated with this
Throttle Position DTC using the manufacturer approved diagnostic
and check throttle position sensor circuits for
short, open circuit, high resistance
P060E64 Internal Control Module Signal plausibility failure Carry out any pinpoint tests associated with this
Throttle Position DTC using the manufacturer approved diagnostic
and check throttle position sensor circuits for
P061043 Control Module Vehicle Special memory failure Re-configure the RJB using the manufacturer
Options Error approved diagnostic system
P061614 Starter Relay Circuit Low Starter relay circuit - short Carry out any pinpoint tests associated with this
to ground, open circuit DTC using the manufacturer approved diagnostic
and check starter relay circuit for short to
P061712 Starter Relay Circuit High Starter relay circuit - short Refer to the electrical circuit diagrams and check
to power starter relay circuit for short to power
P061A00 Internal Control Module No sub type information Suspect the ECM, check and install a new
Torque Performance module as required, refer to the new
DTC Index
P061A29 Internal Control Module Signal invalid Suspect the ECM, check and install a new
DTC Index
P061A64 Internal Control Module Signal plausibility failure Suspect the ECM, check and install a new
DTC Index
P061B29 Internal Control Module Signal invalid Suspect the ECM, check and install a new
Torque Calculation module as required, refer to the new
Performance module/component installation note at top of
DTC Index
P061B64 Internal Control Module Signal plausibility failure Suspect the ECM, check and install a new
Torque Calculation module as required, refer to the new
Performance module/component installation note at top of
DTC Index
P062001 Generator Control Circuit Generator B+ or battery Carry out any pinpoint tests associated with this
terminal disconnected/poor DTC using the manufacturer approved diagnostic
connection system. Check for good/clean contact at
Charging circuit - short, open generator B+ and battery terminal connectors.
circuit Refer to the electrical circuit diagrams and check
Generator failure charging circuit for short, open circuit. Clear DTC
and repeat automated diagnostic procedure
using the manufacturer approved diagnostic
system. If DTC remains suspect the generator,
check and install a new generator as required,
refer to the new module/component installation
P062700 Fuel Pump A Control Fuel pump control circuit Refer to the electrical circuit diagrams and check
Circuit/Open fault (FPDM to ECM) the FPDM to ECM circuit for short to ground,
power, open circuit
P062A00 Fuel Pump A Control Circuit Invalid fuel pump duty Refer to the electrical circuit diagrams and check
Range/Performance requested by the ECM the FPDM to ECM circuit for short to ground,
power, open circuit
P063000 VIN Not Programmed or CCF to CAN VIN mismatch Configure the ECM using the manufacturer
Incompatible - ECM/PCM approved diagnostic system, clear DTC and
re-test, if DTC remains suspect the ECM. Check
and install a new ECM as required, refer to the
new module/component installation note at the
P065B16 Generator Control Circuit Charging circuit - short, open Carry out any pinpoint tests associated with this
Range/Performance circuit DTC using the manufacturer approved diagnostic
Quiescent current high system. Refer to the electrical circuit diagrams
Battery damaged/worn out and check charging circuit for short, open circuit.
Generator failure Clear DTC and repeat automated diagnostic
procedure using the manufacturer approved
diagnostic system. If DTC remains check battery
is in fully charged and serviceable condition
using the Midtronics battery tester and battery
care manual. If ok suspect the generator, check
and install a new generator as required, refer to
the new module/component installation note at
the top of the DTC Index
P065B17 Generator Control Circuit Charging circuit - short, open Carry out any pinpoint tests associated with this
Range/Performance circuit DTC using the manufacturer approved diagnostic
Generator/ECM failure system. Check ECM for over charging related
DTCs and refer to the relevant DTC Index. Clear
DTC and re-test, if DTC remains suspect the
generator. Check and install a new generator as
P065C00 Generator Mechanical Poor FEAD belt tension Check FEAD belt condition/contamination and for
Performance Generator pulley correct tension. Check generator pulley for
loose/failure failure. Clear DTC and repeat automated
Generator failure diagnostic procedure using manufacturer
approved diagnostic system. If DTC remains
check and install a new generator as required,
P068773 ECM/PCM Power Relay EMS relay stuck closed Refer to electrical circuit diagrams and check
Control Circuit High EMS relay control circuit for short to ground
P072186 Output Shaft Speed Sensor Signal invalid Check the TCM for related DTCs and refer to the
Circuit Range/Performance relevant DTC Index
P081713 Starter Disable Circuit/Open Starter relay negative Refer to the electrical circuit diagrams and check
control circuit - open circuit starter relay negative control circuit for open
circuit
P081A11 Starter Disable Circuit Low Starter relay negative Refer to the electrical circuit diagrams and check
control circuit - short to starter relay negative control circuit for short to
ground ground
P081B12 Starter Disable Circuit High Starter relay negative Refer to the electrical circuit diagrams and check
control circuit - short to starter relay negative control circuit for short to
power power
P085086 Park/Neutral Switch Input Park/Neutral switch input Refer to the electrical circuit diagrams and check
Circuit circuit - signal invalid Park/Neutral switch input circuit for short to
P08508F Park/Neutral Switch Input Park/Neutral switch input Refer to the electrical circuit diagrams and check
Circuit circuit - erratic Park/Neutral switch input circuit for short to
P085114 Park/Neutral Switch Input Park/Neutral switch input Carry out any pinpoint tests associated with this
Circuit Low circuit - low DTC using the manufacturer approved diagnostic
and check Park/Neutral switch input circuit for
P085212 Park/Neutral Switch Input Park/Neutral switch input Carry out any pinpoint tests associated with this
Circuit High circuit - high DTC using the manufacturer approved diagnostic
and check Park/Neutral switch input circuit for
short to power
P0A1A87 Generator Control Module Generator to ECM LIN circuit Check for good/clean contact at generator and
- open circuit ECM LIN circuit connectors/pins. Refer to the
Generator/ECM failure electrical circuit diagrams and check generator
to ECM LIN circuit for open circuit. Check for ECM
hardware DTCs and refer to relevant DTC Index.
Clear DTCs and repeat automated diagnostic
procedure using the manufacturer approved
diagnostic system. If DTC remains check and
install a new generator/ECM as required, refer to
the top of the DTC Index
P0A3B68 Generator Over Generator wiring/connectors Check the generator wiring and connectors for
Temperature heat damaged heat damage. Clear the DTC and repeat the
Generator failure automated diagnostic procedure using the
manufacturer approved diagnostic system. If
DTC remains check and install a new generator
as required, refer to the new module/component
P125900 Immobilizer to PCM Signal Incorrect ID received from Re-configure the instrument cluster using the
Error instrument cluster manufacturer approved diagnostic system
P131500 Persistent Misfire ECM to ignition coil primary Check for cylinder mis-fire, ignition and injector
circuit fault (cylinder misfire DTCs and refer to the DTC Index. Check for fuel
detected DTC also flagged) system failure. Check and install spark plug as
Fuel injector circuit fault(s) required. Carry out cylinder compression tests
/incorrect gap
P131600 Misfire Rate Exceeds Misfire rate exceeds Check for individual cylinder misfire DTCs and
Emissions emissions thresholds refer to DTC Index in this section
monitoring circuit 1 - short ignition module/coil monitoring circuit 1 for short
to ground, short to power, to ground, short to power, high resistance
high resistance
monitoring circuit 2 - short ignition module/coil monitoring circuit 2 for short
to ground, short to power, to ground, short to power, high resistance
high resistance
P160300 EEPROM Malfunction ECM fault Suspect the ECM, check and install a new
module as required. Refer to the new
DTC Index
P209600 Post Catalytic converter Heated Oxygen Sensor Check integrity and correct installation of air
Fuel Trim System Too Lean (HO2S) fuel adaption - lean intake system. Check for any HO2S codes also
Bank 1 logged and refer to DTC Index in this section.
Check for air leaks between, or on, upstream
and downstream sensors. Check for air leak on
Catalytic converter and exhaust path
pre-Catalytic converter
Fuel Trim System Too Rich (HO2S) fuel adaption - rich intake system. Check for any HO2S codes also
Fuel Trim System Too Lean (HO2S) fuel adaption - lean intake system. Check for any HO2S codes also
Fuel Trim System Too Rich (HO2S) fuel adaption - rich intake system. Check for any HO2S codes also
P210129 Throttle Actuator Control Signal invalid Carry out any pinpoint tests associated with this
Motor Circuit Jammed throttle blade, DTC using the manufacturer approved diagnostic
Range/Performance gearing or motor system. Refer to the electrical circuit diagrams
and test throttle actuator control motor circuit
for short to ground, power, high resistance.
Suspect the throttle body, check and install a
new throttle body as required, refer to the new
of the DTC Index
P210162 Throttle Actuator Control Signal compare failure Carry out any pinpoint tests associated with this
of the DTC Index
P210164 Throttle Actuator Control Signal plausibility failure Carry out any pinpoint tests associated with this
of the DTC Index
P210177 Throttle Actuator Control Commanded position not Carry out any pinpoint tests associated with this
Motor Circuit achievable DTC using the manufacturer approved diagnostic
Range/Performance Throttle blade stuck open system. Refer to the electrical circuit diagrams
Intake air system leak and test throttle actuator control motor circuit
of the DTC Index
P210329 Throttle Actuator Control Signal invalid Carry out any pinpoint tests associated with this
Motor Circuit High Throttle motor control circuit DTC using the manufacturer approved diagnostic
- short to power system. Refer to the electrical circuit diagrams
ECM fault and check throttle motor control circuit for short
to power. If ECM is suspect, check and install a
new module as required, refer to new
DTC Index
P210364 Throttle Actuator Control Signal plausibility failure Carry out any pinpoint tests associated with this
Motor Circuit High Throttle motor control circuit DTC using the manufacturer approved diagnostic
- short to power system. Refer to the electrical circuit diagrams
ECM fault and check throttle motor control circuit for short
to power. If ECM is suspect, check and install a
new module as required, refer to new
DTC Index
P210500 Throttle Actuator Control Throttle MIL request due to Carry out any pinpoint tests associated with this
System - Forced Engine fuel cut DTC using the manufacturer approved diagnostic
Shutdown system
P211800 Throttle Actuator Control Throttle motor control circuit Carry out any pinpoint tests associated with this
Motor Current - short to ground, power, DTC using the manufacturer approved diagnostic
Range/Performance high resistance system. Refer to the electrical circuit diagrams
and check throttle motor control circuit for short
P211900 Throttle Actuator Control Throttle spring faulty Carry out any pinpoint tests associated with this
Throttle Body DTC using the manufacturer approved diagnostic
Range/Performance system. Suspect throttle body faulty. Check and
install a new throttle body as required, refer to
top of DTC Index
P212200 Throttle/Pedal Position APP sensor circuit 2 - low Carry out any pinpoint tests associated with this
Sensor/Switch D Circuit Low input DTC using the manufacturer approved diagnostic
and check APP sensor circuit 2 for short to
P212300 Throttle/Pedal Position APP sensor circuit 2 - high Carry out any pinpoint tests associated with this
Sensor/Switch D Circuit input DTC using the manufacturer approved diagnostic
High system. Refer to the electrical circuit diagrams
and check APP sensor circuit 2 for short to power
P213528 Throttle/Pedal Position APP sensor circuit 1 and 2 Carry out any pinpoint tests associated with this
Sensor/Switch A/B Voltage range performance - DTC using the manufacturer approved diagnostic
Correlation sub-processor system. Refer to the electrical circuit diagrams
and check APP sensor circuits 1 and 2 for short
to ground, power and high resistance. Clear the
DTCs and retest. If the code remains, replace
the APP sensor
P213529 Throttle/Pedal Position APP sensor - excessive Carry out any pinpoint tests associated with this
Sensor/Switch A/B Voltage difference between raw DTC using the manufacturer approved diagnostic
Correlation values of circuit 1 and 2 - system. Refer to the electrical circuit diagrams
sub-processor and check APP sensor circuits 1 and 2 for short,
open circuit
Sensor/Switch A/B Voltage range performance - DTC using the manufacturer approved diagnostic
Correlation sub-processor system. Refer to the electrical circuit diagrams
and check APP sensor circuits 1 and 2 for short
to ground, power and high resistance. Clear the
DTCs and retest. If the code remains, replace
the APP sensor
Sensor/Switch A/B Voltage range performance DTC using the manufacturer approved diagnostic
Correlation system. Refer to the electrical circuit diagrams
and check APP sensor circuits 1 and 2 for short,
open circuit
P222800 Barometric Pressure Circuit BARO sensor failure (internal Suspect the ECM, check and install a new
Low ECM fault) module as required, refer to the new
of the DTC Index
P222900 Barometric Pressure Circuit BARO sensor failure (internal Suspect the ECM, check and install a new
High ECM fault) module as required, refer to the new
of the DTC Index
P240100 Evaporative Emission DMTL pump circuit - short to Carry out any pinpoint tests associated with this
System Leak Detection ground DTC using the manufacturer approved diagnostic
Pump Control Circuit Low system. Refer to the electrical circuit diagrams
and check DMTL pump circuit for short to ground
P240200 Evaporative Emission DMTL pump circuit - short to Carry out any pinpoint tests associated with this
System Leak Detection power DTC using the manufacturer approved diagnostic
Pump Control Circuit High system. Refer to the electrical circuit diagrams
and check DMTL pump circuit for short to power
P240429 Evaporative Emission DMTL reference leak Check integrity of evaporative emissions
System Leak Detection DMTL pump circuit - short to system, i.e. blocked/leaking. Refer to the
Pump Sense Circuit ground, power, high electrical circuit diagrams and check DMTL pump
Range/Performance resistance circuit for short to ground, power, high
DMTL pipework resistance
blocked/leaking
P24042F Evaporative Emission DMTL reference leak Check integrity of evaporative emissions
System Leak Detection DMTL pump circuit - short to system, i.e. blocked/leaking. Refer to the
Pump Sense Circuit ground, power, high electrical circuit diagrams and check DMTL pump
Range/Performance resistance circuit for short to ground, power, high
DMTL pipework resistance
blocked/leaking
P240500 Evaporative Emission DMTL pump circuit - short to Refer to the electrical circuit diagrams and check
System Leak Detection ground, power, high DMTL pump circuit for short to ground, power,
Pump Sense Circuit Low resistance high resistance
P240600 Evaporative Emission DMTL pump circuit - short to Refer to the electrical circuit diagrams and check
System Leak Detection ground, power, high DMTL pump circuit for short to ground, power,
Pump Sense Circuit High resistance high resistance
P240B00 Evaporative Emission DMTL heater control circuit Carry out any pinpoint tests associated with this
System Leak Detection low DTC using the manufacturer approved diagnostic
Pump Heater Circuit Low system. Refer to the electrical circuit diagrams
and check DMTL heater control circuit for short
to ground, open circuit
P240C00 Evaporative Emission DMTL heater control circuit Carry out any pinpoint tests associated with this
System Leak Detection high DTC using the manufacturer approved diagnostic
Pump Heater Circuit High system. Refer to the electrical circuit diagrams
and check DMTL heater control circuit for short
to power
P243100 Secondary Air Injection Secondary air injection Carry out any pinpoint tests associated with this
System Air Flow/Pressure system leaks DTC using the manufacturer approved diagnostic
Sensor Circuit Secondary air injection pump system. Refer to the electrical circuit diagrams
Range/Performance Bank 1 Secondary air injection valve and check secondary air injection system circuits
for short, open circuit. Check the integrity of the
secondary air injection system
System Air Flow/Pressure manifold absolute pressure DTC using the manufacturer approved diagnostic
Sensor Circuit Low Bank 1 sensor circuit - short to system. Refer to the electrical circuit diagrams
ground, high resistance and check secondary air injection manifold
absolute pressure sensor circuit for short to
ground, high resistance
System Air Flow/Pressure manifold pressure (MAP) DTC using the manufacturer approved diagnostic
Sensor Circuit High Bank 1 sensor circuit - short to system. Refer to the electrical circuit diagrams
power and check secondary air injection manifold
pressure (MAP) sensor circuit for short to power
P244400 Secondary Air Injection Secondary air injection pump Carry out any pinpoint tests associated with this
System Pump Stuck On control circuit - short to DTC using the manufacturer approved diagnostic
Bank 1 ground system. Refer to the electrical circuit diagrams
and check secondary air injection pump control
P244500 Secondary Air Injection Secondary air injection pump Carry out any pinpoint tests associated with this
System Pump Stuck Off control circuit - short to DTC using the manufacturer approved diagnostic
Bank 1 power system. Refer to the electrical circuit diagrams
and check secondary air injection pump control
P245000 Evaporative Emission DMTL system circuit - short Carry out any pinpoint tests associated with this
Control System Switching to ground, power, high DTC using the manufacturer approved diagnostic
Valve Performance/Stuck resistance system. Refer to the electrical circuit diagrams
Open and check DMTL system circuit for short to
ground, power, high resistance. Check for stuck
valve
P245100 Evaporative Emission DMTL system circuit - short Carry out any pinpoint tests associated with this
Control System Switching to ground, power, high DTC using the manufacturer approved diagnostic
Valve Stuck Closed resistance system. Refer to the electrical circuit diagrams
and check DMTL system circuit for short to
ground, power, high resistance. Check for stuck
valve
P260100 Coolant Pump Control Incorrect installation of Check for correct installation of the charge air
Circuit Range/Performance electrical connector cooler coolant pump electrical connector. Check
Restricted coolant flow for restriction in charge air cooler coolant pump
Charge air cooler coolant and pipes. Check and install a new pump as
pump failure required. Check for relay failure related DTCs
Charge air cooler coolant and refer to relevant DTC Index. Check and
pump relay failure install a new relay as required
P261064 ECM/PCM Internal Engine Instrument cluster fault Check for DTCs related to any of the
Off Timer Performance ECT sensor fault components listed, and refer to relevant DTC
Ambient temperature sensor Index. Refer to the electrical circuit diagrams
fault and check ECT sensor, ambient air temperature
Body processor module fault sensor circuits for short, open circuit. Carry out
(time) the CAN network integrity test using the
CAN error manufacturer approved diagnostic system
P261087 ECM/PCM Internal Engine Instrument cluster fault Check for DTCs related to any of the
Off Timer Performance ECT sensor fault components listed, and refer to relevant DTC
Ambient temperature sensor Index. Refer to the electrical circuit diagrams
fault and check ECT sensor, ambient air temperature
Body processor module fault sensor circuits for short, open circuit. Carry out
(time) the CAN network integrity test using the
CAN error manufacturer approved diagnostic system
U000188 High Speed CAN Bus off Carry out any pinpoint tests associated with this
Communication Bus DTC using the manufacturer approved diagnostic
and check CAN network for short, open circuit.
Carry out CAN network integrity test using the
manufacturer approved diagnostic system
U010100 Lost Communication with CAN Link ECM/TCM network Carry out any pinpoint tests associated with this
TCM malfunction DTC using the manufacturer approved diagnostic
and check power and ground supplies to TCM.
Carry out the CAN network integrity test using
the manufacturer approved diagnostic system
U010300 Lost Communication With CAN Link ECM/gear shift Carry out any pinpoint tests associated with this
Gear Shift Module network malfunction DTC using the manufacturer approved diagnostic
and check power and ground supplies to
transmission shift module. Carry out the CAN
network integrity test using the manufacturer
U010400 Lost Communication With CAN Link ECM/speed control Carry out any pinpoint tests associated with this
Cruise Control Module module network malfunction DTC using the manufacturer approved diagnostic
and check power and ground supplies to speed
control module. Carry out the CAN network
integrity test using the manufacturer approved
diagnostic system
U012100 Lost Communication With CAN Link ECM/ABS module Carry out any pinpoint tests associated with this
Anti-Lock Brake System network malfunction DTC using the manufacturer approved diagnostic
(ABS) Control Module system. Refer to the electrical circuit diagrams
and check power and ground supplies to ABS
module. Carry out the CAN network integrity
test using the manufacturer approved diagnostic
system
U012800 Lost Communication With CAN Link ECM/Electronic Carry out any pinpoint tests associated with this
Park Brake Control Module parking brake signal missing DTC using the manufacturer approved diagnostic
network malfunction system. Refer to the electrical circuit diagrams
and check power and ground supplies to parking
brake module. Carry out the CAN network
diagnostic system
U015100 Lost Communication With Lost communication - CAN or Carry out any pinpoint tests associated with this
Restraints Control Module hardwired DTC using the manufacturer approved diagnostic
and check power and ground supplies to RCM.
U015187 Lost Communication With Lost communication - SRS Carry out any pinpoint tests associated with this
Restraints Control Module fault DTC using the manufacturer approved diagnostic
and check power and ground supplies to RCM.
U015500 Lost Communication With CAN Link ECM/instrument Carry out any pinpoint tests associated with this
Instrument Panel Cluster cluster network malfunction DTC using the manufacturer approved diagnostic
(IPC) Control Module system. Refer to the electrical circuit diagrams
and check power and ground supplies to
instrument cluster. Carry out the CAN network
diagnostic system
U016400 Lost Communication With no sub type information Refer to electrical circuit diagrams and check
HVAC Control Module power and ground feeds to HVAC module. Carry
out the CAN network integrity test using the
manufacturer approved diagnostic system. Check
HVAC module for DTCs and refer to the relevant
DTC Index
U016700 Lost Communication With Security challenge response Carry out any pinpoint tests associated with this
Vehicle Immobilizer Control timeout DTC using the manufacturer approved diagnostic
Module system. Refer to the electrical circuit diagrams
and check power and ground supplies to vehicle
immobilizer module. Carry out the CAN network
diagnostic system
U030000 Internal Control Module The ECM is in Expulsion Check and install the correct ECM as required,
Software Incompatibility mode. An incorrect refer to the new module/component installation
specification module has note at the top of the DTC Index
been installed to the vehicle
U040208 Invalid Data Received from TCM engine speed control Check TCM for related DTCs and refer to relevant
TCM monitor DTC Index
U040264 Invalid Data Received from Actual gear position status Check TCM for related DTCs and refer to relevant
TCM DTC Index
U040267 Invalid Data Received from Selector lever position Check TCM for related DTCs and refer to relevant
TCM status DTC Index
U040281 Invalid Data Received from Output shaft speed signal Check TCM for related DTCs and refer to relevant
TCM DTC Index
U040282 Invalid Data Received from Alive/sequence counter Check TCM for related DTCs and refer to relevant
TCM incorrect/not updated DTC Index
TCM monitor - plausibility DTC Index
TCM monitor - rationality DTC Index
U040581 Invalid Data Received From Invalid data received from Check speed control module for related DTCs
Cruise Control Module speed control module and refer to relevant DTC Index
U040583 Invalid Data Received From Invalid data received from Check speed control module for related DTCs
U04058F Invalid Data Received From Invalid data received from Check speed control module for related DTCs
U041500 Invalid Data Received From Brake Position Switch Check ABS module for related DTCs and refer to
Anti-Lock Brake System relevant DTC Index
(ABS) Control Module
U041564 Invalid Data Received From Engine drag torque control Check ABS module for related DTCs and refer to
Anti-Lock Brake System monitoring - plausibility relevant DTC Index
Control Module
U041567 Invalid Data Received From Engine drag torque control Check ABS module for related DTCs and refer to
Anti-Lock Brake System monitoring - rationality relevant DTC Index
Control Module
U042386 Invalid Data Received From Battery voltage level Check instrument cluster for related DTCs and
Instrument Panel Control refer to relevant DTC Index
Module
U042481 Invalid Data Received From External ambient Check HVAC module for related DTCs and refer
HVAC Control Module temperature to relevant DTC Index
U042600 Invalid Data Received From Security code mis-match Check CAN network between ECM and
Vehicle Immobilizer Control instrument cluster. Check power and grounds to
Module ECM and instrument cluster. Check correct ECM
and instrument cluster installed. Re-synchronise
ID by re-configuring the ECM and instrument
cluster as new modules
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.
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.
Camshaft Position (CMP) Sensor LH
Removal
Procedures).
Installation).
3. Disconnect the camshaft position (CMP) sensor electrical
connector.
4. Release the CMP sensor electrical connector.
Installation
2. Tighten to 7 Nm.

Camshaft Position (CMP) Sensor RH
Removal
Procedures).
Installation).
3. Disconnect the camshaft position (CMP) sensor electrical
connector.
Installation
2. Tighten to 7 Nm.

Electronic Engine Controls - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8 - Catalyst
Monitor Sensor
General Equipment
Snap-on tool S6176
Removal
For additional information, refer to Section 100-02 Jacking and
Lifting.
2. Disconnect the catalyst monitor sensor.
3. CAUTION: Make sure the wiring harness is not twisted or

damaged on removal. Failure to follow this instruction may result
Using the Snap-on tool S6176, remove the catalyst monitor

sensor.
Installation
1. CAUTION: Make sure the wiring harness is not twisted or

damaged on installation. Failure to follow this instruction may
Tighten to 45 Nm.
Crankshaft Position (CKP) Sensor4.2L NA V8 - AJV8
Removal
WARNING: Do not work on or under a vehicle supported only by a jack. Always support the vehicle on safety stands.

connector.
Installation
Tighten to 7 Nm.
Electronic Engine Controls - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8 - Engine
Control Module (ECM)
Removal
Procedures).
Installation).

6. Remove the pedestrian protection actuator.
7. Reposition the pedestrian protection actuator bracket.

9. Remove the ECM.
Installation
3. Tighten to 6 Nm.
4. Tighten to 8 Nm.
Electronic Engine Controls - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8 - Engine
Coolant Temperature (ECT) Sensor
Removal
W ARNINGS:
Never remove the coolant pressure cap under any circumstances while the engine is operating. Failure to follow this
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. W ait 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.

Procedures).

stands.

Installation).
5. Remove the engine coolant temperature (ECT) sensor.
Remove the retaining clip.
Remove and discard the O-rings.
Installation
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 W SS M97B44-D and fifty
percent water.
Electronic Engine Controls - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8 - Fuel
Temperature Sensor
Removal
Procedures).
Installation).
3. WARNING: The spilling of fuel is unavoidable during

this operation. Ensure that all necessary precautions are taken
to prevent fire and explosion.

contamination.
Remove the fuel temperature sensor.
Position an absorbent cloth to collect fluid spillage.
Installation
1. WARNING: After carrying out repairs, the fuel system

must be checked visually for leaks. Failure to follow this
Tighten to 7 Nm.

Electronic Engine Controls - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8 - Heated
Oxygen Sensor (HO2S)
General Equipment
Snap-on tool S6176
Removal


3. Disconnect the heated oxygen sensor (HO2S) electrical
connector.
4. CAUTION: Make sure the H02S wiring harness is not

twisted more than 180 degrees and is not in contact with either
the exhaust or driveshaft.
Remove the HO2S.
Using the Snap-on tool S6176, remove the HO2S.
Installation
1. W ARNING: Make sure the H02S wiring harness is not

twisted more than 180 degrees and is not in contact with the
exhaust.
Tighten to 45 Nm.
Electronic Engine Controls - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8 - Intake
Air Temperature (IAT) Sensor
Removal
1. Remove the air temperature sensor.
Installation
Tighten to 3 Nm.
Electronic Engine Controls - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8 - Knock
Sensor (KS)
Removal
1. Remove the intake manifold assembly.
Remove the knock sensor.
Remove the knock sensor.
Installation
Tighten to 25 Nm
Electronic Engine Controls - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8 - Manifold
Absolute Pressure (MAP) Sensor
Removal
Procedures).
3. Remove the manifold absolute pressure (MAP) sensor.
Remove and discard the MAP sensor O-ring seal.
Installation
Install a new MAP sensor O-ring seal.

Procedures).
Electronic Engine Controls - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8 - Mass Air
Flow (MAF) Sensor
Removal
1. Remove the mass air flow (MAF) sensor.
Installation
Tighten to 3 Nm.

Procedures).
Electronic Engine Controls - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8 - Oil
Temperature Sensor
Removal
4. Remove the oil temperature sensor.
Installation
1. NOTE: Apply a small bead of sealant meeting Jaguar
specification on the first three threads of the oil temperature
sensor.
Tighten to 15 Nm.
Electronic Engine Controls - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8 - Variable
Camshaft Timing (VCT) Oil Control Solenoid
Removal
Procedures).
Remove the variable camshaft timing (VCT) oil control

solenoid.
Installation
Tighten to 10 Nm.

Procedures).
Automatic Transmission/Transaxle - 2.7L V6 - TdV6/3.0L NA V6 -
AJ27/4.2L NA V8 - AJV8/4.2L SC V8 - AJV8 - Transmission
DescriptionVehicles With: ZF 6HP26 - Component Location
Component Location
ItemDescription
1 Torque converter
2 Transmission assembly
3 Breather
4 Emergency park release cable
5 JaguarDrive selector
6 Emergency park release lever
7 Drive shaft flange
8 Emergency park release arm
DescriptionVehicles With: ZF 6HP26 - Overview
OVERVIEW
The ZF 6HP26 transmission is an electronically controlled, six speed unit. The transmission is manufactured by ZF
Transmissions GmbH in Saarbrcken, Germany.
This transmission represents the latest in automatic transmission technology and incorporates new features to enhance
the transmission functionality:
The hydraulic and electronic control elements of the transmission, including the TCM (transmission control module)
, are incorporated in a single unit located inside the transmission and is known as 'Mechatronic'
Another new strategy is Adaptive Shift Strategy (ASIS). ASIS represents the continuous adaptation of shift changes
to suit the driving style of the driver which can vary from sporting to economical.
On supercharged models, the transmission used is an uprated derivative of the 6HP26 transmission used in the 4.2L
naturally aspirated model. The uprated transmission includes additional clutch plates to enable the transmission to
manage the additional power output of the supercharged engine.
The 6HP26 transmission has the following features:
Designed to be maintenance free

Transmission fluid is 'fill for life'
The torque converter features a controlled slip feature with electronically regulated control of lock-up, creating a
smooth transition to the fully locked condition
Shift programs controlled by the TCM
Connected to the ECM (engine control module) via the High Speed CAN (controller area network) bus for
communications
Uses a High Speed CAN bus and a 'K' Line (early build vehicles only) connection to the diagnostic socket for
diagnostic connection
Default mode if major faults occur
Diagnostics available from the TCM via the high speed CAN bus.
The gearbox comprises the main casing which houses all of the transmission components. The main case also incorporates
an integral bell housing. A fluid pan is bolted to the lower face of the main case and is secured with bolts. The fluid pan is
sealed to the main case with a gasket. Removal of the fluid pan allows access to the Mechatronic valve block. The fluid
pan has a magnet located around the drain plug which collects any metallic particles present in the transmission fluid. A
fluid filter is located inside the fluid pan. If the transmission fluid becomes contaminated or after any service work, the
fluid pan with integral filter must be replaced.
The integral bell housing provides protection for the torque converter assembly and also provides the attachment for the
gearbox to the engine cylinder block. The torque converter is a non-serviceable assembly which also contains the lock-up
clutch mechanism.
The torque converter drives a crescent type pump via drive tangs. The fluid pump is located in the main case, behind the
torque converter.
The main case contains the following major components:
Input shaft
Output shaft
Mechatronic valve block which contains the solenoids, speed sensors and the TCM
Three rotating multiplate drive clutches
Two fixed multiplate brake clutches
A single planetary gear train and a double planetary gear train.
DescriptionVehicles With: ZF 6HP26 - System Operation and Component
Description
System Operation
POWER FLOWS
Operation of the transmission is controlled by the TCM (transmission control module) which electrically activates various
solenoids to control the transmission gear selection. The sequence of solenoid activation is based on programmed
information in the TCM memory and physical transmission operating conditions such as vehicle speed, throttle position,
engine load and JaguarDrive selector position.
ItemDescription
1 Torque input from engine
2 Torque converter lock-up clutch
3 Single web planetary gear carrier
4 Single web planetary gears
5 Single web sunwheel 1
6 Double web sunwheel 2
7 Double web planetary gears - Long
8 Double web planetary gear carrier
9 Double web planetary gears - Short
10 Double web sunwheel 3
11 Torque output from transmission
A Multiplate clutch
B Multiplate clutch
C Multiplate brake
D Multiplate brake
E Multiplate clutch
Engine torque is transferred, via operation of single or combinations of clutches to the 2 planetary gear trains. Both gear
trains are controlled by reactionary inputs from brake clutches to produce the 6 forward gears and 1 reverse gear. The
ratios are as follows:
Gear 1st 2nd 3rd 4th 5th 6th Reverse

Ratio 4.171 2.340 1.521 1.143 0.867 0.691 3.403
The following table shows which solenoids are activated to produce the required torque output from the transmission.
Electronic Transmission Selector Shift Control Solenoid Electronic Pressure Regulator Solenoids
Position Valve (EPRS)
1 2 3 4 5 6
P - - - - ON -ON- -
R - - ON - ON -ON- -
Electronic Transmission Selector Shift Control Solenoid Electronic Pressure Regulator Solenoids
Position Valve (EPRS)
1 2 3 4 5 6
N - - - - ON -ON- -
D1 - ON - - ON -ON- -ON-
D2 - ON - ON - -ON- -ON-
D3 - ON ON - - -ON- -ON-
D4 ON ON - - ON -ON- -ON-
D5 ON - ON - ON -ON- -ON-
D6 ON - - ON ON -ON- -ON-
ON = Active (pressure build up)
OFF = Inactive
-ON- = Inactive (pressure drain)
The following table shows which clutches are operating for selected gear ratios to produce the required torque output from
the transmission.
JaguarDrive Selector Position Shift Control Solenoid Valve Clutch Brake

A B E WK C D
P - - - - - - X
R - - X - - - X
N - - - - - - X
D1 - X - - X - X
D2 - X - - X X -
D3 - X X - X - -
D4 ON X - X X - -
D5 ON - X X X - -
D6 ON - - X X X -
X = clutch applied
Shift Elements
ItemDescription
1 Turbine shaft
2 Stator shaft
3 Single web planetary gear train
4 Ring gear 1
5 Clutch A
6 Clutch B
7 Clutch E
8 Brake clutch C
9 Fixed connection to transmission housing
10 Shaft key
11 Brake clutch D
12 Double web planetary gear train
13 Planetary gears - Long
14 Ring gear 2
15 Sunwheel 2
16 Sunwheel 3
17 Double web planetary gear carrier
18 Planetary gears - short
19 Single web planetary gear carrier
20 Sunwheel 1
The shift elements are 3 rotating multiplate clutches (A, B and E) and 2 fixed multiplate brakes and D). All shifts from
1st to 6th gears are power-on overlapping shifts. Overlapping shifts can be described as one of the clutches continuing to
transmit drive at a lower main pressure until the next required clutch is able to accept the input torque.
The shift elements, clutches and brakes are actuated hydraulically. Fluid pressure is applied to the required clutch and/or
brake, pressing the plates together and allowing drive to be transmitted through the plates. The purpose of the shift
elements is to perform power-on shifts with no interruption to traction and smooth transition between gear ratios.
POWER FLOW 1st GEAR
The JaguarDrive selector and the selector valve spool are in the 'D' position. Engine torque is transmitted from the torque
converter turbine shaft to the ring gear 1 of the single web planetary gear train and the outer plate carrier of clutch 'E'.
Ring gear 1 drives the planetary gears which rotate around sunwheel 1. This drives the planetary gear carrier 1 and also
the outer plate carrier of clutch 'A' and the inner plate carrier of clutch 'B'.
When clutch 'A' is engaged, sunwheel 3 in the double web planetary gear train is driven and meshes with the short
planetary gears.
The double web planetary gear train is locked against the transmission housing by brake 'D'. This allows ring gear 2
(output shaft) to be driven in the same direction as the engine via the long planetary gears.
NOTE: Refer to 'Shift Elements' illustration for key

POWER FLOW 2nd GEAR
The JaguarDrive selector and the selector spool valve are in the 'D' position. Engine torque is transmitted from the torque
planetary gears.
Sunwheel 2 is locked to the transmission housing by brake clutch 'C'. The long planetary gears, which are also meshed with
the short planetary gears, roll around the fixed sunwheel 2 and transmit drive to the double web planetary gear train
carrier and ring gear 2 in the direction of engine rotation.

POWER FLOW 3rd GEAR
planetary gears.
Sunwheel 2 is driven via clutch 'B' which is engaged. The long planetary gears, which are also meshed with the short
planetary gears, cannot roll around the fixed sunwheel 2 and therefore transmit drive to the locked double web planetary
gear train carrier in the direction of engine rotation.

POWER FLOW4th GEAR
converter turbine shaft to ring gear 1 of the single web planetary gear train and the outer plate carrier of clutch 'E'.
planetary gears.
The double web planetary gear carrier is driven via clutch 'E' which is engaged. The long planetary gears, which are also
meshed with the short planetary gears and the double web planetary gear carrier, drive ring gear 2 in the direction of
engine rotation.

POWER FLOW 5th GEAR
planetary gears.
The long planetary gears, which are also meshed with the short planetary gears and the double web planetary gear carrier,
drive ring gear 2 in the direction of engine rotation.

POWER FLOW 6th GEAR
Clutches 'A' and 'B' are released, removing the effect of the single web planetary gear train.
Clutch brake 'C' is applied which locks sunwheel 2 to the transmission housing.
Clutch 'E' is engaged and drives the double web planetary gear carrier. This causes the long planetary gears to rotate
around the fixed sunwheel 2 and transmit drive to ring gear 2 which is driven in the direction of engine rotation.

POWER FLOW REVERSE GEAR
The JaguarDrive selector and the selector spool valve are in the 'R' position. Engine torque is transmitted from the torque
Ring gear 1 drives the planetary gears of the single web planetary gear train which rotate around the fixed sunwheel 1.
This transmits the drive to the single web planetary gear carrier, the outer plate carrier of clutch 'A' and the inner plate
carrier of clutch 'B'.
With clutch 'B' applied, sunwheel 2 in the double web planetary gear train is driven and meshes with the long planetary
gears.
The double web planetary gear carrier is locked to the transmission housing by brake clutch 'D'. This allows ring gear 2 to
be driven in the opposite direction to engine rotation by the long planetary gears.

INSTRUMENT CLUSTER
ItemDescription
1 Transmission selected gear status
2 Malfunction Indicator Lamp (MIL)
3 Message center
The instrument cluster is connected to the TCM via the high speed CAN (controller area network) bus. Transmission status
is transmitted by the TCM and displayed to the driver in one of 2 displays in the instrument cluster.
Malfunction Indicator Lamp (MIL)
The MIL (malfunction indicator lamp) is located in the tachometer in the instrument cluster. Transmission related faults
which may affect the vehicle emissions output will illuminate the MIL.
The MIL is illuminated by the ECM (engine control module) on receipt of a relevant fault message from the TCM on the high
speed CAN. The nature of the fault can be diagnosed using a Jaguar approved diagnostic system which reads the fault
codes stored in the TCM memory.
Transmission Status Display
The transmission status display is located in a LCD (liquid crystal display) at the top of the instrument cluster, between
the speedometer and the tachometer. The LCD shows the JaguarDrive selector position or the selected gear when in
manual 'Jaguar Sequential Shift' mode.
The following table shows the displays and their descriptions.
Symbol Description
P Park selected
R Reverse selected
N Neutral selected
D Drive selected
S Sport mode selected
1 1st gear selected (Manual 'Jaguar Sequential Shift' mode)
2 2nd gear selected (Manual 'Jaguar Sequential Shift' mode)
3 3rd gear selected (Manual 'Jaguar Sequential Shift' mode)
4 4th gear selected (Manual 'Jaguar Sequential Shift' mode)
Message Center Display
The message center is located in the lower center of the instrument cluster. The message center is a LCD to relay vehicle
status and operating information to the driver and can display messages relating to a number of the vehicle systems. If a
transmission fault occurs, the message center will display the message 'GEARBOX FAULT'.
TRANSMISSION CONTROL MODULE (TCM)

The TCM is an integral part of the Mechatronic valve block which is located at the bottom of the transmission, within the
fluid pan. The TCM is the main controlling component of the transmission.
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 TCM calculates the correct gear, torque converter clutch setting
and optimum pressure settings for gear shift and lock-up clutch control.
The TCM outputs signals to control the shift control solenoid valve and the Electronic Pressure Regulator Solenoids (EPRS)
to control the hydraulic operation of the transmission.
The ECM supplies the engine management data on the high speed CAN bus system. The TCM requires engine data to
efficiently control the transmission operation, for example; flywheel torque, engine speed, accelerator pedal angle, engine
temperature etc.
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 Mechatronic valve block also contains the speed and temperature sensors. These are integral with the Mechatronic
valve block and cannot be serviced individually. The speed sensors measure the transmission input and output speeds and
pass signals to the TCM. The fluid temperature sensor is also located in the valve block and measures the fluid
temperature of the transmission fluid in the fluid pan.
CONTROLLER AREA NETWORK (CAN)

The high speed CAN bus is used to connect the powertrain modules. The CAN bus is connected between the following
electronic units:
High Speed CAN Bus
TCM
Instrument cluster
Adaptive Damping Control Module (ADCM) - if fitted
Steering angle sensor
Electric park brake module
Restraints control module
ECM
ABS module
Adaptive speed control module - if fitted
Diagnostic socket.
The CAN bus allows a fast exchange of data between modules. The CAN bus comprises 2 wires which are identified as CAN
high (H) and CAN low (L). The 2 wires are coloured white/blue (H) and white (L) and are twisted together to minimise
electromagnetic interference (noise) produced by the CAN bus messages.
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 (limp home) mode

Torque converter lock-up clutch control is disabled (unlocked)
Gear position indication in instrument cluster message center inoperative (this will also occur with any transmission
fault).
DRIVING MODES
There are a number of different driving modes of operation. Some can be selected by the driver and some are
automatically initiated by the TCM during driving:
Normal mode (driver selected)

Sport mode (driver selected)
Manual ('Jaguar Sequential Shift') mode (driver selected)
Adaptive Shift Strategy (ASIS) which comprises the following:
- Cruise mode
- Hill mode
- Default (Limp home) mode
- Reverse lock-out mode
- Cooling strategy
- Curve recognition mode
- Fast off recognition.
Normal Mode
Normal mode is automatically selected by the TCM on power up. In this mode all automatic and adaptive modes are
active. Normal mode uses gear shift and lock-up maps to allow for vehicle operation which offers fuel consumption and
emissions or driveability depending on the driving style. If the transmission is operated in sport or manual mode and the
JaguarDrive selector is moved to the 'D' position, normal mode is automatically resumed.
Sport mode is selected by moving the JaguarDrive selector to the 'S' position. When the sport mode is first selected, if 6th
gear is currently engaged, the TCM downshifts to 5th provided the correct engine speed parameters are met.
Manual ('Jaguar Sequential Shift') Mode
Manual mode allows the transmission to operate as a semi-automatic 'Jaguar Sequential Shift' unit. The driver can change
up and down the 6 forward gears with the freedom of a manual transmission.
Shift maps are provided for manual mode to protect the engine at high engine 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 labouring and
stalling.
When kickdown is requested the TCM downshifts to the lowest available gear within the allowed engine speed parameters.
When the vehicle is stationary, to drive off, the driver can select 1st , 2nd or 3rd gear. Any other gear selection will be
rejected by the TCM.
When driving off, upshifts can be pre-selected by making + selections with the appropriate steering wheel upshift or
downshift paddle for the number of upshifts required. The TCM then automatically performs a corresponding number of
upshifts when the appropriate shift points are reached. So, for example, when starting off in 1st gear, if three upshift (+)
selections are made in quick succession, the TCM will automatically change up through the box to 4th gear as the vehicle
accelerates, without any further selections being made.
In manual mode a low gear can be selected to provide engine braking for descending a slope without continuous use of the
brake pedal. The driver can prepare for the end of the descent by moving the JaguarDrive selector to the 'D' position. The
TCM will maintain the low gear and only revert to automatic shift control when the throttle is opened and vehicle speed
increases.
Adaptive Shift Strategy (ASIS)
With the TCM linked via the CAN bus to other vehicle systems, signals are received which can allow the TCM to calculate
the way in which the vehicle is being driven. The type of signals include the following:
Longitudinal and lateral acceleration

Engine speed
Engine torque
Oil temperature
Accelerator pedal position
Wheel speed.
Using these signals, additional transmission control can be obtained. The TCM can calculate when the vehicle is cornering,
all wheels are gripping, the driver is braking or if the driver is accelerating. This is the conventional 'Adaptive' transmission
control. ASIS uses this system but adds the continuous adaptation of the gear changes to suit the individual driving style
of the driver.
Cruise Mode
When speed control is activated, the TCM receives a cruise active message on the CAN bus. The TCM activates a speed
control map which prevents locking and unlocking of the torque converter clutch and minimizes up and down shifts.
Hill Mode
Hill mode is initiated by the TCM when the engine torque, received via ECM signals on the CAN bus, exceeds the
theoretical load curve for normal operation. The TCM monitors this signal to determine when the vehicle is travelling up or
down a steep gradient.
In hill mode the TCM adopts one of four shift maps, three uphill and one downhill. The shift map chosen depends on the
severity of the slope as determined from the engine signals and the appropriate gear is selected to assist with the ascent
or descent.
Hill mode can also be initiated when the vehicle is at very high altitudes or ambient temperatures.
Default (Limp Home) Mode
If a transmission fault is detected by the TCM, the TCM adopts a limp home mode strategy. 'GEARBOX FAULT' is displayed
in the message center and, if the fault has an effect on engine emissions, the MIL will also be illuminated.
In default mode, P, R and N functions operate normally (if the fault allows these selections) and the TCM locks the
transmission in 3rd or 5th gear to allow the driver to take the vehicle to the nearest dealer. The torque converter lock-up
clutch is disabled and reverse lock-out will not function.
If the vehicle is stopped and subsequently restarted in the default mode condition, the TCM operates normally until the
fault which caused the condition is detected again.
If electrical power is lost and the transmission is operating in mechanical limp home mode, the transmission will be
electronically locked in the 'P' position when the ignition is off. This can be released mechanically if required by operating
the emergency park release lever located in the floor console.
Reverse Lock-Out Mode
When the vehicle is travelling forwards, selecting reverse could cause transmission damage. To protect against this,
reverse gear is prohibited if the vehicle is travelling forwards at a road speed of 5 mph (8 km/h) or higher.
Cooling Strategy
The purpose of the cooling strategy is to reduce engine and transmission temperatures during high load conditions. Under
these conditions the engine and transmission may generate excessive heat.
If the transmission fluid temperature increases to 125C (257F) or higher, the TCM employs the cooling strategy. No
message is displayed in the message center for transmission overheat.
The strategy uses a specific shift and torque converter lock-up clutch map. This map allows torque converter clutch lock-up
and gear shifts to operate outside of their normal operation. This will reduce the engine speed and/or slip in the torque
converter, therefore reducing heat generated by the engine and the transmission.
If the transmission fluid temperature increases to 137C (278F) or higher, the transmission will use the default (limp
home mode). If the temperature exceeds 140C (284F), CAN bus transmission is disabled.
The cooling strategy is cancelled when the transmission fluid temperature decreases to less than 120C (248F) or below.
Curve Recognition
Curve recognition is activated when high levels of lateral acceleration and/or steering angle are detected via the ABS
module and steering angle sensor signals on the CAN bus. When this condition is detected, the TCM prevents the
transmission from changing to a higher gear to assist with cornering. When the vehicle completes it's manoeuvre, the
transmission will shift to the correct ratio.
Fast Off Recognition
Fast off recognition is activated when the TCM detects that the driver has backed off the accelerator pedal quickly in a
'change of mind' manoeuvre. This is detected by monitoring for a high level of negative pedal angle from the ECM signal on
the high speed CAN bus. If this condition is detected, the TCM holds the current gear ratio to allow the driver to complete
his original action without the need for a downshift. The mode remains active for a predetermined time period or if the
driving style remains passive.
TRANSMISSION FAULT STATUS

If the TCM detects a fault with the transmission system, it will enter a default mode to prevent further damage to the
transmission and allow the vehicle to be driven.
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 an emissions related fault occurs and displays 'GEARBOX FAULT' in the message
center.
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 high speed
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.
TOWING FOR RECOVERY

The following procedure must be used to ensure that the vehicle is towed in a safe condition and damage to the vehicle
transmission systems is prevented.
Secure the towing attachment from the recovery vehicle to the towing eye of the vehicle to be recovered.
Make sure that the parking brake is on. Press the start/stop button to switch the ignition on.
Apply the footbrake and move the JaguarDrive selector to the neutral position. If electrical power is not available,
use the emergency park release lever to select neutral.
Make sure that the Smart Key is placed in the start control module to ensure that the electric steering lock is
disengaged and, if the stop lamps and turn signal indicators are required, the start/stop button is pressed and the
ignition is on.
Make sure that the parking brake is released before the vehicle is towed.
The vehicle can only be towed for a maximum of 0.5 miles (0.8 km) at a maximum speed of 30 mph (48 km/h).
WARNING: Do not remove the Smart Key from the vehicle when the vehicle is being towed. The electric steering lock
will be engaged preventing the steering from being turned.
With the engine not running, the brake booster and power steering pump will be inoperative. Care must be taken to ensure
the vehicle is manoeuvred and driven accordingly.
ZF 6HP26 Automatic Transmission Exploded View
NOTE: The transmission shown is exploded to the extent of the serviceable items
ItemDescription
1 Breather tube
2 Plug
3 Seal sleeves
4 Selector shaft seal
5 Gasket
6 Drain plug
7 Fluid pan and filter assembly
8 Torx screws
9 Mechatronic valve block
10 Element seal
11 Electrical connector guide sleeve
12 O-ring
13 O-ring
14 Pump housing
15 Input shaft seal
16 Torque converter
The transmission comprises the main casing which houses all of the transmission components. The main case also
incorporates an integral bell housing.
A fluid pan is attached to the lower face of the main case and is secured with bolts. The fluid pan is sealed to the main
case with a gasket. Removal of the fluid pan allows access to the Mechatronic valve block. The fluid pan has a magnet
located around the drain plug which collects any metallic particles present in the transmission fluid.
A fluid filter is located inside the fluid pan. If the transmission fluid becomes contaminated or after any service work, the
fluid pan with integral filter must be replaced.
The integral bell housing provides protection for the torque converter assembly and also provides the attachment for the
gearbox to the engine cylinder block. The torque converter is a non-serviceable assembly which also contains the lock-up
clutch mechanism. The torque converter drives a crescent type pump via drive tangs. The fluid pump is located in the main
case, behind the torque converter.
The main case contains the following major components:
Input shaft
Output shaft
Mechatronic valve block which contains the solenoids, speed sensors and the TCM
3 rotating multiplate drive clutches
2 fixed multiplate brake clutches
A single planetary gear train and a double planetary gear train.
ItemDescription
1 Torque converter lock-up clutch
2 Torque converter
3 Fluid pump
4 Single planetary gearset
5 Clutch A
6 Clutch B
7 Clutch E
8 Brake C
9 Brake D
10 Double planetary gearset
11 Park lock gear
12 Output shaft
13 Park lock pawl
14 Drain plug
15 Magnet
16 Pressure regulator
17 Mechatronic valve block
18 Fluid filter
19 Fluid filter
20 Input shaft
21 Bell housing
TORQUE CONVERTER
ItemDescription
1 Impeller
2 Turbine
3 Stator
4 Freewheel clutch
5 Torque converter hub
6 Stator shaft
7 Turbine shaft
8 Drive plate
9 Journal - Drive plate/crankshaft location
10 Torque converter cover
11 Lock-up clutch piston
12 Lock-up clutch plate
The torque converter is the coupling element between the engine and the transmission and is located in the bell 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. W ith the impeller welded to the converter housing cover, the impeller is therefore
driven at engine crankshaft speed.
The converter housing cover has 4 threaded bosses which provide for attachment of the engine drive plate which is
connected to the engine crankshaft. The threaded bosses also provide for location of special tools which are required to
remove the torque converter from the bell housing.
Impeller
Fluid Flow
ItemDescription
1 Turbine
2 Stator
3 Impeller
When the engine is running the rotating impeller acts as a centrifugal pump, picking up fluid at its center and discharging
it at high velocity through the blades on its outer rim. The design and shape of the blades and the curve of the impeller
body cause the fluid to rotate in a clockwise direction as it leaves the impeller. This rotation improves the efficiency of the
fluid as it contacts the outer row of blades on the turbine.
The centrifugal force of the fluid leaving the blades of the impeller is passed to the curved inner surface of the turbine via
the tip of the blades. The velocity and clockwise rotation of the fluid causes the turbine to rotate.
Turbine
The turbine is similar in design to the impeller with a continuous row of blades. Fluid from the impeller enters the turbine
through the tip of the blades and is directed around the curved body of the turbine to the root of the blades. The curved
surface redirects the fluid back in the opposite direction to which it entered the turbine, effectively increasing the turning
force applied to the turbine from the impeller. This principle is known as torque multiplication.
When engine speed increases, turbine speed also increases. The fluid leaving the inner row of the turbine blades is
rotated in a counter-clockwise direction due to the curve of the turbine and the shape of the blades. The fluid is now
flowing in the opposite direction to the engine rotation and therefore the impeller. If the fluid was allowed to hit the
impeller in this condition, it would have the effect of applying a brake to the impeller, eliminating the torque multiplication
effect. To prevent this, the stator is located between the impeller and the turbine.
Stator
The stator is located on the splined transmission input shaft via a freewheel clutch. The stator comprises a number of
blades which are aligned in an opposite direction to those of the impeller and turbine. The main function of the stator is to
redirect the returning fluid from the turbine, changing its direction to that of the impeller.
The redirected fluid from the stator is directed at the inner row of blades of the impeller, assisting the engine in turning
the impeller. This sequence increases the force of the fluid emitted from the impeller and thereby increases the torque
multiplication effect of the torque converter.
NOTE: The following illustration shows a typical stator
Stator Functions
ItemDescription
1 Blades
2 Stator held fluid flow redirected
3 Stator rotates freely
4 Roller
5 Converter at coupling speed
6 Fluid flow from turbine
7 Converter multiplying
8 Fluid flow from impeller
9 Drive from engine
10 Impeller
11 Stator
12 Turbine
13 Output to transmission
Refer to the 'Stator Functions' illustration
Fluid emitted from the impeller acts on the turbine. If the turbine is rotating at a slower speed than the fluid from the
impeller, the fluid will be deflected by the turbine blades in the path 'A'. The fluid is directed at and deflected by the
stator blades from path 'B' to path 'C'. This ensures that the fluid is directed back to the pump in the optimum direction.
In this condition the sprag clutch is engaged and the force of the fluid on the stator blades assists the engine in rotating
the impeller.
As the rotational speed of the engine and therefore the turbine increases, the direction of the fluid leaving the turbine
changes to path 'D'. The fluid is now directed from the turbine to the opposite side of the stator blades, rotating the
stator in the opposite direction. To prevent the stator from resisting the smooth flow of the fluid from the turbine, the
sprag clutch releases, allowing the stator to rotate freely on its shaft.
When the stator becomes inactive, the torque converter no longer multiplies the engine torque. W hen the torque converter
reaches this operational condition it ceases to multiply the engine torque and acts solely as a fluid coupling, with the
impeller and the turbine rotating at approximately the same speed.
The stator uses a sprag type, one way, freewheel clutch. When the stator is rotated in a clockwise direction the sprags
twist and are wedged between the inner and outer races. In this condition the sprags transfer the rotation of the outer
race to the inner race which rotates at the same speed.
One Way Free Wheel Clutch Typical

ItemDescription
1 Sprags
2 Inner race
3 Outer race
4 Sprag and cage assembly
5 Sprag outer race
6 Sprag inner race
7 Retaining ring
The free wheel clutch can perform three functions; hold the stator stationary, drive the stator and free wheel allowing the
stator to rotate without a drive output. The free wheel clutch used in the 6HP26 transmission is of the sprag type and
comprises an inner and outer race and a sprag and cage assembly. The inner and outer races are pressed into their related
components with which they rotate. The sprag and cage assembly is located between the inner and outer races.
The sprags are located in a cage which is a spring which holds the sprags in the 'wedge' direction and maintains them in
contact with the inner and outer races.
Referring to the illustration, the sprags are designed so that the dimension 'B' is larger than the distance between the
inner and outer race bearing surfaces. When the outer race rotates in a clockwise direction, the sprags twist and the edges
across the dimension 'B' wedge between the races, providing a positive drive through each sprag to the inner race. The
dimension 'A' is smaller than the distance between the inner and outer race bearing surfaces. When the outer race rotates
in an anti-clockwise direction, the dimension 'A' is too small to allow the sprags to wedge between the races, allowing the
outer race to rotate freely.
On the illustration shown, when the outer race is rotated in a clockwise direction, the sprags twist and are 'wedged'
between the inner and outer races. The sprags then transfer the rotation of the outer race to the inner race, which rotates
at the same speed.
Lock-Up Clutch Mechanism
The Torque Converter Clutch (TCC) is hydraulically controlled by an electronic pressure regulating solenoid (EPRS6) which is
controlled by the TCM. This allows the torque converter to have 3 states of operation as follows:
Fully engaged
Controlled slip variable engagement
Fully disengaged.
The TCC is controlled by two hydraulic spool valves located in the valve block. These valves are actuated by pilot pressure
supplied via a solenoid valve which is also located in the valve block. The solenoid valve is operated by PWM (pulse width
modulation) signals from the TCM to give full, partial or no lock-up of the torque converter.
ItemDescription
A Unlocked condition
B Locked condition
1 Clutch plate
2 Clutch piston
3 Torque converter body
4 Turbine
5 Impeller
6 Stator
7 Piston chamber
8 Turbine chamber
The lock-up clutch is a hydro-mechanical device which eliminates torque converter slip, improving fuel consumption. The
engagement and disengagement is controlled by the TCM to allow a certain amount of controlled 'slip'. This allows a small
difference in the rotational speeds of the impeller and the turbine which results in improved shift quality. The lock-up
clutch comprises a piston and a clutch friction plate.
In the unlocked condition, the oil pressure supplied to the piston chamber and the turbine chamber is equal. Pressurized
fluid flows through a drilling in the turbine shaft and through the piston chamber to the turbine chamber. In this condition
the clutch plate is held away from the torque converter body and torque converter slip is permitted.
In the locked condition, the TCC spool valves are actuated by the electronic pressure regulating solenoid (EPRS6). The fluid
flow in the unlocked condition is reversed and the piston chamber is vented. Pressurized fluid is directed into the turbine
chamber and is applied to the clutch piston. The piston moves with the pressure and pushes the clutch plate against the
torque converter body. As the pressure increases, the friction between the clutch plate and the body increases, finally
resulting in full lock-up of the clutch plate with the body. In this condition there is direct mechanical drive from the engine
crankshaft to the transmission planetary gear train.
FLUID PUMP
The fluid pump is an integral part of the transmission. The fluid pump is used to supply hydraulic pressure for the
operation of the control valves and clutches, to pass the fluid through the transmission cooler and to lubricate the gears
and shafts.
The 6HP26 fluid pump is a crescent type pump and is located between the intermediate plate and the torque converter.
The pump has a delivery rate of 16 cm3 per revolution.
ItemDescription
1 Securing ring
2 Shaft oil seal
3 O-ring seal
4 Pump housing
5 Ring gear
6 Crescent spacer
7 Roller bearing
8 Impeller
9 Centring pin
10 Spring washer
11 Outlet port (high pressure)
12 Inlet port (low pressure)
The pump comprises a housing, a crescent spacer, an impeller and a ring gear. The housing has inlet and outlet ports to
direct flow and is located in the intermediate plate by a centring pin. The pump action is achieved by the impeller, ring
gear and crescent spacer.
The crescent spacer is fixed in its position by a pin and is located between the ring gear and the impeller. The impeller is
driven by drive from the torque converter hub which is located on a needle roller bearing in the pump housing. The impeller
teeth mesh with those of the ring gear. When the impeller is rotated, the motion is transferred to the ring gear which
rotates in the same direction.
The rotational motion of the ring gear and the impeller collects fluid from the intake port in the spaces between the teeth.
When the teeth reach the crescent spacer, the oil is trapped in the spaces between the teeth and is carried with the
rotation of the gears. The spacer tapers near the outlet port. This reduces the space between the gear teeth causing a
build up of fluid pressure as the oil reaches the outlet port. W hen the teeth pass the end of the spacer the pressurized
fluid is released into the outlet port.
The fluid emerging from the outlet port is passed through the fluid pressure control valve. At high operating speeds the
pressure control valve maintains the output pressure to the gearbox at a predetermined maximum level. Excess fluid is
relieved from the pressure control valve and is directed, via the main pressure valve in the valve block, back to the pump
inlet port. This provides a pressurized feed to the pump inlet which prevents cavitation and reduces pump noise.
MECHATRONIC VALVE BLOCK

The Mechatronic valve block is located in the bottom of the transmission and is covered by the fluid pan. The valve block
houses the TCM, electrical actuators, speed sensors and control valves which provide all electro-hydraulic control for all
transmission functions. The Mechatronic valve block comprises the following components:
TCM
6 pressure regulator solenoids
1 shift control solenoid
1 damper
21 hydraulic spool valves
Manually operated selector valve
Temperature sensor
Turbine speed sensor
Output shaft speed sensor.
ZF 6HP26 Automatic Transmission Mechatronic Valve Block
ItemDescription
1 Position switch
2 Sliding block
3 Park lock cylinder
4 Position switch assembly
5 Solenoid valve 2
6 Electronic Pressure Regulator Solenoid (EPRS) 6
7 Solenoid valve 1
8 EPRS 4
9 EPRS 5
10 EPRS 3
11 EPRS 2
12 EPRS 1
14 TCM
15 Valve housing
16 Valve plate
17 Torque converter retaining valve
18 Element seal
19 Pressure regulator dampers
20 Clutch return valve
21 Intermediate plate
22 Solenoid valve 3 (park lock)
ZF 6HP26 Automatic Transmission Valve Housing Components
ItemDescription
1 Park lock valve
2 Solenoid valve 2
3 Torque converter pressure valve
4 Lubricating valve
5 System pressure valve
6 Torque converter lock-up clutch valve
7 Retaining valve Clutch E
8 Clutch valve E
9 Clutch valve A
10 Valve housing
11 Bolts
12 Retaining valve Clutch A
13 Retaining valve Clutch B
14 Pressure reducing valve
15 Retaining valve Brake D
16 Shift valve 2
17 Shift valve 1
18 Solenoid valve 3 (park lock)
19 Electronic Pressure Regulator Solenoid (EPRS) 6
20 Solenoid valve 1
21 EPRS 5
22 EPRS 2
23 EPRS 4
24 EPRS 3
25 EPRS 1
ZF 6HP26 Automatic Transmission Valve Plate Components
ItemDescription
1 Clutch valve B
2 Clutch valve Brake D2
3 Position valve D
4 Retaining valve Brake D2
5 Valve plate
6 Clutch valve Brake D1
7 Clutch valve Brake C
Electronic Pressure Regulator Solenoids (EPRS)
Six Electronic Pressure Regulator Solenoids (EPRS) are located in the valve block. The solenoids are controlled by PW M
signals from the TCM. The solenoids convert the electrical signals into hydraulic control pressure proportional to the signal
to actuate the spool valves for precise transmission operation.
The following table shows the EPRS and their associated functions:
EPRS Function
1 Clutch A
2 Clutch B
3 Clutch C
4 Brake clutches D and E
5 System pressure control
6 Torque converter lock-up control
Solenoids EPRS 1, 3 and 6 supply a lower control pressure as the signal amperage increases and can be identified by a
black connector cap. The TCM operates the solenoids using PWM signals. The TCM monitors engine load and clutch slip and
varies the solenoid duty cycle accordingly. The solenoids have a 12 V operating voltage and a pressure range of 0 - 4.6 bar
(0 - 67 lbf.in2).
Solenoids EPRS 2, 4 and 5 supply a higher control pressure as the signal amperage increases and can be identified by a
green connector cap. The solenoids are normally open, regulating flow solenoid valves. The TCM operates the solenoids
using a PW M ground proportional to the required increasing or decreasing clutch pressures. The solenoids have a 12 V
operating voltage and a pressure range of 4.6 - 0 bar (67 - 0 lbf.in2).
The resistance of the coil winding for the EPRS solenoids is 5.05 ohms at 20C (68F).
Solenoid Valves
Solenoid Valves (SV) are located in the valve block. The solenoids are controlled by the TCM and converts electrical signals
into hydraulic control signals to control clutch application and park lock cylinder operation.
The control solenoids are open/closed, on/off solenoids which are controlled by the TCM switching the solenoid to earth.
The TCM also supplies power to the solenoids. The TCM energises the solenoids in a programmed sequence for clutch
application for gear ratio changes, shift control and parl lock application.
The resistance of the solenoid coil winding within the solenoid is between 26 to 30.4 ohms at 20C (68F).
SENSORS
Speed Sensors
The turbine speed sensor and the output shaft speed sensor are Hall effect type sensors located in the Mechatronic valve
block and are not serviceable items. The TCM monitors the signals from each sensor to determine the input (turbine)
speed and the output shaft speed.
The turbine speed is monitored by the TCM to calculate the slip of the torque converter clutch and internal clutch slip. This
signal allows the TCM to accurately control the slip timing during shifts and adjust clutch application or release pressure
for overlap shift control.
The output shaft speed is monitored by the TCM and compared to engine speed signals received on the CAN bus from the
ECM. Using a comparison of the two signals the TCM calculates the transmission slip ratio for plausibility and maintains
adaptive pressure control.
Temperature Sensor
The temperature sensor is also located in the Mechatronic valve block. The TCM uses the temperature sensor signals to
determine the temperature of the transmission fluid. These signals are used by the TCM to control the transmission
operation to promote faster warm-up in cold conditions or to assist with fluid cooling by controlling the transmission
operation when high fluid temperatures are experienced. If the sensor fails, the TCM will use a default value and a fault
code will be stored in the TCM.
DAMPER
There is one damper located in the valve housing. The damper is used to regulate and dampen the regulated pressure
supplied via EPRS 5. The damper is load dependent through modulation of the damper against return spring pressure.
The damper comprises a piston, a housing bore and a spring. The piston is subject to the pressure applied by the spring.
The bore has a connecting port to the function to which it applies. Fluid pressure applied to the applicable component (i.e.
a clutch) is also subjected to the full area of the piston, which moves against the opposing force applied by the spring.
The movement of the piston creates an action similar to a shock absorber, momentarily delaying the build up of pressure
in the circuit. This results in a more gradual application of clutches improving shift quality.
SPOOL VALVES
The valve block contains 21 spool valves which control various functions of the transmission. The spool valves are of
conventional design and are operated by fluid pressure.
Each spool valve is located in its spool bore and held in a default (unpressurized) position by a spring. The spool bore has
a number of ports which allow fluid to flow to other valves and clutches to enable transmission operation. Each spool has a
piston which is waisted to allow fluid to be diverted into the applicable ports when the valve is operated.
When fluid pressure moves a spool, one or more ports in the spool bore are covered or uncovered. Fluid is prevented from
flowing or is allowed to flow around the applicable waisted area of the spool and into another uncovered port. The fluid is
either passed through galleries to actuate another spool, operate a clutch or is returned to the fluid pan.
DRIVE CLUTCHES
Multiplate Drive or Brake Clutch Typical
ItemDescription
1 Input shaft
2 Main pressure supply port
3 Piston
4 Cylinder External plate carrier
5 Clutch plate assembly
6 Baffle plate
7 Diaphragm spring
8 Output shaft
9 Bearing
10 Dynamic pressure equalisation chamber
11 Piston chamber
12 Lubrication channel
There are 3 drive clutches and 2 brake clutches used in the 6HP26 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.
On supercharged models, the uprated transmission includes additional clutch plates to enable the transmission to manage
the additional power output of the supercharged engine.
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 equalisation 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 equalisation chamber. The
piston moves, against the pressure applied by the diaphragm spring, and compresses the clutch plate assembly. W hen the
main pressure falls, the diaphragm spring pushes the piston away from the clutch plate assembly, disengaging the clutch.
PLANETARY GEAR TRAINS

The planetary gear trains used on the 6HP26 transmission comprise a single web planetary gear train and a double web
planetary gear train. These gear trains are known as Lepelletier type gear trains and together produce the 6 forward gears
and the 1 reverse gear.
Single Web Planetary Gear Train
The single web planetary gear train comprises:
1 sunwheel
3 planetary gears
1 planetary gear carrier (spider)
1 ring gear or annulus
ItemDescription
1 Cylinder
2 Baffle plate
3 Ring gear
4 Sun gear
5 Planetary gear spider
6 Torque converter input shaft
Torque converter input shaft
ItemDescription
1 Planetary gear spider
2 Planetary gears (short)
3 Ring gear
4 Output shaft
5 Planetary gear carrier
6 Sunwheel
7 Double planetary gears (long)
8 Sunwheel
The double planetary gear train comprises:
2 sunwheels
3 short planetary gears
3 long planetary gears
1 planetary gear carrier
1 ring gear or annulus
ELECTRONIC PARK LOCK

The park lock is electronically actuated by solenoid valve located in the valve block. The park lock is engaged by a
mechanical spring system comprising a parking disc and a lock cylinder controlled by a solenoid valve.
The park lock is engaged when the TCM receives a park request from the JaguarDrive selector. W hen the park lock is
released, a solenoid valve in the valve housing directs hydraulic pressure to the lock cylinder, which moves the piston
within the cylinder and releases the park lock pawl at the rear of the transmission by means of a connecting rod. The
solenoid on the lock cylinder is energized and locks the cylinder piston in the unlocked position. Additional locking of the
piston is achieved with ball catches within the lock cylinder.
When park is selected, the solenoid on the lock cylinder is de-energized, the ball catches are released and the piston is
free to move in the lock cylinder. The solenoid in the valve housing is also de-energized. The spring loaded parking disc
pulls the cylinder piston in the park direction which allows the park disc to move on its mounting. This movement is
transferred via the connecting rod to parking pawl, which is engaged in the park lock gear.
If an electrical failure occurs, the park lock can be manually released by means of an emergency park release lever located
in the floor console. The lever is connected to the parking disc by a cable and allows the park lock to be released
manually.
AJ27/4.2L NA V8 - AJV8/4.2L SC V8 - AJV8 - Transmission Electronic
Control SystemVehicles With: ZF 6HP26 - Component Location
COMPONENT LOCATION
ItemDescription
1 Automatic Transmission
4 Gasket
5 Fluid pan
Control SystemVehicles With: ZF 6HP26 - Overview
OVERVIEW
The TCM (transmission control module) is an integral part of the Mechatronic valve block which is located at the bottom of
the transmission, within the fluid pan. The TCM is the main controlling component of the transmission.
The TCM processes signals from the transmission speed and temperature sensors, ECM (engine control module) 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.
Unlike previous transmissions, this application has a fully electronic, JaguarDrive selector with no Bowden cable connection
to the transmission. The transmission selections are made using a rotary JaguarDrive selector which rises from the floor
console once the engine is running. Rotation of the JaguarDrive selector to any of the 5 positions is sensed by the TCM
which reacts according to the selected position.
Another new feature is the electronic park lock which is controlled by the TCM. A mechanical link is fitted for emergency
park release in the event of an electrical failure.
Control SystemVehicles With: ZF 6HP26 - System Operation and Component
Description
Control Diagram
NOTE: A = Hardwired; B = K bus; D = High speed CAN bus; N = Medium speed CAN bus
ItemDescription
1 Battery
7 Diagnostic socket
9 Engine start/stop switch
System Operation
TRANSMISSION CONTROL MODULE OPERATION
The TCM outputs signals to control the shift control solenoid valve and the Electronic Pressure Regulator Solenoids (EPRS)
to control the hydraulic operation of the transmission.
The TCM processes signals from the transmission speed and temperature sensors, the 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 ECM supplies the engine management data over the high speed CAN (controller area network) bus. The TCM requires
engine data to efficiently control the transmission operation, for example; flywheel torque, engine speed, accelerator pedal
angle, engine temperature. The steering angle sensor and the ABS (anti-lock brake system) module also supply data to
the TCM on the high speed CAN bus. 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.
Using the signal inputs and the memorized data, the TCM control program computes the correct gear and torque converter
lock-up clutch setting and the optimum pressure settings for gear shift and lock-up clutch control. Special output-side
modules (power output stages, current regulator circuits), allow the TCM to control the solenoid valves and pressure
regulators and consequently precisely control the hydraulics of the automatic transmission. In addition, the amount and
duration of engine interventions are supplied to the engine management by way of the CAN bus.
The transmission has a fully electronic JaguarDrive selector with no Bowden cable connection to the transmission. The
transmission selections are made using a rotary JaguarDrive selector which rises from the floor console once the engine is
running. Rotation of the JaguarDrive selector to any of the 5 positions is sensed by the TCM via the high speed CAN bus.
The TCM then reacts according to the selected position. The 'Sport' (S) position selection allows the TCM to operate the
transmission using the semi-automatic 'Jaguar Sequential Shift'.
Gear selections are sensed by the TCM when the driver operates the steering wheel paddle switches. Once the JaguarDrive
selector position is confirmed, the TCM outputs appropriate information on the high speed CAN bus.
If the JaguarDrive selector is in 'D', 'Jaguar Sequential Shift' is temporary and will cancel after a time period or can be
cancelled by pressing and holding the + paddle for approximately 2 seconds.
If the JaguarDrive selector is in 'S', 'Jaguar Sequential Shift' is permanent and can only be cancelled by pressing and
holding the + paddle for approximately 2 seconds or by moving the JaguarDrive selector to the 'D' position.
The TCM can be reprogrammed using an approved Jaguar diagnostic system using a flash code. The TCM's processor has a
440 Kb internal flash memory. Of this capacity, approximately 370 Kb are used by the basic transmission program. The
remainder, approximately 70 Kb is used to store vehicle-specific application data.
Engine Stall
If the vehicle stalls it will coast down in gear, with the transmission providing drive to the engine. A restart can be
attempted at this point and the engine may start and the driver can continue.
If the coast down speed reduces such that the speed of the engine is less than 600rpm, the transmission will go to
neutral, D illumination will flash in the instrument cluster. The driver needs to select neutral or park and then press the
brake pedal to restart the engine.
If the driver presses the start/stop button when driving, there will be no change to the ignition state, the driver will
receive a message in the instrument cluster "Start button Pressed". If the driver requires to switch off the engine, the
start/stop button must be pressed for a second time. The engine will be stopped and will be back driven by the
transmission as the vehicle coasts down. When the engine speed is less than 600 rpm the transmission engages neutral
(flashing D illumination in the instrument cluster). W hen vehicle speed is less than 2 km/h (1.2 mph) Park is engaged. The
JaguarDrive selector automatically rotates back to its lowered P position and the vehicle ignition is switched off.
The park engagement is prevented in a stall case as the ignition power is on and D was the last selected gear. The park
engagement speed at ignition off is from the least value of the wheel speeds (CAN signal) and transmission output speed
(internal signal).
TRANSMISSION CONTROL MODULE DESCRIPTION
The TCM is an integral part of the Mechatronic valve block which is located at the bottom of the transmission, within the
fluid pan. The TCM is the main controlling component of the transmission.
The Mechatronic valve block also contains the speed and temperature sensors. These are integral with the Mechatronic
valve block and cannot be serviced individually. The speed sensors measure the transmission input and output speeds and
pass signals to the TCM. The fluid temperature sensor is also located in the valve block and measures the fluid
temperature of the transmission fluid in the fluid pan.
AJ27/4.2L NA V8 - AJV8/4.2L SC V8 - AJV8 - Diagnostic Strategy
For a detailed description of the automatic transmission/transaxle, refer to the relevant Description and Operation sections
in the workshop manual. REFER to: (307-01 Automatic Transmission/Transaxle - 2.7L V6 - TdV6/3.0L NA V6 - AJ27/4.2L NA
V8 - AJV8/4.2L SC V8 - AJV8)
Transmission Description - Vehicles With: ZF 6HP26 (Description and Operation),

Transmission Electronic Control System - Vehicles W ith: ZF 6HP26 (Description and Operation),
Transmission Electronic Control System - Vehicles W ith: ZF 6HP26 (Description and Operation),
Transmission Electronic Control System - Vehicles W ith: ZF 6HP26 (Description and Operation).
Fluid Level and Condition Check
CAUTION: The vehicle should not be driven if the fluid level is low as internal failure can result.
NOTE: The transmission fluid temperature must not be allowed to exceed 50C (122F) whilst checking level. Should the
temperature rise above this figure, abort the check and allow the transmission fluid to cool to below 30C (86F).
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 (307-01 Automatic Transmission/Transaxle - 2.7L V6 - TdV6/3.0L NA V6 -
AJ27/4.2L NA V8 - AJV8/4.2L SC V8 - AJV8, General Procedures).
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 condition is identified, with the engine at idle ensure the fluid temperature is within the specified range and
allow the excess fluid to drain until a small thread of fluid runs from the filler/level plug hole.
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.
REFER to: Transmission Fluid Level Check (307-01 Automatic Transmission/Transaxle - 2.7L V6 - TdV6/3.0L NA V6 -
AJ27/4.2L NA V8 - AJV8/4.2L SC V8 - AJV8, General Procedures).
Adding Fluid
CAUTION: The use of any other type of transmission fluid other than that specified can result in 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 Specification section in this section.
REFER to: Specifications (307-01 Automatic Transmission/Transaxle - 2.7L V6 - TdV6/3.0L NA V6 - AJ27/4.2L NA V8 -
AJV8/4.2L SC V8 - AJV8, Specifications).
Fluid Condition Check
1. 1. Check the fluid level.

REFER to: Transmission Fluid Level Check (307-01 Automatic Transmission/Transaxle - 2.7L V6 - TdV6/3.0L NA V6
- AJ27/4.2L NA V8 - AJV8/4.2L SC V8 - AJV8, General Procedures).
2. 2. Observe the color and the odor of the fluid. The color under normal circumstances should be like honey, not dark
brown or black.
3. 3. Allow the fluid to drip onto a facial tissue and examine the stain.
4. 4. If evidence of solid material is found, the transmission fluid pan should be removed for further inspection.
NOTE: In the event of a transmission unit replacement for internal failure, the oil cooler and pipes must also be replaced.
vehicle.

Visual Inspection
Mechanical Electrical Hydraulic
Damaged/stuck shift mechanism Blown fuse(s) Fluid level too
Damaged automatic transmission Damaged, loose or corroded high/low
casing connectors Poor condition of fluid
Wiring harness Fluid leak
DTC Index
NOTE: If the control module/transmission is suspect and the vehicle remains under manufacturer warranty, refer to the
to the installation of a new module/transmission.

B108782 Lost LIN Alivecounter fault Check transmission shift module for related DTCs and
Communications with refer to the relevant DTC Index. Refer to the electrical
ETS circuit diagrams and check TCM to transmission shift
module for short, open circuit
B108783 Lost LIN Checksum error Check transmission shift module for related DTCs and
B108787 Lost LIN LIN-timeout Carry out any diagnostic pinpoint tests associated with
Communications with this DTC using the manufacturer approved diagnostic
ETS system. Check transmission shift module for related
DTCs and refer to the relevant DTC Index. Refer to the
electrical circuit diagrams and check TCM to transmission
shift module for short, open circuit
B108788 Lost LIN LIN Bus off Check transmission shift module for related DTCs and
P012186 Throttle/Pedal Position Kickdown flag set Carry out any diagnostic pinpoint tests associated with
Sensor A Circuit erroneously at low pedal this DTC using the manufacturer approved diagnostic
Range/Performance values system. Check ECM for related DTCs and refer to the
relevant DTC Index
P021986 Engine Overspeed Engine speed too low or Check ECM for related DTCs and refer to the relevant DTC
Condition too high Index
P050081 Vehicle Speed Signal Fault with any wheel Check ABS for vehicle speed related DTCs and refer to
Not Detected speed on CAN the relevant DTC Index
P050181 Vehicle Speed Sensor A Difference between Check ABS for vehicle speed related DTCs and refer to
Range/Performance output shaft speed and the relevant DTC Index. Check correct differential is
wheels speeds on CAN installed to the vehicle
P05611C System Voltage Power supply voltage - Carry out any pinpoint tests associated with this DTC
Unstable out of range when using the manufacturer approved diagnostic system.
engine running Check ECM for charging system related DTCs and refer to
the relevant DTC Index. Check output of generator,
voltage regulator and battery
P056221 System Voltage Low Battery supply voltage Carry out any pinpoint tests associated with this DTC
to TCM circuit - low using the manufacturer approved diagnostic system.
voltage Ensure battery is in a fully charged and serviceable
condition, refer to the battery care manual. Also check for
additional charging system DTCs and refer to relevant
DTC Index
P056322 System Voltage High High battery charge, Check output of generator, voltage regulator and battery.
alternator fault Check for additional generator related DTCs and refer to
relevant DTC Index
P060141 Internal Control Module Software error Re-configure the transmission using the manufacturer
Memory Check Sum TCM failure approved diagnostic system, clear DTC and re-test. If
Error DTC remains, suspect the TCM, check and install a new
TCM as required, refer to the new module/component
P060400 Internal Control Module Shift-by-W ire Suspect the TCM, check and install a new TCM as
RAM error Level2/Data calibration required, refer to the new module/component installation
error note at the top of the DTC Index
P060541 Internal Control Module General checksum failure Suspect the TCM, check and install a new TCM as
Read Only Memory required, refer to the new module/component installation
(ROM) Error note at the top of the DTC Index
P061300 TCM processor W atchdog fault Suspect the TCM, check and install a new TCM as
required, refer to the new module/component installation
P061304 TCM processor Microcontroller Suspect the TCM, check and install a new TCM as
component faults required, refer to the new module/component installation
P061311 TCM Processor W atchdog fault Suspect the TCM, check and install a new TCM as
P061326 TCM Processor Microcontroller Suspect the TCM, check and install a new TCM as
P061349 TCM Processor Microcontroller Suspect the TCM, check and install a new TCM as
P061B26 Internal Control Module TCM positive torque Suspect the TCM, check and install a new TCM as
Torque Calculation signal not valid required, refer to the new module/component installation
Performance note at the top of the DTC Index
P062F04 Internal Control Module EEPROM communication Suspect the TCM, check and install a new TCM as
EEPROM Error error required, refer to the new module/component installation
P064221 Sensor Reference Sensor supply voltage Carry out any pinpoint tests associated with this DTC
Voltage A Circuit Low fault low using the manufacturer approved diagnostic system.
Suspect the TCM, check and install a new TCM as
P064322 Sensor Reference Sensor supply voltage Carry out any pinpoint tests associated with this DTC
Voltage A Circuit High fault high using the manufacturer approved diagnostic system.
Suspect the TCM, check and install a new TCM as
P065713 Actuator Supply Actuator supply Suspect the TCM, check and install a new TCM as
Voltage A Circuit/Open (pressure control valves required, refer to the new module/component installation
etc) open circuit note at the top of the DTC Index
P06571C Actuator Supply Actuator supply Refer to electrical circuit diagrams and check TCM
Voltage A Circuit/Open (pressure control valves connector pin 7 for short to ground. If no fault identified,
etc) voltage plausibilitysuspect the TCM. Check and install a new TCM as
fault required, refer to the new module/component installation
Voltage A Circuit Low (pressure control valves required, refer to the new module/component installation
etc) voltage short to note at the top of the DTC Index
ground
Voltage A Circuit High (pressure control valves required, refer to the new module/component installation
etc) voltage short to note at the top of the DTC Index
power
P066701 PCM/ECM/TCM Internal General electrical failure Suspect the TCM, check and install a new TCM as
Temperature Sensor A required, refer to the new module/component installation
Range/Performance note at the top of the DTC Index
P066749 PCM/ECM/TCM Internal Internal electronic Suspect the TCM, check and install a new TCM as
Temperature Sensor A failure required, refer to the new module/component installation
P070002 Transmission Control General signal failure Carry out any diagnostic pinpoint tests associated with
System (MIL Request) this DTC using the manufacturer approved diagnostic
system. Clear DTC and re-test, if DTC remains check for
additional DTCs and refer to the relevant DTC Index
P070022 Transmission Control Double fault from Carry out any diagnostic pinpoint tests associated with
System (MIL Request) monitoring of internal this DTC using the manufacturer approved diagnostic
power supply and system. If any of the following DTCs are also present;
pressure P096312, P096712, P096413, P097112, P272112,
regulator/solenoid P273012, P272713, P276312, P074013, suspect the TCM,
control software check and install a new TCM as required, refer to the new
module/component installation note at the top of the
DTC Index
P071013 Transmission Fluid Transmission fluid Suspect the TCM, check and install a new TCM as
Temperature Sensor A temperature sensor required, refer to the new module/component installation
Circuit circuit - open circuit note at the top of the DTC Index
P071101 Transmission Fluid General electrical failure Carry out any pinpoint tests associated with this DTC
Temperature Sensor A using the manufacturer approved diagnostic system.
Circuit Suspect the TCM, check and install a new TCM as
Range/Performance required, refer to the new module/component installation
P071122 Transmission Fluid Signal amplitude > Clear DTC and re-test from cold and at normal operating
Temperature Sensor A maximum. Excessive temperature. If DTC remains, suspect the TCM. Check
Circuit jump in temperature and install a new TCM as required, refer to the new
Range/Performance module/component installation note at the top of the
DTC Index
Circuit Low circuit - short to ground note at the top of the DTC Index
P071301 Transmission Fluid General electrical failure Carry out any pinpoint tests associated with this DTC
Temperature Sensor A using the manufacturer approved diagnostic system.
Circuit High Suspect the TCM, check and install a new TCM as
Circuit High circuit - short to power note at the top of the DTC Index
P071614 Turbine/Input Shaft Turbine/Input Shaft Carry out any pinpoint tests associated with this DTC
Speed Sensor A Circuit Speed Sensor circuit - using the manufacturer approved diagnostic system.
Range/Performance short to ground, open Suspect the TCM, check and install a new TCM as
circuit required, refer to the new module/component installation
Speed Sensor A Circuit Speed Sensor signal too using the manufacturer approved diagnostic system.
Range/Performance small Clear DTC and re-test, if DTC remains 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
Speed Sensor A Circuit Speed Sensor signal too using the manufacturer approved diagnostic system.
Range/Performance large Clear DTC and re-test, if DTC remains suspect the TCM.
Check and install a new TCM as required, refer to the
the DTC Index
P071712 Turbine/Input Shaft Turbine/input shaft Suspect the TCM, check and install a new TCM as
Speed Sensor A Circuit speed sensor A circuit - required, refer to the new module/component installation
No Signal short to power note at the top of the DTC Index
P072012 Output Shaft Speed Transmission output Suspect the TCM, check and install a new TCM as
Sensor Circuit shaft speed sensor required, refer to the new module/component installation
circuit - short to power note at the top of the DTC Index
P072014 Output Shaft Speed Transmission output Suspect the TCM, check and install a new TCM as
Sensor Circuit shaft speed sensor required, refer to the new module/component installation
circuit - short to ground, note at the top of the DTC Index
open circuit
P072122 Output Shaft Speed Transmission output Clear DTC and re-test, if DTC remains suspect the TCM.
Sensor Circuit shaft speed sensor Check and install a new TCM as required, refer to the
Range/Performance signal too large new module/component installation note at the top of
the DTC Index
P072127 Output Shaft Speed Output shaft speed Clear DTC and re-test, if DTC remains suspect the TCM.
Sensor Circuit negative gradient too Check and install a new TCM as required, refer to the
Range/Performance high new module/component installation note at the top of
the DTC Index
P072164 Output Shaft Speed Signal plausibility failure Suspect the TCM, check and install a new TCM as
Sensor Circuit required, refer to the new module/component installation
P073007 Gear 1 Incorrect Ratio Gear ratio monitoring. Check oil level, top up if required. Delete DTC and
Mechanical failures recheck system.
P074013 Torque Converter Pressure control Suspect the TCM, check and install a new TCM as
Clutch Pressure solenoid 6 circuit - open required, refer to the new module/component installation
Solenoid Circuit/Open circuit note at the top of the DTC Index
P074107 Torque Converter Too high slip at torque Suspect torque converter lockup clutch. Install a new
Clutch Solenoid Circuit converter clutch. torque converter, refer to the new module/component
Performance Or Stuck Mechanical failures installation note at the top of the DTC Index. If
Off transmission fluid is in very poor condition and dirty,
install a new transmission, refer to the new
DTC Index
P074500 Pressure Control No sub type information Suspect the TCM, check and install a new TCM as
Solenoid A required, refer to the new module/component installation
P075113 Shift Solenoid A Solenoid valve 1 or Suspect the TCM, check and install a new TCM as
Performance/Stuck off Pressure control required, refer to the new module/component installation
Solenoid G circuit - open note at the top of the DTC Index
circuit
P075114 Shift Solenoid A Solenoid valve 1 or Carry out any diagnostic pinpoint tests associated with
Performance/Stuck off Pressure control this DTC using the manufacturer approved diagnostic
solenoid 7 circuit - short system. Suspect the TCM, check and install a new TCM as
to ground, open circuit required, refer to the new module/component installation
P075211 Shift Solenoid A Stuck Solenoid valve 1 or Suspect the TCM, check and install a new TCM as
on Pressure control required, refer to the new module/component installation
solenoid 7 circuit - short note at the top of the DTC Index
to ground
P075312 Shift Solenoid A Solenoid valve 1 or Suspect the TCM, check and install a new TCM as
Electrical Pressure control required, refer to the new module/component installation
Solenoid G circuit - short note at the top of the DTC Index
to power
P075812 Shift Solenoid B Solenoid valve 2 circuit - Suspect the TCM, check and install a new TCM as
Electrical short to power required, refer to the new module/component installation
Electrical open circuit required, refer to the new module/component installation
P077171 Shift Solenoid E Actuator stuck Suspect the TCM, check and install a new TCM as
Performance/Stuck off required, refer to the new module/component installation
Solenoid B required, refer to the new module/component installation
P077811 Pressure Control Pressure control Suspect the TCM, check and install a new TCM as
Solenoid B Electrical solenoid B electrical required, refer to the new module/component installation
circuit - short to ground note at the top of the DTC Index
P077821 Pressure Control Pressure control Carry out any diagnostic pinpoint tests associated with
Solenoid B Electrical solenoid 2 current too this DTC using the manufacturer approved diagnostic
small system. Suspect the TCM, check and install a new TCM as
P078107 1-2 Shift Gear ratio monitoring. Check oil level, top up if required. Delete DTC and
Mechanical failures recheck the system.
Solenoid C required, refer to the new module/component installation
Solenoid C Electrical solenoid C circuit - short required, refer to the new module/component installation
to ground note at the top of the DTC Index
Solenoid C Electrical solenoid 3 current too this DTC using the manufacturer approved diagnostic
large system. Suspect the TCM, check and install a new TCM as
P081462 Reverse Output Circuit Transmission range Suspect the TCM, check and install a new TCM as
display circuit required, refer to the new module/component installation
P085001 Park/Neutral Switch General electrical failure Carry out any diagnostic pinpoint tests associated with
Input Circuit this DTC using the manufacturer approved diagnostic
system. Suspect the TCM, check and install a new TCM as
P085002 Park/Neutral Switch General signal failure Carry out any diagnostic pinpoint tests associated with
Input Circuit this DTC using the manufacturer approved diagnostic
P085029 Park/Neutral Switch W rong voltage level Carry out any diagnostic pinpoint tests associated with
Input Circuit detected on Park/No this DTC using the manufacturer approved diagnostic
Park signal system. Check for correct output at TCM Park signal pin
(check in all positions) 12 volts in Park, 0 volts in all
other positions. If NO fault identified, check Park signal
circuit to transmission shift module for short, open
circuit. If fault identified, suspect the TCM, check and
install a new TCM as required, refer to the new
DTC Index
P091993 Gear Shift Position No shifting despite Carry out any diagnostic pinpoint tests associated with
Control Error driver request this DTC using the manufacturer approved diagnostic
P091994 Gear Shift Position Shifting without driver Carry out any diagnostic pinpoint tests associated with
Control Error request this DTC using the manufacturer approved diagnostic
P093829 Hydraulic Oil Transmission fluid Clear DTC and re-test from cold and at normal operating
Temperature Sensor temperature compared temperature. If DTC remains suspect the TCM. Check and
Range/Performance with module install a new TCM as required, refer to the new
temperature fault module/component installation note at the top of the
DTC Index
Solenoid A Control solenoid 1 circuit - short required, refer to the new module/component installation
Circuit High to power note at the top of the DTC Index
Solenoid B Control solenoid 2 circuit - short required, refer to the new module/component installation
Circuit Low to ground note at the top of the DTC Index
Solenoid B Control solenoid 2 circuit - short required, refer to the new module/component installation
Solenoid C Control solenoid 3 circuit - short this DTC using the manufacturer approved diagnostic
Circuit/Open to ground, open circuit system. Suspect the TCM, check and install a new TCM as
Solenoid C Control solenoid 3 circuit - short required, refer to the new module/component installation
Solenoid C Control solenoid 3 circuit - short required, refer to the new module/component installation
P097222 Shift Solenoid A Pressure control Carry out any diagnostic pinpoint tests associated with
Control Circuit solenoid 1 - current too this DTC using the manufacturer approved diagnostic
Range/Performance large system. Suspect the TCM, check and install a new TCM as
P097311 Shift Solenoid A Shift solenoid A control Suspect the TCM, check and install a new TCM as
Control Circuit Low circuit - short to ground required, refer to the new module/component installation
P097314 Shift Solenoid A Pressure control Carry out any diagnostic pinpoint tests associated with
Control Circuit Low solenoid 1 circuit - short this DTC using the manufacturer approved diagnostic
to ground, open circuit system. Suspect the TCM, check and install a new TCM as
short to ground required, refer to the new module/component installation
short to ground, open required, refer to the new module/component installation
circuit note at the top of the DTC Index
P167400 Control Module No sub type information Suspect the TCM, check and install a new TCM as
Software Corrupted required, refer to the new module/component installation
P170777 Transfer case Neutral commanded position not Make sure the emergency park position release lever has
OR Park/Neutral reachable not been activated, and is not sticking. Clear the DTC
Indication Circuit and re-test, engaging and dis-engaging the park lock
several times. If DTC remains, check and install new park
lock components as required. Clear the DTC and re-test,
engaging and dis-engaging the park lock several times. If
DTC still remains, suspect the TCM, check and install a
new TCM as required, refer to the new
DTC Index
P270007 Transmission Friction Gear ratio monitoring. Check oil level, top up if required. Delete DTC and
Element A Apply Time Mechanical failures recheck the system.
Range/Performance
Element B Apply Time Mechanical failures recheck the system.
Range/Performance
Element C Apply Time Mechanical failures recheck the system.
Range/Performance
Element D Apply Time Mechanical failures recheck the system.
Range/Performance
Element E Apply Time Mechanical failures recheck the system.
Range/Performance
Solenoid D required, refer to the new module/component installation
Solenoid D Electrical solenoid D circuit - short required, refer to the new module/component installation
Solenoid D Electrical solenoid D circuit - this DTC using the manufacturer approved diagnostic
current too small system. Suspect the TCM, check and install a new TCM as
Solenoid D Control solenoid D circuit - short this DTC using the manufacturer approved diagnostic
Circuit/Open to ground, open circuit system. Suspect the TCM, check and install a new TCM as
Solenoid D Control solenoid D circuit - short required, refer to the new module/component installation
Solenoid D Control solenoid D circuit - short required, refer to the new module/component installation
Solenoid E Electrical solenoid E circuit - short required, refer to the new module/component installation
Solenoid E Control solenoid E circuit - open required, refer to the new module/component installation
Circuit/Open circuit note at the top of the DTC Index
Solenoid E Control solenoid E circuit - short required, refer to the new module/component installation
Solenoid E Control solenoid E circuit - short required, refer to the new module/component installation
P276312 Torque Converter Pressure control Suspect the TCM, check and install a new TCM as
Clutch Pressure Control solenoid F circuit - short required, refer to the new module/component installation
Solenoid Control Circuit to power note at the top of the DTC Index
High
P276411 Torque Converter Torque converter clutch Suspect the TCM, check and install a new TCM as
Clutch Pressure Control pressure control required, refer to the new module/component installation
Solenoid Control Circuit solenoid control circuit - note at the top of the DTC Index
Low short to ground
P280711 Pressure Control Park solenoid circuit - Suspect the TCM, check and install a new TCM as
Solenoid G short to ground required, refer to the new module/component installation
Solenoid G short to power required, refer to the new module/component installation
Solenoid G open circuit required, refer to the new module/component installation
P280714 Pressure Control Park solenoid circuit - Carry out any diagnostic pinpoint tests associated with
Solenoid G short to ground, open this DTC using the manufacturer approved diagnostic
circuit system. Suspect the TCM, check and install a new TCM as
U000188 High speed CAN CAN Bus off Carry out any diagnostic pinpoint tests associated with
communication Bus this DTC using the manufacturer approved diagnostic
system
U010082 Lost Communication Alivecounter fault Check ECM for DTCs and refer to the relevant DTC Index
W ith Engine/Powertrain
Control Module
U010083 Lost Communication Checksum fault Check ECM for DTCs and refer to the relevant DTC Index
W ith Engine/Powertrain
Control Module
U010087 Lost Communication CAN Timeout NOTE: Do NOT install a new ECM if an ECM Timeout
W ith Engine/Powertrain DTC is only logged in the TCM, the failure is NOT with
Control Module the ECM
Carry out any diagnostic pinpoint tests associated with

this DTC using the manufacturer approved diagnostic
system. Carry out CAN network integrity test using the
U010382 Lost CAN Alivecounter fault Check transmission shift module for DTCs and refer to
Communications with the relevant DTC Index
Gear Shift Module
U010383 Lost CAN Checksum fault Check transmission shift module for DTCs and refer to
Communications with the relevant DTC Index
Gear Shift Module
U010387 Lost CAN CAN Timeout Carry out any diagnostic pinpoint tests associated with
Communications with this DTC using the manufacturer approved diagnostic
Gear Shift Module system. Check transmission shift module for DTCs and
U012282 Lost Communication Alivecounter fault Check ABS module for DTCs and refer to the relevant DTC
W ith Vehicle Dynamics Index
Control Module
U012283 Lost Communication Checksum fault Check ABS module for DTCs and refer to the relevant DTC
W ith Vehicle Dynamics Index
Control Module
U012287 Lost Communication CAN Timeout Carry out any diagnostic pinpoint tests associated with
W ith Vehicle Dynamics this DTC using the manufacturer approved diagnostic
Control Module system. Check ABS module for DTCs and refer to the
relevant DTC Index
U012887 Lost Communication CAN timeout electronic Carry out any diagnostic pinpoint tests associated with
W ith Electric Park parking brake module this DTC using the manufacturer approved diagnostic
Brake Module system. Check electronic parking brake module for DTCs
and refer to the relevant DTC Index
U014082 Lost Communication Alivecounter fault Check CJB for DTCs and refer to the relevant DTC Index
with Body Control
Module
U014083 Lost Communication Checksum fault Check CJB for DTCs and refer to the relevant DTC Index
with Body Control
Module
U014087 Lost Communication CAN Timeout Carry out any diagnostic pinpoint tests associated with
with Body Control this DTC using the manufacturer approved diagnostic
Module system. Check CJB for DTCs and refer to the relevant DTC
Index
U015587 Lost Communication CAN timeout instrument Carry out any diagnostic pinpoint tests associated with
W ith Instrument Panel cluster this DTC using the manufacturer approved diagnostic
Cluster (IPC) Control system. Check instrument cluster for DTCs and refer to
Module the relevant DTC Index
U030068 Internal Control Module CAN level Re-configure the TCM using the manufacturer approved
Software diagnostic system
Incompatibility
U040168 Invalid Data Received Faulty/inaccurate engine Check ECM for DTCs and refer to relevant DTC Index
from Engine/Powertrain speed, torque
Control Module information
U040468 Invalid CAN/LIN Data Invalid transmission Check transmission shift module for DTCs and refer to
received from Gear shift information the relevant DTC Index
Shift Module
U041668 Invalid Data Received Event information - Check ECM and ABS module for DTCs and refer to the
from Vehicle Dynamics brake information relevant DTC Index
Control Module
U042268 Invalid CAN Data Event information - Check instrument cluster and CJB for DTCs and refer to
received from Body invalid power mode the relevant DTC Index
Control Module information
U101B87 Lost CAN and LIN Missing message - lost Carry out any diagnostic pinpoint tests associated with
Communication with communication with this DTC using the manufacturer approved diagnostic
ETS transmission shift system. Check transmission shift module for DTCs and
module - multiple Bus refer to the relevant DTC Index. Check CAN and LIN
networks to TCM
U300081 Control Module Invalid serial data Re-configure the TCM using the manufacturer approved
received diagnostic system
AJ27/4.2L NA V8 - AJV8/4.2L SC V8 - AJV8 - Transmission Fluid Drain and
Refill
General Procedures
Special Tool(s)
Adapter
307-452


3. Place a container under the transmission.
4. WARNINGS:
Observe due care when draining, as the fluid can be very

hot.
Observe due care when working near a hot exhaust

system.
Using the special tool, remove the transmission fluid

filler/level plug.
5. WARNINGS:
Observe due care when draining, as the fluid can be very

hot.
Observe due care when working near a hot exhaust

system.
Remove the transmission fluid drain plug.
Allow the fluid to drain.

6. Install the new transmission fluid drain plug.
Tighten to 8 Nm.
7. NOTE: Use transmission fluid meeting Jaguar specification.
Refill the transmission with fluid.
8. Allow the transmission fluid to drain from the transmission

fluid filler plug hole until the flow almost stops.
Using the special tool, install the new transmission fluid fill
plug.
Loosely install the transmission fluid fill plug.

11. Carry out a transmission fluid level check.
AJ27/4.2L NA V8 - AJV8/4.2L SC V8 - AJV8 - Transmission Fluid Level
Check
General Procedures
Special Tool(s)
Adapter
307-452
1. The following steps must be observed before starting the

transmission fluid level check.
The vehicle must be on a horizontal ramp.
The parking brake must be applied.
The engine must be running for 2 minutes with the

transmission control switch (TCS) in the "P" position.
2. Connect the Jaguar approved diagnostic system.

3. Make sure that the TCS is in the "P" position.
4. NOTE: Make sure the transmission fluid temperature is below
30 C (86 F) on the Jaguar approved diagnostic system.
W ith the engine running and the foot brake applied, circulate
the transmission fluid by:
Moving the TCS to the "R" position.
Waiting for 3 seconds.
Moving the TCS to the "D" position.
Waiting for 3 seconds.
Moving the TCS to the "P" position.


7. Place a suitable container under the transmission fluid fill
plug.
8. WARNING: Make sure that care is exercised near
rotating parts. Failure to follow this instruction may result in
personal injury.
With the engine running, using the special tool remove the
transmission fluid fill plug.
Remove and discard the transmission fluid fill plug.
9. NOTE: Use transmission fluid meeting Jaguar specification.
If the transmission fluid does not come out of the

transmission fluid fill plug hole the transmission fluid level is
insufficient. If this is the case add the transmission fluid in
0.5 liter units into the transmission fluid fill plug hole until
fluid comes out.
10. NOTE: Make sure the transmission fluid temperature does

not exceed 50 C (122 F). If the transmission fluid
temperature does exceed 50 C (122 F) stop the transmission
fluid level check and allow the transmission fluid to cool until
the temperature is below 30 C (86 F).
Allow the transmission fluid to drain from the transmission

fluid filler plug hole until the flow almost stops.
Using the special tool, install the new transmission fluid fill
plug.
12. CAUTION: Make sure the transmission fluid fill plug is

tightened to the correct specification. Failure to follow this
Using the special tool and torque wrench, tighten the

transmission fluid fill plug.
To make sure the transmission fill plug is torqued to the

correct specification. Using the special tool and torque
wrench the following calculation steps must be followed.
Step 1. Multiply 35 Nm by the effective length of the

torque wrench (1).
Step 2. Add the effective length of the special tool (2) to

the effective length of the torque wrench (1).
Step 3. Divide the total of step 1 by the total of step 2.
Step 4. Set the torque wrench to the figure arrived at in

step 3.
Tighten the transmission fluid fill plug to the torque given

by the calculation.

14. Remove the container.
17. Disconnect the Jaguar approved diagnostic system.
AJ27/4.2L NA V8 - AJV8/4.2L SC V8 - AJV8 - Extension Housing Seal
In-vehicle Repair
Special Tool(s)
Crankshaft Damper Remover
303-D121
Output Shaft Flange Holding Tool
205-053
Pinion Seal Replacer
204-264
Powertrain Assembly Jack
HTJ1200-2
Seal Remover Input and Output
308-375
Slide Hammer
100-012
Slide Hammer Adaptor
100-012-01
Socket Output Flange Remover/Installer
205-789
Removal
1. CAUTIONS:
Under no circumstances must the flexible coupling (or its

fixings) be loosened or removed from the driveshaft. Failure to
Make sure the front of the driveshaft does not put an

excessive load on the center bearing. Failure to follow this
Detach the driveshaft from the transmission flange.

transmission flange.

transmission flexible joint.
2. Loosen the heat shield retaining nut.
3. Install suitable cord to the heat shield retaining nut stud.
Tighten the retaining nut.
4. Reposition the driveshaft.

5. Using the special tool, remove the transmission support.
Lower the transmission to a siutable height.
6. Using the special tools, remove and discard the output shaft
flange retaining nut.
7. Using the special tool, remove the output shaft flange.
Remove the output shaft flange spacing shim.
8. CAUTION: Make sure the transmission housing seal face

is not damaged when removing the extension housing seal.
vehicle.
Using the special tools, remove the extension housing seal.

9. NOTE: Using a suitable metal surface cleaner meeting Jaguar
specification, clean the seal face on the housing before installing
the new seal.
Clean and inspect the transmission housing seal face.
Installation
1. Using the special tool, install the extension housing seal.
2. Using the special tools install a new output shaft flange

retaining nut.
Install the output shaft flange spacing shim.
Install the output shaft flange.
Tighten to 60 Nm.
3. Install the transmission support.
Using the special tool, raise the transmission.
Tighten to 55 Nm.
5. CAUTION: Make sure the front of the driveshaft does not

put an excessive load on the center bearing. Failure to follow this
Reposition the driveshaft.
Undo the cord.
6. Loosen the retaining nut.
Remove the cord from the heat shield retaining nut stud.
7. Tighten the retaining nut.

8. CAUTIONS:
Make sure the front of the driveshaft does not put an

excessive load on the center bearing. Failure to follow this
Make sure all components are installed to the position they

were removed from. Failure to follow this instruction may result
Attach the driveshaft to the transmission flange.
Tighten to 88 Nm.

Check (307-01, General Procedures).
AJ27/4.2L NA V8 - AJV8/4.2L SC V8 - AJV8 - Transmission Fluid Pan,
Gasket and Filter
In-vehicle Repair
Removal
All vehicles
For additional information, refer to: Battery Disconnect

All vehicles
3. Drain the transmission.
For additional information, refer to: Transmission Fluid Drain
and Refill (307-01, General Procedures).

4. Detach the catalytic converter temperature sensor wiring
harness from the fluid pan.
All vehicles
5. NOTE: Discard the fluid pan, gasket and filter.
Remove the fluid pan, gasket and filter.
Installation
All vehicles
1. Install the new fluid pan, gasket and filter.
Tighten to 8 Nm.

2. Attach the catalytic converter temperature sensor wiring
harness onto the fluid pan.
All vehicles
3. Fill the transmission.
For additional information, refer to: Transmission Fluid Drain
and Refill (307-01, General Procedures).

All vehicles
For additional information, refer to: Battery Connect (414-01,
AJ27/4.2L NA V8 - AJV8/4.2L SC V8 - AJV8 - Transmission Control Module
(TCM) and Main Control Valve Body
In-vehicle Repair
General Equipment
Anti-Static Wrist Strap
Removal
1. Remove the fluid pan, gasket and filter.
For additional information, refer to: Transmission Fluid Pan,
Gasket and Filter (307-01 Automatic Transmission/Transaxle -
2.7L V6 - TdV6/3.0L NA V6 - AJ27/4.2L NA V8 - AJV8/4.2L SC
V8 - AJV8, In-vehicle Repair).
2. CAUTION: Make sure the transmission control module

(TCM) and main control valve body are protected against
electrostatic discharge. Failure to follow this instruction may
result in component damage.
Reposition the locking device.
3. Disconnect the TCM and main control valve body electrical

connector.
1. Reposition the electrical connector retaining ring.
4. CAUTION: Make sure all suitable safety precautions are

taken to protect the TCM and main control valve body electrical
connector pins against electrostatic discharge.
Remove the sealing tube.

5. Remove and discard the seals.
6. Remove the TCM and main control valve body.
7. Remove the TCM and main control valve body sealing block.

Installation
1. Install the new seals.
3. Install the TCM and main control valve body sealing block.
4. CAUTION: Make sure the TCM and main control valve
body are protected against electrostatic discharge. Failure to
follow this instruction may result in component damage.
Align the transmission selector shaft to the TCM and main

control valve body.
5. Install the TCM and main control valve body retaining bolts.
Tighten to 8 Nm.
7. CAUTION: Make sure all suitable safety precautions are

taken to protect the TCM and main control valve body electrical
connector pins against electrostatic discharge.
Install the sealing tube.

8. Reposition the TCM and main control valve body electrical
connector retaining ring.
2. Reposition the electrical connector retaining ring.
9. Reposition the locking device.
10. Install the fluid pan, gasket and filter.

For additional information, refer to: Transmission Fluid Pan,
Gasket and Filter (307-01 Automatic Transmission/Transaxle -
2.7L V6 - TdV6/3.0L NA V6 - AJ27/4.2L NA V8 - AJV8/4.2L SC
V8 - AJV8, In-vehicle Repair).
Automatic Transmission/Transaxle - V8 4.2L Petrol/V8 S/C 4.2L Petrol/V6 3.0L
Petrol/TDV6 2.7L Diesel - TransmissionTDV6 2.7L Diesel
Removal
Special Tool(s)
1200-2
303-021
303-1129
Removal
1. Place the transmission control switch (TCS) knob in the N position.
2. Release the electronic parking brake.
Rotate the special tool adjustment bolt a suitable amount of turns

to support the engine.


8. Remove the catalytic converters.
Release and disconnect the 2 transmission wiring harness electrical

connectors.
10. CAUTION: Under no circumstances must the flexible coupling (or

it's fixings) be loosened or removed from the driveshaft.
NOTE: Note the fitted position of the component/s prior to removal.
Mark the position of the driveshaft in relation to the transmission

flange.

transmission fllexible joint.
Tie aside.
11. Release the transmission fluid cooler tubes.
Allow the transmission fluid to drain into a suitable container.
12. Detach the transmission fluid cooler tubes from the retaining bracket.
13. Detach the transmission park interlock release cable from the
transmission.
Release the transmission park interlock release cable from the

transmission park interlock release lever.
14. Detach the diesel particulate filter (DPF) high and low-pressure pipes
from the transmission.
Remove the bolt.
Remove the rubber access cover.
Rotate the torque converter to align with the flexplate bolt holes.
19. Using the special tool, lower the rear of the transmission.
20. W ARNING: Secure the transmission to the transmission jack.
Secure the retaining strap.
21. Remove the retaining bolts.

24. Remove the transmission and converter.
2. Displace the transmission from the engine locating dowels.
3. Lower the transmission.
25. With assistance, remove the transmission from the special tool.
access only.
Remove the wiring harness.
27. Remove the transmission rear support bracket.
Remove the two support bracket retaining bolts.

Petrol/TDV6 2.7L Diesel - TransmissionV6 3.0L Petrol
Removal
Special Tool(s)
303-021
HTJ1200-2
Removal


For additional information, refer to: Engine Rear Undershield (501-02
For additional information, refer to: Starter Motor (303-06B Starting
System - V6 3.0L Petrol, Removal and Installation).


flange.


contamination.
NOTE: Position cloth to collect fluid spillage.
Release the transmission fluid lines.
Remove the bolt.

9. Detach the transmission park interlock release cable from the
transmission.
Release the transmission park interlock release cable from the

10. Release the torque convertor from the flexplate.
Remove the access plugs.
Rotate the crankshaft to access the retaining bolts.
Remove the 3 bolts.
11. Using a transmission jack, support the transmission.

12. Release the transmission support insulator.
Remove the 4 bolts.

13. Release the wiring harness from the RH side of the transmission.
Disconnect the transmission electrical connector.
Carefully release the 3 clips.
15. WARNINGS:
Secure the transmission to the transmission jack.
Support the engine. The engine will fall forward when the
transmission is removed.
CAUTION: Make sure the torque converter remains connected to the

transmission.
W ith assistance, remove the transmission.

AJ27/4.2L NA V8 - AJV8/4.2L SC V8 - AJV8 - Transmission4.2L NA V8 -
Removal
Special Tool(s)
303-021
HTJ1200-2
Removal
Procedures).


For additional information, refer to: Starter Motor (303-06
Starting System - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8,

coupling (or it's fixings) be loosened or removed from the
driveshaft.
NOTE: Note the fitted position of the component/s prior to

removal.

transmission flange.

NOTE: Position cloth to collect fluid spillage.
Release the transmission fluid lines.
Remove the bolt.
8. Detach the transmission park interlock release cable from

the transmission.
Release the transmission park interlock release cable

from the transmission park interlock release lever.
9. Release the torque convertor from the flexplate.
Remove the access plugs.
Remove the 3 bolts.

11. Release the transmission support insulator.
Remove the 4 bolts.
12. Release the wiring harness from the RH side of the

transmission.
Disconnect the transmission electrical connector.
Carefully release the 3 clips.

14. WARNINGS:
Support the engine. The engine will fall forward when

the transmission is removed.
CAUTION: Make sure the torque converter remains

connected to the transmission.
With assistance, remove the transmission.

Petrol/TDV6 2.7L Diesel - TransmissionTDV6 2.7L Diesel
Installation
Special Tool(s)
1200-2
303-021
303-1129
Installation
1. CAUTION: If installing a new transmission, the oil cooler must be

flushed.
Flush the transmission oil cooler and fluid tubes.

2. Install the transmission rear support bracket.
Install the the two support bracket retaining bolts.
Tighten to 45 Nm.
Attach the 3 wiring harness clips.

4. With assistance, install the transmission to the special tool.
Secure the retaining strap.
5. CAUTION: Apply grease of the correct specification to the torque

converter spigot.
Apply a thin layer of high-temperature grease to the centering spigot

bore on the torque converter.
6. CAUTION: Make sure the torque converter remains connected to

the transmission.
Install the transmission and converter.
Using a transmission jack, carefully raise the assembly.
Make sure the transmission engages correctly with the engine

locating dowels.
Loosely install the bolts.
7. Install the retaining bolts.
Tighten to 48 Nm.
Tighten to 48 Nm.
Tighten to 48 Nm.
Tighten to 48 Nm.
12. Remove the retaining strap.
13. Using the special tool, raise the rear of the transmission.
Install the retaining bolts.
Tighten to 50 Nm.

Install the retaining bolts.
Rotate the torque converter to align with the flexplate bolt holes.
Tighten to 55 Nm.
Install the rubber access cover.
Install and tighten the bolt.
Tighten to 9 Nm.

18. Attach the DPF high and low-pressure pipes to the transmission.
Tighten to 9 Nm.
19. Attach the transmission park interlock release cable to the

transmission.
Secure the transmission park interlock release cable to the

Tighten to 9 Nm.
20. Attach the transmission fluid cooler tubes to the automatic

transmission.
Lubricate the O-ring seals.
Tighten to 23 Nm.
21. Attach the transmission fluid cooler tubes to the retaining bracket.
22. NOTE: Install the components to their original fitted positions.
Attach the driveshaft to the transmission flange.
Tighten to 127 Nm.
Connect the transmission wiring harness electrical connectors.
24. Install the catalytic converters.


29. Apply the electronic parking brake.
Petrol/V6 3.0L Petrol/TDV6 2.7L Diesel, General Procedures).
Petrol/TDV6 2.7L Diesel - TransmissionV6 3.0L Petrol
Installation
Special Tool(s)
303-021
HTJ1200-2
Installation
1. W ARNING: Secure the transmission to the transmission jack.
CAUTION: Make sure the torque converter remains connected to the

transmission.
W ith assistance, install the transmission.
Tighten to 48 Nm.

3. Install the transmission wiring harness.
Connect the transmission electrical connector.
Carefully secure the 3 clips.
4. Install the transmission support insulator.

transmission.
Secure the transmission park interlock release cable to the

Tighten to 9 Nm.
7. Attach the flexplate to the torque converter.
Tighten to 55 Nm.
8. Secure and connect the selector lever cable.

Connect the driveshaft to the rear flange.

flange.

Tighten to 127 Nm.

For additional information, refer to: Starter Motor (303-06B Starting
System - V6 3.0L Petrol, Removal and Installation).
For additional information, refer to: Engine Rear Undershield (501-02
AJ27/4.2L NA V8 - AJV8/4.2L SC V8 - AJV8 - Transmission4.2L NA V8 -
Installation
Special Tool(s)
303-021
HTJ1200-2
Installation
1. WARNINGS:
Support the engine. The engine will fall forward when

the transmission is removed.
CAUTION: Make sure the torque converter remains

connected to the transmission.
With assistance, install the transmission.

3. Install the transmission wiring harness.
Connect the transmission electrical connector.
Attach the 3 wiring harness clips.

4. Install the transmission support insulator.

transmission.
Secure the transmission park interlock release cable to

the transmission park interlock release lever.
Tighten to 9 Nm.
7. Attach the flexplate to the torque converter.
Tighten to 55 Nm.
8. Secure and connect the selector lever cable.

coupling (or it's fixings) be loosened or removed from the
driveshaft.
NOTE: Note the fitted position of the component/s prior to

removal.
Connect the driveshaft to the rear flange.
Tighten to 127 Nm.

For additional information, refer to: Starter Motor (303-06
Starting System - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8,
(309-00 Exhaust System - 3.0L NA V6 - AJ27, Removal and
Installation).
Procedures).
Transmission/Transaxle Cooling - 2.7L V6 - TdV6/3.0L NA V6 - AJ27/4.2L
NA V8 - AJV8/4.2L SC V8 - AJV8 - Transmission CoolingVehicles With: ZF
6HP26 - Component Location
COMPONENT LOCATION - PETROL ENGINES
ItemDescription
1 Engine cooling radiator
2 Return pipe (to transmission)
3 Feed pipe (from transmission)
COMPONENT LOCATION - DIESEL ENGINE
ItemDescription
1 Engine coolant hose connections
2 Transmission fluid cooler
3 Return pipe (to transmission)
4 Feed pipe (from transmission)
6HP26 - Overview
OVERVIEW
All models have transmission fluid coolers.
On models with petrol engines, the fluid cooler is incorporated into the LH (left-hand) end tank of the engine cooling
radiator.
On models with diesel engines, the fluid cooler is a dedicated cooler unit located near the lower front LH side of the
engine compartment.
6HP26 - System Operation and Component Description
System Operation
MODELS WITH V8 AND V6 PETROL ENGINES
Fluid is supplied from the transmission fluid pump into the upper connection of the engine cooling radiator. After passing
through the radiator in tank cooler, the fluid passes out of the lower connection and is returned to the transmission fluid
pan.
MODELS WITH 2.7L V6 DIESEL ENGINE

Fluid is supplied from the transmission fluid pump into the forward most connection of the cooler. After passing through
the cooler, the fluid passes out of the rearmost connection and is returned to the transmission fluid pan.
MODELS WITH V8 AND V6 PETROL ENGINES
The transmission fluid cooler is integrated into the LH (left-hand) end tank of the engine cooling radiator. The
transmission fluid is cooled by the temperature differential between the transmission fluid and the engine coolant.
The fluid cooler is an aluminium cooler comprising louvered fins and plates. The plates allow a cross-flow of transmission
fluid through the cooler. The fins are immersed in engine coolant on the 'cold' side of the radiator which provides cooling of
the transmission fluid via heat transfer.
This fluid cooler design provides an advantage over an air-cooled cooler in that the fluid cooling is controlled with engine
coolant temperature. Fluid temperature control is also improved when the vehicle is moving slowly or is stationary with the
engine running.
MODELS WITH 2.7L V6 DIESEL ENGINE

The transmission fluid cooler is a separate cooling unit located behind the engine cooling radiator. The transmission is
connected to the fluid cooler via flexible hoses and metal pipes.
The transmission fluid cooler is a dedicated fluid cooler which is connected into the engine cooling system circuit. The
transmission fluid is cooled by the temperature differential between the transmission fluid and the engine coolant flowing
through the cooler.
NA V8 - AJV8/4.2L SC V8 - AJV8 - Transmission Cooling
For a detailed description of the automatic transmission cooling system, refer to the relevant Description and Operation
sections in the workshop manual. REFER to: (307-02 Transmission/Transaxle Cooling - 2.7L V6 - TdV6/3.0L NA V6 -
AJ27/4.2L NA V8 - AJV8/4.2L SC V8 - AJV8)
Transmission Cooling - Vehicles With: ZF 6HP26 (Description and Operation),

Transmission Cooling - Vehicles With: ZF 6HP26 (Description and Operation),
Transmission Cooling - Vehicles With: ZF 6HP26 (Description and Operation).

1. 1. Verify the customer concern by operating the system.
Visual Inspection
Mechanical
Feed and return tubes
Connections to the automatic transmission and the automatic transmission fluid cooler
Automatic transmission fluid level
Symptom Chart
Condition Possible Cause Action

Over heating of the Obstruction in the automatic Flush out the automatic transmission fluid cooler with new
automatic transmission fluid cooler automatic transmission fluid. If the flushing is unsuccessful,
transmission install a new transmission fluid cooler.
REFER to: Transmission Fluid Cooler (307-02, Removal and
Installation).
Over heating of the Obstruction in the automatic Flush out the automatic transmission fluid cooler tubes with new
automatic transmission fluid tubes automatic transmission fluid. If the flushing is unsuccessful
transmission install new automatic transmission fluid cooler tubes.
REFER to: Transmission Fluid Cooler Tubes (307-02, Removal
and Installation).
Loss of automatic Connections to the automatic Check the integrity of the tubes, connections and seals. Check
transmission fluid transmission and the automatic the torque of the tube fixings.
transmission fluid cooler REFER to: Specifications (307-02, Specifications).
Loss of automatic Leak at oil cooler Check the integrity of tubes, connections and seals. Check the
transmission fluid torque of the tube fixings.
REFER to: Specifications (307-02, Specifications).
Transmission/Transaxle Cooling - V8 4.2L Petrol/V8 S/C 4.2L Petrol/V6 3.0L
Petrol/TDV6 2.7L Diesel - Transmission Fluid CoolerTDV6 2.7L Diesel
Special Tool(s)
303-397
Removal


Installation).
Procedures).
5. Detach the transmission fluid cooler tubes.
6. Using the special tool, detach the transmission fluid cooler coolant
hose.
7. Using the special tool, detach the transmission fluid cooler coolant
hose.
8. Detach the transmission fluid cooler.
9. Remove the transmission fluid cooler retaining bracket.
10. W ARNING: Fluid loss is unavoidable, use absorbent cloth or a

container to collect the fluid.
Remove the transmission fluid cooler.
Installation
1. Attach the transmission fluid cooler.
2. Install the transmission fluid cooler retaining bracket.
Tighten to 20 Nm.
3. Install the transmission fluid cooler.
Tighten to 10 Nm.
4. Attach the transmission fluid cooler tubes.
Tighten to 11 Nm.
5. Using the special tool, attach the transmission fluid cooler coolant
hose.
6. Using the special tool, attach the transmission fluid cooler coolant
hose.

Installation).
Procedures).
Transmission/Transaxle Cooling - V8 4.2L Petrol/V8 S/C 4.2L Petrol/V6 3.0L
Petrol/TDV6 2.7L Diesel - Transmission Fluid Cooler TubesTDV6 2.7L Diesel
Special Tool(s)
303-021
303-1129
Removal


2. Center the steering wheel.
Installation).
blanking caps.
Detach the transmission fluid cooler tubes.

7. Detach the hose.
9. Detach the lower steering column.

12. Remove the retaining nut.
13. Remove the left-hand catalytic converter heat shield.
14. Remove the left-hand catalytic converter heat shield retaining bracket.
15. Remove the retaining bracket.
16. Remove the left-hand engine mounting retaining nut.

20. Using the special tools, raise the engine to a suitable height.
21. Release the bracket.
22. Release the transmission fluid cooler tubes bracket.
23. Detach the transmission fluid cooler tubes from the retaining bracket.
blanking caps.
Remove the transmission fluid cooler tubes.
Installation
Install the transmission fluid cooler tubes.
Tighten to 11 Nm.
Install the transmission fluid cooler tubes.
Tighten to 23 Nm.

6. Install the retaining bracket.


11. Install the left-hand engine mounting retaining nut.
Tighten to 63 Nm.
12. Install the retaining bracket.
Tighten to 9 Nm.
13. Install the left-hand catalytic converter heat shield retaining bracket.
Tighten to 22 Nm.
14. Install the left-hand catalytic converter heat shield.
Tighten to 22 Nm.
Remove the cable tie.
Tighten to 100 Nm.

19. Attach the lower steering column.
Install the steering gear shaft pinch bolt.
20. Attach the hose.

Installation).
Automatic Transmission/Transaxle External Controls -
Emergency park release arm retaining bolt 12 9 -
Emergency park release cable bracket retaiing bollts 10 - 89
Automatic Transmission/Transaxle External Controls - External
ControlsVehicles With: ZF 6HP26 - Component Location
COMPONENT LOCATION
ItemDescription
1 Emergency park release cable
4 Transmission control lever
ControlsVehicles With: ZF 6HP26 - Overview
OVERVIEW
The TCM (transmission control module) 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
JaguarDrive selector. Unlike previous transmissions, this application uses a fully electronic rotary transmission selector
with no mechanical connection to the transmission.
Rotation of the JaguarDrive selector allows the selection of Park (P), Reverse ), Neutral (N) and Drive (D). By depressing
the JaguarDrive selector and rotating clockwise from the 'D' position, Sport (S) mode can be selected.
Two gear change 'paddle' switches are fitted at the rear of the steering wheel and allow the driver to operate the
transmission as a semi-automatic manual gearbox using the Jaguar Sequential Shift feature.
Four additional switches are located adjacent to the JaguarDrive selector and control the JaguarDrive Optimisation Control
functions.
ControlsVehicles With: ZF 6HP26 - System Operation and Component
Description
Control Diagram
NOTE: A = Hardwired; D = High speed CAN bus; O = LIN bus
ItemDescription
1 Battery
2 BJB (battery junction box) - Megafuse
6 Clockspring
7 Steering wheel audio switch assembly
8 Upshift paddle switch
9 Downshift paddle switch
System Operation
JAGUARDRIVE SELECTOR
Rotation of the JaguarDrive selector to any of the 5 positions is sensed by the TCM via the high speed CAN (controller area
network) bus. A LIN (local interconnect network) bus connection is also provided but is only used in the event of a CAN bus
failure as a back-up. The TCM then reacts according to the selected position. The JaguarDrive selector is a magnetic
system using Hall effect sensors to determine the selected position of the selector.
The 'Sport' (S) position selection allows the TCM to operate the transmission using the semi-automatic 'Jaguar Sequential
Shift'. Gear selections are sensed by the TCM when the driver operates the steering wheel paddle switches. Once the
JaguarDrive selector position is confirmed, 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.
Refer to: Information and Message Center (413-08 Information and Message Center, Description and Operation) /
Information and Message Center (413-08, Description and Operation).
The paddles can also be used on a temporary basis when the JaguarDrive selector is in the 'D' position to override the
automatic gear selection if required.
PADDLE SWITCHES
Each paddle switch has 3 connections; ground, illumination (PWM (pulse width modulation) ) supply and ground switch
signal. The paddle switches are hardwired to the steering wheel audio switches. Operation of the paddle switch completes
a ground path to the audio switch assembly. The audio switch assembly converts the competed ground signal into a LIN
bus signal which is passed via the clockspring to the instrument cluster. The instrument cluster converts the signal into a
high speed CAN bus signal to the TCM.
Pulling the LH (left-hand) downshift - paddle provides down changes and pulling the RH (right-hand) upshift (+) paddle
provides up changes. The first operation of either paddle, after Sport mode is selected, puts the transmission into
permanent manual 'Jaguar Sequential Shift' mode. Rotation of the JaguarDrive selector back to the 'D' position, returns the
transmission to conventional automatic operation.
Temporary operation of manual 'Jaguar Sequential Shift' mode can also be operated with the JaguarDrive selector in the 'D'
position. Operation of either the upshift or downshift paddles activates the manual mode operation. If the JaguarDrive
selector is in 'D', 'Jaguar Sequential Shift' will cancel after a time period or can be cancelled by pressing and holding the +
paddle for approximately 2 seconds.
JAGUARDRIVE SELECTOR
ItemDescription
1 Emergency park release lever locking mechanism
3 Trim cover - emergency park release lever
5 Dynamic mode switch
6 Automatic speed limiter switch
7 Slip control mode switch
8 Dynamic Stability Control (DSC) switch
10 Selector position LED (light emitting diode)
11 Start/Stop switch
12 Screw (5 off)
13 Release cable connector
14 Emergency park release lever cable
The JaguarDrive selector assembly is located in a central position in the floor console. The assembly is attached to a
molding in the floor console with 5 screws.
Transmission selections are made using the rotary JaguarDrive selector which rises from the floor console once the engine
is running. When the engine is stopped with the selector in any position other than 'N', the JaguarDrive selector retracts
into the floor console. If the selector remains in position 'N' when the engine is stopped, the selector will remain in the
raised position for up to 10 minutes, for use in a drive through car wash for example. After 10 minutes the selector will
automatically retract into the floor console or if 'P' is selected before the 10 minute period the selector will retract.
If JaguarDrive selector does not rise from the console when the engine is started but electrical power is supplied to the
selector, selections can still be made by rotating the selector to the required position using your fingertip. If electrical
power to the JaguarDrive selector is lost, the selector will not rise from the console when the engine is started and
selections cannot be made by rotating the selector using your fingertip.
The JaguarDrive selector contains an internal interlock solenoid to prevent the selector from being rotated when the engine
is not running.
The engine can be stopped with the JaguarDrive selector in any position. Once the engine is stopped the selector will
automatically reset to the Park (P) position and the transmission park lock will be engaged, except if the selector is moved
to the 'N' position when the engine is stopped.
Emergency Park Release

In the event of the vehicle requiring recovery, Park can be released manually with the use of the Emergency Park Release
cable. To de-select Park, remove the trim cover from the rear of the floor console and locate the emergency park release
lever. Rotate the locking mechanism of the release lever through 90 degrees in a counterclockwise direction to unlock the
lever. Apply the footbrake and pull the lever upwards and ensure it is locked in the vertical position. This mechanically
disengages the parking pawl and engages the transmission in neutral via a cable to the transmission.
When the Emergency Park Release lever is pulled, the vehicle will be able to free wheel.
To re-engage the transmission into Park, hold the strap on the emergency park release hand lever; release the latch and
lower the hand lever to its horizontal position. Lock the hand lever by turning the locking mechanism 90 degrees in a
clockwise direction and replace trim cover.
PARK INTERLOCK AND NEUTRAL LOCK

Neutral lock is a new feature introduced as a requirement for the JaguarDrive selector. The selector is always locked at
ignition on when the engine is not running, except after an engine stall when the selector in not in 'P' or 'N'.
If, when driving with the JaguarDrive selector in 'S', 'D' or 'R' at a speed of more than 5 km/h (3 mph), the driver selects 'P'
or 'N':
without the brake pedal pressed, the JaguarDrive selector will be immediately locked once the vehicle speed falls to
below 5 km/h (3 mph)
with the brake pedal pressed, the JaguarDrive selector will remain locked for as long as the brake pedal remains
pressed, regardless of vehicle speed.
The transmission will only engage Park once the vehicle speed is less than 2 km/h (1 mph).
If the driver selects 'N' and releases the brake pedal with a vehicle speed of less than 5 km/h (3 mph), the JaguarDrive
selector will be locked 2 seconds after 'N' is selected. The selector will remain locked until the driver presses the brake
pedal again.
To ensure that a driver request to change from a non-driving range ('N' for example) to a driving range ('D' for example),
the park interlock and neutral lock features are used in conjunction with the 'intermediate position'.
If the transmission receives a range change request without the brake pedal pressed, the TCM initiates a 'soft lock'
function. The transmission will remain in Park or Neutral, depending on the starting position.
If a transmission position letter is flashing in the message center and the vehicle has no drive, the driver must:
press the brake pedal

reselect 'N' or 'P' on the JaguarDrive selector
then select the required driving range, ensuring that the brake pedal is pressed.
Rocking Function
The rocking function is a new feature introduced to compliment the neutral lock function. For all changes from a non-driving
range to a driving range, it is necessary to press the brake pedal (to release either the Park interlock or Neutral lock).
In situations where the driver will require to change the gear selection from 'R' to 'D' or from 'D' to 'R' without brake pedal
input (car park manoeuvring, 3 point turns or 'rocking' the vehicle from a slippery surface for example) the 'rocking function'
gives a 2 second lock delay when 'N' is selected on the JaguarDrive selector and the brake pedal is not pressed.
Intermediate Position
If the JaguarDrive selector is rotated slowly from 'P' to 'S' and back to position 'P' with the brake pedal pressed, the 'R' or
'D' position display letter in the message center will flash and the transmission will remain in Park or Neutral depending on
the previous starting position of the selector.
If the brake pedal is released when 'R' or 'D' is flashing in the message center and the JaguarDrive selector is rotated to
the 'R' or 'D' position, the driver's required range will not be selected and the transmission will remain in Park or Neutral,
depending on the previous starting position. This feature is known as 'soft lock'.
If the driving range letter in the message center is flashing and the vehicle has no drive, the driver should depress the
brake pedal to reselect 'N' or 'P', and then select the required driving range ensuring the brake pedal is pressed.
Automatic Transmission/Transaxle External Controls - External Controls
For a detailed description of the transmission external controls, refer to the relevant Description and Operation sections in
the workshop manual. REFER to: (307-05 Automatic Transmission/Transaxle External Controls)
External Controls - Vehicles W ith: ZF 6HP26 (Description and Operation),

External Controls - Vehicles W ith: ZF 6HP26 (Description and Operation),
External Controls - Vehicles W ith: ZF 6HP26 (Description and Operation).
vehicle.
Visual Inspection
Check for stuck/jammed switches and buttons Fuse(s)
Visibly damaged or worn components Loose or corroded electrical connector(s)
Loose or missing fasteners
DTC Index
NOTE: If the control module/component is suspect and the vehicle remains under manufacturer warranty, refer to the

B1087-08 LIN Bus "A" - Bus LIN Bus "A" Error Refer to the electrical circuit diagrams and
Signal / Message check LIN input signal circuit for short, open
Failures circuit
B1087-81 LIN Bus "A" - invalid Transmission control module LIN Refer to the electrical circuit diagrams and
serial data received message error: complement fault check LIN input signal circuit for short, open
circuit faults. Check Transmission control
module for related DTCs and refer to
relevant DTC Index
B1087-82 LIN Bus "A" - alive / Transmission control module LIN Refer to the electrical circuit diagrams and
sequence counter message error: Alive counter fault check LIN input signal circuit for short, open
incorrect / not circuit faults. Check Transmission control
updated module for related DTCs and refer to
relevant DTC Index
B1087-83 LIN Bus "A" - value Transmission control module LIN Refer to the electrical circuit diagrams and
of signal protection message error: checksum fault check LIN input signal circuit for short, open
calculation incorrect circuit faults. Check Transmission control
relevant DTC Index
B1087-87 LIN Bus "A" - Transmission control module LIN Refer to the electrical circuit diagrams and
missing message message error: missing message check LIN input signal circuit for short, open
circuit faults. Check Transmission control
relevant DTC Index
B1142-62 Ignition Status 1 - Hardwired Ignition and CAN powermode Refer to the electrical circuit diagrams and
signal compare signals differ check ignition supply circuit for short, open
failure circuit
B123C-01 Dynamic Stability Dynamic stability control LED failure Suspect transmission shift module, check
Control Status operation of the Dynamic stability control
Indicator - General button status illumination, check and install
Electrical Failure new transmission shift module as required,
refer to the new module/component
installation note at the top of the DTC
Index
B123D-64 Dynamic Stability Dynamic stability control button may be Check for normal Dynamic stability control
Control Button - stuck, May be due to a faulty button or button functionality. If it operates normally
signal plausibility to the user holding the button for a then no further action required. If the
failure prolonged period. (Dynamic stability Dynamic stability control button fails to
control button detected as pressed for operate normally then may be due to an
30 seconds) (S1) internal fault, check and install new
transmission shift module as required, refer
to the new module/component installation
B123F-01 Adaptive Speed Adaptive Speed Limiter LED failure Suspect transmission shift module, check
Limiter Mode operation of the active speed limiter button
Indicator - General status illumination, check and install new
Electrical Failure transmission shift module as required, refer
B1241-64 Adaptive Speed May be due to a faulty button or to the Check for normal adaptive speed limiter
Limiter Button - user holding the button for a prolonged button functionality. If it operates normally
signal plausibility period (Adaptive Speed Limiter button then no further action required. If the
failure detected as pressed for 30 seconds) adaptive speed limiter button fails to
operate normally then may be due to an
internal fault, check and install new
B1242-64 Winter Button - May be due to a faulty button or to the Check for normal winter button
signal plausibility user holding the button for a prolonged functionality. If it operates normally then
failure period. (Winter button detected as no further action required. If the winter
pressed for 30 seconds) button fails to operate normally then may
be due to an internal fault, check and
install new transmission shift module as
module/component installation note at the
B1243-01 Winter Button Mode Winter LED failure Suspect transmission shift module, check
Indicator - General operation of the winter button status
Electrical Failure illumination, check and install new
B1244-64 Dynamic / Sport May be due to a faulty button or to the Check for normal dynamic mode button
Button - signal user holding the button for a prolonged functionality. If it operates normally then
plausibility failure period. (Dynamic/Performance button no further action required. If the dynamic
detected as pressed for 30 seconds) mode button fails to operate normally then
may be due to an internal fault, check and
install new transmission shift module as
B1245-01 Dynamic / Sport Dynamic / Sport LED Failure Suspect transmission shift module, check
Button Mode operation of the dynamic mode button
Indicator - General status illumination, check and install new
Electrical Failure transmission shift module as required, refer
C113A-62 Wake up Control - Hardwired delayed power and CAN Bus Refer to the electrical circuit diagrams and
signal compare Engine Running status differ. check hardwired wake up (start stop
failure illumination) input circuit for short, open
circuit
P0603-44 Internal Control Transmission shift module Internal Suspect transmission shift module, check
Module Keep Alive failure and install new transmission shift module
Memory (KAM) Error as required, refer to the new
- data memory module/component installation note at the
failure top of the DTC Index
Module Random failure and install new transmission shift module
Access Memory as required, refer to the new
(RAM) Error - data module/component installation note at the
memory failure top of the DTC Index
Module Read Only failure and install new transmission shift module
Memory (ROM) Error as required, refer to the new
- program memory module/component installation note at the
P0606-2F Control Module Transmission shift module Internal Suspect transmission shift module, check
Processor - signal failure and install new transmission shift module
erratic as required, refer to the new
P0606-47 Control Module Transmission shift module Internal Suspect transmission shift module, check
Processor - failure and install new transmission shift module
watchdog / safety as required, refer to the new
Micro controller module/component installation note at the
P0705-09 Transmission Range PRNDS sensor fault Suspect transmission shift module, check
Sensor A Circuit and install new transmission shift module
(PRNDL Input) - as required, refer to the new
Component Failures module/component installation note at the
P0705-46 Transmission Range PRNDS calibration missing/invalid Suspect transmission shift module, check
calibration / module/component installation note at the
parameter memory top of the DTC Index
failure
P0705-86 Transmission Range Received signal incorrect Suspect transmission shift module, check
signal invalid module/component installation note at the
P0814-01 Transmission Range PRNDS LED failure Suspect transmission shift module, check
Display Circuit - operation of PRNDS display, check and
General Electrical install new transmission shift module as
Failure required, refer to the new
P081C-64 Park Input Circuit - Hardwired Park and Transmission control Refer to electrical circuit diagrams and
signal plausibility module Position Display signals are not check Park input signal circuit for short,
failure consistent open circuit. Check Transmission control
module for Park signal failure DTCs. Check
operation of signal - should be set (equal
to vehicle supply voltage) when
transmission in P and un-set (equal to
vehicle ground) when transmission in
R,N,D,S
P084F-11 Park/Neutral Switch Park/neutral signal circuit short to Refer to the electrical circuit diagrams and
Output Circuit - ground check the park/neutral signal circuit for
circuit short to short to ground
ground
P084F-15 Park / Neutral Park/neutral signal circuit short to power Refer to the electrical circuit diagrams and
Switch Output or open circuit check the park/neutral signal circuit for
Circuit - circuit short short to power or open circuit
to battery or open
P176A-01 Transmission Range Raise/Lower mechanism up / down Suspect transmission shift module, check
Selector Up and sensor fault and install new transmission shift module
Down Position as required, refer to the new
Circuit - General module/component installation note at the
Electrical Failure top of the DTC Index
P176A-13 Transmission Range Raise/Lower mechanism current sense Suspect transmission shift module, check
Selector Up and fault and install new transmission shift module
Circuit - circuit open module/component installation note at the
P176A-19 Transmission Range Raise/Lower mechanism motor over Suspect transmission shift module, check
Selector Up and current and install new transmission shift module
Circuit - circuit module/component installation note at the
current above top of the DTC Index
threshold
P176A-94 Transmission Range Motor current detected while gear Suspect transmission shift module, check
Selector Up and selector knob not moving up or down for and install new transmission shift module
Down Position 100ms as required, refer to the new
Circuit - unexpected module/component installation note at the
operation top of the DTC Index
P176B-71 Transmission Range Raise Lower failure. Note: Can be due to Check that no visible obstructions are
Selector Up and driver abuse! If DTC is detected then present and test for normal raise/lower
Down Position test raise/lower functionality to confirm operation. If transmission shift module
Control Error - OK with no abuse forces or obstructions raises and lowers normally then no further
actuator stuck present. Only replace Transmission shift action is required. If the transmission shift
module if raise/lower issues are present module fails to raise and lower normally
with no abuse forces or obstructions even though no obstructions or abuse
present. forces are present then may be due to an
internal fault, check and install new
P176C-07 Transmission Range Gear selector movement detected while Check for normal shift interlock lock/unlock
Selector Lock locked. DTC set after 100ms. Park lock operation, and check for short circuit DTCs.
Control Error - failure Transmission shift module has If the transmission shift module locks and
Mechanical Failures detected that the selector has been unlocks normally then no further action is
turned while a lock request has been required. If the transmission shift module
received from the Transmission control fails to lock normally when fully in the P
module This is usually due to the driver position then may be due to an internal
releasing the brake pedal with the fault, check and install new transmission
selector in between positions and does shift module as required, refer to the new
not represent a fault. module/component installation note at the
P176C-11 Transmission Range Short to ground detected while solenoid Suspect transmission shift module, check
Selector Lock active for 100ms. operation of the shift interlock, check and
Control Error - install new transmission shift module as
circuit short to required, refer to the new
ground module/component installation note at the
P176C-12 Transmission Range Short to power detected for 100ms. Suspect transmission shift module, check
Selector Lock operation of the shift interlock, check and
Control Error - install new transmission shift module as
circuit short to required, refer to the new
power module/component installation note at the
P176C-73 Transmission Range Solenoid Unlock Failure. This may be due Check for normal shift interlock lock/unlock
Selector Lock either to the user applying a prolonged operation. If the transmission shift module
Control Error - rotational force against the selector lock locks and unlocks normally then no further
actuator stuck mechanism while it is attempting to action is required. If the transmission shift
closed unlock or due to an internal failure module fails to lock and unlock normally
then may be due to an internal fault, check
and install new transmission shift module
as required, refer to the new
U0001-88 High Speed CAN HS CAN Failure (Bus Off) Refer to the electrical circuit diagrams and
Communication Bus check CAN bus for short, open circuit
- bus off
U0100-00 Lost Communication Lost communication with the engine Refer to the electrical circuit diagrams and
With ECM/PCM "A" - control module check the CAN Bus connection to the engine
missing message Engine speed signal not received for control module for short, open circuit. Check
450mS (S3) the engine control module for related DTCs
U0101-00 Lost Communication Lost communication with the Refer to the electrical circuit diagrams and
with TCM - missing transmission control module check the CAN Bus connection to the
message TCM_PosDisp signal not received for transmission control module for short, open
75mS. (S3) circuit. Check the transmission control
module for related DTCs and refer to the
relevant DTC Index
U0121-00 Lost Communication Lost communication with the anti-lock Refer to the electrical circuit diagrams and
With Anti-Lock brake system (ABS) control module check the CAN Bus connection to the
Brake System (ABS) Message containing TCSSwitchSports is anti-lock brake system (ABS) control
Control Module - not received for 450mS. (S3) module for short, open circuit. Check the
missing message anti-lock brake system (ABS) control
module for related DTCs and refer to the
relevant DTC Index
U0139-00 Lost Communication Lost communication with the suspension Refer to the electrical circuit diagrams and
With Suspension control module "B" check the CAN Bus connection to the
Control Module "B" - Message containing SUMB signals is not suspension control module "B for short,
missing message received for 750mS. (S3) open circuit. Check the suspension control
module "B" for related DTCs and refer to
the relevant DTC Index
U0155-00 Lost Communication Lost communication with instrument Refer to the electrical circuit diagrams and
With Instrument panel cluster check the CAN Bus connection to the
Panel Cluster (IPC) Message containing Powermode is not instrument panel cluster for short, open
Control Module - received for 350mS. (S3) circuit. Check the instrument panel cluster
missing message for related DTCs and refer to the relevant
DTC Index
U0300-00 Internal Control Invalid master configuration ID received Re-configure the RJB using the
Module Software manufacturer approved diagnostic system.
Incompatibility - no Clear DTC and re-test, if DTC remains
sub type suspect the transmission shift module.
information Check and install a new module as
U0401-92 Invalid Data Jaguar Drive Optimisation W inter/ Check ECM for related DTCs and refer to the
Received From Performance modes not available. Fault relevant DTC Index
ECM/PCM - message if a Jaguar Drive Optimization
performance or mode button is pressed
incorrect operation Message received from Engine Control
Module indicates it is unable to support
Jaguar Drive Optimisation modes.
U0402-64 Invalid Data Implausible lock request received Unexpected lock data received from
Received from Transmission control module. Check for
Transmission additional communication DTCs and follow
control module - relevant service actions. If no other
signal plausibility communication DTCs present, check
failure Transmission control module for related
U0402-81 Invalid Data Transmission control module CAN Check Transmission control module for
Received from message error: complement fault DTCs and refer to the relevant DTC Index.
Transmission If no fault found then refer to the electrical
control module - circuit diagrams and check CAN bus for
invalid serial data short, open circuit
received
U0402-82 Invalid Data Alive Counter fault detected (Stuck, Check Transmission control module for
Received from jumps or Fault Flag). More than 1 fault DTCs and refer to the relevant DTC Index.
Transmission in 200ms. If no fault found then refer to the electrical
control module - circuit diagrams and check CAN bus for
alive / sequence short, open circuit
counter incorrect /
not updated
U0402-83 Invalid Data Calculated checksum for Transmission Check Transmission control module for
Received from control module message data does not DTCs and refer to the relevant DTC Index.
Transmission match received checksum. More than 1 If no fault found then refer to the electrical
control module - fault in 200ms. circuit diagrams and check CAN bus for
value of signal short, open circuit
protection
calculation incorrect
U0402-92 Invalid Data Message received from Transmission Check Transmission control module for
Received from Control Module indicates it is unable to DTCs and refer to the relevant DTC Index
Transmission support Jaguar Drive Optimisation
control module - modes.
performance or
incorrect operation
U0415-92 Invalid Data Information only. Message received from Check ABS module for DTCs and refer to the
Received From Anti-Lock Brake System module relevant DTC Index
Anti-Lock Brake indicates it is unable to support Jaguar
System (ABS) Drive Optimisation modes.
Control Module -
performance or
incorrect operation
U0422-08 Invalid Data Update bit for powermode signal not Check central junction box for DTCs and
Received From Body received from central junction box. refer to the relevant DTC Index
Control Module - Possible CAN fault
Bus Signal /
Message Failures
U0422-81 Invalid Data Invalid powermode complement data Check central junction box for DTCs and
Received From received from central junction box refer to the relevant DTC Index
central junction box
- invalid serial data
received
U0422-92 Invalid Data Message received from power assisted Check instrument cluster and central
Received From steering module indicates that it is junction box for DTCs and refer to the
central junction box unable to support Jaguar Drive relevant DTC Index. If no fault found then
- performance or Optimisation modes refer to the electrical circuit diagrams and
incorrect operation check CAN bus for short, open circuit
U043A-92 Invalid Data Information only, Suspension Module Check Suspension Control Module "B" for
Received From unable to support Jaguar Drive related DTCs and refer to the relevant DTC
Suspension Control Optimisation modes( Invalid Data is Index
Module "B" - received from the SUMB )
performance or
incorrect operation
U101A-86 Lost Communication CAN and LIN bus failed. FOR Check for Transmission control module CAN
With Transmission INFORMATION ONLY - No action and/or LIN DTCs present in transmission
control module necessary if no additional CAN or LIN shift module then refer to actions for these
(Multiple Bus) - DTCs present specific DTCs. If no additional Transmission
signal invalid control module CAN and/or LIN DTCs
present in transmission shift module then
no further action required
U1A14-04 CAN Initialization Signal configuration not present / Suspect transmission shift module, check
Failure - System incorrect. and install new transmission shift module
Internal Failures as required, refer to the new
U2012-4A Car Configuration Mismatch detected between vehicle Check correct transmission shift hardware
Parameter(s) - configuration and installed gear selectorvariant is installed for the vehicle
incorrect component variant. Check correct part fitted, and if
configuration - i.e. for supercharged
installed fault still present, check vehicle variants, transmission shift modules with
configuration dynamic mode button should be installed
only. All other vehicles should contain
hardware without the dynamic mode
button. If correct hardware installed then
check/amend car configuration parameters
using the manufacturer approved diagnostic
system
U2100-00 Initial Configuration Transmission shift module not fully Suspect transmission shift module, check
Not Complete - no configured. and install new transmission shift module
sub type as required, refer to the new
information module/component installation note at the
U3003-16 Battery Voltage - Low voltage detected at Transmission Ensure battery is in a fully charged and
circuit voltage shift module (Battery voltage < 8.5V for serviceable condition, refer to the battery
below threshold 660mS) care manual. Check ECM for alternator
related DTCs, Check battery power feed
circuit to Transmission shift module, Clear
DTCs, Cycle ignition
U3003-17 Battery Voltage - High voltage detected at Transmission Check ECM for alternator/over charging
circuit voltage shift module (Battery voltage > 16.5V related DTCs, Clear DTCs, Cycle ignition
above threshold for 660mS)
U3003-62 Battery Voltage - Measured voltage different to CAN Compare vehicle voltage to voltage present
signal compare received voltage (Voltage difference > at the Transmission shift module, Repair
failure 2V for > 10s) fault, Clear DTCs, Cycle ignition
Automatic Transmission/Transaxle External Controls - Transmission Control
Switch (TCS)
Removal

2. Refer to: Audio and Climate Control Assembly (415-01 Information

and Entertainment System, Removal and Installation).
3.
4.
5. Torque: 4 Nm
6. Torque: 4 Nm
7. Torque: 4 Nm
8.
Installation
1. 1. CAUTION: Make sure that all diagnostic trouble codes

(DTCs) have been removed after the road test.

Automatic Transmission/Transaxle External Controls - Transmission Control
Switch (TCS) Knob
Removal
1.
Start the engine and make sure that 'P' is
selected.
2. Torque: 2 Nm
Installation

Automatic Transmission/Transaxle External Controls - Emergency Park
Position Release Lever
Removal

3. Refer to: Engine Rear Undershield (501-02 Front End Body Panels,
4. Refer to: Floor Console Side Trim Panel (501-12 Instrument Panel
5. 5. WARNING: Make sure to support the vehicle

with axle stands.
Torque: 11 Nm
6.
7. Torque: 7 Nm
8.
9.
10. Torque: 3 Nm
11.
Installation

Automatic Transmission/Transaxle External Controls - Upshift Paddle
Switch
Removal
1. Torque: 3 Nm
2.
Installation
1. 1. NOTE: Make sure the wiring harness is routed correctly.

Automatic Transmission/Transaxle External Controls - Downshift Paddle
Switch
Removal
1. Torque: 3 Nm
2.
Installation
1. 1. NOTE: Make sure the wiring harness is routed correctly.

Exhaust System - TDV6 2.7L Diesel -
Catalyst support bracket 22 16 -
Muffler under body support bracket 30 22 -
Front muffler retaining clamps 55 41 -
Muffler and tailpipe retaining clamp 55 41 -
Catalyst temperature sensors 35 26 -
Diesel particulate filter (DPF) temperature sensor 35 26 -
Turbocharger to downpipe catalytic converter retaining studs 15 11 -
Turbocharger to downpipe catalytic converter retaining nuts 25 18 -
Downpipe catalytic converter to DPF securing clamp retaining bolts 11 8 -
DPF to front muffler securing clamp retaining bolts 55 41 -
DPF differential pressure sensor retaining nuts 17 12 -
DPF support bracket to body retaining screws 9 - 80
Bracket to catalyst retaining nuts 7 - 62
DPF shield retaining screws 6 - 53
Pressure pipe clamp retaining bolt 2 - 18
DPF isolater to bracket retaining fixings 6 - 53
Exhaust System - TDV6 2.7L Diesel - Exhaust System - Component Location
COMPONENT LOCATION 2.7L V6
ItemDescription
1 Differential pressure sensor
2 Pre-catalyst exhaust gas temperature sensor (2 off)
3 Diesel Particulate Filter (DPF)
4 Center silencer
5 Mounting rubber (8 off)
6 Rear silencer (2 off)
7 Exhaust trim (2 off)
8 Damper
9 Catalytic converter (2 off)
10 Manifold flange (2 off)
11 Post catalyst exhaust gas temperature sensor (2 off)
12 Pre DPF temperature sensor
Exhaust System - TDV6 2.7L Diesel - Exhaust System - Overview
OVERVIEW
The 2.7L V6 diesel exhaust system is fabricated from stainless steel and is supplied as 6 separate assemblies; a front section incorporating
a catalytic converter for each bank of cylinders and the Diesel Particulate Filter (DPF) and a rear section incorporating a center silencer and
two rear silencers.
The system is attached to the underside of the body with mounting rubbers which are located on mild steel hanger bars that are welded to
the system. The mounting rubbers locate on corresponding hangers which are welded or bolted to the underside of the vehicle body.
The exhaust system incorporates a DPF which allows the vehicle to exceed European Stage 4 emission standards.
Exhaust System - TDV6 2.7L Diesel - Exhaust System - System Operation and
System Operation
DIESEL PARTICULATE FILTER (DPF)
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 travelled and back pressure signals from the differential pressure
sensor.
Active regeneration generally occurs every 450 miles (725 km) although this is highly 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 a mileage trigger which is used as back-up 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 distance travelled.
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 introducing post-injection of fuel after the
pilot and main fuel injections have occurred.
This 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 one or two post-injections of fuel:
The first post-injection of fuel retards combustion 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
unburnt 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 500C
(932F). 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 830C (1526F) 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 Recirculation (EGR) valve is closed. The use of EGR decreases the exhaust gas temperature and therefore prevents
the optimum DPF temperature being achieved.
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 a Jaguar approved diagnostic
system to the vehicle which will guide the technician through an automated 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 three separate control software modules; a DPF supervisor module, a DPF fuel management module
and a DPF air management module.
These three 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 four split injections per stroke (pilot, main and two post injections
Injection pressure and the transition between the three 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 four split injections, for each of the three calibration levels for injection
pressure, and also manages the transition between the levels.
The two 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 unburnt 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
Intake air temperature and pressure 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 and temperature. 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 intake air temperature by actuating the EGR throttle and by adjustment of the turbocharger boost pressure control.
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
Engine load increase
Control of air pressure and temperature in the intake manifold
Fuel injection control.
When the supervisor module issues a regeneration request, the co-ordinator module requests EGR cut-off and a regeneration specific
turbocharger boost pressure control. It then waits for a feedback signal from the EGR system confirming that the EGR valve is closed.
When the EGR valve is closed, the co-ordinator module initiates requests to increase engine load by controlling the intake air temperature
and pressure.
Once confirmation is received that intake conditions are controlled or a calibration time has expired, the co-ordinator module then changes
to a state awaiting an accelerator pedal release manoeuvre from the driver. If this occurs or a calibration time has expired, the co-ordinator
module generates a request to control fuel injections to increase exhaust gas temperature.
FRONT SECTION
The front section comprises two catalytic converters. Each catalytic converter has an welded inlet pipe which is curved through 90 degrees
The outer end of the pipe is fitted with a flange which mates with the turbocharger for each bank of cylinders. Three holes in each flange
locate on studs in the mating flange on the turbocharger and is secured with 3 flanged nuts. The base of each catalytic converter has an
outlet pipe which is fitted with a cone. Two curved pipes from the front of the DPF locate over the outlet pipe on each catalytic converter
and are sealed with a gasket against the cone. The joint is compressed and sealed with a clamp.
The curved pipes are welded to the front inlet cone which forms part of the DPF body. The curved pipe has an inner pipe which is secured in
the outer pipe by 2 crimped indentations. The DPF inlet cone has 2 bosses which provide for the connection of a DPF temperature sensor
and the high pressure pipe for the differential pressure sensor. The DPF is oval in shape and is closed at the rear by an outlet cone with 2
welded short pipes. The LH (left-hand) pipe has a bosses which allows for the attachment of the low pressure pipe for the differential
pressure sensor. The 2 pipes are held together by a welded hanger brackets which supports the front section of the exhaust system on 2
mounting rubbers.
REAR SECTION
The 2 pipes from the DPF connect into 2 pipes which are welded to the front of the center resonator silencer. The resonator silencer is oval
in shape and houses 2 perforated tubes separated by a baffle plate. Exhaust gasses exit the resonator silencer via one of 2 outlet pipes.
The outlet pipes are braced together with a bracket and also each have a welded hanger bracket which allow the rear section to be
supported on mounting rubbers.
The 2 rear silencers each have a welded inlet pipe which mate with the 2 outlet pipes from the center resonator silencer and are each
secured with a clamp. The inlet pipes each have a welded hanger bracket which support each rear silencer at the rear of the vehicle on
mounting rubbers. The fabricated rear silencers have 3 perforated tubes which are supported on 2 perforated baffle plates. The exhaust
gasses are expelled from the rear silencer via a single outlet pipe. The outlet pipe from each silencer has a welded hanger bar which
support the rear silencer on mounting rubbers. The outlet pipe is fitted with a welded outlet which is covered with a polished stainless steel
finisher.
CATALYTIC CONVERTERS
The oxidizing catalytic converters are fitted in the front section of each exhaust system, after the pre-catalyst exhaust gas temperature
sensor. The pre and post catalyst exhaust gas temperature sensors are used by the engine management system to monitor the DPF for
regeneration purposes.
The engine management system provides accurately metered quantities of fuel to the combustion chambers to ensure the most efficient
use of fuel and to minimise the exhaust emissions. To further reduce the carbon monoxide and hydrocarbons content of the exhaust gases,
a catalytic converter is integrated into each front pipe of the exhaust system. In the catalytic converter the exhaust gases are passed
through honeycombed ceramic elements coated with a special surface treatment called 'washcoat'. The washcoat increases the surface area
of the ceramic elements by a factor of approximately 7000. On top of the washcoat is a coating containing platinum and palladium, which
are the active constituents for converting harmful emissions into inert by-products. The platinum and palladium add oxygen to the carbon
monoxide and the hydrocarbons in the exhaust gases, to convert them into carbon dioxide and water respectively.
DIESEL PARTICULATE FILTER (DPF)

ItemDescription
1 Differential pressure sensor
2 Pre-catalyst exhaust gas temperature sensor (2 off)
3 Post catalyst exhaust gas temperature sensor (2 off)
4 High pressure pipe
5 Low pressure pipe
6 DPF
7 DPF temperature sensor
The DPF system reduces diesel particulate emissions to negligible levels to meet current European stage 4 emission standards. 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 microspheres on which hydrocarbons from the
engine's fuel and lubricant condense.
The DPF is located in the exhaust system, downstream of the catalytic converters. 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 itself be damaged or destroyed. The material
trapped in the filter is in the most part carbon particles with some absorbed hydrocarbons.
The DPF system comprises the following components:
Diesel particulate filter

DPF control software incorporated into the ECM (engine control module)
Exhaust gas temperature sensors
Differential pressure sensor.
ItemDescription
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 a number 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 oxidizes the particles.
DPF regeneration is controlled by the temperature of the exhaust gasses and the DPF. The DPF includes a wash coat to the filter surface
which comprises platinum and other active components and is similar to the catalytic converter. At certain exhaust gas and DPF
temperatures the wash coat promotes combustion of the particles in addition to oxidizing carbon monoxide and hydrocarbon emissions.
The exhaust gas and DPF temperatures are controlled by the DPF software located in the ECM. The DPF software monitors the load status of
the DPF based on driving style, distance travelled and signals from the differential pressure sensor and temperature sensors. When the
particulate loading of the DPF reaches predetermined levels, the DPF is actively regenerated by adjusting, in conjunction with the ECM,
various engine control functions such as:
fuel injection
intake air throttle
exhaust gas recirculation
turbocharger boost pressure control.
The regeneration process is possible because of the flexibility of the common-rail fuel injection engine which provides precise control of fuel
flow, fuel pressure and injection timing which are essential requirements to promote the efficient regeneration process. Two processes are
used to regenerate the DPF; passive and active.
DIFFERENTIAL PRESSURE SENSOR
ItemDescription
1 Low pressure connection
2 High pressure connection
The differential pressure sensor is located in the engine compartment, on the lower RH (right-hand) side of the secondary bulkhead. The
sensor is secured with 2 screws.
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 (high) and outlet (low )
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

Five temperature sensors are used in the DPF system. Two temperature sensors are located in the inlet and outlet sides of each catalytic
converter and the fifth sensor is located in the front of the DPF.
The sensors measure the temperature of exhaust gas entering and exiting the catalytic converters 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

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 as follows.
When the DPF becomes full the driver will be alerted to this condition by a message 'DPF FULL' accompanied by a handbook symbol. As
detailed in the Owners Handbook, the driver should drive the vehicle until the engine is at its normal operating temperature and then drive
for a further 20 minutes at speeds of not less than 30 mph (48 km/h). Successful regeneration of the DPF is indicated to the driver by the
'DPF FULL' message no longer being displayed.
If the DPF software detects that the DPF is still blocked, the message will change to 'DPF FULL VISIT DEALER', the driver should take the
vehicle to an authorized dealer to have the DPF force regenerated.
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 an 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. However, because active regeneration
occurs infrequently and for limited periods of time, the overall effect on fuel consumption is approximately 2%. The additional fuel used
during the active regeneration process is accounted for in the instantaneous and average fuel consumption displays in the instrument
cluster.
Exhaust System - TDV6 2.7L Diesel - Exhaust System
For a detailed description of the diesel engine exhaust system, refer to the relevant Description and Operation sections in the workshop
manual. REFER to: (309-00A)
Exhaust System (Description and Operation),

Exhaust System (Description and Operation).
Visual Inspection
Mechanical
Leaks
Metal fatigue
Pipes, mufflers and catalytic converters
Joints
Mountings
Clearance around components
step.
Symptom Chart

Excessively Exhaust Inspect exhaust system, refer to Visual Inspection above. Rectify leaks and install new
noisy/leaking system/components components as required. Refer to Removal and Installation instructions in this section
exhaust
Loss of power Restricted exhaust Install new exhaust components as required. Refer to Removal and Installation
system instructions in this section. Check for fuel, ignition and electronic engine control DTCs
Ignition system
Electronic engine
control
DTC Index
3548-1358-00.
module/component.

P042600 Catalyst Temperature Sensor Upstream catalytic converter A Refer to the electrical circuit diagrams and check
Circuit Range/Performance temperature sensor signal circuit - Upstream catalytic converter A temperature sensor signal
(Bank 1, Sensor Circuit 1) short to ground, power, open circuit for short to ground, power, open circuit,
circuit intermittent poor or dirty connections. Check and install
Upstream catalytic converter A a new sensor as required
P042626 Catalyst Temperature Sensor TPC plausibility check at cold Refer to the electrical circuit diagrams and check
Circuit Range/Performance engine catalytic converter temperature sensor circuits for short,
(Bank 1, Sensor Circuit 1) open circuit. Check and install a new sensor as required
P042627 Catalyst Temperature Sensor TPC gradient check Refer to the electrical circuit diagrams and check
Circuit Range/Performance catalytic converter temperature sensor circuits for
(Bank 1, Sensor Circuit 1) intermittent short, open circuit. Check for poor, loose
connections. Check and install a new sensor as required
P042700 Catalyst Temperature Sensor Upstream catalytic converter A Refer to the electrical circuit diagram and check
Circuit Low Input (Bank 1, temperature sensor signal circuit - Upstream catalytic converter A temperature sensor signal
Sensor Circuit 1) short to ground, open circuit circuit for short to ground, open circuit. Check and install
Upstream catalytic converter A a new sensor as required
P042800 Catalyst Temperature Sensor Upstream catalytic converter A Refer to the electrical circuit diagram and check
Circuit High Input (Bank 1, temperature sensor signal circuit - Upstream catalytic converter A temperature sensor signal
Sensor Circuit 1) short to power circuit for short to power. Check and install a new sensor
Upstream catalytic converter A as required
P042B00 Catalyst Temperature Sensor Downstream catalytic converter A Refer to the electrical circuit diagrams and check
Circuit Range/Performance temperature sensor signal circuit - Downstream catalytic converter A temperature sensor
(Bank1, Sensor Circuit 2) short to ground, open circuit signal circuit for short to ground, open circuit. Check and
Downstream catalytic converter A install a new sensor as required
P042C00 Catalyst Temperature Sensor Downstream catalytic converter A Refer to the electrical circuit diagrams and check
Circuit Low Input (Bank 1, temperature sensor signal circuit - Downstream catalytic converter A temperature sensor
Sensor Circuit 2) short to ground, open circuit signal circuit for short to ground, open circuit. Check and
Downstream catalytic converter A install a new sensor as required
P042D00 Catalyst Temperature Sensor Downstream catalytic converter A Refer to the electrical circuit diagrams and check
Circuit High Input (Bank 1, temperature sensor signal circuit - Downstream catalytic converter A temperature sensor
Sensor Circuit 2) short to power signal circuit for short to power. Check and install a new
Downstream catalytic converter A sensor as required
P043600 Catalyst Temperature Sensor Upstream catalytic converter B Refer to the electrical circuit diagrams and check
Circuit Range/Performance temperature sensor signal circuit - Upstream catalytic converter B temperature sensor signal
(Bank 2, Sensor Circuit 1) short to ground, power, open circuit for short to ground, power, open circuit. Check and
circuit install a new sensor as required
Upstream catalytic converter B
Circuit Low Input (Bank 2, temperature sensor signal circuit - Upstream catalytic converter B temperature sensor signal
Sensor Circuit 1) short to ground, open circuit circuit for short to ground, open circuit. Check and install
Upstream catalytic converter B a new sensor as required
Circuit High Input (Bank 2, temperature sensor signal circuit - Upstream catalytic converter B temperature sensor signal
Sensor Circuit 1) short to power circuit for short to power. Check and install a new sensor
Upstream catalytic converter B as required
P043B00 Catalyst Temperature Sensor Downstream catalytic converter B Refer to the electrical circuit diagrams and check
Circuit Range/Performance temperature sensor signal circuit - Downstream catalytic converter B temperature sensor
(Bank 2, Sensor Circuit 2) short to ground, power, open signal circuit for short to ground, power, open circuit.
circuit Check and install a new sensor as required
Downstream catalytic converter B
P043C00 Catalyst Temperature Sensor Downstream catalytic converter B Refer to the electrical circuit diagrams and check
Circuit Low Input (Bank 2, temperature sensor signal circuit - Downstream catalytic converter B temperature sensor
Sensor Circuit 2) short to ground, open circuit signal circuit for short to ground, open circuit. Check and
Downstream catalytic converter B install a new sensor as required
P043D00 Catalyst Temperature Sensor Downstream catalytic converter B Refer to the electrical circuit diagrams and check
Circuit High Input (Bank 2, temperature sensor signal circuit - Downstream catalytic converter B temperature sensor
Sensor Circuit 2) short to power signal circuit for short to power. Check and install a new
Downstream catalytic converter B sensor as required
P242B00 Exhaust Gas Temperature Pre catalytic converter DPF Refer to the electrical circuit diagrams and check pre
Sensor Circuit temperature sensor signal circuit - catalytic converter DPF temperature sensor signal circuit
Range/Performance - Bank 1 short to ground, power, open for short to ground, power, open circuit. Check and
Sensor 3 circuit install a new sensor as required
Pre catalytic converter DPF
P242C00 Exhaust Gas Temperature Pre catalytic converter DPF Refer to the electrical circuit diagrams and check pre
Sensor Circuit Low - Bank 1 temperature sensor signal circuit - catalytic converter DPF temperature sensor signal circuit
Sensor 3 short to ground, open circuit for short to ground, open circuit. Check and install a new
Pre catalytic converter DPF sensor as required
P242D00 Exhaust Gas Temperature Pre catalytic converter DPF Refer to the electrical circuit diagrams and check pre
Sensor Circuit High - Bank 1 temperature sensor signal circuit - catalytic converter DPF temperature sensor signal circuit
Sensor 3 short to power for short to power. Check and install a new sensor as
Pre catalytic converter DPF required
P242E00 Exhaust Gas Temperature Pre catalytic converter DPF Refer to the electrical circuit diagrams and check pre
Sensor Circuit temperature sensor signal circuit - catalytic converter DPF temperature sensor signal circuit
Intermittent/Erratic - Bank 1 short to ground, power, open for short to ground, power, open circuit and intermittent
sensor 3 circuit poor and dirty connections. Check and install a new
Pre catalytic converter DPF sensor as required
P244A00 Diesel Particulate Filter Differential pressure sensor Check integrity of differential pressure sensor
Differential pressure too Low tubes/hoses split/leaking tubes/hoses. Check integrity of Diesel Particulate Filter
DPF split/leaking
P244B00 Diesel Particulate Filter Differential pressure sensor Check integrity of differential pressure sensor
Differential Pressure Too High tubes/hoses blockage/restriction tubes/hoses. Check integrity of Diesel Particulate Filter.
DPF blockage/restriction Contact Dealer Technical Support for further information
P245300 Diesel Particulate Filter Exhaust blockage/restriction Check integrity of exhaust system. Check integrity of
Differential Pressure Sensor DPF blockage/restriction Diesel Particulate Filter. Refer to the electrical circuit
Circuit Range/Performance Differential pressure sensor signal diagrams and check differential pressure sensor signal
circuit - short to ground, power, circuit for short to ground, power, open circuit. Check and
open circuit install a new sensor as required
Differential pressure sensor failure
P245400 Diesel Particulate Filter Differential pressure sensor signal Refer to the electrical circuit diagrams and check
Differential Pressure Sensor circuit - short to ground, power, differential pressure sensor signal circuit for short to
Circuit Low open circuit ground, power, open circuit. Check and install a new
Differential pressure sensor failure sensor as required
P245500 Diesel Particulate Filter Differential pressure sensor signal Refer to the electrical circuit diagrams and check
Differential Pressure Sensor circuit - short to ground, power, differential pressure sensor signal circuit for short to
Circuit High open circuit ground, power, open circuit. Check and install a new
Differential pressure sensor failure sensor as required
P245600 Diesel Particulate Filter Differential pressure sensor Check integrity of differential pressure sensor
Differential Pressure Sensor tubes/hoses split/leaking tubes/hoses. Refer to the electrical circuit diagrams and
Circuit Intermittent/Erratic Differential pressure sensor circuit check differential pressure sensor circuit for short to
- short to ground, power, open ground, power, open circuit. Check and install a new
circuit sensor as required
Differential pressure sensor failure
P245900 Diesel particulate filter DPF load too high due to Carry out DPF service regeneration procedure using the
regeneration frequency inappropriate driving condition manufacturer approved diagnostic system
Exhaust System - TDV6 2.7L Diesel - Catalytic Converter
Removal
WARNING: Observe due care when working near a hot exhaust system.

CAUTION: Make sure that the exhaust system is supported with a

suitable transmission stand.

For additional information, refer to: Engine Rear Undershield (501-02,
Installation).
Disconnect the diesel particulate filter (DPF) wiring harness electrical

connectors.
Release the catalyst monitor sensor wiring harness.
6. CAUTION: Make sure that the catalytic converter is supported

using suitable retaining straps.
Detach the catalytic converter.

Loosen the catalytic converter to diesel particulate filter (DPF) retaining

clamp.

Remove the catalytic converter.

access only.
Remove the catalytic converter temperature sensors.
Installation
1. Install the catayltic converter temperature sensors.
Tighten to 35 Nm.
2. CAUTION: Jointing compound must not be used forward of the

catalytic converter.
Loosely install the catalytic converter.
Install new nuts.
Tighten the catalytic converter to DPF retaining clamp.
Tighten to 55 Nm.

Attach the catalytic coverter.
Tighten to 22 Nm.
Attach the catalyst monitor sensor wiring harness.
Connect the DPF wiring harness electrical connectors.

Exhaust System - TDV6 2.7L Diesel - Exhaust System
Removal


2. Remove both muffler and tailpipes.
For additional information, refer to: Muffler and Tailpipe (309-00,
Installation).
Loosen the catalytic converter to diesel particulate filter (DPF) retaining

clamp.
6. Disconnect the DPF wiring harness electrical connector.
7. CAUTION: Make a note of the connection orientation of the high

and low pressure hoses to the sensor ports. Make sure the hoses are
located to the correct sensor port when installed. Failure to follow these
Disconnect the high and low pressure hoses from the DPF differential
pressure sensor.
10. CAUTION: Make sure that the exhaust system is supported with
a suitable transmission stand.
Release the DPF mount bracket.
11. With assistance, remove the exhaust system.
Discard the gaskets.
Installation
5. Tighten to 9 Nm.
Exhaust System - TDV6 2.7L Diesel - Diesel Particulate Filter (DPF)
Removal

Raise the vehicle.

Installation).
4. Disconnect the diesel particulate filter (DPF) wiring harness electrical
connector.

pressure sensor.
6. Loosen the DPF to center muffler retaining clamps.

7. Remove the DPF mount bracket.
8. With assistance, remove the DPF.
Installation
2. Tighten to 9 Nm.
Tighten to 11 Nm.
Exhaust System - TDV6 2.7L Diesel - Diesel Particulate Filter (DPF) Differential
Pressure Sensor
Removal
2. Disconnect the diesel particulate filter (DPF) differential pressure sensor

pressure sensor.
4. Remove the DPF differential pressure sensor.
Installation
Tighten to 2 Nm.
Exhaust System - TDV6 2.7L Diesel - Front Muffler
Removal

2. Remove the muffler and tailpipe.
Remove the 4 bolts.

8. Release the exhaust clamps.
9. With assistance, remove the front muffler.
Release both front muffler hanger insulators.
Installation
1. CAUTION: The hanger insulators are constructed of a special

material. Use only the correct specification insulators.
NOTE: Check the hanger insulators for damage or fatigue. Install new
hangers if required
Tighten the catalytic converter retaining clamp to 55 Nm.
Tighten to 62 Nm.
Tighten to 30 Nm.
Tighten to 6 Nm.
Exhaust System - TDV6 2.7L Diesel - Rear Muffler
Removal
2. 2. CAUTION: Make sure that these components are installed to the

Torque:
M8 25 Nm
M10 55 Nm
Installation

Exhaust System - V6 3.0L Petrol -
Exhaust manifold to catalytic converter studs 40 30 -
Exhaust clamps 55 41 -
Heated oxygen sensors 48 35 -
Catalyst monitor sensors 48 35 -
Exhaust manifold to catalytic converter retaining nuts 40 30 -
Exhaust System - V6 3.0L Petrol - Exhaust System - Component Location
COMPONENT LOCATION - 3.0L V6
ItemDescription
2 Pre-catalyst HO2S (heated oxygen sensor) (2 off)
4 Post catalyst HO2S
5 Clamp (2 off)
6 Center resonator silencer (2 off)
Exhaust System - V6 3.0L Petrol - Exhaust System - Overview
OVERVIEW
The 3.0L V6 exhaust system is fabricated from stainless steel and is supplied as 5 separate assemblies. The system is very similar in
design to the system used on the 4.2L V8 naturally aspirated engine variant.
The front section comprises 2 separate assemblies; LH (left-hand) and RH (right-hand), incorporating a catalytic converter for each bank of
cylinders. The rear section comprises of 3 separate sections incorporating a center resonator silencer and a rear silencer.
The system is attached to the underside of the body with mounting rubbers which are located on mild steel hanger bars that are welded to
the system. The mounting rubbers locate on corresponding hangers which are welded or bolted to the underside of the vehicle body.
Exhaust System - V6 3.0L Petrol - Exhaust System - System Operation and Component
Description
System Operation
In the catalytic converters, the exhaust gases are passed through honeycombed ceramic elements coated with a special surface treatment
called 'washcoat'. The washcoat increases the surface area of the ceramic elements by a factor of approximately 7000. On top of the
washcoat is a coating containing palladium and rhodium, which is the active constituent for converting harmful emissions into inert
by-products. The palladium and rhodium add oxygen to the carbon monoxide and the hydrocarbons in the exhaust gases, to convert them
into carbon dioxide and water respectively.
FRONT SECTION
The front section comprises two separate pipes, each incorporating a catalytic converter. Each catalytic converter has a welded inlet pipe
with a flange. The inlet pipe is flared into a cone which mates with the exhaust manifold. The flange has two holes which locate on studs in
the exhaust manifold and is secured with flanged nuts. Each catalytic converter is fitted with a pre and post catalyst HO2S (heated oxygen
sensor).
Each catalytic converter has a curved outlet pipe which mates with the respective inlet pipe for the applicable resonator silencer. The joint
is secured compressed and sealed with a clamp.
REAR SECTION
The 2 inlet pipes each connect into a separate resonator silencer. Each resonator silencer is cylindrical in shape and houses 2 perforated
tubes separated by 2 baffle plates. Exhaust gasses exit each resonator silencer via an outlet pipe. The 2 outlet pipes are joined together
behind the resonator silencers with a cross over pipe. Each pipe also has a welded hanger bracket which allow the rear section to be
supported on mounting rubbers. A further bracket is welded to each pipe which braces the 2 pipes together.
The 2 rear silencers each have a welded inlet pipe which mate with the outlet pipes from the resonator silencers and are each secured with
a clamp. The inlet pipes each have a welded hanger bracket which support each rear silencer at the rear of the vehicle on mounting rubbers.
The fabricated rear silencers have 3 perforated tubes which are supported on 3 perforated baffle plates. The exhaust gasses are expelled
from the rear silencer via a single outlet pipe. The outlet pipe from each silencer has a welded hanger bar which support the rear silencer on
mounting rubbers. The outlet pipe is fitted with a welded outlet which is covered with a polished stainless steel finisher.
A catalytic converter is fitted in each front section of the exhaust system. Each catalytic converter is fitted with 2 HO2S.
The HO2S monitors the exhaust gasses leaving the engine. The ECM (engine control module) uses this information to provide accurately
metered quantities of fuel to the combustion chambers to ensure the most efficient use of fuel and to minimize the exhaust emissions.
Exhaust System - V6 3.0L Petrol - Exhaust System
For a detailed description of the exhaust system, refer to the relevant Description and Operation sections in the workshop manual. REFER
to:
Exhaust System (309-00B Exhaust System - V6 3.0L Petrol, Description and Operation),
Exhaust System (309-00C Exhaust System - V8 4.2L Petrol/V8 S/C 4.2L Petrol, Description and Operation),
Exhaust System (309-00C Exhaust System - V8 4.2L Petrol/V8 S/C 4.2L Petrol, Description and Operation),
Exhaust System (309-00C Exhaust System - V8 4.2L Petrol/V8 S/C 4.2L Petrol, Description and Operation).
Visual Inspection
Mechanical
Leaks
Metal fatigue
Joints
Mountings
step.
4. 4. If the concern is not visually evident, verify the symptom and refer to the Symptom Chart, alternatively, check for Diagnostic
Symptom Chart

Excessively Exhaust Inspect exhaust system, refer to Visual Inspection above. Rectify leaks and install
noisy/leaking system/components new components as required. Refer to Removal and Installation instructions in this
exhaust section
Loss of power Restricted exhaust system Inspect exhaust system, refer to Visual Inspection above. Install new exhaust
Exhaust sound components as required. Refer to Removal and Installation instructions in this
enhancement valve stuck section. Check for fuel, ignition and electronic engine control system DTCs and refer
closed to the relevant DTC Index
Fuel system
Ignition system
DTC Index
3548-1358-00.

P003100 HO2S Heater HO2S heater circuit - circuit Carry out any pinpoint tests associated with this DTC using the
Control Circuit Low fault manufacturer approved diagnostic system. Refer to the electrical circuit
(Bank 1, Sensor 1) HO2S heater failure diagrams and check HO2S heater circuits for short, open circuit. Check
and install a new HO2S as required
Control Circuit High fault manufacturer approved diagnostic system. Refer to the electrical circuit
P003600 HO2S Heater Catalytic converter monitor Carry out any pinpoint tests associated with this DTC using the
Control Circuit sensor heater circuit - circuit manufacturer approved diagnostic system. Refer to the electrical circuit
(Bank 1, Sensor 2) fault diagrams and check Catalytic converter monitor sensor heater circuits for
Catalytic converter monitor short, open circuit. Check and install new Catalytic converter monitor
sensor heater failure sensor as required
Control Circuit Low fault manufacturer approved diagnostic system. Refer to the electrical circuit
Control Circuit High fault manufacturer approved diagnostic system. Refer to the electrical circuit
P005600 HO2S Heater Catalytic converter monitor Carry out any pinpoint tests associated with this DTC using the
Control Circuit sensor heater circuit - circuit manufacturer approved diagnostic system. Refer to the electrical circuit
(Bank 2, Sensor 2) fault diagrams and check Catalytic converter monitor sensor heater circuits for
Catalytic converter monitor short, open circuit. Check and install new Catalytic converter monitor
sensor heater failure sensor as required
P01311A O2 Circuit Low Exhaust gas leakage Carry out any pinpoint tests associated with this DTC using the
Voltage (Bank 1, H02S variable/constant circuit manufacturer approved diagnostic system. Check for and rectify any
Sensor 1) - circuit fault, disconnected exhaust leak between cylinder head and catalytic converter (e.g.
H02S failure manifolds, EGR system etc.). Refer to the electrical circuit diagrams and
check H02S variable/constant circuit for short, open circuit, disconnected
connector. Check and install a new HO2S as required
P01321B O2 Circuit High Exhaust gas leakage Carry out any pinpoint tests associated with this DTC using the
Voltage (Bank 1, H02S variable/constant circuit manufacturer approved diagnostic system. Check for and rectify any
Sensor 1) - circuit fault, disconnected exhaust leak between cylinder head and catalytic converter (e.g.
H02S failure manifolds, EGR system etc.). Refer to the electrical circuit diagrams and
check H02S variable/constant circuit for short, open circuit, disconnected
connector. Check and install a new HO2S as required
P013300 O2 Circuit Slow Exhaust leak Carry out any pinpoint tests associated with this DTC using the
Response (Bank 1, HO2S to ECM wiring shield manufacturer approved diagnostic system. Check for and rectify any
Sensor 1) high resistance exhaust leak between cylinder head and catalytic converter (e.g.
Fuel control system fault manifolds, EGR system etc.). Refer to the electrical circuit diagrams and
HO2 sensor failure check HO2S to ECM wiring shield for high resistance. Check fuel control
system for failure. Check and install a new HO2S as required
P013400 O2 Circuit No HO2S slow activation Carry out any pinpoint tests associated with this DTC using the
Activity Detected manufacturer approved diagnostic system
(Bank 1, Sensor 1)
P013700 O2 Circuit Low Catalytic converter monitor Carry out any pinpoint tests associated with this DTC using the
Voltage (Bank 1, sensor sensing circuit - short manufacturer approved diagnostic system. Refer to the electrical circuit
Sensor 2) to ground, high resistance, diagrams and check Catalytic converter monitor sensor sensing circuit for
disconnected short to ground, high resistance, disconnected connector. Check and
Catalytic converter monitor install new Catalytic converter monitor sensor as required
sensor failure
P013800 O2 Circuit High Catalytic converter monitor Carry out any pinpoint tests associated with this DTC using the
Sensor 2) to power diagrams and check Catalytic converter monitor sensor circuits for short
Catalytic converter monitor to power, and ground braided shield for high resistance. Check and install
sensor ground braided shield - new Catalytic converter monitor sensor as required
high resistance
Catalytic converter monitor
sensor failure
P013900 O2 Circuit Slow Catalytic converter monitor Carry out any pinpoint tests associated with this DTC using the
Response (Bank 1, sensor tip damaged or manufacturer approved diagnostic system. Check Catalytic converter
Sensor 2) blocked monitor sensor tip for damage or blockage, install a new sensor as
required
P014000 O2 Circuit No Catalytic converter monitor Carry out any pinpoint tests associated with this DTC using the
Activity Detected sensing circuit - short to manufacturer approved diagnostic system. Refer to the electrical circuit
(Bank 1, Sensor 2) ground, short to power, high diagrams and check Catalytic converter monitor sensor circuits for short
resistance, disconnected to ground, power, high resistance, disconnected connector and ground
Catalytic converter monitor braided shield for high resistance. Check and install new Catalytic
sensor ground braided shield - converter monitor sensor as required
high resistance
sensor - mechanical damage
P014100 O2 Heater Circuit Catalytic converter monitor Carry out any pinpoint tests associated with this DTC using the
(Bank 1, Sensor 2) sensor heater control circuit - manufacturer approved diagnostic system. Refer to the electrical circuit
high resistance diagrams and check Catalytic converter monitor sensor heater control
Catalytic converter monitor circuit for high resistance. Check and install a new Catalytic converter
sensor heater failure monitor sensor as required
P01511A O2 Circuit Low HO2S sensing circuit - short Carry out any pinpoint tests associated with this DTC using the
Voltage (Bank 2, to ground, short to power, manufacturer approved diagnostic system. Refer to the electrical circuit
Sensor 1) high resistance diagrams and check HO2S sensing circuit for short to ground, power, high
HO2S failure resistance. Check and install a new HO2S as required
P01521B O2 Circuit High H02S sensing circuit - short to Carry out any pinpoint tests associated with this DTC using the
Voltage (Bank 2, ground, short to power, high manufacturer approved diagnostic system. Refer to the electrical circuit
Sensor 1) resistance diagrams and check HO2S sensing circuit for short to ground, power, high
H02S failure resistance. Check and install a new HO2S as required
P015300 O2 Circuit Slow HO2S to ECM wiring shield Carry out any pinpoint tests associated with this DTC using the
Response (Bank 2, high resistance manufacturer approved diagnostic system. Refer to the electrical circuit
Sensor 1) Exhaust leak diagrams and check HO2S to ECM wiring shield for high resistance. Check
Fuel control system fault for and rectify any exhaust leak between cylinder head and catalytic
HO2 sensor failure converter (e.g. manifolds, EGR system etc.). Check fuel control system for
failure. Check and install a new HO2S as required
P015400 O2 Circuit No H02S slow activation Carry out any pinpoint tests associated with this DTC using the
Activity Detected manufacturer approved diagnostic system
(Bank 2, Sensor 1)
P015700 O2 Circuit Low Catalytic converter monitor Carry out any pinpoint tests associated with this DTC using the
Sensor 2) to ground, high resistance, diagrams and check Catalytic converter monitor sensor sensing circuit for
disconnected short to ground, high resistance, disconnected connector. Check and
Catalytic converter monitor install a new Catalytic converter monitor sensor as required
sensor failure
P015800 O2 Circuit High Catalytic converter monitor Carry out any pinpoint tests associated with this DTC using the
Sensor 2) to power diagrams and check Catalytic converter monitor sensor sensing circuit for
Catalytic converter monitor short to power, and sensor ground braided shield for high resistance.
sensor ground braided shield - Check and install a new Catalytic converter monitor sensor as required
high resistance
sensor failure
P015900 O2 Circuit Slow Catalytic converter monitor Carry out any pinpoint tests associated with this DTC using the
Response (Bank 2, sensor tip damaged or manufacturer approved diagnostic system. Check Catalytic converter
Sensor 2) blocked monitor sensor tip for damage or blockage, install a new sensor as
required
P016000 O2 Circuit No Catalytic converter monitor Carry out any pinpoint tests associated with this DTC using the
Activity Detected sensing circuit - short to manufacturer approved diagnostic system. Refer to the electrical circuit
(Bank 2, Sensor 2) ground, short to power, high diagrams and check Catalytic converter monitor sensing circuit for short
resistance, disconnected to ground, short to power, high resistance, disconnected connector, and
Catalytic converter monitor sensor ground braided shield for high resistance. Check and install a new
sensor ground braided shield - Catalytic converter monitor sensor as required
high resistance
sensor - mechanical damage
P016100 O2 Heater Circuit Catalytic converter monitor Carry out any pinpoint tests associated with this DTC using the
(Bank 2, Sensor 2) sensor heater control circuit manufacturer approved diagnostic system. Refer to the electrical circuit
malfunction diagrams and check Catalytic converter monitor sensor heater control
circuit for short, open circuit
P042000 Catalytic converter Catalytic converter failure due Check for misfire/lean combustion DTCs and refer to DTC Index in this
System Efficiency to overheating damage section. Check the oil and fuel condition/level. Check the catalytic
Below Threshold caused by misfire and/or lean converter for damage
(Bank 1) combustion
Catalytic converter failure due
to poisoning caused by
P043000 Catalytic converter Catalytic converter failure due Check for misfire/lean combustion DTCs and refer to DTC Index in this
System Efficiency to overheating damage section. Check the oil and fuel condition/level. Check the catalytic
Below Threshold caused by misfire and/or lean converter for damage
(Bank 2) combustion
Catalytic converter failure due
to poisoning caused by
P209600 Post Catalytic Heated Oxygen Sensor Check integrity and correct installation of air intake system. Check for any
converter Fuel Trim (HO2S) fuel adaption - lean HO2S codes also logged and refer to DTC Index in this section. Check for
System Too Lean air leaks between, or on, upstream and downstream sensors. Check for
Bank 1 air leak on Catalytic converter and exhaust path pre-Catalytic converter
converter Fuel Trim (HO2S) fuel adaption - rich HO2S codes also logged and refer to DTC Index in this section. Check for
System Too Rich air leaks between, or on, upstream and downstream sensors. Check for
converter Fuel Trim (HO2S) fuel adaption - lean HO2S codes also logged and refer to DTC Index in this section. Check for
System Too Lean air leaks between, or on, upstream and downstream sensors. Check for
converter Fuel Trim (HO2S) fuel adaption - rich HO2S codes also logged and refer to DTC Index in this section. Check for
System Too Rich air leaks between, or on, upstream and downstream sensors. Check for
Exhaust System - V6 3.0L Petrol - Catalytic Converter
Removal

Raise the vehicle.

Installation).
3. Remove the heated oxygen sensor (HO2S).
1. Release the electrical connector from the bracket.
3. Remove the HO2S.
4. Remove the catalyst monitor sensor.
Release the electrical connector from the bracket.
Remove the catalyst monitor sensor.
5. Loosen the catalytic converter exhaust clamps and release the front
silencer.
6. Release the catalytic converter.

Installation
4. Install catalyst monitor sensor and tighten to 40 Nm.

5. Install the HO2S and tighten to 40 Nm.

Exhaust System - V6 3.0L Petrol - Exhaust System
Removal

CAUTION: Make sure that the exhaust system is supported with a

suitable transmission stand.

Installation).
Disconnect the heated oxygen sensor (HO2S) electrical connector.

Disconnect the catalyst monitor sensor electrical connector.
10. NOTE: Check the hanger insulators for damage or fatigue. Install new
hangers if required

Installation
Exhaust System - V6 3.0L Petrol - Front Muffler
Removal

Remove the 4 bolts.

Installation
1. CAUTION: The hanger insulators are constructed of a special

material. Use only the correct specification insulators.
NOTE: Check the hanger insulators for damage or fatigue. Install new
hangers if required
Tighten to 62 Nm.
Tighten to 30 Nm.
Tighten to 6 Nm.
Exhaust System - V6 3.0L Petrol - Rear Muffler
Removal
2. 2. CAUTION: Make sure that these components are installed to the

Torque:
M8 25 Nm
M10 55 Nm
Installation

Exhaust System - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8 -
Exhaust manifold to catalytic converter studs 40 30 -
Exhaust clamps 55 41 -
Heated oxygen sensors 40 30 -
Catalyst monitor sensors 40 30 -
Exhaust manifold to catalytic converter retaining nuts 40 30 -
Exhaust System - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8 - Exhaust System -
Component Location
COMPONENT LOCATION - 4.2L V8 NATURALLY ASPIRATED
ItemDescription
2 Pre-catalyst HO2S (heated oxygen sensor) (2 off)
4 Post catalyst HO2S (2 off)
5 Clamp (2 off)
6 Center resonator silencer (2 off)
COMPONENT LOCATION - 4.2L V8 SUPERCHARGED
ItemDescription
2 Pre-catalyst HO2S (2 off)
4 Post catalyst HO2S (2 off)
5 Clamp (2 off)
6 Center resonator silencer
Overview
OVERVIEW
The 4.2L V8 exhaust system is fabricated from stainless steel and is supplied as 5 separate assemblies. The 4.2L V8
naturally aspirated system is similar in design to the system used on the 3.0L V6 engine variant. The 4.2L V8
supercharged system is also similar but uses a different design of center resonator silencer.
The front section comprises 2 separate assemblies (LH (left-hand) and RH (right-hand)) incorporating a catalytic converter
for each bank of cylinders. The rear section also comprises 3 separate sections. Each section incorporates a center
resonator silencer and a rear silencer.
The system is attached to the underside of the body with mounting rubbers which are located on mild steel hanger bars
that are welded to the system. The mounting rubbers locate on corresponding hangers which are welded or bolted to the
underside of the vehicle body.
System Operation
In the catalytic converters, the exhaust gases are passed through honeycombed ceramic elements coated with a special
surface treatment called 'washcoat'. The washcoat increases the surface area of the ceramic elements by a factor of
approximately 7000. On top of the washcoat is a coating containing palladium and rhodium, which are the active
constituents for converting harmful emissions into inert by-products. The palladium and rhodium add oxygen to the carbon
monoxide and the hydrocarbons in the exhaust gases, to convert them into carbon dioxide and water respectively.
FRONT SECTION - NORMALLY ASPIRATED ENGINES
The front section comprises two separate pipes, each incorporating a catalytic converter. Each catalytic converter has a
welded inlet pipe with a flange. The inlet pipe is flared into a cone which mates with the exhaust manifold. The flange has
two holes which locate on studs in the exhaust manifold and is secured with flanged nuts. Each catalytic converter is fitted
with a pre and post catalyst HO2S (heated oxygen sensor).
Each catalytic converter has a curved outlet pipe which mates with the respective inlet pipe for the applicable resonator.
The joint is secured compressed and sealed with a clamp.
FRONT SECTION - SUPERCHARGED ENGINES

The front section comprises two separate pipes, each incorporating a catalytic converter. Each catalytic converter has a
welded inlet pipe with a flange. The inlet pipe is flared into a cone which mates with the exhaust manifold. The flange has
two holes which locate on studs in the exhaust manifold and is secured with flanged nuts. Each catalytic converter is fitted
with a pre and post catalyst HO2S.
Each catalytic converter has a curved outlet pipe which mates with the respective inlet pipe for the resonator. The joint is
secured compressed and sealed with a clamp.
REAR SECTION - NORMALLY ASPIRATED ENGINES

The 2 inlet pipes each connect into a separate resonator silencer. Each resonator silencer is cylindrical in shape and
houses 2 perforated tubes separated by 2 baffle plates. Exhaust gasses exit each resonator silencer via an outlet pipe.
The 2 outlet pipes are joined together behind the resonators with a cross over pipe. Each pipe also has a welded hanger
bracket which allow the rear section to be supported on mounting rubbers. A further bracket is welded to each pipe which
braces the 2 pipes together.
The 2 rear silencers each have a welded inlet pipe which mate with the outlet pipes from the resonator silencers and are
each secured with a clamp. The inlet pipes each have a welded hanger bracket which support each rear silencer at the rear
of the vehicle on mounting rubbers. The fabricated rear silencers have 2 perforated tubes which are supported on 2
perforated baffle plates. The exhaust gasses are expelled from the rear silencer via a single outlet pipe. The outlet pipe
from each silencer has a welded hanger bar which support the rear silencer on mounting rubbers. The outlet pipe is fitted
with a welded outlet which is covered with a polished stainless steel finisher.
REAR SECTION - SUPERCHARGED ENGINES

The 2 inlet pipes each connect into a single resonator silencer housing perforated tubes separated by 2 baffle plates.
Exhaust gasses exit the resonator silencer via 2 outlet pipes. Each outlet pipe has a welded hanger bracket which allow
the rear section to be supported on mounting rubbers. A further bracket is welded to each pipe which braces the 2 pipes
together.
The 2 rear silencers each have a welded inlet pipe which mate with the outlet pipes from the resonator silencer and are
each secured with a clamp. The inlet pipes each have a welded hanger bracket which support each rear silencer at the rear
of the vehicle on mounting rubbers. The fabricated rear silencers have 2 perforated baffle tubes which are supported on 2
perforated baffle plates. The exhaust gasses are expelled from the rear silencer via a single outlet pipe. The outlet pipe
from each silencer has a welded hanger bar which support the rear silencer on mounting rubbers. The outlet pipe is fitted
with a welded outlet which is covered with a polished stainless steel finisher.
A catalytic converter is fitted in each front section of the exhaust system. Each catalytic converter is fitted with 2 HO2S.
The HO2S monitors the exhaust gasses leaving the engine. The ECM (engine control module) uses this information to
provide accurately metered quantities of fuel to the combustion chambers to ensure the most efficient use of fuel and to
minimize the exhaust emissions.
Exhaust System - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8 - Exhaust System
For a detailed description of the exhaust system, refer to the relevant Description and Operation sections in the workshop
manual. REFER to: (309-00 Exhaust System - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8)

Exhaust System (Description and Operation).
vehicle.
Visual Inspection
Mechanical
Leaks
Metal fatigue
Joints
Mountings
4. 4. If the concern is not visually evident, verify the symptom and refer to the Symptom Chart, alternatively, check
for Diagnostic Trouble Codes (DTCs) and refer to the DTC Index.
Symptom Chart

Excessively Exhaust Inspect exhaust system, refer to Visual Inspection above. Rectify
noisy/leaking system/components leaks and install new components as required. Refer to Removal and
exhaust Installation instructions in this section
Loss of power Restricted exhaust Inspect exhaust system, refer to Visual Inspection above. Install new
system exhaust components as required. Refer to Removal and Installation
Exhaust sound instructions in this section. Check for fuel, ignition and electronic
enhancement valve stuck engine control system DTCs and refer to the relevant DTC Index
closed
Fuel system
Ignition system
DTC Index

P003100 HO2S Heater HO2S heater circuit - circuit Carry out any pinpoint tests associated with this DTC using
Control Circuit fault the manufacturer approved diagnostic system. Refer to the
Low (Bank 1, HO2S heater failure electrical circuit diagrams and check HO2S heater circuits for
Sensor 1) short, open circuit. Check and install a new HO2S as required
High (Bank 1, HO2S heater failure electrical circuit diagrams and check HO2S heater circuits for
P003600 HO2S Heater Catalytic converter monitor Carry out any pinpoint tests associated with this DTC using
Control Circuit sensor heater circuit - the manufacturer approved diagnostic system. Refer to the
(Bank 1, Sensor circuit fault electrical circuit diagrams and check Catalytic converter
2) Catalytic converter monitor monitor sensor heater circuits for short, open circuit. Check
sensor heater failure and install new Catalytic converter monitor sensor as
required
Low (Bank 2, HO2S heater failure electrical circuit diagrams and check HO2S heater circuits for
High (Bank 2, HO2S heater failure electrical circuit diagrams and check HO2S heater circuits for
P005600 HO2S Heater Catalytic converter monitor Carry out any pinpoint tests associated with this DTC using
Control Circuit sensor heater circuit - the manufacturer approved diagnostic system. Refer to the
(Bank 2, Sensor circuit fault electrical circuit diagrams and check Catalytic converter
2) Catalytic converter monitor monitor sensor heater circuits for short, open circuit. Check
sensor heater failure and install new Catalytic converter monitor sensor as
required
P01311A O2 Circuit Low Exhaust gas leakage Carry out any pinpoint tests associated with this DTC using
Voltage (Bank 1, H02S variable/constant the manufacturer approved diagnostic system. Check for and
Sensor 1) circuit - circuit fault, rectify any exhaust leak between cylinder head and catalytic
disconnected converter (e.g. manifolds, EGR system etc.). Refer to the
H02S failure electrical circuit diagrams and check H02S variable/constant
circuit for short, open circuit, disconnected connector. Check
P01321B O2 Circuit High Exhaust gas leakage Carry out any pinpoint tests associated with this DTC using
Voltage (Bank 1, H02S variable/constant the manufacturer approved diagnostic system. Check for and
Sensor 1) circuit - circuit fault, rectify any exhaust leak between cylinder head and catalytic
disconnected converter (e.g. manifolds, EGR system etc.). Refer to the
H02S failure electrical circuit diagrams and check H02S variable/constant
circuit for short, open circuit, disconnected connector. Check
P013300 O2 Circuit Slow Exhaust leak Carry out any pinpoint tests associated with this DTC using
Response (Bank HO2S to ECM wiring shield the manufacturer approved diagnostic system. Check for and
1, Sensor 1) high resistance rectify any exhaust leak between cylinder head and catalytic
Fuel control system fault converter (e.g. manifolds, EGR system etc.). Refer to the
HO2 sensor failure electrical circuit diagrams and check HO2S to ECM wiring
shield for high resistance. Check fuel control system for
P013400 O2 Circuit No HO2S slow activation Carry out any pinpoint tests associated with this DTC using
Activity Detected the manufacturer approved diagnostic system
(Bank 1, Sensor
1)
P013700 O2 Circuit Low Catalytic converter monitor Carry out any pinpoint tests associated with this DTC using
Voltage (Bank 1, sensor sensing circuit - the manufacturer approved diagnostic system. Refer to the
Sensor 2) short to ground, high electrical circuit diagrams and check Catalytic converter
resistance, disconnected monitor sensor sensing circuit for short to ground, high
Catalytic converter monitor resistance, disconnected connector. Check and install new
sensor failure Catalytic converter monitor sensor as required
P013800 O2 Circuit High Catalytic converter monitor Carry out any pinpoint tests associated with this DTC using
Sensor 2) short to power electrical circuit diagrams and check Catalytic converter
Catalytic converter monitor monitor sensor circuits for short to power, and ground
sensor ground braided braided shield for high resistance. Check and install new
shield - high resistance Catalytic converter monitor sensor as required
sensor failure
P013900 O2 Circuit Slow Catalytic converter monitor Carry out any pinpoint tests associated with this DTC using
Response (Bank sensor tip damaged or the manufacturer approved diagnostic system. Check
1, Sensor 2) blocked Catalytic converter monitor sensor tip for damage or
blockage, install a new sensor as required
P014000 O2 Circuit No Catalytic converter monitor Carry out any pinpoint tests associated with this DTC using
Activity Detected sensing circuit - short to the manufacturer approved diagnostic system. Refer to the
(Bank 1, Sensor ground, short to power, electrical circuit diagrams and check Catalytic converter
2) high resistance, monitor sensor circuits for short to ground, power, high
disconnected resistance, disconnected connector and ground braided
Catalytic converter monitor shield for high resistance. Check and install new Catalytic
sensor ground braided converter monitor sensor as required
shield - high resistance
sensor - mechanical
damage
P014100 O2 Heater Circuit Catalytic converter monitor Carry out any pinpoint tests associated with this DTC using
(Bank 1, Sensor sensor heater control the manufacturer approved diagnostic system. Refer to the
2) circuit - high resistance electrical circuit diagrams and check Catalytic converter
Catalytic converter monitor monitor sensor heater control circuit for high resistance.
sensor heater failure Check and install a new Catalytic converter monitor sensor
as required
P01511A O2 Circuit Low HO2S sensing circuit - Carry out any pinpoint tests associated with this DTC using
Voltage (Bank 2, short to ground, short to the manufacturer approved diagnostic system. Refer to the
Sensor 1) power, high resistance electrical circuit diagrams and check HO2S sensing circuit for
HO2S failure short to ground, power, high resistance. Check and install a
P01521B O2 Circuit High H02S sensing circuit - short Carry out any pinpoint tests associated with this DTC using
Voltage (Bank 2, to ground, short to power, the manufacturer approved diagnostic system. Refer to the
Sensor 1) high resistance electrical circuit diagrams and check HO2S sensing circuit for
H02S failure short to ground, power, high resistance. Check and install a
P015300 O2 Circuit Slow HO2S to ECM wiring shield Carry out any pinpoint tests associated with this DTC using
Response (Bank high resistance the manufacturer approved diagnostic system. Refer to the
2, Sensor 1) Exhaust leak electrical circuit diagrams and check HO2S to ECM wiring
Fuel control system fault shield for high resistance. Check for and rectify any exhaust
HO2 sensor failure leak between cylinder head and catalytic converter (e.g.
manifolds, EGR system etc.). Check fuel control system for
P015400 O2 Circuit No H02S slow activation Carry out any pinpoint tests associated with this DTC using
Activity Detected the manufacturer approved diagnostic system
(Bank 2, Sensor
1)
P015700 O2 Circuit Low Catalytic converter monitor Carry out any pinpoint tests associated with this DTC using
Sensor 2) short to ground, high electrical circuit diagrams and check Catalytic converter
resistance, disconnected monitor sensor sensing circuit for short to ground, high
Catalytic converter monitor resistance, disconnected connector. Check and install a new
sensor failure Catalytic converter monitor sensor as required
P015800 O2 Circuit High Catalytic converter monitor Carry out any pinpoint tests associated with this DTC using
Sensor 2) short to power electrical circuit diagrams and check Catalytic converter
Catalytic converter monitor monitor sensor sensing circuit for short to power, and sensor
sensor ground braided ground braided shield for high resistance. Check and install a
shield - high resistance new Catalytic converter monitor sensor as required
sensor failure
P015900 O2 Circuit Slow Catalytic converter monitor Carry out any pinpoint tests associated with this DTC using
Response (Bank sensor tip damaged or the manufacturer approved diagnostic system. Check
2, Sensor 2) blocked Catalytic converter monitor sensor tip for damage or
blockage, install a new sensor as required
P016000 O2 Circuit No Catalytic converter monitor Carry out any pinpoint tests associated with this DTC using
Activity Detected sensing circuit - short to the manufacturer approved diagnostic system. Refer to the
(Bank 2, Sensor ground, short to power, electrical circuit diagrams and check Catalytic converter
2) high resistance, monitor sensing circuit for short to ground, short to power,
disconnected high resistance, disconnected connector, and sensor ground
Catalytic converter monitor braided shield for high resistance. Check and install a new
sensor ground braided Catalytic converter monitor sensor as required
shield - high resistance
sensor - mechanical
damage
P016100 O2 Heater Circuit Catalytic converter monitor Carry out any pinpoint tests associated with this DTC using
(Bank 2, Sensor sensor heater control the manufacturer approved diagnostic system. Refer to the
2) circuit malfunction electrical circuit diagrams and check Catalytic converter
monitor sensor heater control circuit for short, open circuit
P042000 Catalytic Catalytic converter failure Check for misfire/lean combustion DTCs and refer to DTC
converter System due to overheating damage Index in this section. Check the oil and fuel condition/level.
Efficiency Below caused by misfire and/or Check the catalytic converter for damage
Threshold (Bank lean combustion
1) Catalytic converter failure
P043000 Catalytic Catalytic converter failure Check for misfire/lean combustion DTCs and refer to DTC
converter System due to overheating damage Index in this section. Check the oil and fuel condition/level.
Efficiency Below caused by misfire and/or Check the catalytic converter for damage
Threshold (Bank lean combustion
2) Catalytic converter failure
P209600 Post Catalytic Heated Oxygen Sensor Check integrity and correct installation of air intake system.
converter Fuel (HO2S) fuel adaption - Check for any HO2S codes also logged and refer to DTC
Trim System Too lean Index in this section. Check for air leaks between, or on,
Lean Bank 1 upstream and downstream sensors. Check for air leak on
Catalytic converter and exhaust path pre-Catalytic converter
converter Fuel (HO2S) fuel adaption - rich Check for any HO2S codes also logged and refer to DTC
Trim System Too Index in this section. Check for air leaks between, or on,
Rich Bank 1 upstream and downstream sensors. Check for air leak on
converter Fuel (HO2S) fuel adaption - Check for any HO2S codes also logged and refer to DTC
Trim System Too lean Index in this section. Check for air leaks between, or on,
Lean Bank 2 upstream and downstream sensors. Check for air leak on
converter Fuel (HO2S) fuel adaption - rich Check for any HO2S codes also logged and refer to DTC
Trim System Too Index in this section. Check for air leaks between, or on,
Rich Bank 2 upstream and downstream sensors. Check for air leak on
Exhaust System - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8 - Catalytic
Converter
Removal

Raise the vehicle.

3. Remove the heated oxygen sensor (HO2S).
1. Release the electrical connector from the bracket.
3. Remove the HO2S.
4. Remove the catalyst monitor sensor.
Release the electrical connector from the bracket.
Remove the catalyst monitor sensor.
5. Loosen the catalytic converter exhaust clamps and release the

front silencer.
6. Release the catalytic converter.
Installation
4. Install catalyst monitor sensor and tighten to 40 Nm.
5. Install the HO2S and tighten to 40 Nm.

(PCM) Long Drive Cycle Self-Test (303-14C, General
Procedures).
Exhaust System - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8 - Exhaust System
Removal

CAUTION: Make sure that the exhaust system is supported

with a suitable transmission stand.

Disconnect the heated oxygen sensor (HO2S) electrical

connector.
Disconnect the catalyst monitor sensor electrical connector.
10. NOTE: Check the hanger insulators for damage or fatigue.

Install new hangers if required

Installation
Exhaust System - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8 - Front Muffler
Removal

For additional information, refer to: Muffler and Tailpipe
Remove the 4 bolts.

Installation
1. CAUTION: The hanger insulators are constructed of a

special material. Use only the correct specification insulators.
NOTE: Check the hanger insulators for damage or fatigue.

Install new hangers if required
Tighten to 62 Nm.
Tighten to 30 Nm.
Tighten to 6 Nm.
Exhaust System - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8 - Rear Muffler
Removal

stands.
2. 2. CAUTION: Make sure that these components

are installed to the noted removal position.
Torque:
M8 25 Nm
M10 55 Nm
Installation

Fuel System - General Information -
Item Specification
Fuel tank gross capacity - all vehicles 77 liters
Fuel tank capacity - vehicles with 3.0L, 4.2L, 2.7L Diesel 69.5 (total) / 64 (usable) liters
Fuel tank capacity - vehicles with 3.0L Diesel 71.1 (total) / 68.1 (usable) liters
Fuel tank capacity - vehicles with 5.0L 71.1 (total) / 69.5 (useable)
liters
Fuel tank capacity - when fuel gauge indicates empty - vehicles with 3.0L Diesel 64 liters
Reserve capacity - when fuel gauge indicates empty - vehicles with 3.0L, 4.2L, 2.7L 5.5 liters
Diesel
Reserve capacity - when fuel gauge indicates empty - vehicles with 5.0L, 3.0L Diesel 7 liters
Fuel System - General Information - Fuel System Pressure Check3.0L NA V6
- AJ27/4.2L NA V8 - AJV8/4.2L SC V8 - AJV8
General Procedures
All vehicles
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.
Do not smoke or carry lighted tobacco or open flame of any

type when working on or near any fuel related components.
Highly flammable vapors are always present and may ignite.
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
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
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.
After carrying out repairs, the fuel system must be checked

visually for leaks. Failure to follow these instructions may result
in personal injury.

For additional information, refer to: Battery Disconnect
Vehicles with 2.5L or 3.0L engine

For additional information, refer to: Air Cleaner Outlet Pipe -
VIN Range: N52048->N99999 (303-12A, Removal and
Installation).
4. Detach the power steering fluid reservoir and reposition.

All vehicles
6. Disconnect the fuel rail feed pipe.
Procedures).

7. NOTE: Make sure the special tool is fully seated to the fuel
pipe connections.

pipe connections.
Vehicles with 4.0L or 4.2L engine without supercharger

pipe connections.
All vehicles
10. NOTE: Vehicles with supercharger shown, others vehicles
similar.
Install the fuel pressure gauge.

11. Install the air cleaner outlet pipe.
For additional information, refer to: Air Cleaner Outlet Pipe -
VIN Range: N52048->N99999 (303-12A, Removal and
Installation).
All vehicles
For additional information, refer to: Battery Connect (414-01,
13. Carry out the fuel system pressure check.
For additional information, refer to: Fuel Charging and Controls
- VIN Range: N52048->N99999 (303-04A, Diagnosis and
Testing) /
Fuel Charging and Controls - VIN Range: N52048->N99999
(303-04B, Diagnosis and Testing).
Fuel System - General Information - Fuel System Pressure Release3.0L NA
V6 - AJ27/4.2L NA V8 - AJV8/4.2L SC V8 - AJV8
General Procedures
CAUTION: W hen depressurising the fuel system, make sure that there is no throttle input. Failure to follow this
1. WARNINGS:
Place the vehicle in a quarantined area and arrange ' No

Smoking/Petrol Fumes' signs about the vehicle.

CAUTION: Make sure the engine is cold before this

procedure is carried out. Failure to follow this instruction may
Remove the fuel pump and sender unit fuse.
2. CAUTIONS:
When depressurising the fuel system, make sure that there

is no throttle input. Failure to follow this instruction may cause
Make sure that as soon as the vehicle is running

roughly/misfiring that the engine is immediately switched off.
vehicle.
Start and run the engine until it runs roughly or starts

misfiring.
3. Refit the fuel pump fuse.
5. Read and clear stored DTC fault codes.
Fuel System - General Information - Fuel Tank Draining
General Procedures
Special Tool(s)
Fuel tank drain adaptor
310-154

1. For additional information, refer to: Diesel Fuel System Health
and Safety Precautions (100-00 General Information,

2. For additional information, refer to: Petrol and Petrol-Ethanol
Fuel Systems Health and Safety Precautions (100-00 General
Information, Description and Operation).

3. Release the pressure in the fuel system.
Procedures).
Vehicles with 5.0L engine

Release - 5.0L (310-00 Fuel System - General Information,
All vehicles
5. Remove the rear seat cushion.
For additional information, refer to: Rear Seat Cushion (501-10
Seating, Removal and Installation).
6. Detach and reposition the door opening weatherstrip.
7. Remove the scuff plate trim panel.
9. Detach and reposition the rear seat cushion insulation.
10. Remove the floor aperture cover.

11. CAUTION: The correct measurement must be used to
remove the fuel tank drain port top. Failure to follow this
NOTE: The fuel tank drain port is marked with DRAIN.
NOTE: Vehicles without Diesel engine shown, vehicles with

Diesel engine similar.
Using a suitable tool, remove the top of the fuel tank drain
port.
12. NOTE: A fuel vacuum drain unit must be attached to the

special tool to achieve full fuel tank drain.

Using the special tool, drain the right-hand side of the fuel
tank.
13. NOTE: Vehicles without Diesel engine shown, vehicles with

14. CAUTION: Make sure the new fuel tank drain port
sealing cap is correctly installed. Failure to follow this instruction

Install a new fuel tank drain port sealing cap.

15. Install the floor aperture cover.
16. Attach the rear seat cushion insulation.
17. Attach the floor covering.
18. Install the scuff plate trim panel.

19. Attach the door opening weatherstrip.
Vehicles with fuel transfer unit


25. CAUTION: The correct measurement must be used to

remove the fuel tank drain port top. Failure to follow this
NOTE: The fuel tank drain port is marked with DRAIN.

Using a suitable tool, remove the top of the fuel tank drain
port.
26. NOTE: A fuel vacuum drain unit must be attached to the

special tool to achieve full fuel tank drain.

Using the special tool, drain the left-hand side of the fuel tank.
27. NOTE: Vehicles without Diesel engine shown, vehicles with
28. CAUTION: Make sure the new fuel tank drain port
sealing cap is correctly installed. Failure to follow this instruction

Install a new fuel tank drain port sealing cap.

All vehicles
33. Install the rear seat cushion.
Fuel System - General Information - Low-Pressure Fuel System BleedingTDV6 2.7L
Diesel
General Procedures
W ARNINGS:
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.
After carrying out repairs, the fuel system must be checked visually for leaks. Failure to follow this instruction may result in 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 immediate medical attention.
W ash hands thoroughly after fuel handling, as prolonged contact may cause irritation. Should irritation develop, seek medical
attention.
CAUTIONS:
This procedure must be carried out before the engine is attempted to be started, following removal or replacement of any fuel system
component involving fuel line intrusion. Failure to follow this instruction will result in damage to the fuel injection pump.
NOTE: This procedure is necessary if any low-pressure fuel system components are removed or replaced. These include the fuel filter, fuel
lines, fuel tank or fuel cooler.
1. NOTE: If the ignition is switched on for more than 10 seconds without

the engine starting the fuel pump will switch off to protect itself.
Switch ignition on for 10 seconds. The fuel pump in the fuel tank will be
audible.
2. Switch the ignition off.
3. NOTE: Do not start the vehicle.
NOTE: Allow 15 seconds between each ignition cycle (between each

ignition ON and ignition OFF) to allow the fuel tank pump to pump fuel to
the fuel injection pump correctly.
Switch the ignition on and off four times.

4. NOTE: The engine must be allowed to idle for two minutes to allow a
full system bleed.
Crank the engine until it starts and allow to idle.

Fuel System - General Information - Spring Lock Couplings
General Procedures
Special Tool(s)
Spring Lock Coupling Tool or Equivalent
310-D005 (23-040)
Disconnect
1. WARNINGS:


work is complete.



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.
Wash hands thoroughly after handling, as prolonged

contact may cause irritation. Should irritation develop, seek
medical attention.
Relieve the fuel system pressure. For additional information,

refer to the procedure in this section: Pressure Relief.
2. Remove the safety clip from the spring lock coupling.
4. Close the special tool and push it into the female end of the
spring lock coupling.
5. Disconnect the spring lock coupling.

Connect
NOTE: Install a new garter spring.
Clean and inspect the male and female ends of the spring lock
coupling.
2. W ARNING: Make sure the garter spring snaps over the

male end of the spring lock coupling.
Connect the spring lock coupling.
3. Check the spring lock coupling to make sure it is correctly

connected.
4. Install the safety clip to the spring lock coupling.
Fuel System - General Information - Quick Release Coupling
General Procedures
Disconnect
1. WARNINGS:


work is complete.



in personal injury.

personal injury.

in personal injury.

medical attention.

refer to the procedure in this section: Pressure Relief.
2. Disconnect the quick release fitting.
1. Release the retaining clip.
2. Disconnect the quick release fitting.
Connect
1. To connect, reverse the disconnect procedure.
Fuel System - General Information - Quick Release Coupling - Push Connect
General Procedures
Disconnect
1. WARNINGS:


work is complete.



in personal injury.

personal injury.

in personal injury.

medical attention.

refer to the procedure in this section:
Release (310-00 Fuel System - General Information, General
Procedures).
2. Disconnect the push connect fitting.
1. Press the tang.
2. Disconnect the push connect fitting.
Connect
1. To connect.
Support the male stub.
Push the connector fitting onto the stub until an audible

click can be heard.
Check the connection by a gentle tug test.

Fuel Tank and Lines - TDV6 2.7L Diesel -
Variant Fuel Pressure at Idle Fuel Pressure at Wide Open Throttle
Vehicles with PTEC engine management: - -
All 2.2 bar (31.9 lb/in) (220 kPa) 2.8 bar (40.6 lb/in) (280 kPa)
Description Nm lb-ft
Fuel tank support strap retaining bolts 35 26
Fuel pump module locking ring 60 44
Fuel transfer pump locking ring 60 44
Fuel Tank and Lines - TDV6 2.7L Diesel - Fuel Tank and Lines - Component Location
ItemDescription
1 Fuel pump module assembly
2 Fuel tank
3 Filler cap and tether
4 Fuel filler pipe
5 Tank breather filter
6 Transfer pump module assembly
7 Fuel level vent valve
8 ROV (roll over valve)
9 Fuel delivery and return pipes
10 Fuel cooler
11 Fuel filter
12 Fuel damper
Fuel Tank and Lines - TDV6 2.7L Diesel - Fuel Tank and Lines - Overview
OVERVIEW
The fuel tank houses an internal fuel lift pump, located in the fuel pump module. The lift pump is employed to provide a low-pressure
supply to the common rail high pressure fuel system.
Two fuel level sensors are installed in either side of the saddle tank. The sensors are a MAPPS (magnetic passive position sensor) which
provide a variable resistance to ground for the output from the fuel gauge.
Two fuel coolers are fitted to the vehicle. One is located in the low pressure side of the system in the fuel return line and is a fuel to air
cooler. The second cooler, in the high pressure side, is located in the 'vee' of the engine block, and has a coolant system connection to aid
heat transfer.
The fuel tank breather system consists of a ROV (roll over valve), fuel level vent valve and a fuel tank breather filter.
The fuel filter is a disposable canister type and is located on the left hand front inner wing turret.
NOTE: The fuel fired additional heating system is discontinued, eliminating the dosing pump and pipework from the fuel tank and lines
system.
Fuel Tank and Lines - TDV6 2.7L Diesel - Fuel Tank and Lines - System Operation and
Control Diagram
ItemDescription
1 Fuel tank
2 Fuel lift pump
3 Air bleed return
4 Fuel filter
5 Fuel cooler (under vehicle)
6 Fuel injection pump
7 Distribution rail
8 Piezo injector
9 Fuel rail
10 Fuel cooler (engine)
11 Lift pump pressure regulator
System Operation
Diesel fuel is drawn from the tank by the internal electric lift pump. The fuel pressure regulator located in the fuel pump module assembly
regulates the delivery pressure at approximately 0.5 bar to the transfer pump housed in the HPP (high pressure pump). A VCV (volume
control valve) governs the amount of fuel supplied to the HPP (high-pressure pump).
The transfer and high pressure pump are driven directly by the engine. Due to the storage volume of the common rail, the injection pressure
will remain practically constant over the complete duration of the injection process.
The HPP (high pressure pump) has a return pipe circuit which is separate from the injector return pipes.
Refer to: Fuel Charging and Controls (303-04A, Description and Operation).
FUEL TANK
ItemDescription
1 Fuel pump module
2 ROV (roll over valve)
3 Tank breather filter
4 Fuel level vent valve
5 Transfer pump module assembly
6 Fuel return pipe
7 Fuel supply to engine
8 Jet pump
9 LH (left-hand) fuel level sensor float
10 Internal fuel transfer pipes
11 RH (right-hand) fuel level sensor float
12 Fuel pick up pipe with integrated coarse filter
The fuel tank is a saddle type tank constructed of HDPE (high density polyethylene), a plastic blow molded material. The tank is located
forward of the rear suspension and is mounted using two metal straps. The tank is a sealed unit with the only internal access being through
the fuel pump module and transfer pump module flange apertures on the top of the tank.
The fuel pump module flange has a six pin external connector which provides the electrical connections for the fuel pump, low fuel level
switch and the right hand fuel level sensor. A quick release connector provides for the connection of the fuel feed pipe.
The transfer pump module flange has a two pin external connector which provides the electrical connection for the left hand fuel level
sensor. A quick release connector provides for the connection of the fuel return pipe.
Each flange is fitted with a collar, clamp and seal which locate in the tank apertures. An arrow on each flange must be aligned between two
molded lines on the tank, adjacent to the fuel pump module or transfer pump flange aperture, to obtain the correct pump orientation. A
collar is located over each flange and is secured with a clamp.
FUEL PUMP MODULE

ItemDescription
1 Fuel pick up pipe with integrated coarse filter
2 RH fuel level sensor
3 Lift pump pressure regulator
4 Electrical connecter
5 Fuel pump module
The low pressure fuel lift pump is located in the fuel pump module and is designed with low level fuel pick-up features. The lift pump is
employed to provide a low pressure supply, approximately 0.5 bar, to the common-rail high pressure fuel system and maintain an equal fuel
level in both compartments of the saddle tank.
The lift pump operation is controlled by the ECM (engine control module), via the fuel pump relay located in the RJB (rear junction box).
When the ignition is switched on the fuel pump operates for 25 seconds to build up fuel pressure. As engine cranking commences the fuel
pump stops running until the engine starts. This function is employed to decrease load on the battery.
In cold conditions, 'waxing' of the fuel can occur. For this reason a coarse mesh filter is attached to the swirl pot inlet port at the bottom of
the pump module.
A four pipe manifold connection is located next to the fuel pressure regulator at the top of the fuel pump module. One connection is the fuel
pump outlet connection which feeds into the manifold. A second connection allows fuel at pump outlet pressure to flow back through the
pump module housing from the manifold to the lower swirl pot area. The third connection feeds the pressure regulator and fuel delivery line.
When the regulator has opened, due to excessive pump output pressure, fuel returns through the fourth manifold connection to the swirlpot.
The right hand fuel level sensor and low fuel level switch are mounted into the pump module housing.
FUEL LEVEL SENSORS

Left Hand Fuel Level Sensor
ItemDescription
1 Transfer pump module
2 Fuel cross-over pipes
3 Fuel level sensor float
4 Filter
5 Jet pump
6 Fuel level sensor
Two fuel level sensors are installed in either side of the saddle tank. One is mounted on the fuel pump module, the other is mounted on the
transfer pump module in the other side of the fuel tank. The sensors are a MAPPS (magnetic passive position sensor) which provide a
variable resistance to ground for the output from the fuel gauge. The sensor is sealed from the fuel preventing contamination of the
contacts, increasing reliability. The fuel level sensors are connected to external electrical connectors on the underside of the fuel and
transfer pump module flanges.
The sensor comprises a series of 51 film resistors mounted in an arc on a ceramic surface. The resistors are wired in series with individual
contacts. A soft magnetic foil with 51 flexible contacts is mounted a small distance above the film resistors. A magnet, located below the
ceramic surface, is attached to the sender unit float arm. As the float arm moves, the magnet follows the same arc as the film resistors.
The magnet pulls the flexible contacts onto the opposite film resistor contacts forming an electrical circuit.
ItemDescription
1 Magnetic foil
2 Spacer
3 Ceramic surface
4 Magnet
5 Resistance film
The film resistors are arranged in a linear arc with resistance ranging from 51.2 to 992.11 Ohms. The electrical output signal is proportional
to the amount of fuel in the tank and the position of the float arm. The measured resistance is processed by the instrument cluster to
implement an anti-slosh function. This monitors the signal and updates the fuel gauge pointer position at regular intervals, preventing
constant pointer movement caused by fuel movement in the tank due to cornering or braking.
A warning lamp is incorporated in the instrument cluster and illuminates when the fuel level is low.
The fuel level sender signal is converted into a CAN (controller area network) message by the instrument cluster as a direct interpretation of
the fuel tank contents in liters.
LOW FUEL LEVEL SWITCH
ItemDescription
1 Low fuel level switch
2 Fuel pump module
A fuel run-dry strategy has been programmed into the ECM software to prevent the fuel tank emptying completely. This strategy prevents
damage to the fuel tank pump and the necessity of priming the fuel system.
In the event that the fuel is allowed to run too low, signals transmitted from a low-level switch, located in the swirl-pot of the fuel pump
module, and both fuel level sensors initiate the fuel run-dry strategy.
Due to the location of the low-level switch there will only be a small amount of fuel left in the tank when the fuel run-dry strategy initiates.
The driver will have been notified much earlier that the vehicle was low on fuel.
Although this is a simulated run-dry procedure, it provides the symptoms of the vehicle running out of fuel and the driver will perceive it as
such. The engine will stop when there is approximately 4-liters of fuel remaining in the fuel tank.
JET PUMP
The fuel system incorporates a single jet pump in the LH side of the tank. The jet pump is located on the LH fuel level sensor carrier. The
jet pump operates on a venturi effect created by the fuel at pump output pressure passing through the jet pump. This draws additional fuel
from the tank through ports in the jet pump body.
The prime function of the jet pump is to collect fuel from the LH side of the tank and transfer it into the fuel pump module swirl pot on the
RH side of the tank. The jet pump feature also serves to maintain an equal fuel level in the fuel tank compartments.
ROLL OVER VALVE

The ROV (roll over valve) is located in the upper half of the fuel tank and is connected via a pipe to the fuel level vent valve. The ROV (roll
over valve) contains a non-return valve which closes in the event of the vehicle overturning, preventing liquid fuel escaping from the tank
via the breather pipe.
FUEL LEVEL VENT VALVE

The fuel level vent valve is located in the upper half of the tank and is connected via pipework to the ROV (roll over valve) and the tank
breather filter. The main purpose of the fuel level vent valve is to control the fill volume of the tank. During filling air, trapped inside the
tank and a small amount of vapor is passed via the fuel level vent valve to the tank breather filter. The air and vapor mix then vents to
atmosphere through the breather filter. During filling, when the tank reaches its full level, the fuel level vent valve closes and prevents
air/vapor passing through to the tank breather filter. The resulting back pressure causes refueling to stop automatically.
Any further rise in air pressure is vented to the tank breather filter via the ROV (roll over valve).
The fuel level vent valve is always open when the fuel tank is below full, providing an unrestricted air/vapor outlet to the tank breather
filter.
If a malfunction occurs in the fuel tank delivery system and the tank overfills, an integral pressure relief valve in the fuel level vent valve
opens to provide a direct vent to the atmosphere.
FUEL FILTER
ItemDescription
1 Fuel damper
2 Fuel supply from fuel tank and under vehicle cooler
3 Air bleed to fuel tank
4 Fuel return to under vehicle cooler
5 Fuel diverter pipe
6 Fuel return from engine
7 Fuel feed to common-rail fuel pump
The fuel filter is a disposable canister type.
To prevent diesel waxing in cold conditions and to aid warm-up, a temperature sensitive regulating valve incorporated in the fuel filter
housing, diverts a portion of the warm fuel returning from the engine into the fuel filter.
The regulating valve commences closing at 30 C (86F) and fully closes at 50 C (122F). W hen the valve is closed the returning fuel is
diverted to the fuel filter via the under vehicle fuel cooler to maintain an optimum fuel temperature.
The filter has an air bleed return to the fuel tank which returns excess air and fuel to the tank.
The filter canister incorporates a chamber for collecting moisture. The moisture contained in the diesel fuel collects on the internal filter
element and forms droplets, which fall into the moisture chamber. A drain plug located on the bottom of the filter canister is used to
discharge the water.
FUEL FILLER PIPE ASSEMBLY

ItemDescription
1 W ide bore filler neck
3 Fuel filler pipe
The aluminum filler neck has a wide bore neck specially designed to reduce diesel frothing while the fuel tank is being replenished.
FUEL COOLER
ItemDescription
1 Fuel cooler (low pressure side under vehicle)
2 Fuel return to under vehicle cooler
3 Fuel return from engine
The low-pressure-side fuel cooler is situated under the vehicle, below the LH (left hand) front seat. The cooler is fuel to air cooled. Fuel flow
through the underfloor cooler is controlled by the fuel filter.
Fuel Tank and Lines - TDV6 2.7L Diesel - Fuel Tank and Lines
For a detailed description of the fuel tank and lines systems, refer to the relevant Description and Operation sections in the workshop
manual. REFER to: (310-01A Fuel Tank and Lines - TDV6 2.7L Diesel)
Fuel Tank and Lines (Description and Operation),

Fuel Tank and Lines (Description and Operation).
Visual Inspection
Fuel leaks Fuses
Damaged fuel lines Loose or corroded electrical connectors
Damaged push connect fittings Harnesses
Fuel level Fuel Pump Driver Module (FPDM)
Fuel contamination/grade/quality Central Junction Box (CJB)
Damaged fuel tank filler pipe cap Fuel pump relay
Damaged fuel tank filler pipe Engine Control Module (ECM)
step.
Symptom Chart

Engine cranks, Low/contaminated fuel Check for low/contaminated fuel. Check integrity of intake air system. Check fuel
but does not fire Intake air leakage system for leaks and blockage/restriction. Check for fuel and electronic engine
Fuel system leak, control system related DTCs and refer to relevant DTC Index
blocked/restricted
Difficult to start Glowplug fault Check integrity of glowplug system. Check for low/contaminated fuel. Check the
Low/contaminated fuel engine coolant level and condition.
Check engine coolant REFER to: Specifications (303-03A Engine Cooling - TDV6 2.7L Diesel,
level/anti-freeze content Specifications).
Battery Ensure the battery is in a fully charged and serviceable condition. Check intake air
Intake air system leak system for leaks. Check for electronic engine control DTCs and refer to the relevant
Electronic engine controls DTC Index. Carry out injector leak tests, install new injectors as required.
Injector leak REFER to: Fuel Injector (303-04A Fuel Charging and Controls - TDV6 2.7L Diesel,
Fuel system leak, Removal and Installation).
blocked/restricted Check fuel system for leaks and blockage/restriction. Check for fuel system related
DTCs and refer to relevant DTC Index
Rough idle Intake air system leak Check intake air system for leaks. Check for low/contaminated fuel. Check fuel
Low/contaminated fuel system for leaks and blockage/restriction. Check for fuel system related DTCs and
Fuel system leak, refer to relevant DTC Index. Check EGR system for failure.
blocked/restricted REFER to: Engine Emission Control (303-08A Engine Emission Control - TDV6 2.7L
EGR valve fault Diesel, Diagnosis and Testing).
Engine Intake air system leak Check intake air system for leaks. Check exhaust system for blockage/restriction.
hesitates/poor Restricted exhaust system Check fuel system for leaks and blockage/restriction. Check for fuel system related
acceleration Fuel system leak, DTCs and refer to relevant DTC Index. Check EGR system for failure.
blocked/restricted REFER to: Engine Emission Control (303-08A Engine Emission Control - TDV6 2.7L
EGR valve fault Diesel, Diagnosis and Testing).
Turbocharger actuator fault Check for turbocharger actuator fault. Check for turbocharger actuator DTCs and
refer to relevant DTC Index
Engine Breather system Ensure the engine breather system is free from restriction and is correctly
stops/stalls disconnected/restricted installed. Check intake air system for leaks/restriction. Check for electronic engine
Intake air system control DTCs and refer to the relevant DTC Index. Check fuel system for leaks and
leak/restricted blockage/restriction. Check for fuel system related DTCs and refer to relevant DTC
Electronic engine controls Index. Check EGR system for failure.
Fuel system leak, REFER to: Engine Emission Control (303-08A Engine Emission Control - TDV6 2.7L
blocked/restricted Diesel, Diagnosis and Testing).
EGR valve fault
Excessive fuel Fuel pressure, fuel pump, fuel Check fuel lines for leakage, blockage/restriction. Check for fuel system related
consumption lines blocked/contaminated, DTCs and refer to relevant DTC Index. Carry out fuel injector leak tests, install
leaking new injectors as necessary.
Injector leak REFER to: Fuel Injector (303-04A Fuel Charging and Controls - TDV6 2.7L Diesel,
Electronic engine controls Removal and Installation).
EGR valve fault Check for electronic engine control DTCs and refer to the relevant DTC Index.
Check EGR system for failure.
REFER to: Engine Emission Control (303-08A Engine Emission Control - TDV6 2.7L
Diesel, Diagnosis and Testing).
DTC Index
3548-1358-00.
NOTE: If a module or component is suspect, and the vehicle remains under the Manufacturers warranty, refer to the Warranty Policy and
Procedure manual (section B1.2), or determine if any prior approval programme is in operation, prior to the installation of a new
module/component.

Control Circuit/Open control circuit - open control circuit for open circuit. Check resistance across fuel regulator
circuit control valve is between 1.5 and 15 Ohms, install a new valve as required
Control Circuit control circuit - short to manufacturer approved diagnostic system. Refer to the electrical circuit
Range/Performance ground, power, high diagrams and check fuel volume regulator control circuit for short to
resistance ground, power, high resistance. Check and install new fuel volume
Fuel volume regulator regulator control valve/ECM as required, refer to the new
ECM failure
Control Circuit Low control circuit - short to control circuit for short to ground. Check resistance across fuel regulator
ground control valve is between 1.5 and 15 Ohms, install a new valve as required
above threshold diagrams and check fuel volume regulator control valve circuit for short,
Fuel volume regulator open circuit. Check resistance across fuel regulator control valve is
control valve failure between 1.5 and 15 Ohms, install a new valve as required
Control Circuit High control circuit - short to control circuit for short to ground, power, open circuit. Check resistance
ground, power, high across fuel regulator control valve is between 1.5 and 15 Ohms, install a
resistance new valve as required
Control Exceeded minimum manufacturer approved diagnostic system. Refer to the electrical circuit
Control Exceeded maximum manufacturer approved diagnostic system. Refer to the electrical circuit
P008772 Fuel Rail/System Lift pump relay driven, Refer to the electrical circuit diagrams and check fuel lift pump relay
Pressure - Too Low pump not activated circuits and is operating correctly. Check the fuel lift pump is operating
correctly
P008873 Fuel Rail/System Lift pump relay not Refer to the electrical circuit diagrams and check fuel lift pump relay
Pressure - Too High driven, pump activated circuits for short to ground, power, open circuit
Control Circuit valve control circuit - valve control circuit for open circuit. Check resistance across fuel pressure
open circuit control valve is 2.7 Ohms 2.7 Ohms
valve failure
Control Circuit Low valve control circuit - valve control circuit for short to ground, power, open circuit. Check
short to ground, power, resistance across fuel pressure control valve is 2.7 Ohms 2.7 Ohms
open circuit
valve failure
P009119 Fuel Pressure Regulator Fuel pressure control Carry out any pinpoint tests associated with this DTC using the
Control Circuit Low valve control circuit - manufacturer approved diagnostic system. Refer to the electrical circuit
current above threshold diagrams and check fuel pressure control valve control circuit for short to
ground, power, open circuit. Check resistance across fuel pressure control
valve is 2.7 Ohms 2.7 Ohms
Control Circuit High valve control circuit - valve control circuit for short to power. Check resistance across fuel
short to power pressure control valve is 2.7 Ohms 2.7 Ohms
P018126 Fuel Temperature Signal rate of change NOTE: This test can only be carried out when the fuel temperature is
Sensor A Circuit below threshold below 30C
Range/Performance Fuel temperature sensor
failure Refer to the electrical circuit diagrams and check fuel temperature sensor
circuits for short, open circuit and poor connections. Check and record fuel
temperature sensor signal, start engine and allow to idle for
approximately 10 minutes, check and record fuel temperature sensor
signal. If the value of the signal has NOT increased by more than 8C
P018216 Fuel Temperature Circuit voltage below Carry out any pinpoint tests associated with this DTC using the
failure ground. Check and install a new sensor as required
P018317 Fuel Temperature Circuit voltage above Carry out any pinpoint tests associated with this DTC using the
failure power. Check and install a new sensor as required
P018427 Fuel Temperature Signal rate of change Refer to the electrical circuit diagrams and check fuel temperature sensor
Sensor A Circuit above threshold circuits for short, open circuit and poor connections. Run engine to normal
Intermittent Fuel temperature sensor operating temperature, check and record fuel temperature sensor signal,
failure increase engine speed to 2000 rpm, after approximately 120 seconds
check and record signal. If value of signal has increased by more than
P019123 Fuel Rail Pressure Signal stuck low Carry out any pinpoint tests associated with this DTC using the
circuit. Check fuel pump for correct operation. Check fuel pressure sensor
circuits for short, open circuit. Check for low fuel level and blocked fuel
lines
P019124 Fuel Rail Pressure Signal stuck high Carry out any pinpoint tests associated with this DTC using the
circuit. W ith engine at idle check and record 'Fuel pressure' datalogger
signal, stop engine check and record signal. If signal is greater than
10MPa after approximately 0.40 seconds suspect the fuel pump, check
and install a new pump as required
P019165 Fuel Rail Pressure Signal has too few Carry out any pinpoint tests associated with this DTC using the
Sensor A Circuit transitions/events manufacturer approved diagnostic system. Refer to the electrical circuit
Range/Performance diagrams and check fuel pump circuits for open circuit. Run engine to
normal operating temperature, check and record 'Fuel pressure'
datalogger signal, increase engine speed to 2000 rpm, check and record
signal. If value of signal changes by more than 40MPa/10ms suspect the
fuel pump, check and install a new pump as required
P019216 Fuel Rail Pressure Circuit voltage below Carry out any pinpoint tests associated with this DTC using the
0MPa suspect the fuel pump, check and install a new pump as required
P019317 Fuel Rail Pressure Circuit voltage above Carry out any pinpoint tests associated with this DTC using the
more than 180MPa suspect the fuel pump, check and install a new pump
as required
P019427 Fuel Rail Pressure Signal rate of change Carry out any pinpoint tests associated with this DTC using the
Sensor A Circuit above threshold manufacturer approved diagnostic system. Refer to the electrical circuit
Intermittent/Erratic diagrams and check fuel pump circuit for open circuit. Run engine at idle
speed, check and record 'Fuel pressure' datalogger signal, increase
engine speed to 2000 rpm, check and record signal. If value of signal
changes by more than 40MPa/10ms suspect the fuel pump, check and
install a new pump as required
P046100 Fuel Level Sensor A Low fuel level Carry out any pinpoint tests associated with this DTC using the
Circuit Fuel level sensor signal manufacturer approved diagnostic system. Check for sufficient amount of
Range/Performance circuit - short to ground, fuel in fuel tank. Refer to the electrical circuit diagrams and check fuel
open circuit level sensor circuits for short to ground, open circuit. Check and install a
Fuel level sensor failure new fuel level sensor as required
P04611A Fuel Level Sensor A Low fuel level Carry out any pinpoint tests associated with this DTC using the
Circuit Circuit resistance below manufacturer approved diagnostic system. Check for sufficient amount of
Range/Performance threshold fuel in fuel tank. Refer to the electrical circuit diagrams and check fuel
Fuel level sensor failure level sensor circuits for short circuit. Check and install a new fuel level
sensor as required
P04611B Fuel Level Sensor A Low fuel level Carry out any pinpoint tests associated with this DTC using the
Circuit Circuit resistance above manufacturer approved diagnostic system. Check for sufficient amount of
Range/Performance threshold fuel in fuel tank. Refer to the electrical circuit diagrams and check fuel
Fuel level sensor failure level sensor circuits for High resistance. Check and install a new fuel level
sensor as required
P062712 Fuel Pump A Control Fuel lift pump relay Refer to the electrical circuit diagrams and check fuel lift pump relay
Circuit/Open control circuit - short to control circuit for short to power. Check and install a new fuel lift pump
power relay as required
Fuel lift pump relay
failure
Circuit Low control circuit - short to control circuit for short to ground. Check and install a new fuel lift pump
ground relay as required
failure
Circuit High control circuit - open control circuit for open circuit. Check and install a new fuel lift pump relay
circuit as required
failure
P115A68 Low Fuel Level - Forced Low level fuel condition Check the fuel level. If there is sufficient fuel, refer to the electrical
Limited Power Critical fuel level switch circuit diagrams and check the critical fuel level switch and fuel level
signal circuit - short to sensor circuits for short, open circuit. Check and install a new critical fuel
ground, power, open level switch/fuel level sensor as required
circuit
Critical fuel level switch
failure
Fuel level sensor signal
circuit - short to ground,
power, open circuit
P115B68 Low Fuel Level - Forced Low level fuel condition Check the fuel level. If there is sufficient fuel, refer to the electrical
Engine Shutdown Critical fuel level switch circuit diagrams and check the critical fuel level switch and fuel level
signal circuit - short to sensor circuits for short, open circuit. Check and install a new critical fuel
ground, power, open level switch/fuel level sensor as required
circuit
Critical fuel level switch
failure
Fuel level sensor signal
circuit - short to ground,
power, open circuit
P213E01 Fuel Injection System Engine stop by electrical Check for additional related DTCs and refer to the relevant DTC Index
Fault - Forced Engine
Shutdown
P213F07 Fuel Pump System Fault Engine stop by hydraulic Check for additional related DTCs and refer to the relevant DTC Index
- Forced Engine
Shutdown
Fuel Tank and Lines - TDV6 2.7L Diesel - Fuel Cooler
Removal
1. Refer to: Diesel Fuel System Health and Safety Precautions (100-00 General

4. Refer to: Engine Rear Undershield (501-02 Front End Body Panels, Removal and
Installation).
5. Torque: 10 Nm
6. 6. CAUTIONS:
Be prepared to collect escaping fluids.
Make sure that all openings are sealed. Use new blanking caps.
Torque:
M6 Bolt 9 Nm
M6 Nut 5 Nm
Installation
1. 1. NOTE: Remove and discard the blanking caps.

Fuel Tank and Lines - TDV6 2.7L Diesel - Fuel Filter
Removal
All vehicles
1.
2.
3.
4.
5.
6.
7. Torque: 3 Nm
Vehicles with 3.0L diesel engine

8.
All vehicles
9. Torque: 3 Nm
Installation
1. 1. CAUTION: Make sure that the fuel filter is correctly aligned. Failure
to follow this instruction may result in damage to the vehicle.
2. Carry out the low-pressure fuel system bleeding.
Refer to: Low-Pressure Fuel System Bleeding - TDV6 2.7L Diesel (310-00 Fuel System
- General Information, General Procedures).
Fuel Tank and Lines - TDV6 2.7L Diesel - Fuel Tank
Removal
All vehicles
2. Refer to: Fuel Tank Draining (310-00 Fuel System - General Information, General
Procedures).

4. Refer to: Driveshaft (205-01 Driveshaft, Removal and Installation).
5.
Torque: 5 Nm
6. 6. WARNING: The spilling of fuel is unavoidable during this

operation. Make sure that all necessary precautions are taken to prevent
fire and explosion.
Vehicles with petrol engine

7.
All vehicles
8.
Torque: 3 Nm
9. 9. WARNING: Secure the component to the transmission jack.
CAUTION: Use suitable packing material to prevent damage to the

component.
Torque: 35 Nm
Installation

Fuel Tank and Lines - TDV6 2.7L Diesel - Fuel Pump Module
Special Tool(s)
Remover/Installer, Fuel Pump Module/Fuel
Transfer Unit Locking Ring
310-146
Removal

2. For additional information, refer to: Fuel Transfer Unit (310-01A Fuel
Tank and Lines - TDV6 2.7L Diesel, Removal and Installation).
3.

removal.
removal.
TORQUE: 70 Nm
6. CAUTIONS:
Note the fitted position of the component prior to removal.
Take extra care not to damage the fuel tank level sensor float and
arm.
Installation
1. CAUTION: Take extra care not to damage the fuel tank level
sensor float and arm.
NOTE: Make sure that the component is installed to the position noted
on removal.

Fuel Tank and Lines - TDV6 2.7L Diesel - Fuel Transfer Unit
Special Tool(s)
310-146
Removal

2. For additional information, refer to: Fuel Tank Draining (310-00 Fuel
System - General Information, General Procedures).
3.

removal.
5.
TORQUE: 70 Nm
6. CAUTIONS:
Note the fitted position of the component prior to removal.
Take extra care not to damage the fuel tank level sensor float and
arm.
Installation
1. CAUTION: Take extra care not to damage the fuel tank level
sensor float and arm.
NOTE: Make sure that the component is installed to the position noted
on removal.

Fuel Tank and Lines - V6 3.0L Petrol -
Variant Fuel Pressure at Idle Fuel Pressure at Wide Open Throttle
Vehicles with PTEC engine management: - -
All 2.2 bar (31.9 lb/in) (220 kPa) 2.8 bar (40.6 lb/in) (280 kPa)
Fuel Tank and Lines - V6 3.0L Petrol - Fuel Tank and Lines - Component Location
ItemDescription
2 Fuel tank
4 Fuel filler pipe
5 Charcoal canister assembly
6 Fuel transfer pump
7 Pressure control valve
8 Fuel vapor valve
9 Pipe - EVAP charcoal canister to purge valve
10 Fuel filter
11 Pipe - Fuel pump to engine (feed)
Fuel Tank and Lines - V6 3.0L Petrol - Fuel Tank and Lines - Overview
Authoring Template
OVERVIEW
The fuel system uses an electronic returnless system. The system comprises a pump module mounted in the fuel tank to deliver fuel at
variable flow and pressure to the fuel rails which in turn supply fuel to the fuel injectors. The fuel pump operation is regulated by a FPDM
(fuel pump driver module) which is controlled by the ECM (engine control module). The FPDM regulates the flow and pressure supplied by
controlling the operation of the fuel pump using a PWM (pulse width modulation) output.
Two fuel level sensors are installed in either side of the saddle tank. The sensors are a MAPPS (magnetic passive position sensor) which
provide a variable resistance to ground for the output from the fuel gauge.
The fuel system also incorporates an EVAP (evaporative emission) system which is part of the on-board refueling and vapor recovery
feature. The function and operation of the system is designed to meet evaporative emission requirements to minimize fuel vapor losses.For
additional information, refer to:
Evaporative Emissions (303-13B, Description and Operation),

Fuel Charging and Controls (303-04D, Description and Operation),
Electronic Engine Controls (303-14C, Description and Operation).
Fuel Tank and Lines - V6 3.0L Petrol - Fuel Tank and Lines - System Operation and
Control Diagram
ItemDescription
1 Fuel pump and level sensor electrical connector
2 Fuel pump module
3 Suction jet pump
4 Fuel pump
5 RH (right-hand) fuel compartment
6 LH (left-hand) fuel compartment
7 Fuel level sensor
8 Parallel pressure relief valve
9 Fuel transfer pump module
10 High-pressure cross-over circulation pipe
11 Low-pressure cross-over circulation pipe
12 Engine fuel delivery pipe
13 Fuel filter
14 Fuel rail
15 Fuel injector
System Operation
The fuel pump is a variable-speed rotary-vane type, which operates in a fuel module located in the right hand fuel tank compartment. A fuel
transfer pump is located in the left hand compartment. Both components are secured by screw on plastic closure rings. The fuel pump
module has an integral top plate for the external pipe work and electrical connectors.
Fuel level is maintained equally in the fuel tank compartments by circulating the fuel through internal crossover pipes via suction jet pumps
which also serve to deliver a constant supply of fuel to the transfer pump and swirl pot assembly. High pressure fuel from the fuel pump is
directed through the jet pump's orifice, creating a low pressure area to be formed around the orifice. The fuel is drawn into this low pressure
area and directed into the swirl pot delivery pipes. This is achieved using the cross-over pipe from the left hand module and a direct link
pipe from the right hand module.
Fuel is pumped from the fuel pump to the fuel rail via the parallel pressure relief valve and fuel filter. The parallel pressure relief valve
contains two spring loaded valves, which operate in opposite directions.
The pressure relief valve assists engine starting by retaining a pre-set fuel pressure in the supply pipe and fuel rail. The fuel pressure valve
also limits fuel rail pressure due to temporary vapor increase in hot conditions and pressure caused by sudden load changes, for example, a
fully open to closed throttle transition. I the event of the fuel delivery pipe being severed, the fuel pressure relief valve will prevent leakage
from the fuel tank.
To meet ORVR (on-board refueling vapor recovery) requirements, the fuel tank and associated components are designed to minimize fuel
vapor loss during refueling. This is achieved by preventing fuel vapor from the fuel tank venting directly to the atmosphere. Instead fuel
vapor is directed into the EVAP (evaporative emission) canister where it is stored before being purged at intervals to the engines intake
manifold.
FUEL TANK
ItemDescription
1 Charcoal canister
2 EVAP hose
3 Vapor pressure control valve
4 Fuel vapor valve
5 LH fine mesh filter pick up
9 Jet pump
10 LH fuel level sensor float
12 RH fuel level sensor float
13 Fuel pump module
14 RH fine mesh filter pick up
15 Fuel pump electrical connection
The fuel tank is a saddle type tank constructed of HDPE (high density polyethylene), a plastic blow molded material. The tank is located
forward of the rear suspension and is mounted using two metal straps. The tank is a sealed unit with the only internal access being through
the fuel pump module and transfer pump module flange apertures on the top of the tank.
The fuel pump module flange has a six pin external connector which provides the electrical connections for the fuel pump and level sensors.
A quick release connector provides for the connection of the fuel feed pipe.
Each flange is fitted with a collar, clamp and seal which locate in the tank apertures. An arrow on each flange must be aligned between two
molded lines on the tank, adjacent to the fuel pump module or transfer pump flange aperture, to obtain the correct pump orientation. A
collar is located over each flange and is secured with a clamp. The flange, seal, collar and clamp arrangements meet the sealing
requirements of LEV2 emissions.
FUEL PUMP MODULE

ItemDescription
2 Fuel pump module
3 Fuel level sensor
4 Level sensor float
The fuel pump is a variable speed rotary vane type. The pump is energized by the fuel pump relay which is located in the RJB (rear junction
box) and the FPDM (fuel pump driver module) which is located under the RH floor pan above the rear suspension stabilizer bar. The relay
and FPDM are controlled by the ECM (engine control module).
A fine mesh filter is located in the lower section of the pump module. This provides filtration to the fuel as it is drawn into the module.
The right hand fuel level sensor is mounted into the pump module housing.
FUEL LEVEL SENSORS

ItemDescription
1 Fuel level sensor
3 Sensor mounting bracket
6 Fine mesh filter
7 Jet pump
Two fuel level sensors are installed in either side of the saddle tank. One is mounted on the fuel pump module, the other is mounted on the
transfer pump module in the other side of the fuel tank. The sensors are a MAPPS (magnetic passive position sensor) which provide a
variable resistance to ground for the output from the fuel gage. The sensor is sealed from the fuel preventing contamination of the
contacts, increasing reliability. The fuel level sensors are connected to the external electrical connector on the flange via the connector on
the underside of the fuel pump module flange.
The sensor comprises a series of 51 film resistors mounted in an arc on a ceramic surface. The resistors are wired in series with individual
contacts. A soft magnetic foil with 51 flexible contacts is mounted a small distance above the film resistors. A magnet, located below the
ceramic surface, is attached to the sender unit float arm. As the float arm moves, the magnet follows the same arc as the film resistors.
The magnet pulls the flexible contacts onto the opposite film resistor contacts forming an electrical circuit.
MAPP Sensor Operating Principle
ItemDescription
1 Magnetic foil
2 Spacer
3 Ceramic surface
4 Magnet
5 Resistance film
The film resistors are arranged in a linear arc with resistance ranging from 51.2 to 992.11 Ohms. The electrical output signal is proportional
to the amount of fuel in the tank and the position of the float arm. The measured resistance is processed by the instrument cluster to
implement an anti-slosh function. This monitors the signal and updates the fuel gage pointer position at regular intervals, preventing
constant pointer movement caused by fuel movement in the tank due to cornering or braking.
The fuel level sender signal is converted into a CAN (controller area network) message by the instrument cluster as a direct interpretation of
the fuel tank contents in liters. The ECM uses the CAN message to store additional OBD (on-board diagnostic) 'P' Codes for misfire
detection when the fuel level is below a predetermined capacity.
JET PUMPS
The fuel system incorporates two jet pumps. The LH jet pump is located on the fuel level sensor carrier on the LH side of the fuel tank. The
RH jet pump is located in the swirl pot below the fuel pump. Both jet pumps operate on a venturi effect created by the fuel at pump output
pressure passing through the jet pump. This draws additional fuel from the tank through ports in the jet pump body, delivering additional
fuel to the swirl pot. This function also serves to maintain an equal fuel level in the fuel tank compartments.
The LH jet pump collects fuel from the LH side of the tank and transfers it into the swirl pot on the RH side of the tank.
The RH jet pump collects fuel from below the swirl pot and transfers it to the upper section of the swirl pot. The action of the jet pumps
ensures a constant supply of fuel to the swirl pot and fuel pump. Both jet pumps have a jet nozzle of 0.5 mm diameter.
FUEL FILTER
The fuel filter is of a conventional construction being that of a paper element sealed within a steel canister. The fuel filter is located behind
the left-hand front fender splash shield.

ItemDescription
1 Fuel filler pipe
3 Charcoal canister
4 EVAP pipe work
The fuel filler head is positioned at the rear of the vehicle, above the right hand rear wheel. The filler head is covered by a molded plastic
cover which is electrically locked when the vehicle is locked. The filler cap is a conventional screw in type which is secured to the vehicle
with a tether.
The filler head is an aluminum fabrication which is secured to the vehicle body by a bracket. The formed aluminum filler pipe locates in a
short flexible hose attached to the tank which is secured with worm drive clamps.
Fuel Tank and Lines - V6 3.0L Petrol - Fuel Tank and Lines
For a detailed description of the fuel tank and lines, refer to the relevant Description and Operation sections in the workshop manual. REFER
to:
Fuel Tank and Lines (310-01B Fuel Tank and Lines - V6 3.0L Petrol, Description and Operation),
Fuel Tank and Lines (310-01C Fuel Tank and Lines - V8 4.2L Petrol/V8 S/C 4.2L Petrol, Description and Operation),
Fuel Tank and Lines (310-01C Fuel Tank and Lines - V8 4.2L Petrol/V8 S/C 4.2L Petrol, Description and Operation),
Fuel Tank and Lines (310-01C Fuel Tank and Lines - V8 4.2L Petrol/V8 S/C 4.2L Petrol, Description and Operation).
Visual Inspection
Fuel leaks Fuses
Fuel contamination/grade/quality Rear Junction Box (RJB)
3. 3. If an obvious cause for an observed or reported symptom is found, correct the cause (if possible) before proceeding to the next
step.
4. 4. If the cause is not visually evident, verify the symptom and refer to the Symptom Chart below, alternatively, check for Diagnostic
Trouble Codes (DTCs) and proceed to the DTC Index.
Symptom Chart

Engine cranks, but does not Engine breather system Ensure the engine breather system is free from restriction and is correctly
fire disconnected/restricted installed. Check for fuel, ignition and electronic engine control system
Ignition system DTCs and refer to the relevant DTC Index
Fuel system
Engine cranks and fires, but Evaporative emissions Check for purge valve, fuel and ignition system DTCs and refer to the
will not start purge valve relevant DTC Index
Fuel pump
Spark plugs
Ignition coil failure(s)
Difficult cold start Check engine coolant Check the engine coolant level and condition. REFER to:
level/anti-freeze content Specifications (303-03B Engine Cooling - V6 3.0L Petrol,
Battery Specifications),
Electronic engine controls Specifications (303-03C Engine Cooling - V8 4.2L Petrol/V8 S/C 4.2L
Exhaust gas recirculation Petrol, Specifications).
(EGR) valve stuck open Ensure the battery is in a fully charged and serviceable condition. Check
Fuel pump for electronic engine control, EGR valve, fuel system and purge valve
Evaporative emissions related DTCs and refer to the relevant DTC Index
purge valve
Difficult hot start Injector leak Carry out injector leak tests, install new injectors as required. REFER to:
Electronic engine controls Fuel Injectors (303-04C Fuel Charging and Controls - V6 3.0L Petrol,
Evaporative emissions Removal and Installation),
purge valve Fuel Injectors (303-04D Fuel Charging and Controls - V8 4.2L Petrol,
Ignition system Check for electronic engine control, EGR valve, fuel system, ignition
EGR valve stuck open system and purge valve related DTCs and refer to the relevant DTC Index
Difficult to start after hot soak Injector leak Carry out injector leak tests, install new injectors as required. REFER to:
(vehicle standing, engine off, Electronic engine controls Fuel Injectors (303-04C Fuel Charging and Controls - V6 3.0L Petrol,
after engine has reached Evaporative emissions Removal and Installation),
operating temperature) purge valve Fuel Injectors (303-04D Fuel Charging and Controls - V8 4.2L Petrol,
Ignition system Check for electronic engine control, EGR valve, fuel system, ignition
EGR valve stuck open system and purge valve related DTCs and refer to the relevant DTC Index
Engine stalls soon after start Breather system Ensure the engine breather system is free from restriction and is correctly
disconnected/restricted installed. Check for ECM relay, electronic engine control and ignition
ECM relay system DTCs and refer to the relevant DTC Index. Check for blockage in air
Electronic engine controls cleaner element and air intake system. Check for leakage in air intake
Ignition system system. Check fuel lines for blockage/restriction. Clear blockage/restriction
Air intake system and install new fuel lines as required
restricted
Air leakage
Fuel lines
Engine hesitates/poor Fuel pressure, fuel pump, Carry out fuel pressure check.
acceleration fuel lines REFER to: Fuel System Pressure Check - V8 4.2L Petrol/V8 S/C 4.2L
Injector leak Petrol/V6 3.0L Petrol (310-00 Fuel System - General Information, General
Air leakage Procedures).
Electronic engine controls Check fuel lines for blockage/restriction. Clear blockage/restriction and
Ignition system install new fuel lines as required. Check for fuel system DTCs and refer to
EGR valve stuck the relevant DTC Index. Carry out fuel injector leak tests, install new
Transmission malfunction injectors as required. REFER to:
Restricted pedal travel Fuel Injectors (303-04C Fuel Charging and Controls - V6 3.0L Petrol,
(carpet, etc) Removal and Installation),
Fuel Injectors (303-04D Fuel Charging and Controls - V8 4.2L Petrol,
Check for leakage from air intake system. Check for electronic engine
control, EGR valve, ignition system and transmission related DTCs and
refer to the relevant DTC Index. Ensure accelerator pedal is free from
restriction
Engine backfires Fuel pump, fuel lines Check for fuel system related DTCs and refer to the relevant DTC Index.
Air leakage Check fuel lines for blockage/restriction. Clear blockage/restriction and
Electronic engine controls install new fuel lines as required. Check for leakage from air intake
Ignition system system. Check for electronic engine control, ignition system and VCT
Sticking variable camshaft related DTCs and refer to the relevant DTC Index
timing (VCT) hub
Engine surges Fuel pump, fuel lines Check for fuel system related DTCs and refer to the relevant DTC Index.
Electronic engine controls Check fuel lines for blockage/restriction. Clear blockage/restriction and
Ignition system install new fuel lines as required. Check for electronic engine control and
ignition system related DTCs and refer to the relevant DTC Index
Engine detonates/knocks Fuel pump, fuel lines, fuel Check for fuel system related DTCs and refer to the relevant DTC Index.
quality Check fuel lines for blockage/restriction. Clear blockage/restriction and
Air leakage install new fuel lines as required. Check for leakage from air intake
Electronic engine controls system. Check for electronic engine control and VCT related DTCs and refer
Sticking VCT hub to the relevant DTC Index
DTC Index
3548-1358-00.
module/component.

P008700 Fuel Rail/System Pressure - Fuel rail pressure (Fuel rail Carry out any pinpoint tests associated with this DTC using the
Too Low pressure) sensor, sensing manufacturer approved diagnostic system. Refer to the electrical
circuit - short to ground, circuit diagrams and check Fuel rail pressure sensor circuits for
open circuit short to ground, open circuit, high resistance. Check and install a
Fuel rail pressure sensor new Fuel rail pressure sensor as required. Check fuel system for
supply circuit - high failure
resistance
failure
Fuel pump failure
P008800 Fuel Rail/System Pressure - Fuel rail pressure sensor Carry out any pinpoint tests associated with this DTC using the
Too High supply/sensing circuits - manufacturer approved diagnostic system. Refer to the electrical
short to each other circuit diagrams and check Fuel rail pressure sensor circuits for
Fuel rail pressure sensor short to each other, power, open circuit, high resistance. Check
sensing circuit - short to and install a new Fuel rail pressure sensor as required. Check
power fuel system for failure
resistance
failure
power
P018123 Fuel Temperature Sensor A Fuel temperature sensor Carry out any pinpoint tests associated with this DTC using the
Circuit Range/Performance sensing circuit - short to manufacturer approved diagnostic system. Refer to the electrical
ground, short to power, high circuit diagrams and check fuel temperature sensor circuits for
resistance short to ground, power, high resistance. Check and install a new
Fuel temperature sensor Fuel temperature sensor as required
resistance
failure
resistance
failure
resistance
failure
Circuit Low sensing circuit - short to manufacturer approved diagnostic system. Refer to the electrical
ground circuit diagrams and check fuel temperature sensor circuits for
Fuel temperature sensor short to ground, power, high resistance. Check and install a new
ground circuit - short circuit Fuel temperature sensor as required
failure
Circuit High sensing circuit - short to manufacturer approved diagnostic system. Refer to the electrical
power, high resistance, circuit diagrams and check fuel temperature sensor circuits for
disconnected short to ground, power, high resistance. Check and install a new
resistance
failure
P019100 Fuel Rail Pressure Sensor A Fuel rail pressure sensor Carry out any pinpoint tests associated with this DTC using the
Circuit Range/Performance stuck manufacturer approved diagnostic system
Circuit Low sensing circuit - short to manufacturer approved diagnostic system. Refer to the electrical
ground, high resistance, circuit diagrams and check fuel rail pressure sensor circuits for
disconnected short to ground, power, high resistance, disconnected connector.
Fuel rail pressure sensor 5V Check and install a new Fuel rail pressure sensor as required
supply circuit - high
resistance
failure
Circuit High supply/sensing circuits - manufacturer approved diagnostic system. Refer to the electrical
short circuit to each other circuit diagrams and check fuel rail pressure sensor circuits for
Fuel rail pressure sensor short to ground, power, high resistance, disconnected connector.
sensing circuit - short to Check and install a new Fuel rail pressure sensor as required
power
resistance
failure
P023100 Fuel Pump Secondary Circuit No sub type information Refer to the electrical circuit diagrams and check FPDM monitor
Low circuit to ECM for short to ground, high resistance
P023200 Fuel Pump Secondary Circuit No sub type information Refer to the electrical circuit diagrams and check FPDM monitor
High circuit to ECM for short to power
P044100 Evaporative Emission Purge valve - Refer to the electrical circuit diagrams and check EVAP purge
System Incorrect Purge Flow range/performance valve control circuit for short, open circuit
P044200 Evaporative Emission No sub type information Check EVAP system for leak using appropriate smoke/leak tester
System Leak Detected
(small leak)
P044700 Evaporative Emission DMTL COV circuit - short to Carry out any pinpoint tests associated with this DTC using the
System Vent Control Circuit ground manufacturer approved diagnostic system. Refer to the electrical
Open circuit diagrams and check DMTL COV circuit for short to ground
P044800 Evaporative Emission DMTL COV circuit - short to Carry out any pinpoint tests associated with this DTC using the
System Vent Control Circuit power manufacturer approved diagnostic system. Refer to the electrical
Shorted circuit diagrams and check DMTL COV circuit for short to power
P045600 Evaporative Emission DMTL system has detected a Check EVAP system for leak using appropriate smoke/leak tester
System Leak Detected (very leak
small leak)
P045800 Evaporative Emission EVAP canister purge valve Carry out any pinpoint tests associated with this DTC using the
System Purge Control Valve control circuit - short to manufacturer approved diagnostic system. Refer to the electrical
Circuit Low ground, high resistance circuit diagrams and check EVAP canister purge valve control
EVAP canister purge valve circuit for short to ground, high resistance. Check and install a
failure new EVAP canister purge valve as required
P045900 Evaporative Emission EVAP canister purge valve Carry out any pinpoint tests associated with this DTC using the
System Purge Control Valve control circuit - short to manufacturer approved diagnostic system. Refer to the electrical
Circuit High power circuit diagrams and check EVAP canister purge valve control
P046129 Fuel Level Sensor A Circuit Fuel level sensor failure Refer to the electrical circuit diagrams and check fuel level
Range/Performance sensor circuits for short, open circuit, high resistance
P04612F Fuel Level Sensor A Circuit Fuel level sensor failure Refer to the electrical circuit diagrams and check fuel level
Range/Performance sensor circuits for short, open circuit, high resistance
Low sensor circuits for short, open circuit, high resistance
High sensor circuits for short, open circuit, high resistance
P062700 Fuel Pump A Control Fuel pump control circuit Refer to the electrical circuit diagrams and check the FPDM to
Circuit/Open fault (FPDM to ECM) ECM circuit for short to ground, power, open circuit
P062A00 Fuel Pump A Control Circuit Invalid fuel pump duty Refer to the electrical circuit diagrams and check the FPDM to
Range/Performance requested by the ECM ECM circuit for short to ground, power, open circuit
P240100 Evaporative Emission DMTL pump circuit - short to Carry out any pinpoint tests associated with this DTC using the
System Leak Detection Pump ground manufacturer approved diagnostic system. Refer to the electrical
Control Circuit Low circuit diagrams and check DMTL pump circuit for short to ground
P240200 Evaporative Emission DMTL pump circuit - short to Carry out any pinpoint tests associated with this DTC using the
System Leak Detection Pump power manufacturer approved diagnostic system. Refer to the electrical
Control Circuit High circuit diagrams and check DMTL pump circuit for short to power
P240429 Evaporative Emission DMTL reference leak Check integrity of evaporative emissions system, i.e.
System Leak Detection Pump DMTL pump circuit - short to blocked/leaking. Refer to the electrical circuit diagrams and
Sense Circuit ground, power, high check DMTL pump circuit for short to ground, power, high
Range/Performance resistance resistance
DMTL pipework
blocked/leaking
P24042F Evaporative Emission DMTL reference leak Check integrity of evaporative emissions system, i.e.
System Leak Detection Pump DMTL pump circuit - short to blocked/leaking. Refer to the electrical circuit diagrams and
Sense Circuit ground, power, high check DMTL pump circuit for short to ground, power, high
Range/Performance resistance resistance
DMTL pipework
blocked/leaking
P240500 Evaporative Emission DMTL pump circuit - short to Refer to the electrical circuit diagrams and check DMTL pump
System Leak Detection Pump ground, power, high circuit for short to ground, power, high resistance
Sense Circuit Low resistance
P240600 Evaporative Emission DMTL pump circuit - short to Refer to the electrical circuit diagrams and check DMTL pump
System Leak Detection Pump ground, power, high circuit for short to ground, power, high resistance
Sense Circuit High resistance
P240B00 Evaporative Emission DMTL heater control circuit Carry out any pinpoint tests associated with this DTC using the
System Leak Detection Pump low manufacturer approved diagnostic system. Refer to the electrical
Heater Circuit Low circuit diagrams and check DMTL heater control circuit for short
to ground, open circuit
P240C00 Evaporative Emission DMTL heater control circuit Carry out any pinpoint tests associated with this DTC using the
System Leak Detection Pump high manufacturer approved diagnostic system. Refer to the electrical
Heater Circuit High circuit diagrams and check DMTL heater control circuit for short
to power
P245000 Evaporative Emission Control DMTL system circuit - short Carry out any pinpoint tests associated with this DTC using the
System Switching Valve to ground, power, high manufacturer approved diagnostic system. Refer to the electrical
Performance/Stuck Open resistance circuit diagrams and check DMTL system circuit for short to
ground, power, high resistance. Check for stuck valve
P245100 Evaporative Emission Control DMTL system circuit - short Carry out any pinpoint tests associated with this DTC using the
System Switching Valve to ground, power, high manufacturer approved diagnostic system. Refer to the electrical
Stuck Closed resistance circuit diagrams and check DMTL system circuit for short to
ground, power, high resistance. Check for stuck valve
Fuel Tank and Lines - V6 3.0L Petrol - Fuel Filter
Removal
WARNING: Refer to: Petrol and Petrol-Ethanol Fuel Systems Health and Safety Precautions (100-00 General Information, Description
and Operation).
1. De-pressurize the fuel system.
Refer to: Fuel System Pressure Release - V8 4.2L Petrol/V8 S/C 4.2L Petrol/V6 3.0L
Petrol (310-00 Fuel System - General Information, General Procedures).
3.
4. 4. CAUTION: Make sure that all openings are sealed. Use new
blanking caps.
5.
6. 6. NOTE: Note the fitted position.
Installation

Fuel Tank and Lines - V6 3.0L Petrol - Fuel Level Sender LH
Removal
W ARNINGS:
Do not carry or operate cellular phones when working on or near any fuel related components. Highly flammable vapors are always
1. Remove the fuel transfer unit.

For additional information, refer to: Fuel Transfer Unit (310-01B Fuel
Tank and Lines - V6 3.0L Petrol, Removal and Installation).
2. Remove the fuel level sender and harness.
Remove and discard the fuel level sender harness tie straps.
Installation
1. WARNINGS:

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.


Fuel Tank and Lines - V6 3.0L Petrol - Fuel Level Sender RH
Removal
W ARNINGS:
Do not carry or operate cellular phones when working on or near any fuel related components. Highly flammable vapors are always
1. Remove the fuel pump module.

For additional information, refer to: Fuel Pump Module (310-01B Fuel
Tank and Lines - V6 3.0L Petrol, Removal and Installation).
2. Disconnect the fuel pump module electrical connector.
3. Disconnect the fuel level sender electrical connector.

Installation
1. WARNINGS:

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.


Fuel Tank and Lines - V6 3.0L Petrol - Fuel Pump Module
Special Tool(s)
310-146
Removal
W ARNINGS:
Place the vehicle in a quarantined area and arrange "No Smoking/Petrol Fumes" signs about the vehicle.
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.
After carrying out repairs, the fuel system must be checked visually for leaks. Failure to follow these instructions may result in
personal injury.
personal injury.
attention.

2. NOTE: All vehicles.
Open the fuel tank filler pipe flap.

4. Detach the fuel tank filler pipe cap.
For additional information, refer to: Fuel System Pressure Release - V8
4.2L Petrol/V8 S/C 4.2L Petrol/V6 3.0L Petrol (310-00 Fuel System -
6. Drain the fuel system.
For additional information, refer to: Fuel Tank Draining (310-00 Fuel
Detach the fuel pump module wiring harness from the retaining
bracket.
13. Disconnect the fuel pump module quick release coupling.
14. Using the special tool, remove the fuel pump module locking ring.
15. Disconnect the fuel transfer module transfer feed tube.
16. Disconnect the left-hand fuel sender gauge electrical connector.
17. Disconnect the fuel transfer module transfer return tube.

18. CAUTION: Make sure no damage occurs to the fuel level float.
Remove the fuel pump module.
Press down and rotate the base of the fuel pump module counter-
clockwise.
Installation
1. CAUTIONS:
On vehicles with supercharger make sure the arrow on the fuel pump
module and the 'SC' marker on the fuel tank are aligned.
On vehicles without supercharger make sure the arrow on the fuel

transfer module and the 'NA' marker on the fuel tank are aligned.
Make sure no damage occurs to the fuel level float.
NOTE: All vehicles.
Install the fuel pump module.
Press down and rotate the base of the fuel pump module clockwise.
2. Connect the transfer module transfer return tube.
Make sure the coupling has latched onto the fuel pump module by
pulling the tube after the connection has been made.
3. Connect the left-hand fuel sender gauge electrical connector.

4. Connect the fuel transfer module transfer feed tube.
Make sure the quick release coupling has latched onto the fuel
pump module fuel tube by pulling the tube after the connection has
been made.
5. Using the special tool, install the fuel pump module locking ring.
Tighten to 60 Nm.
6. Connect the fuel pump module quick release coupling.
pump module fuel pipe by pulling the pipe after the connection has
been made.
7. Connect the fuel pump module electrical connector.
Attach the fuel pump module wiring harness to the retaining

bracket.

13. Attach the fuel tank filler pipe cap.

15. Close the fuel tank filler pipe flap.
Fuel Tank and Lines - V6 3.0L Petrol - Fuel Tank
Removal
All vehicles
2. Refer to: Fuel Tank Draining (310-00 Fuel System - General Information, General
Procedures).

5.
Torque: 5 Nm
6. 6. WARNING: The spilling of fuel is unavoidable during this

operation. Make sure that all necessary precautions are taken to prevent
fire and explosion.

7.
All vehicles
8.
Torque: 3 Nm
9. 9. WARNING: Secure the component to the transmission jack.
CAUTION: Use suitable packing material to prevent damage to the

component.
Torque: 35 Nm
Installation

Fuel Tank and Lines - V6 3.0L Petrol - Fuel Tank Filler Pipe
Removal
W ARNINGS:
Before any work is carried out on the vehicle the fuel tank must have less than a 1/4 of a tank of fuel. This will prevent excessive fuel
loss.
Place the vehicle in a well ventilated, quarantined area and arrange ' No Smoking/Petrol Fumes' signs about the vehicle.
complete.
personal injury.
personal injury.
attention.

2. Remove the fuel tank filler pipe cap.
3. Remove the right-hand rear wheel and tire.
4. Remove the right-hand rear fender splash shield.
5. Remove the fuel tank filler pipe retaining nut.
7. Remove the fuel tank filler pipe retaining bolt.
8. Detach the fuel tank filler pipe.
9. Remove the fuel tank filler pipe.
Installation
Fuel Tank and Lines - V6 3.0L Petrol - Fuel Transfer Unit
Special Tool(s)
310-146
Removal
W ARNINGS:
complete.
personal injury.
personal injury.
attention.

For additional information, refer to: Fuel Tank Draining (310-00 Fuel
Detach the fuel pump module wiring harness from the retaining
bracket.
5. Using the special tool, remove the fuel pump module locking ring.
7. Disconnect the left-hand fuel sender gauge electrical connector.

Release the fuel pump module.
Press down and rotate the base of the fuel pump module counter-
clockwise.

15. Using the special tool, remove the fuel transfer unit locking ring.
Remove the fuel transfer unit.
Press down and rotate the base of the fuel transfer unit counter-
clockwise.
Installation
Install the fuel transfer unit.
Press down and rotate the base of the fuel transfer unit clockwise.
2. Using the special tool, install the fuel transfer unit locking ring.
Tighten to 60 Nm.

8. CAUTIONS:
On vehicles with supercharger make sure the arrow on the fuel pump
module and the 'SC' marker on the fuel tank are aligned.
On vehicles without supercharger make sure the arrow on the fuel

transfer module and the 'NA' marker on the fuel tank are aligned.
Secure the fuel pump module.
Press down and rotate the base of the fuel pump module clockwise.
9. Connect the fuel transfer unit transfer return tube.
Make sure the coupling has latched onto the fuel pump module by
pulling the tube after the connection has been made.
11. Connect the fuel transfer unit transfer feed tube.
pump module fuel tube by pulling the tube after the connection has
been made.
12. Using the special tool, install the fuel pump module locking ring.
Tighten to 60 Nm.
pump module fuel pipe by pulling the pipe after the connection has
been made.
Attach the fuel pump module wiring harness to the retaining

bracket.

Fuel Tank and Lines - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8 -
Varient Fuel Pressure at Idle Fuel Pressure at Wide Open Throttle
Vehicles with Denso engine management: - -
V8 Naturally aspirated 3 bar (43.5 lb/in) (300 kPa) 3.8 bar (55.1 lb/in) (380 kPa)
V6 Naturally aspirated 3.3 bar (47.9 lb/in) (330 kPa) 3.8 bar (55.1 lb/in) (380 kPa)
V8 Supercharged 3 bar (43.5 lb/in) (300 kPa) 5 bar (72.5 lb/in) (500 kPa)
Fuel Tank and Lines - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8 - Fuel Tank and
Lines - Component Location
ItemDescription
2 Fuel tank
3 Filler cap and lanyard
4 Fuel filler pipe
5 Charcoal canister assembly
8 Fuel vapor valve
10 Fuel filter
11 Pipe - Fuel pump to engine (feed)
12 NAS vehicles only
13 Fuel tank leakage monitoring filter (NAS only)
14 Fuel tank leakage monitoring pump (NAS only)
15 Fuel vapor pressure control valve (NAS only)
Lines - Overview
OVERVIEW
The fuel system uses an electronic returnless system. The system comprises a pump module mounted in the fuel tank to
deliver fuel at variable flow and pressure to the fuel rails which in turn supply fuel to the fuel injectors. Fuel pump
operation is regulated by a FPDM (fuel pump driver module) which is controlled by the ECM (engine control module). The
FPDM regulates the flow and pressure supplied by controlling the operation of the fuel pump using a PW M (pulse width
modulation) output.
Two fuel level sensors are installed in either side of the saddle tank. The sensors are a MAPPS (magnetic passive position
sensor) which provide a variable resistance to ground for the output from the fuel gauge.
The fuel system also incorporates an EVAP (evaporative emission) system which is part of the on-board refueling and
vapor recovery feature. The function and operation of the system is designed to meet EVAP requirements to minimize fuel
vapor losses.
Lines - System Operation and Component Description
Control Diagram
ItemDescription
1 Fuel pump and level sensor electrical connector
2 Fuel pump module
3 Suction jet pump
4 Fuel pump
5 Right hand fuel compartment
6 Left hand fuel compartment
7 Fuel level sensor
8 Parallel pressure relief valve
9 Fuel transfer pump module
10 High-pressure cross-over circulation pipe
11 Low-pressure cross-over circulation pipe
12 Engine fuel delivery pipe
13 Fuel filter
14 Fuel rail
15 Fuel injector
System Operation
System Operation
The fuel pump is a variable-speed rotary-vane type, which operates in a fuel module located in the right hand fuel tank
compartment. A fuel transfer pump is located in the left hand compartment. Both components are secured by screw on
plastic closure rings. The fuel pump module has an integral top plate for the external pipe work and electrical connectors.
Fuel level is maintained equally in the fuel tank compartments by circulating the fuel through internal crossover pipes via
suction jet pumps which also serve to deliver a constant supply of fuel to the transfer pump and swirl pot assembly. High
pressure fuel from the fuel pump is directed through the jet pump's orifice, creating a low pressure area to be formed
around the orifice. The fuel is drawn into this low pressure area and directed into the swirl pot delivery pipes. This is
achieved using the cross-over pipe from the left hand module and a direct link pipe from the right hand module.
Fuel is pumped from the fuel pump to the fuel rail via the parallel pressure relief valve and fuel filter. The parallel pressure
relief valve contains two spring loaded valves, which operate in opposite directions.
The function of the valve is to
Assist engine starting by retaining a pre-set fuel pressure in the supply pipe and fuel rail
Limit fuel rail pressure due to temporary vapor increase in hot conditions
Limit fuel rail pressure caused by sudden load changes, for example, a fully open to closed throttle transition
Prevent leakage from the tank in the event that the fuel delivery pipe is severed
To meet ORVR (on-board refueling vapor recovery) requirements, the fuel tank and associated components are designed to
minimize fuel vapor loss during refueling. This is achieved by preventing fuel vapor from the fuel tank venting directly to
the atmosphere. Instead fuel vapor is directed into the EVAP (evaporative emission) canister where it is stored before
being purged at intervals to the engines intake manifold.
FUEL TANK
ItemDescription
1 Charcoal canister
2 Fuel vapor valve
4 EVAP hose
5 Fuel filler pipe breather hose (NAS only)
6 Fuel vapor pressure control valve (NAS only)
10 Jet pump
11 LH fine mesh filter pick up
12 LH fuel level sensor float
14 RH fuel level sensor float
15 Fuel pump module
16 RH fine mesh filter pick up
17 Fuel pump electrical connection
The fuel tank is a saddle type tank constructed of HDPE (high density polyethylene), a plastic blow molded material. The
tank is located forward of the rear suspension and is mounted using two metal straps. The tank is a sealed unit with the
only internal access being through the fuel pump module and transfer pump module flange apertures on the top of the
tank.
The fuel pump module flange has a six pin external connector which provides the electrical connections for the fuel pump
and level sensors. A quick release connector provides for the connection of the fuel feed pipe.
Each flange is fitted with a collar, clamp and seal which locate in the tank apertures. An arrow on each flange must be
aligned between two molded lines on the tank, adjacent to the fuel pump module or transfer pump flange aperture, to
obtain the correct pump orientation. A collar is located over each flange and is secured with a clamp. The flange, seal,
collar and clamp arrangements meet the sealing requirements of LEV2 emissions.
paragraph
FUEL PUMP MODULE
ItemDescription
2 Fuel pump module
3 Fuel level sensor
4 Level sensor float
The fuel pump is a variable speed rotary vane type. The supercharged variant incorporates a high flow rate pump . The
pump is energized by the fuel pump relay which is located in the RJB (rear junction box) and the FPDM (fuel pump driver
module) which is located under the RH floor pan above the rear suspension stabilizer bar . The relay and FPDM are
controlled by the ECM (engine control module).
A fine mesh filter is located in the lower section of the pump module. This provides filtration to the fuel as it is drawn into
the module.
The right hand fuel level sensor is mounted into the pump module housing.
FUEL LEVEL SENSORS

ItemDescription
1 Fuel level sensor
3 Sensor mounting bracket
6 Fine mesh filter
7 Jet pump
Two fuel level sensors are installed in either side of the saddle tank. One is mounted on the fuel pump module, the other
is mounted on the transfer pump module in the other side of the fuel tank. The sensors are a MAPPS (magnetic passive
position sensor) which provide a variable resistance to ground for the output from the fuel gage. The sensor is sealed from
the fuel preventing contamination of the contacts, increasing reliability. The fuel level sensors are connected to the
external electrical connector on the flange via the connector on the underside of the fuel pump module flange.
The sensor comprises a series of 51 film resistors mounted in an arc on a ceramic surface. The resistors are wired in series
with individual contacts. A soft magnetic foil with 51 flexible contacts is mounted a small distance above the film
resistors. A magnet, located below the ceramic surface, is attached to the sender unit float arm. As the float arm moves,
the magnet follows the same arc as the film resistors. The magnet pulls the flexible contacts onto the opposite film
resistor contacts forming an electrical circuit.
ItemDescription
1 Magnetic foil
2 Spacer
3 Ceramic surface
4 Magnet
5 Resistance film
The film resistors are arranged in a linear arc with resistance ranging from 51.2 to 992.11 Ohms. The electrical output
signal is proportional to the amount of fuel in the tank and the position of the float arm. The measured resistance is
processed by the instrument cluster to implement an anti-slosh function. This monitors the signal and updates the fuel
gage pointer position at regular intervals, preventing constant pointer movement caused by fuel movement in the tank due
to cornering or braking.
The fuel level sender signal is converted into a CAN (controller area network) message by the instrument cluster as a
direct interpretation of the fuel tank contents in liters. The ECM uses the CAN message to store additional OBD (on-board
diagnostic) 'P' Codes for misfire detection when the fuel level is below a predetermined capacity.
JET PUMPS
The fuel system incorporates two jet pumps. The LH (left hand) jet pump is located on the fuel level sensor carrier on the
LH (left hand) side of the fuel tank. The RH jet pump is located in the swirl pot below the fuel pump. Both jet pumps
operate on a venturi effect created by the fuel at pump output pressure passing through the jet pump. This draws
additional fuel from the tank through ports in the jet pump body, delivering additional fuel to the swirl pot. This function
also serves to maintain an equal fuel level in the fuel tank compartments.
The LH (left hand) jet pump collects fuel from the LH (left hand) side of the tank and transfers it into the swirl pot on the
RH (right hand) side of the tank.
The RH (right hand) jet pump collects fuel from below the swirl pot and transfers it to the upper section of the swirl pot.
The action of the jet pumps ensures a constant supply of fuel to the swirl pot and fuel pump. Both jet pumps have a jet
nozzle of 0.5 mm diameter.
FUEL FILTER
The fuel filter is of a conventional construction being that of a paper element sealed within a steel canister. The fuel filter
is located behind the left-hand front fender splash shield.
ItemDescription
1 Filler cap and lanyard
2 EVAP pipe work
3 Charcoal canister
4 Fuel filler pipe
5 Filler cap and lanyard (NAS only)
6 Fuel filler pipe (NAS only) only)
7 Fuel tank leakage monitoring pump (NAS only)
8 EVAP pipe work (NAS only)
9 Charcoal canister (NAS only)
10 Fuel tank leakage monitoring fresh air filter (NAS)
The fuel filler head is positioned at the rear of the vehicle, above the right hand rear wheel. The filler head is covered by a
molded plastic cover which is electrically locked when the vehicle is locked. The filler cap is a conventional screw in type
which is secured to the vehicle with a lanyard.
The filler head is an aluminum fabrication which is secured to the vehicle body by a bracket. The formed aluminum filler
pipe locates in a short flexible hose attached to the tank which is secured with worm drive clamps.
NAS (North American Specification) vehicles feature connections and pipework on the rear of the filler head to allow for the
functioning of the fuel tank EVAP (evaporative emission) system.
Lines
For a detailed description of the fuel tank and lines, refer to the relevant Description and Operation sections in the
workshop manual. REFER to: (310-01 Fuel Tank and Lines - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8)

Fuel Tank and Lines (Description and Operation).
vehicle.
Visual Inspection
Fuel leaks Fuses
Fuel contamination/grade/quality Rear Junction Box (RJB)
3. 3. If an obvious cause for an observed or reported symptom is found, correct the cause (if possible) before
4. 4. If the cause is not visually evident, verify the symptom and refer to the Symptom Chart below, alternatively,
check for Diagnostic Trouble Codes (DTCs) and proceed to the DTC Index.
Symptom Chart

Engine cranks, but does Engine breather system Ensure the engine breather system is free from restriction and is
not fire disconnected/restricted correctly installed. Check for fuel, ignition and electronic engine
Ignition system control system DTCs and refer to the relevant DTC Index
Fuel system
Electronic engine
controls
Engine cranks and fires, Evaporative emissions Check for purge valve, fuel and ignition system DTCs and refer to
but will not start purge valve the relevant DTC Index
Fuel pump
Spark plugs
Ignition coil failure(s)
Difficult cold start Check engine coolant Check the engine coolant level and condition. REFER to:
level/anti-freeze content Specifications (303-03A Engine Cooling - 4.2L NA V8 - AJV8/4.2L
Battery SC V8 - AJV8, Specifications). Ensure the battery is in a fully
Electronic engine charged and serviceable condition. Check for electronic engine
controls control, EGR valve, fuel system and purge valve related DTCs
Exhaust gas recirculation and refer to the relevant DTC Index
Fuel pump
Evaporative emissions
purge valve
Difficult hot start Injector leak Carry out injector leak tests, install new injectors as required.
Electronic engine REFER to: Fuel Injectors (303-04A Fuel Charging and Controls -
controls 4.2L NA V8 - AJV8, Removal and Installation).Check for
Evaporative emissions electronic engine control, EGR valve, fuel system, ignition
purge valve system and purge valve related DTCs and refer to the relevant
Fuel pump DTC Index
Ignition system
Difficult to start after Injector leak Carry out injector leak tests, install new injectors as required.
hot soak (vehicle Electronic engine REFER to: Fuel Injectors (303-04A Fuel Charging and Controls -
standing, engine off, controls 4.2L NA V8 - AJV8, Removal and Installation).Check for
after engine has Evaporative emissions electronic engine control, EGR valve, fuel system, ignition
reached operating purge valve system and purge valve related DTCs and refer to the relevant
temperature) Fuel pump DTC Index
Ignition system
Engine stalls soon after Breather system Ensure the engine breather system is free from restriction and is
start disconnected/restricted correctly installed. Check for ECM relay, electronic engine control
ECM relay and ignition system DTCs and refer to the relevant DTC Index.
Electronic engine Check for blockage in air cleaner element and air intake system.
controls Check for leakage in air intake system. Check fuel lines for
Ignition system blockage/restriction. Clear blockage/restriction and install new
Air intake system fuel lines as required
restricted
Air leakage
Fuel lines
Engine hesitates/poor Fuel pressure, fuel Carry out fuel pressure check. Check fuel lines for
acceleration pump, fuel lines blockage/restriction. Clear blockage/restriction and install new
Injector leak fuel lines as required. Check for fuel system DTCs and refer to
Air leakage the relevant DTC Index. Carry out fuel injector leak tests, install
Electronic engine new injectors as required. REFER to: Fuel Injectors (303-04A Fuel
controls Charging and Controls - 4.2L NA V8 - AJV8, Removal and
Ignition system Installation).Check for leakage from air intake system. Check for
EGR valve stuck electronic engine control, EGR valve, ignition system and
Transmission transmission related DTCs and refer to the relevant DTC Index.
malfunction Ensure accelerator pedal is free from restriction
Restricted pedal travel
(carpet, etc)
Engine backfires Fuel pump, fuel lines Check for fuel system related DTCs and refer to the relevant DTC
Air leakage Index. Check fuel lines for blockage/restriction. Clear
Electronic engine blockage/restriction and install new fuel lines as required. Check
controls for leakage from air intake system. Check for electronic engine
Ignition system control, ignition system and VCT related DTCs and refer to the
Sticking variable relevant DTC Index
camshaft timing (VCT)
hub
Engine surges Fuel pump, fuel lines Check for fuel system related DTCs and refer to the relevant DTC
Electronic engine Index. Check fuel lines for blockage/restriction. Clear
controls blockage/restriction and install new fuel lines as required. Check
Ignition system for electronic engine control and ignition system related DTCs
Engine Fuel pump, fuel lines, Check for fuel system related DTCs and refer to the relevant DTC
detonates/knocks fuel quality Index. Check fuel lines for blockage/restriction. Clear
Air leakage blockage/restriction and install new fuel lines as required. Check
Electronic engine for leakage from air intake system. Check for electronic engine
controls control and VCT related DTCs and refer to the relevant DTC
Sticking VCT hub Index
DTC Index
NOTE: If a module or component is suspect, and the vehicle remains under the Manufacturers warranty, refer to the

P008700 Fuel Rail/System Pressure Fuel rail pressure (Fuel rail Carry out any pinpoint tests associated with this
- Too Low pressure) sensor, sensing DTC using the manufacturer approved diagnostic
circuit - short to ground, system. Refer to the electrical circuit diagrams and
open circuit check Fuel rail pressure sensor circuits for short to
Fuel rail pressure sensor ground, open circuit, high resistance. Check and
supply circuit - high install a new Fuel rail pressure sensor as required.
resistance Check fuel system for failure
failure
Fuel pump failure
P008800 Fuel Rail/System Pressure Fuel rail pressure sensor Carry out any pinpoint tests associated with this
- Too High supply/sensing circuits - DTC using the manufacturer approved diagnostic
short to each other system. Refer to the electrical circuit diagrams and
Fuel rail pressure sensor check Fuel rail pressure sensor circuits for short to
sensing circuit - short to each other, power, open circuit, high resistance.
power Check and install a new Fuel rail pressure sensor as
Fuel rail pressure sensor required. Check fuel system for failure
resistance
failure
power
P018123 Fuel Temperature Sensor Fuel temperature sensor Carry out any pinpoint tests associated with this
A Circuit sensing circuit - short to DTC using the manufacturer approved diagnostic
Range/Performance ground, short to power, system. Refer to the electrical circuit diagrams and
high resistance check fuel temperature sensor circuits for short to
Fuel temperature sensor ground, power, high resistance. Check and install a
ground circuit - high new Fuel temperature sensor as required
resistance
failure
resistance
failure
resistance
failure
A Circuit Low sensing circuit - short to DTC using the manufacturer approved diagnostic
ground system. Refer to the electrical circuit diagrams and
Fuel temperature sensor check fuel temperature sensor circuits for short to
ground circuit - short ground, power, high resistance. Check and install a
circuit new Fuel temperature sensor as required
failure
A Circuit High sensing circuit - short to DTC using the manufacturer approved diagnostic
power, high resistance, system. Refer to the electrical circuit diagrams and
disconnected check fuel temperature sensor circuits for short to
resistance
failure
P019100 Fuel Rail Pressure Sensor Fuel rail pressure sensor Carry out any pinpoint tests associated with this
A Circuit stuck DTC using the manufacturer approved diagnostic
Range/Performance system
A Circuit Low sensing circuit - short to DTC using the manufacturer approved diagnostic
ground, high resistance, system. Refer to the electrical circuit diagrams and
disconnected check fuel rail pressure sensor circuits for short to
Fuel rail pressure sensor ground, power, high resistance, disconnected
5V supply circuit - high connector. Check and install a new Fuel rail pressure
resistance sensor as required
failure
A Circuit High supply/sensing circuits - DTC using the manufacturer approved diagnostic
short circuit to each other system. Refer to the electrical circuit diagrams and
Fuel rail pressure sensor check fuel rail pressure sensor circuits for short to
sensing circuit - short to ground, power, high resistance, disconnected
power connector. Check and install a new Fuel rail pressure
Fuel rail pressure sensor sensor as required
resistance
failure
P023100 Fuel Pump Secondary No sub type information Refer to the electrical circuit diagrams and check
Circuit Low FPDM monitor circuit to ECM for short to ground, high
resistance
P023200 Fuel Pump Secondary No sub type information Refer to the electrical circuit diagrams and check
Circuit High FPDM monitor circuit to ECM for short to power
System Incorrect Purge range/performance EVAP purge valve control circuit for short, open
Flow circuit
(small leak)
System Vent Control to ground DTC using the manufacturer approved diagnostic
Circuit Open system. Refer to the electrical circuit diagrams and
check DMTL COV circuit for short to ground
System Vent Control to power DTC using the manufacturer approved diagnostic
Circuit Shorted system. Refer to the electrical circuit diagrams and
check DMTL COV circuit for short to power
P045600 Evaporative Emission DMTL system has Check EVAP system for leak using appropriate
System Leak Detected detected a leak smoke/leak tester
(very small leak)
System Purge Control control circuit - short to DTC using the manufacturer approved diagnostic
Valve Circuit Low ground, high resistance system. Refer to the electrical circuit diagrams and
EVAP canister purge valve check EVAP canister purge valve control circuit for
failure short to ground, high resistance. Check and install a
new EVAP canister purge valve as required
System Purge Control control circuit - short to DTC using the manufacturer approved diagnostic
Valve Circuit High power system. Refer to the electrical circuit diagrams and
check EVAP canister purge valve control circuit for
short to power
P046129 Fuel Level Sensor A Circuit Fuel level sensor failure Refer to the electrical circuit diagrams and check fuel
Range/Performance level sensor circuits for short, open circuit, high
resistance
P04612F Fuel Level Sensor A Circuit Fuel level sensor failure Refer to the electrical circuit diagrams and check fuel
Range/Performance level sensor circuits for short, open circuit, high
resistance
Low level sensor circuits for short, open circuit, high
resistance
High level sensor circuits for short, open circuit, high
resistance
P062700 Fuel Pump A Control Fuel pump control circuit Refer to the electrical circuit diagrams and check the
Circuit/Open fault (FPDM to ECM) FPDM to ECM circuit for short to ground, power, open
circuit
P062A00 Fuel Pump A Control Invalid fuel pump duty Refer to the electrical circuit diagrams and check the
Circuit Range/Performance requested by the ECM FPDM to ECM circuit for short to ground, power, open
circuit
System Leak Detection to ground DTC using the manufacturer approved diagnostic
Pump Control Circuit Low system. Refer to the electrical circuit diagrams and
check DMTL pump circuit for short to ground
System Leak Detection to power DTC using the manufacturer approved diagnostic
Pump Control Circuit High system. Refer to the electrical circuit diagrams and
check DMTL pump circuit for short to power
P240429 Evaporative Emission DMTL reference leak Check integrity of evaporative emissions system, i.e.
System Leak Detection DMTL pump circuit - short blocked/leaking. Refer to the electrical circuit
DMTL pipework
blocked/leaking
P24042F Evaporative Emission DMTL reference leak Check integrity of evaporative emissions system, i.e.
System Leak Detection DMTL pump circuit - short blocked/leaking. Refer to the electrical circuit
DMTL pipework
blocked/leaking
Pump Sense Circuit Low resistance resistance
Pump Sense Circuit High resistance resistance
P240B00 Evaporative Emission DMTL heater control circuit Carry out any pinpoint tests associated with this
System Leak Detection low DTC using the manufacturer approved diagnostic
Pump Heater Circuit Low system. Refer to the electrical circuit diagrams and
check DMTL heater control circuit for short to ground,
open circuit
P240C00 Evaporative Emission DMTL heater control circuit Carry out any pinpoint tests associated with this
System Leak Detection high DTC using the manufacturer approved diagnostic
Pump Heater Circuit High system. Refer to the electrical circuit diagrams and
check DMTL heater control circuit for short to power
Valve Performance/Stuck high resistance system. Refer to the electrical circuit diagrams and
Open check DMTL system circuit for short to ground,
Valve Stuck Closed high resistance system. Refer to the electrical circuit diagrams and
check DMTL system circuit for short to ground,
Fuel Tank and Lines - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8 - Fuel Filter
Removal
WARNING: Refer to: Petrol and Petrol-Ethanol Fuel Systems Health and Safety Precautions (100-00 General
1. De-pressurize the fuel system.
Refer to: Fuel System Pressure Release - 3.0L NA V6 - AJ27/4.2L NA

V8 - AJV8/4.2L SC V8 - AJV8 (310-00 Fuel System - General

stands.
3.
4. 4. CAUTION: Make sure that all openings are

sealed. Use new blanking caps.
5.
6. 6. NOTE: Note the fitted position.
Installation

Fuel Tank and Lines - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8 - Fuel Level
Sender LH
Removal
W ARNINGS:
personal injury.
1. Remove the fuel transfer unit.

For additional information, refer to: Fuel Transfer Unit (310-01,
Remove and discard the fuel level sender harness tie

straps.
Installation
1. WARNINGS:



personal injury.

Fuel Tank and Lines - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8 - Fuel Level
Sender RH
Removal
W ARNINGS:
personal injury.
1. Remove the fuel pump module.

For additional information, refer to: Fuel Pump Module (310-01,

Installation
1. WARNINGS:



personal injury.

Fuel Tank and Lines - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8 - Fuel Pump
Module
Special Tool(s)
Remover/Installer, Fuel Pump
Module/Fuel Transfer Unit Locking
Ring
310-146
Removal
W ARNINGS:
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.
personal injury.
After carrying out repairs, the fuel system must be checked visually for leaks. Failure to follow these instructions
If taken internally, do not induce vomiting, seek immediate medical attention. Failure to follow these instructions
W ash hands thoroughly after fuel handling, as prolonged contact may cause irritation. Should irritation develop, seek
medical attention.

2. NOTE: All vehicles.
Open the fuel tank filler pipe flap.

Procedures).
4. Detach the fuel tank filler pipe cap.
Procedures).

Detach the fuel pump module wiring harness from the

retaining bracket.
14. Using the special tool, remove the fuel pump module locking
ring.

16. Disconnect the left-hand fuel sender gauge electrical

connector.
18. CAUTION: Make sure no damage occurs to the fuel

level float.
Remove the fuel pump module.
Press down and rotate the base of the fuel pump module
counter-clockwise.
Installation
1. CAUTIONS:
On vehicles with supercharger make sure the arrow on the

fuel pump module and the 'SC' marker on the fuel tank are
aligned.
On vehicles without supercharger make sure the arrow on

the fuel transfer module and the 'NA' marker on the fuel tank are
aligned.
Make sure no damage occurs to the fuel level float.
NOTE: All vehicles.
Install the fuel pump module.
clockwise.
2. Connect the transfer module transfer return tube.
Make sure the coupling has latched onto the fuel pump
module by pulling the tube after the connection has been
made.
4. Connect the fuel transfer module transfer feed tube.
Make sure the quick release coupling has latched onto the
fuel pump module fuel tube by pulling the tube after the
connection has been made.
5. Using the special tool, install the fuel pump module locking
ring.
Tighten to 60 Nm.
fuel pump module fuel pipe by pulling the pipe after the
Attach the fuel pump module wiring harness to the

retaining bracket.

13. Attach the fuel tank filler pipe cap.

Procedures).
15. Close the fuel tank filler pipe flap.
Fuel Tank and Lines - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8 - Fuel Tank
Removal
All vehicles

2. Refer to: Fuel Tank Draining (310-00 Fuel System - General


5.
Torque: 5 Nm
6. 6. WARNING: The spilling of fuel is unavoidable

during this operation. Make sure that all necessary
precautions are taken to prevent fire and explosion.

7.
All vehicles
8.
Torque: 3 Nm
9. 9. WARNING: Secure the component to the

transmission jack.
CAUTION: Use suitable packing material to

prevent damage to the component.
Torque: 35 Nm
Installation

Fuel Tank and Lines - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8 - Fuel Tank
Filler Pipe
Removal
W ARNINGS:
Before any work is carried out on the vehicle the fuel tank must have less than a 1/4 of a tank of fuel. This will
prevent excessive fuel loss.
Place the vehicle in a well ventilated, quarantined area and arrange ' No Smoking/Petrol Fumes' signs about the
vehicle.
personal injury.
medical attention.

2. Remove the fuel tank filler pipe cap.
3. Remove the right-hand rear wheel and tire.
4. Remove the right-hand rear fender splash shield.
7. Remove the fuel tank filler pipe retaining bolt.
8. Detach the fuel tank filler pipe.
9. Remove the fuel tank filler pipe.
Installation
Fuel Tank and Lines - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8 - Fuel Transfer
Unit
Special Tool(s)
Remover/Installer, Fuel Pump
Module/Fuel Transfer Unit Locking
Ring
310-146
Removal
W ARNINGS:
personal injury.
medical attention.

Procedures).
3.
4. Disconnect the
the fuel pump module electrical connector.
5. Disconnect
Using the specialfuel pump
tool, module
remove thequick release
fuel pump coupling.
module locking
ring. Detach the fuel pump module wiring harness from the
retaining bracket.
7. Disconnect the left-hand fuel sender gauge electrical

connector.
9. CAUTION: Make sure no damage occurs to the fuel level

float.
Release the fuel pump module.
counter-clockwise.

15. Using the special tool, remove the fuel transfer unit locking
ring.
16. CAUTION: Make sure no damage occurs to the fuel

level float.
Remove the fuel transfer unit.
Press down and rotate the base of the fuel transfer unit
counter-clockwise.
Installation
1. CAUTION: Make sure no damage occurs to the fuel level

float.
Install the fuel transfer unit.
Press down and rotate the base of the fuel transfer unit
clockwise.

2. Using the special tool, install the fuel transfer unit locking
ring.
Tighten to 60 Nm.

8. CAUTIONS:
On vehicles with supercharger make sure the arrow on the

fuel pump module and the 'SC' marker on the fuel tank are
aligned.
On vehicles without supercharger make sure the arrow on

the fuel transfer module and the 'NA' marker on the fuel tank are
aligned.
Secure the fuel pump module.
clockwise.
9. Connect the fuel transfer unit transfer return tube.
Make sure the coupling has latched onto the fuel pump
module by pulling the tube after the connection has been
made.
11. Connect the fuel transfer unit transfer feed tube.
fuel pump module fuel tube by pulling the tube after the
12. Using the special tool, install the fuel pump module locking
ring.
Tighten to 60 Nm.
fuel pump module fuel pipe by pulling the pipe after the
Attach the fuel pump module wiring harness to the

retaining bracket.

Procedures).
Acceleration Control -
Acceleratror pedal 10 7 89
Acceleration Control - Acceleration Control
For a detailed description of the acceleration controls, refer to the relevant Description and Operation sections in the
workshop manual. REFER to: Acceleration Control (310-02, Description and Operation).
vehicle.
Visual Inspection
Accelerator pedal Fuses
Throttle body W iring harness
Sensor(s)
DTC Index

P012100 Throttle/Pedal TP sensor sensing Carry out any pinpoint tests associated with this DTC using the
Position Sensor A circuits TP 1 and manufacturer approved diagnostic system. Refer to the
Circuit TP 2 - short to electrical circuit diagrams and check TP sensor sensing circuits
Range/Performance power, high TP 1 and TP 2 for short to power, high resistance. Check and
resistance install a new throttle body as required
TP sensor failure
Position Sensor A circuit TP 1 - short manufacturer approved diagnostic system. Refer to the
Circuit Low to ground, high electrical circuit diagrams and check TP sensor sensing circuit TP
resistance 1 for short to ground, high resistance. Check and install a new
TP sensor failure throttle body as required
Position Sensor A circuit TP1 - short manufacturer approved diagnostic system. Refer to the
Circuit High to power electrical circuit diagrams and check TP sensor sensing circuit TP
TP sensor failure 1 for short to power. Check and install a new throttle body as
required
Position circuit TP 2 - short manufacturer approved diagnostic system. Refer to the
Sensor/Switch B to ground, high electrical circuit diagrams and check TP sensor sensing circuit TP
Circuit Low resistance 2 for short to ground, high resistance. Check and install a new
TP sensor failure throttle body as required
Position circuit TP 2- short manufacturer approved diagnostic system. Refer to the
Sensor/Switch B to power electrical circuit diagrams and check TP sensor sensing circuit TP
Circuit High TP sensor failure 2 for short to power. Check and install a new throttle body as
required
P022700 Throttle/Pedal APP sensor circuit Carry out any pinpoint tests associated with this DTC using the
Position APP 1 - short to manufacturer approved diagnostic system. Refer to the
Sensor/Switch C ground, high electrical circuit diagrams and check APP sensor circuit APP 1 for
Circuit Low resistance short to ground, high resistance
Position APP 1 - short to manufacturer approved diagnostic system. Refer to the
Sensor/Switch C power electrical circuit diagrams and check APP sensor circuit APP 1 for
Circuit High short to power
P210129 Throttle Actuator Signal invalid Carry out any pinpoint tests associated with this DTC using the
Control Motor Circuit Jammed throttle manufacturer approved diagnostic system. Refer to the
Range/Performance blade, gearing or electrical circuit diagrams and test throttle actuator control
motor motor circuit for short to ground, power, high resistance.
Suspect the throttle body, check and install a new throttle body
as required, refer to the new module/component installation
P210162 Throttle Actuator Signal compare Carry out any pinpoint tests associated with this DTC using the
Control Motor Circuit failure manufacturer approved diagnostic system. Refer to the
Range/Performance Jammed throttle electrical circuit diagrams and test throttle actuator control
blade, gearing or motor circuit for short to ground, power, high resistance.
motor Suspect the throttle body, check and install a new throttle body
P210164 Throttle Actuator Signal plausibility Carry out any pinpoint tests associated with this DTC using the
Range/Performance Jammed throttle electrical circuit diagrams and test throttle actuator control
blade, gearing or motor circuit for short to ground, power, high resistance.
motor Suspect the throttle body, check and install a new throttle body
P210177 Throttle Actuator Commanded Carry out any pinpoint tests associated with this DTC using the
Control Motor Circuit position not manufacturer approved diagnostic system. Refer to the
Range/Performance achievable electrical circuit diagrams and test throttle actuator control
Throttle blade motor circuit for short to ground, power, high resistance.
stuck open Suspect the throttle body, check and install a new throttle body
Intake air system as required, refer to the new module/component installation
leak note at the top of the DTC Index
P210329 Throttle Actuator Signal invalid Carry out any pinpoint tests associated with this DTC using the
Control Motor Circuit Throttle motor manufacturer approved diagnostic system. Refer to the
High control circuit - electrical circuit diagrams and check throttle motor control
short to power circuit for short to power. If ECM is suspect, check and install a
ECM fault new module as required, refer to new module/component
installation note at top of DTC Index
P210364 Throttle Actuator Signal plausibility Carry out any pinpoint tests associated with this DTC using the
High Throttle motor electrical circuit diagrams and check throttle motor control
control circuit - circuit for short to power. If ECM is suspect, check and install a
short to power new module as required, refer to new module/component
ECM fault installation note at top of DTC Index
P210500 Throttle Actuator Throttle MIL Carry out any pinpoint tests associated with this DTC using the
Control System - request due to fuel manufacturer approved diagnostic system
Forced Engine cut
Shutdown
P211800 Throttle Actuator Throttle motor Carry out any pinpoint tests associated with this DTC using the
Control Motor Current control circuit - manufacturer approved diagnostic system. Refer to the
Range/Performance short to ground, electrical circuit diagrams and check throttle motor control
power, high circuit for short to ground, power, high resistance
resistance
P211900 Throttle Actuator Throttle spring Carry out any pinpoint tests associated with this DTC using the
Control Throttle Body faulty manufacturer approved diagnostic system. Suspect throttle body
Range/Performance faulty. Check and install a new throttle body as required, refer
to the new module/component installation note at top of DTC
Index
Position 2 - low input manufacturer approved diagnostic system. Refer to the
Sensor/Switch D electrical circuit diagrams and check APP sensor circuit 2 for
Circuit Low short to ground, open circuit
P212216 Throttle/Pedal Accelerator pedal Carry out any pinpoint tests associated with this DTC using the
Position position (APP) manufacturer approved diagnostic system. Refer to electrical
Sensor/Switch D sensor circuit 1 - circuit diagrams and check accelerator pedal position (APP)
Circuit Low Input short to ground, sensor circuit 1 for short to ground, power. Set ignition status
power to 'ON' engine 'OFF' check and record 'Pedal value sensor 1'
Accelerator pedal datalogger signal. With pedal in idle position, value of signal
position (APP) should be approximately 0%, if not suspect the pedal position
sensor failure sensor, check and install a new sensor as required
Acceleration Control - Accelerator Pedal
Removal

2.
3. Torque: 9 Nm
Installation

Speed Control - TDV6 2.7L Diesel -
Item Specification
Speed control module vertical alignment 90 0.75
Speed control module retaining nuts 5 - 44
Speed control module alignment bolt lock nut 5 - 44
Speed Control - TDV6 2.7L Diesel - Speed Control - Component Location
ItemDescription
3 Clock spring
5 Forward alert switch
8 APP (accelerator pedal position)
9 Adaptive speed control radar sensor
Speed Control - TDV6 2.7L Diesel - Speed Control - Overview
Overview
There are two variants of speed control available, a standard system and an adaptive system. The standard system maintains a set speed
selected by the driver until operation is suspended or cancelled by a further input from the driver and is controlled by the ECM (engine
control module)ECM. The adaptive system includes the same functionality as the standard system, but also has the ability to:
Reduce vehicle speed, to less than the set speed, in order to maintain a selected distance behind a slower moving vehicle
Accelerate the vehicle back to the set speed, once the way ahead is clear, after reducing the set speed because of a slower moving
vehicle
Alert the driver when the vehicle comes within a given distance of a slower moving vehicle
The standard system and the adaptive system both have the following components:
A set +/- switch

A RESUME switch
A CANCEL switch
Both systems also use:
The ECM
The brake switch.
The APP (accelerator pedal position) sensor.
The adaptive system incorporates the following additional components:
An adaptive speed control module

An adaptive speed control sensor
A forward alert switch
The ABS (anti-lock brake system) control module
Speed Control - TDV6 2.7L Diesel - Speed Control - System Operation and Component
Description
Control Diagram
NOTE: A = Hardwired; D = High speed CAN (controller area network) bus; O = LIN bus; U = Private CAN bus
ItemDescription
5 Audio control switches
6 Clockspring
8 Electric throttle
System Operation
Overview
The speed control system is integrated with the engine management system and uses Fueling intervention to automatically maintain a set
vehicle speed. Once engaged, the system can also be used to accelerate the vehicle without using the accelerator pedal. The speed control
system comprises the following components:
'+' and '-' (set/accelerate and decelerate) steering wheel switches

Resume switch
Clock spring
Speed control warning lamp.
The speed control system also uses inputs from the brake pedal switch, the APP sensor, the ECM and the ABS control module.
The speed control is operated by the driver using only the steering wheel switches. When speed control is active, the ECM regulates the
PWM (pulse width modulation) signals to the fuel injectors to adjust the fuel supply as required to maintain the set speed.
During speed control operation, the ECM controls vehicle speed by adjusting fuel injection duration and timing. When the accelerator pedal
is pressed with speed control active, the ECM outputs a calculated throttle angle signal in place of the actual throttle angle signals
produced by the APP sensor. The calculated throttle angle is derived from fuel demand.
The minimum set speed for speed control is 20 mph (32 (km/h). Speed control is automatically suspended if the following conditions apply:
Vehicle speed falls below 16 mph (26 km/h).

The brake pedal is pressed.
The cancel button is pressed.
Neutral, park or reverse gear is selected.
The difference between actual speed and the set speed is too great.
When the vehicle speed reaches a maximum speed of 150 mph (240 kph).
If the accelerator pedal is used to accelerate beyond the set speed for too long.
Adaptive Speed Control

The adaptive speed control system comprises the following components:
Adaptive Speed Control Sensor

Adaptive Speed Control module
Steering wheel control switches
ECM
Electric throttle
ABS module and pump
Adaptive Speed Control warning lamp (in the instrument cluster)
The adaptive speed control system uses a forward looking radar sensor to scan the road ahead, looking for objects that are moving at a
different rate to itself. When a target is identified the adaptive speed control system will monitor the time gap between it and the target
vehicle. When that gap falls below a set driver selected level the adaptive speed control system will intervene slowing the vehicle by
backing off the throttle and/ or applying the brakes, until the correct gap is attained. The driver can chose between four gap settings, 1,
1.4, 1.8 and 2.2 seconds.
The system will detect but not react to the following:
Vehicles in the oncoming lane

Stationary vehicles
Pedestrians
Vehicles not in the same lane
Adaptive speed control is active when the vehicle is moving. Adaptive Speed Control only functions when a set speed is entered in normal
speed control mode. The adaptive speed control system only intervenes with the set speed when it detects a target vehicle, and then only
if the minimum time gap is breached.
It is important to note that the system is intended for use in limited driving situations, does not remove control and responsibility from the
driver, and at all times can be quickly overridden. The adaptive speed control system is not a collision warning system and will not react to
stationary objects. The system does not operate below a minimum speed of approximately 16 mph (26 km/h) since it is unsuitable for use
in cities or congested traffic. The system is best suited to main roads/ highways with gradual bends.
The ECM, throttle body and throttle control are unchanged from those used for non Adaptive Speed Control variants.
The adaptive speed control system is based on the use of a front mounted radar sensor. The sensor transmits a 1.5 wide beam forward of
the vehicle and detects the returning signals reflected off other vehicles and objects ahead.
The 1.5 wide radar beam is mechanically scanned at a rate of 10 sweeps/second across a total arc of 15 centered on the longitudinal axis
of the vehicle. The radar operates at millimetric wavelengths (76 - 77 GHz) and transmits a frequency modulated continuous wave signal at
a relatively low power level (no high power pulses).
With the ignition switched ON, the adaptive speed control module is powered up but no radar transmissions are emitted until the vehicle is
in motion.
In follow mode a set speed is selected in the normal speed control manner and this speed is maintained until a slower vehicle is
encountered in the lane ahead. When the vehicle ahead comes within the effective range of the radar sensor, the system identifies it as a
target vehicle and an icon is illuminated on the instrument cluster to indicate that the system is in "follow mode". W hen the distance
between the two vehicles closes to a set time gap, the adaptive speed control system closes the throttle and if necessary applies the
brakes to maintain the set time gap. Follow mode is effectively a closed loop system. If several vehicles are ahead, the closest vehicle is
chosen as the target to follow. If the target vehicle moves out of radar range, or if either vehicle changes lane or drops below the minimum
operating speed, the system exits follow mode and the follow mode icon is extinguished. The adaptive speed control system will only raise
its speed to the originally set speed, it will not accelerate past this speed to maintain a time gap.
Driver operation of the foot brake or control switches will immediately cancel adaptive speed control.
When the vehicle is in follow mode the follow mode warning indicator is illuminated in the instrument cluster and the current gap setting
will be displayed in the message center.
ItemDescription
1 Forward Alert warning indicator
2 Follow mode warning indicator
The radar sensor detects three primary parameters of objects within the scanned arc. These are:
Range
Relative velocity
Angle
Range: The radar sensor detects the presence and ranges of different vehicles and objects within the scanned arc up to a distance of
approximately 130 meters. The transmitted signal frequency changes continuously in a cyclic pattern (modulation). This means that, in the
time taken for the signal wave front, to travel to and from a target vehicle (or other object), the transmission frequency will have changed.
The difference between the received signal frequency and the new transmission frequency is proportional to the distance between the
transmitting vehicle and the target vehicle.
Relative velocity: W hen the signal is reflected off a vehicle moving at a different speed (opening or closing gap) an effect known as the
Doppler shift causes an extra frequency modulation to be imposed on the signal. This Doppler frequency varies with the relative speed of
the vehicle being followed, enabling the system to differentiate between vehicles traveling at different speeds and also between moving
vehicles and stationary objects.
Angle: Using a narrow angle beam to scan horizontally enables the system to distinguish between vehicles in different lanes and between
vehicles and roadside objects.
System Restrictions
The adaptive speed control system is only intended to provide enhanced speed control as described above in certain restricted conditions.
The following points should be noted:
Automatic braking is limited to approximately 30% of full pressure (0.3G deceleration) and is intended to provide a smooth, gradual
deceleration in follow mode conditions. Harsh braking by the target vehicle or following the target vehicle down to very low speeds or
to a halt will require driver override of the brakes.
While the radar sensor detects moving and stationary targets for assessment of the environment ahead, the system does not react
to or provide any control in situations other than follow mode conditions. Stationary or slow moving vehicles (below 10 km/h),
pedestrians, objects on the road and oncoming vehicles in the same lane are not recognized.
WARNING: It must be emphasized that the adaptive speed control system is not a collision warning or avoidance system and that,
other than the limited conditions of follow mode, driver intervention will be necessary to control the vehicle speed.
In follow mode, some situations may cause target ambiguities for the detection system. These situations include:
The nearby presence of a third vehicle when driving on a line slightly offset to the target vehicle.
Vehicles edging into the lane ahead which are not detected by the system until they have moved into the radar beam.
On the approach to, or exit from a bend, a target vehicle may be lost or a new target acquired as vehicles ahead change their angular
position with respect to the radar sensor. On a straight road, if the sensing vehicle is in follow mode below its selected set speed, losing
the target vehicle will cause the sensing vehicle to accelerate to this set speed. This acceleration is undesirable either on, or entering a
bend when the target is suddenly lost, and in this situation the system inhibits the resumption of the set speed.
The speed control system compares vehicle speed data from the ABS system with the relative speed of an external object as detected by
the radar sensor to ascertain whether the object is stationary or not.
NOTE: If tires are fitted which are different in diameter from those specified for the vehicle, the vehicle speed calculated by the ABS will
not be the true road speed. This situation may cause stationary objects to be falsely identified as moving vehicles and result in automatic
deceleration on a clear road.
Speed Control Switches
ItemDescription
1 Set speed adjustment switch
2 Time gap switch
3 Cancel switch
4 Resume switch
The speed control switches are located on the RH (Right-hand) side of the steering wheel. The switches are connected via fly leads to the
clock spring. The speed control switches are resistive ladder type switches which vary the resistance of a 5 volt signal sent to them. The
signal is returned along a Lin bus to the instrument cluster. The instrument cluster routes the control signals to the ECM on the HS CAN.
Speed control is engaged by rotating the speed adjustment switch to the + or - positions. Once engaged the speed can be varied by the
speed adjustment switches. Each press of the speed adjustment switch will increase or decrease the set speed in steps of 1 mph (2 kph).
Adaptive Speed Control Module
The Adaptive Speed Control module, located on the drivers side at the bottom of the A post. The control module is connected to the other
vehicle systems via the high speed CAN bus. Signals from the Adaptive Speed Control forward looking radar sensor are received on a
dedicated CAN bus between the two modules.
Adaptive Speed Control Radar Sensor

The adaptive speed control radar sensor is located in the front bumper, on the RH (right-hand) side above the radiator grill behind the
bumper cover. The sensor is connected to the Adaptive Speed Control, module via a private CAN bus. If the unit is replaced in service the
unit must be re-aligned vertically. Horizontal alignment is achieved by putting the sensor in service mode via the recommended Jaguar
diagnostic tool.
The vehicle is then driven for a short period while the sensor calibrates itself. Calibration is complete when the 'follow' icon in the
instrument cluster stops flashing.
Forward Alert Switches
ItemDescription
The forward alert system utilizes the Adaptive Speed Control system components. Forward alert is turned on and off independently of
Adaptive Speed Control, via a switch mounted in the lower outboard knee bolster switchpack. Forward alert will notify the driver by means of
a chime, and warning indicator in the instrument cluster and indication in the message center, when a target vehicle comes into range. The
system will NOT use throttle or brake intervention to slow the vehicle.
The forward alert switch is connected to the instrument cluster in a resistive ladder with the luggage compartment opening switch and the
fuel filler flap switch. The instrument cluster sends the forward alert information to the Adaptive speed control module on the CAN bus.
NOTE: This system is intended as a driver aid and should be used as such. The system is NOT a collision warning or avoidance device.
The system sensitivity can be adjusted in the same manner as the Adaptive Speed Control, via the steering wheel mounted switches. Each
adjustment is accompanied by a message in the message center.
Speed Control - TDV6 2.7L Diesel - Speed Control
For a detailed description of the speed control system, refer to the relevant Description and Operation sections in the workshop manual.
REFER to:
Speed Control (310-03A Speed Control - TDV6 2.7L Diesel, Description and Operation),
Speed Control (310-03 Speed Control - 3.0L, Description and Operation),
Speed Control (310-03C Speed Control - V8 4.2L Petrol/V8 S/C 4.2L Petrol, Description and Operation),
Speed Control (310-03C Speed Control - V8 4.2L Petrol/V8 S/C 4.2L Petrol, Description and Operation),
Speed Control (310-03C Speed Control - V8 4.2L Petrol/V8 S/C 4.2L Petrol, Description and Operation).
Visual Inspection
Speed control sensor Fuses
Ensure the speed control sensor is free from obstructions W iring harness
Speed control module Electrical connector(s)
Brake switch Steering wheel switches
Brake switch
Speed control sensor
Speed control module
step.
Speed Control Sensor Adjustment (vehicles with adaptive system installed)

An incorrectly aligned speed control sensor can cause incorrect system operation. Before starting any repair work on the speed control
system, on vehicles with the adaptive system installed, check speed control sensor for correct vertical alignment, and carry out speed
control sensor alignment procedure using manufacturer approved diagnostic system.
Symptom Chart

Speed control inhibited or Power or ground supply to speed Check for DTCs that could be caused by power or ground failure
disabled control module or speed control to the module or sensor and refer to DTC Index
sensor Check for sticking, jammed and broken speed control switches.
Steering wheel speed control Refer to the electrical circuit diagrams and check speed control
switch/circuits switch circuits for short, open circuit
Throttle sensors For throttle position sensor tests. REFER to:
Brake switch Electronic Engine Controls (303-14A Electronic Engine
Anti-Lock Brake System fault Controls - TDV6 2.7L Diesel, Diagnosis and Testing),
Electronic Engine Controls (303-14B Electronic Engine
Controls - V6 3.0L Petrol, Diagnosis and Testing),
Electronic Engine Controls (303-14C Electronic Engine
Controls - V8 4.2L Petrol/V8 S/C 4.2L Petrol, Diagnosis and
Testing).
Check for correct installation and adjustment of brake switch.
Refer to the electrical circuit diagrams and check brake switch
Check ABS system for related DTCs and refer to the relevant
DTC Index
Unable to regulate/adjust Steering wheel switch Check for sticking, jammed and broken speed control switches.
vehicle speed malfunction Refer to the electrical circuit diagrams and check speed control
switch circuits for short, open circuit
Unable to cancel speed Steering wheel switch Check for sticking, jammed and broken speed control switches.
control from steering wheel malfunction Refer to the electrical circuit diagrams and check speed control
switch circuits for short, open circuit
Unable to cancel speed Brake switch malfunction Check for correct installation and adjustment of brake switch.
control from brake pedal Refer to the electrical circuit diagrams and check brake switch
DTC Index
Vehicles WITH Adaptive System Installed
3548-1358-00
module/component.

B1A8481 Car Configuration RJB reporting invalid data Re-configure the RJB using manufacturer approved diagnostic system
Data
C1A6754 Forward Looking Speed control sensor out Check speed control sensor for correct vertical alignment, and carry out
Sensor of alignment speed control sensor alignment procedure using manufacturer approved
diagnostic system
C1A6781 Forward Looking Yaw voltage unreasonable Clear DTC and re-test, if DTC remains suspect speed control sensor.
Sensor for 0.5 seconds or Check and install a new sensor as required, refer to the new
unchanged for 1.2 seconds. module/component installation note at the top of the DTC Index
Note: Yaw sensor internal
to speed control sensor
C1A6787 Forward Looking Incorrect or missing data from Carry out any pinpoint tests associated with this DTC using the
Sensor speed control sensor manufacturer approved diagnostic system. Refer to the electrical circuit
diagrams and check power and ground supplies for short, open circuit.
Check private CAN network between speed control sensor and speed
control module for failure, clear DTC and re-test. If DTC remains suspect
the speed control sensor, check and install a new sensor as required,
refer to the new module/component installation note at the top of the
DTC Index
C1A6796 Forward Looking Internal hardware failure Suspect the speed control sensor. Check and install a new sensor as
Sensor required, refer to the new module/component installation note at the top
of the DTC Index
C1A6797 Forward Looking Sensor reduced visibility Check for blockage in front of radar. Note: This DTC will be cleared
Sensor automatically when environmental conditions allow
C1A6798 Forward Looking Speed control sensor Allow system to cool. Note: This DTC will be cleared automatically when
Sensor internal temperature environmental conditions allow
exceeded threshold
P174E81 Output Shaft Follow speed is Clear DTC and re-test

Speed/ABS W heel mis-calculated to too high
Speed Correlation a value
U000188 High Speed CAN Vehicle CAN Bus off Carry out any pinpoint tests associated with this DTC using the
Communication Bus condition manufacturer approved diagnostic system. Carry out CAN network
integrity tests using the manufacturer approved diagnostic system
U010000 Lost Communications ECM missing message Carry out any pinpoint tests associated with this DTC using the
W ith ECM/PCM "A" manufacturer approved diagnostic system. Check ECM for related DTCs
U010100 Lost Communications TCM missing message Carry out any pinpoint tests associated with this DTC using the
W ith TCM manufacturer approved diagnostic system. Check TCM for related DTCs
U010387 Lost Communication Transmission shift module Carry out any pinpoint tests associated with this DTC using the
W ith Gear Shift missing message manufacturer approved diagnostic system. Check transmission shift
Module module for related DTCs and refer to the relevant DTC Index
U012100 Lost Communication ABS missing message Carry out any pinpoint tests associated with this DTC using the
W ith Anti-lock Brake manufacturer approved diagnostic system. Check ABS for related DTCs
System (ABS) Control and refer to the relevant DTC Index
Module
U012800 Lost Communications Parking brake missing Carry out any pinpoint tests associated with this DTC using the
W ith Park Brake message manufacturer approved diagnostic system. Check parking brake module
Module for related DTCs and refer to the relevant DTC Index
U015500 Lost Communications Instrument cluster missing Carry out any pinpoint tests associated with this DTC using the
W ith Instrument message manufacturer approved diagnostic system. Check instrument cluster for
Panel Cluster (IPC) related DTCs and refer to the relevant DTC Index
Control Module
U030000 Internal Control Invalid configuration Re-configure the speed control module using the manufacturer approved
Module Software message is received diagnostic system. Clear DTCs and re-test. If DTC still logged, suspect
Incompatibility incorrect speed control module installed. Check and install a new module
as required, refer to new module/component installation note at top of
DTC Index
U030055 Internal Control RJB - at least one of the Re-configure the RJB using the manufacturer approved diagnostic system
Module Software car configuration
Incompatibility parameters is not
configured
U040100 Invalid Data Received ECM did not respond Check ECM for related DTCs and refer to relevant DTC Index
From ECM/PCM A properly to speed control
cancel or auto brake cancel
request
U040167 Invalid Data Received ECM did not respond Check ECM for related DTCs and refer to relevant DTC Index
From ECM/PCM A properly to speed control
resume request
U040181 Invalid Data Received Invalid data received from Check the Engine Control Module for related DTCs and refer to relevant
From ECM/PCM A engine control module DTC Index. If U040181 is logged as historic but no other DTCs have
Bus signal/message failure logged in the engine control module at the same time and distance, it
Speed control inhibited by may be caused by cranking with low voltage conditions. Check battery
ECM and charging system according to instructions in the battery care manual.
Install the latest Engine Control Module software using the manufacturer
approved diagnostic system, contact Dealer Technical Support before
replacing components
U041581 Invalid Data Received Stability assist fault Check ABS module for related DTCs and refer to relevant DTC Index
From Anti-lock Brake
System (ABS) Control
Module
U041767 Invalid Data Received Parking brake module did Check parking brake module for related DTCs and refer to relevant DTC
From Park Brake not respond properly to Index
Control Module apply request
U041781 Invalid Data Received Speed control inhibited by Check parking brake module for related DTCs and refer to relevant DTC
From Park Brake parking brake module Index
Control Module
U042381 Invalid Data Received Speed control inhibited by Check instrument cluster, CJB and RJB for related DTCs and refer to
From Instrument instrument cluster relevant DTC Index
Panel Control Module
U1A1449 CAN Initialisation Internal electronic failure Suspect the speed control module. Check and install a new module as
Failure required, refer to the new module/component installation note at the top
of the DTC Index
U210100 Control Module Data sent from RJB is Check/amend Car Configuration File using the manufacturer approved
Configuration invalid diagnostic system, clear DTC and re-test. If DTC remains, re-configure
Incompatible RJB using manufacturer approved diagnostic system, clear DTC and
re-test. If DTC remains check RJB for DTCs and refer to DTC Index
U300041 Control Module Internal micro controller Suspect the speed control module. Check and install a new module as
error required, refer to the new module/component installation note at the top
Checksum fault of the DTC Index
U300042 Control Module Internal RAM test fault Suspect the speed control module. Check and install a new module as
required, refer to the new module/component installation note at the top
of the DTC Index
U300049 Control Module Internal control module Suspect the speed control module. Check and install a new module as
failure required, refer to the new module/component installation note at the top
of the DTC Index
Vehicles WITHOUT Adaptive System Installed
3548-1358-00
module/component.

P050082 Vehicle Speed Sensor A Vehicle speed - invalid signal Check ABS for related DTCs and refer to relevant DTC Index
received over CAN
P050086 Vehicle Speed Sensor A Vehicle speed - invalid signal Check ABS for related DTCs and refer to relevant DTC Index
received over CAN
P050100 Vehicle Speed Sensor A Vehicle speed signal from Carry out CAN network integrity test using the manufacturer
Range/Performance ABS not plausible approved diagnostic system. Contact Dealer Technical Support
for further assistance
P050162 Vehicle Speed Sensor A Vehicle speed - range Check ABS/TCM for related DTCs and refer to relevant DTC
Range/Performance performance Index
P050400 Brake Switch A / B Correlation The brake pressure reading Carry out any pinpoint tests associated with this DTC using the
does not agree with the manufacturer approved diagnostic system. Refer to the
brake light switch value electrical circuit diagrams and check brake switch circuits for
P050401 Brake Switch A / B Correlation Brake switch high fault: Carry out any pinpoint tests associated with this DTC using the
- Brake lights stuck on manufacturer approved diagnostic system. Refer to the
- Gearshift interlock electrical circuit diagrams and check brake switch circuits for
inoperative short, open circuit, high resistance
- Speed control
inoperative
- Brake lights inoperative
- Gearshift stuck in Park
- Reduced engine braking
P056600 Cruise Control OFF Signal Speed control Cancel switch 2 Refer to the electrical circuit diagrams and check speed control
stuck closed switch circuits for short, open circuit. Check for stuck switch.
Check and install a new speed control switch as required
P056700 Cruise Control DECREASE Speed control Resume switch Refer to the electrical circuit diagrams and check speed control
DISTANCE Signal 7 stuck closed switch circuits for short, open circuit. Check for stuck switch.
P056800 Cruise Control INCREASE Speed control Accel Set Plus Check and install a new speed control switch as required
DISTANCE Signal Switch 6 stuck closed
P056900 Cruise Control COAST Signal Speed control Coast Set Refer to the electrical circuit diagrams and check speed control
Minus switch 3 stuck closed switch circuits for short, open circuit. Check for stuck switch.
P056A00 Cruise Control INCREASE Speed control Headway Plus Refer to the electrical circuit diagrams and check speed control
DISTANCE Signal switch 4 stuck closed switch circuits for short, open circuit. Check for stuck switch.
P056B00 Cruise Control DECREASE Speed control Headway Minus Refer to the electrical circuit diagrams and check speed control
DISTANCE Signal switch 5 stuck closed switch circuits for short, open circuit. Check for stuck switch.
P057162 Brake Switch A Circuit Plausibility error Refer to the electrical circuit diagrams and check brake light
switch signal circuits for short, open circuit. Check and install a
new brake light switch as required
P057501 Cruise Control Input Circuit General electrical failure Check speed control system for related DTCs and refer to
relevant DTC Index. Carry out CAN network integrity tests
P057616 Cruise Control Input Circuit Circuit voltage below Check speed control system for related DTCs and refer to
Low threshold relevant DTC Index. Carry out CAN network integrity tests
P057717 Cruise Control Input Circuit Circuit voltage above Check speed control system for related DTCs and refer to
High threshold relevant DTC Index. Carry out CAN network integrity tests
P057800 Cruise Control Multi-Function One of speed control Check for stuck speed control switch, install a new switch pack
Input A Circuit Stuck switches stuck as required
P05781C Cruise Control Multi-Function Circuit voltage out of range Refer to the electrical circuit diagrams and check speed control
Input A Circuit Stuck switch circuits for short, open circuit. Check for stuck switch.
P05791C Cruise Control Multi-Function Speed control switch pack Check and install a new speed control switch pack as required
Input A Circuit internal failure
Range/Performance
P057929 Cruise Control Multi-Function Signal invalid Refer to the electrical circuit diagrams and check speed control
Input A Circuit switch circuits for short, open circuit. Check for stuck switch.
Range/Performance Check and install a new speed control switch as required
P059000 Cruise Control Multi-Function Active speed limiter fault Check for active speed limiter fault, install a new transmission
Input B Circuit Stuck shift module as required
Speed Control - TDV6 2.7L Diesel - Speed Control Sensor Adjustment
General Procedures
Special Tool(s)
501-F007
Inclinometer
1. 1. CAUTION: Protect the surrounding paintwork to avoid damage.
2. 2. NOTE: Make sure that the vehicle is standing on a level surface.
Special Tool(s): 501-F007

4. 4. NOTE: Do not release the lock nut.
NOTE: Make sure that the vehicle is standing on a level surface.
6.
Configure the ACC module using the diagnostic tool.
This procedure is required if:
A new ACC radar and, or ACC module are installed.
The ACC radar needed to be removed or is misaligned in its position due to
another repair operation.
7.
From the diagnostic tool menu, select: Service Alignment Mode.
The follow indicator will now be flashing, this indicates that the vehicle is in
"service alignment" and now requires driving.
The vehicle speed must be above 30mph (48 kph).
Choose a road with plenty of stationary objects, like street lights, road signs,
or barriers. Use an inside or outside lane.
Following vehicles too closely will obscure the stationary targets from the
radar, a time gap of 2 seconds is recommended.
A straight road will produce a quicker and better result, although the process
will still operate on a curved road.
The time that the ACC module takes to align will vary, depending on the route,
speed, number of targets, and individual module.
W hen the flashing follow indicator light extinguishes, the ACC system is now
functional, and a required vehicle speed can now be set by the driver and the
ACC system will operate as normal.
Speed Control - TDV6 2.7L Diesel - Speed Control Deactivator Switch
Removal
2.
3.
4. 4. CAUTION: Make sure that the brake pedal remains in the rest
position during this procedure.
Installation

Speed Control - TDV6 2.7L Diesel - Speed Control Module
Removal
2. Refer to: Speed Control Sensor Adjustment (310-03, General Procedures).
3. Refer to: Instrument Panel Lower Trim Panel (501-12 Instrument Panel and Console,
4.
5. 5. CAUTION: Make sure that all diagnostic trouble codes (DTCs)

have been removed after the road test.
Torque: 4 Nm
Installation

Speed Control - TDV6 2.7L Diesel - Speed Control Sensor
Removal
4. Torque: 5 Nm

NOTE: Make sure that the sensor is aligned after installation as

described in the speed control sensor adjustment procedure.
Installation

Speed Control - TDV6 2.7L Diesel - Speed Control Switch
Removal
Refer to: Standard W orkshop Practices (100-00 General Information, Description and
Operation).
2. Refer to: Driver Air Bag Module (501-20B Supplemental Restraint System, Removal
and Installation).
3. Refer to: Upshift Paddle Switch (307-05 Automatic Transmission/Transaxle External

Controls, Removal and Installation).
4. Refer to: Downshift Paddle Switch (307-05 Automatic Transmission/Transaxle External

Controls, Removal and Installation).
5. Torque: 3 Nm
6. Torque: 3 Nm
7. Torque: 6 Nm
8.
Installation

Speed Control - V6 3.0L Petrol -
Item Specification
Published: 23-Aug-2011
Speed Control - V6 3.0L Petrol - Speed Control - Component Location
COMPONENT LOCATION 3.0L V6 PETROL
ItemDescription
1 Engine Control Module (ECM)
3 Clockspring
5 Stop lamp/brake test switch
6 Accelerator Pedal Position (APP) sensor
7 Electric throttle
8 Anti-lock Brake System (ABS) module
Published: 23-Aug-2011
Speed Control - V6 3.0L Petrol - Speed Control - Overview
OVERVIEW
The speed control system maintains a set speed selected by the driver until operation is suspended or cancelled by a further input from the
driver and is controlled by the ECM (engine control module).
The speed control system has the following components:
A SET + switch
A - switch
A RESUME switch
A CANCEL switch
The speed control system also uses:
The ECM
The stop lamp switch
The APP (accelerator pedal position) sensor.
Speed Control - V6 3.0L Petrol - Speed Control - System Operation and Component
Description
Control Diagram
NOTE: A = Hardwired; D = High speed CAN (controller area network) bus; O = LIN bus;
ItemDescription
5 Audio system control switches
6 Clockspring
8 Electric throttle
9 Stop lamp/brake test switch
System Operation
SPEED CONTROL
The speed control system is integrated with the engine management system and uses fueling intervention to automatically maintain a set
vehicle speed. Once engaged, the system can also be used to accelerate the vehicle without using the accelerator pedal. The speed control
system comprises the following components:

Resume switch
Cancel switch
Clock spring
Speed control warning indicator.
The speed control system also uses inputs from the brake pedal switch, the APP sensor, the ECM and the ABS module.
The speed control is operated by the driver using only the steering wheel switches. When speed control is active, the ECM regulates the
PWM (pulse width modulation) signals to the fuel injectors to adjust the fuel supply as required to maintain the set speed.
During speed control operation, the ECM controls vehicle speed by adjusting fuel injection duration and timing. When the accelerator pedal
is pressed with speed control active, the ECM outputs a calculated throttle angle signal in place of the actual throttle angle signals
produced by the APP sensor. The calculated throttle angle is derived from fuel demand based on the torque required to overcome the rolling
resistance (vehicle motion drag).
The minimum set speed for speed control is 20 mph (32 (km/h). Speed control is automatically suspended if the following conditions apply:

If the accelerator pedal is used to accelerate beyond the set speed for too long (more than 5 minutes).
Stability control system intervention
System error causes shut-off.
There are 4 standard speed control switches:
Set speed + accelerate switch

Decelerate - switch
Cancel switch
Resume switch.
The standard speed control switches are located on the RH (right-hand) side of the steering wheel. The switches are resistive ladder type
switches which vary the resistance of a voltage signal sent to them. The resistive ladder is wired to a control module within the switch
assembly, the control module is a LIN (local interconnect network) node which transmits the data to the CJB (central junction box) which
passes the data onto the high speed CAN bus. In the event of the ECM logging a cruise switch fault DTC (diagnostic trouble code), fault
finding should start at the switch assembly and clockspring. The ECM diagnostic detects that the switch assembly control module hasn't
provided an updated live counter.
Engage Speed Control
Speed control is engaged by pressing the set speed accelerate + switch. Once engaged the speed can be increased by one of 3 methods:
Press and hold the set speed accelerate + switch which will cause the vehicle to accelerate. When the switch is released the
attained speed will be set as the cruise speed.
Repeatedly pressing the set speed accelerate + switch. Each press increases the vehicle speed by 1 mph (2 km/h).
Use the accelerator pedal to increase the vehicle speed. Once the required speed is reached, a single press of the set speed
accelerate + switch will set the cruise speed.
Reduce Cruising Speed
The set speed can be reduced by pressing and holding the decelerate - switch until the required speed is reached. W hen the switch is
released the speed is reset at that value. The set speed can be reduced incrementally by pressing and releasing the decelerate - switch.
Each press will reduce the speed by 1 mph (2 km/h). Adaptive speed control braking can be induced by using the SET switch to decelerate
the vehicle.
Set Speed Adjustment
Speed control adjustment is limited around the current vehicle speed. This means speed adjustment won't occur when resuming or if the
vehicle speed is noticeably different to set speed. This is noticeable when resuming speed control and a large difference exists between the
set speed and the current speed. The driver can set a new speed, but can't adjust the old speed.
Suspend Speed control
Suspending speed control means speed control has been deactivated without loss of the memory speed. In all suspend events the memory
speed is maintained. Speed control can be suspended in a number of ways, as described in the general description.
A single press of the RESUME switch will resume speed control at the previously set speed.
NOTE: In the event that a memory speed has been lost during a driving cycle, confirm with the customer if the "Cruise Not Available"
message was observed. Loss of memory speed implies a fault has occurred. The message 'Cruise Not Available' may only be displayed on
demand for some errors, so speed control needs to be requested via the SET + switch to drive the message.
Speed Control - V6 3.0L Petrol - Speed Control

REFER to: Speed Control (310-03A, Diagnosis and Testing).
Speed Control - V6 3.0L Petrol - Speed Control Sensor Adjustment
General Procedures
Special Tool(s)
501-F007
Inclinometer

NOTE: Make sure that the vehicle is standing on a level surface.
6.
The ACC radar needed to be removed or is misaligned in its position due to
another repair operation.
7.
From the diagnostic tool menu, select: Service Alignment Mode.
The follow indicator will now be flashing, this indicates that the vehicle is in
"service alignment" and now requires driving.
Choose a road with plenty of stationary objects, like street lights, road signs,
or barriers. Use an inside or outside lane.
Following vehicles too closely will obscure the stationary targets from the
radar, a time gap of 2 seconds is recommended.
A straight road will produce a quicker and better result, although the process
will still operate on a curved road.
The time that the ACC module takes to align will vary, depending on the route,
speed, number of targets, and individual module.
W hen the flashing follow indicator light extinguishes, the ACC system is now
functional, and a required vehicle speed can now be set by the driver and the
ACC system will operate as normal.
Speed Control - V6 3.0L Petrol - Speed Control Deactivator Switch
Removal
2.
3.
Installation

Speed Control - V6 3.0L Petrol - Speed Control Module
Removal
3. Refer to: Instrument Panel Lower Trim Panel (501-12 Instrument Panel and Console,
4.

Torque: 4 Nm
Installation

Speed Control - V6 3.0L Petrol - Speed Control Sensor
Removal
4. Torque: 5 Nm

NOTE: Make sure that the sensor is aligned after installation as

described in the speed control sensor adjustment procedure.
Installation

Speed Control - V6 3.0L Petrol - Speed Control Switch
Removal
1. Refer to: Speed Control Switch (310-03A, Removal and Installation).
Installation
1.
Speed Control - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8 -
Item Specification
Speed Control - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8 - Speed Control -
Component Location
ItemDescription
3 Clock spring
Overview
Speed Control
The speed control system is integrated with the engine management system and uses fueling intervention to
automatically maintain a set vehicle speed. Once engaged, the system can also be used to accelerate the vehicle without
using the accelerator pedal. The speed control system comprises the following components:
On/Off/Suspend switch
Resume switch
Clock spring
The speed control system also uses inputs from the brake pedal switch, the APP (accelerator pedal position) sensor, the
ECM (engine control module) and the ABS (anti-lock brake system) control module.
The speed control is operated by the driver using only the steering wheel switches. When speed is active, the ECM
regulates the PW M signals to the fuel injectors to adjust the fuel supply as required to maintain the set speed.
During speed control operation, the ECM controls vehicle speed by adjusting fuel injection duration and timing. When the
accelerator pedal is pressed with speed control active, the ECM outputs a calculated throttle angle signal in place of the
actual throttle angle signals produced by the APP sensor. The calculated throttle angle is derived from fuel demand.
Control Diagram
NOTE: A = Hardwired; D = High speed CAN (controller area network) bus; O = LIN bus; U = Private CAN bus
ItemDescription
4 Audio system control switches
5 Clock spring
7 Electric throttle
8 Diagnostic socket
12 Transmission control module
System Operation
Overview
The speed control system is integrated with the engine management system and uses Fueling intervention to
automatically maintain a set vehicle speed. Once engaged, the system can also be used to accelerate the vehicle without
using the accelerator pedal. The speed control system comprises the following components:
On/Off/Suspend switch
Resume switch
Clock spring
The speed control system also uses inputs from the brake pedal switch, the APP sensor, the ECM and the ABS control
module.
The speed control is operated by the driver using only the steering wheel switches. When speed control is active, the ECM
regulates the PW M (pulse width modulation) signals to the fuel injectors to adjust the fuel supply as required to maintain
the set speed.
During speed control operation, the ECM controls vehicle speed by adjusting the electronic throttle. When the accelerator
pedal is pressed with speed control active, the ECM outputs a calculated throttle angle signal in place of the actual
throttle angle signals produced by the APP sensor. The calculated throttle angle is derived from fuel demand.
The minimum set speed for speed control is 18 mph (30 (km/h). Speed control is automatically suspended if the following
conditions apply:

When the vehicle speed reaches a maximum speed of 120 mph (192 kph).
If the accelerator pedal is used to accelerate beyond the set speed for too long.
Adaptive Speed Control

The adaptive speed control system comprises the following components:
Adaptive Speed Control Sensor

Adaptive Speed Control module
Steering wheel control switches
ECM
Electric throttle
ABS module and pump
Adaptive Speed Control warning lamp (in the instrument cluster)
The adaptive speed control system uses a forward looking radar sensor to scan the road ahead, looking for objects that
are moving at a different rate to itself. W hen a target is identified the adaptive speed control system will monitor the time
gap between it and the target vehicle. When that gap falls below a set driver selected level the adaptive speed control
system will intervene slowing the vehicle by backing off the throttle and/ or applying the brakes, until the correct gap is
attained. The driver can chose between four gap settings, 1, 1.4, 1.8 and 2.2 seconds.
The system will detect but not react to the following:
Vehicles in the oncoming lane

Stationary vehicles
Pedestrians
Vehicles not in the same lane
Adaptive speed control is active when the vehicle is moving. Adaptive Speed Control only functions when a set speed is
entered in normal speed control mode. The adaptive speed control system only intervenes with the set speed when it
detects a target vehicle, and then only if the minimum time gap is breached.
It is important to note that the system is intended for use in limited driving situations, does not remove control and
responsibility from the driver, and at all times can be quickly overridden. The adaptive speed control system is not a
collision warning system and will not react to stationary objects. The system does not operate below a minimum speed of
approximately 30 km/h (20 mph) since it is unsuitable for use in cities or congested traffic. The system is best suited to
main roads/ highways with gradual bends.
The ECM, throttle body and throttle control are unchanged from those used for non Adaptive Speed Control variants.
The adaptive speed control system is based on the use of a front mounted radar sensor. The sensor transmits a 1.5 wide
beam forward of the vehicle and detects the returning signals reflected off other vehicles and objects ahead.
The 1.5 wide radar beam is mechanically scanned at a rate of 10 sweeps/second across a total arc of 15 centered on the
longitudinal axis of the vehicle. The radar operates at millimetric wavelengths (76 - 77 GHz) and transmits a frequency
modulated continuous wave signal at a relatively low power level (no high power pulses).
With the ignition switched ON, the adaptive speed control module is powered up but no radar transmissions are emitted
until the vehicle is in motion.
In follow mode a set speed is selected in the normal speed control manner and this speed is maintained until a slower
vehicle is encountered in the lane ahead. When the vehicle ahead comes within the effective range of the radar sensor,
the system identifies it as a target vehicle and an icon is illuminated on the instrument cluster to indicate that the system
is in "follow mode". When the distance betweeen the two vehicles closes to a set time gap, the adaptive speed control
system closes the throttle and if necessary applies the brakes to maintain the set time gap. Follow mode is effectively a
closed loop system. If several vehicles are ahead, the closest vehicle is chosen as the target to follow. If the target
vehicle moves out of radar range, or if either vehicle changes lane or drops below the minimum operating speed, the
system exits follow mode and the follow mode icon is extinguished. The adaptive speed control system will only raise its
speed to the originally set speed, it will not accelerate past this speed to maintain a time gap.
Driver operation of the foot brake or control switches will immediately cancel adaptive speed control.
When the vehicle is in follow mode the follow mode warning indicator is illuminated in the instrument cluster and the
current gap setting will be displayed in the message center.
ItemDescription
1 Forward Alert warning indicator
2 Follow mode warning indicator
The radar sensor detects three primary parameters of objects within the scanned arc. These are:
Range
Relative velocity
Angle
Range: The radar sensor detects the presence and ranges of different vehicles and objects within the scanned arc up to a
distance of approximately 130 meters. The transmitted signal frequency changes continuously in a cyclic pattern
(modulation). This means that, in the time taken for the signal wave front, to travel to and from a target vehicle (or other
object), the transmission frequency will have changed. The difference between the received signal frequency and the new
transmission frequency is proportional to the distance between the transmitting vehicle and the target vehicle.
Relative velocity: W hen the signal is reflected off a vehicle moving at a different speed (opening or closing gap) an effect
known as the Doppler shift causes an extra frequency modulation to be imposed on the signal. This Doppler frequency
varies with the relative speed of the vehicle being followed, enabling the system to differentiate between vehicles
traveling at different speeds and also between moving vehicles and stationary objects.
Angle: Using a narrow angle beam to scan horizontally enables the system to distinguish between vehicles in different
lanes and between vehicles and roadside objects.
System Restrictions
The adaptive speed control system is only intended to provide enhanced speed control as described above in certain
restricted conditions. The following points should be noted:
Automatic braking is limited to approximately 30% of full pressure (0.3G deceleration) and is intended to provide a
smooth, gradual deceleration in follow mode conditions. Harsh braking by the target vehicle or following the target
vehicle down to very low speeds or to a halt will require driver override of the brakes.
While the radar sensor detects moving and stationary targets for assessment of the environment ahead, the
system does not react to or provide any control in situations other than follow mode conditions. Stationary or slow
moving vehicles (below 10 km/h), pedestrians, objects on the road and oncoming vehicles in the same lane are not
recognized.
WARNING: It must be emphasized that the adaptive speed control system is not a collision warning or avoidance
system and that, other than the limited conditions of follow mode, driver intervention will be necessary to control the
vehicle speed.
In follow mode, some situations may cause target ambiguities for the detection system. These situations include:
The nearby presence of a third vehicle when driving on a line slightly offset to the target vehicle.
Vehicles edging into the lane ahead which are not detected by the system until they have moved into the radar
beam.
On the approach to, or exit from a bend, a target vehicle may be lost or a new target acquired as vehicles ahead change
their angular position with respect to the radar sensor. On a straight road, if the sensing vehicle is in follow mode below
its selected set speed, losing the target vehicle will cause the sensing vehicle to accelerate to this set speed. This
acceleration is undesirable either on, or entering a bend when the target is suddenly lost, and in this situation the system
inhibits the resumption of the set speed.
The speed control system compares vehicle speed data from the ABS system with the relative speed of an external object
as detected by the radar sensor to ascertain whether the object is stationary or not.
NOTE: If tires are fitted which are different in diameter from those specified for the vehicle, the vehicle speed calculated
by the ABS will not be the true road speed. This situation may cause stationary objects to be falsely identified as moving
vehicles and result in automatic deceleration on a clear road.
Speed Control Switches
ItemDescription
1 Set speed adjustment switch
2 Time gap switch
3 Cancel switch
4 Resume switch
The speed control switches are located on the RH (Right-hand) side of the steering wheel. The switches are connected via
fly leads to the clock spring. The speed control switches are resistive ladder type switches which vary the resistance of a 5
volt signal sent to them. The signal is returned along a Lin bus to the instrument cluster. The instrument cluster routes
the control signals to the ECM on the MS CAN.
Speed control is engaged by rotating the speed adjustment switch to the + or - positions. Once engaged the speed can be
varied by the speed adjustment switches. Each press of the speed adjustment switch will increase or decrease the set
speed in steps of 1 mph (2 kph).
Adaptive Speed Control Module
The Adaptive Speed Control module, located on the drivers side at the bottom of the A post. The control module is
connected to the other vehicle systems via the high speed CAN bus. Signals from the Adaptive Speed Control forward
looking radar sensor are received on a dedicated CAN bus between the two modules.
Adaptive Speed Control Radar Sensor
The adaptive speed control radar sensor is located in the front bumper, on the RH side above the radiator grill behind the
bumper cover. The sensor is connected to the Adaptive Speed Control, module via a private CAN bus. If the unit is
replaced in service the unit must be re-aligned vertically. Horizontal alignment is achieved by putting the sensor in service
mode via the recommended Jaguar diagnostic tool.
The vehicle is then driven for a short period while the sensor calibrates itself. Calibration is complete when the 'follow'
icon in the instrument cluster stops flashing.
Forward Alert Switches

The forward alert system utilizes the Adaptive Speed Control system components. Forward alert is turned on and off
independently of Adaptive Speed Control, via a switch mounted in the lower outboard knee bolster switchpack. Forward
alert will notify the driver by means of a chime, and warning indicator in the instrument cluster and indication in the
message center, when a target vehicle comes into range. The system will NOT use throttle or brake intervention to slow
the vehicle.
The forward alert switch is connected to the instrument cluster in a resistive ladder with the luggage compartment opening
switch and the fuel filler flap switch. The instrument cluster sends the forward alert information to the Adaptive speed
control module on the CAN bus.
NOTE: This system is intended as a driver aid and should be used as such. The system is NOT a collision warning or
avoidance device.
The system sensitivity can be adjusted in the same manner as the Adaptive Speed Control, via the steering wheel
mounted switches. Each adjustment is accompanied by a message in the message center.
Speed Control - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8 - Speed Control
For a detailed description of the speed control system, refer to the relevant Description and Operation sections in the
workshop manual. REFER to: (310-03 Speed Control - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8)
Speed Control (Description and Operation),

Speed Control (Description and Operation),
Speed Control (Description and Operation).
vehicle.
Visual Inspection
Speed control sensor Fuses
Ensure the speed control sensor is free from obstructions W iring harness
Speed control module Electrical connector(s)
Brake switch Steering wheel switches
Brake switch
Speed control sensor
Speed control module
4. 4. If the cause is not visually evident, verify the symptom and refer to the Symptom Chart, alternatively, check for
Speed Control Sensor Adjustment (vehicles with adaptive system installed)

An incorrectly aligned speed control sensor can cause incorrect system operation. Before starting any repair work on the
speed control system, on vehicles with the adaptive system installed, check speed control sensor for correct vertical
alignment, and carry out speed control sensor alignment procedure using manufacturer approved diagnostic system.
Symptom Chart

Speed control inhibited Power or ground supply to Check for DTCs that could be caused by power or
or disabled speed control module or ground failure to the module or sensor and refer to
speed control sensor DTC Index
Steering wheel speed control Check for sticking, jammed and broken speed control
switch/circuits switches. Refer to the electrical circuit diagrams and
Throttle sensors check speed control switch circuits for short, open
Brake switch circuit
Anti-Lock Brake System fault For throttle position sensor tests. REFER to:
Electronic Engine Controls (303-14 Electronic Engine
Controls - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8,
Check for correct installation and adjustment of
brake switch. Refer to the electrical circuit diagrams
and check brake switch circuits for short, open circuit
Check ABS system for related DTCs and refer to the
relevant DTC Index
Unable to Steering wheel switch Check for sticking, jammed and broken speed control
regulate/adjust vehicle malfunction switches. Refer to the electrical circuit diagrams and
speed check speed control switch circuits for short, open
circuit
Unable to cancel speed Steering wheel switch Check for sticking, jammed and broken speed control
control from steering malfunction switches. Refer to the electrical circuit diagrams and
wheel check speed control switch circuits for short, open
circuit
Unable to cancel speed Brake switch malfunction Check for correct installation and adjustment of
control from brake pedal brake switch. Refer to the electrical circuit diagrams
and check brake switch circuits for short, open circuit
DTC Index
Vehicles WITH Adaptive System Installed
account.

B1A8481 Car Configuration RJB reporting invalid Re-configure the RJB using manufacturer approved
Data data diagnostic system
C1A6754 Forward Looking Speed control sensor Check speed control sensor for correct vertical alignment,
Sensor out of alignment and carry out speed control sensor alignment procedure
using manufacturer approved diagnostic system
C1A6781 Forward Looking Yaw voltage Clear DTC and re-test, if DTC remains suspect speed control
Sensor unreasonable for 0.5 sensor. Check and install a new sensor as required, refer to
seconds or unchanged the new module/component installation note at the top of
for 1.2 seconds. Note: the DTC Index
Yaw sensor internal to
speed control sensor
C1A6787 Forward Looking Incorrect or missing data from Carry out any pinpoint tests associated with this DTC using
Sensor speed control sensor the manufacturer approved diagnostic system. Refer to the
electrical circuit diagrams and check power and ground
supplies for short, open circuit. Check private CAN network
between speed control sensor and speed control module for
failure, clear DTC and re-test. If DTC remains suspect the
speed control sensor, check and install a new sensor as
C1A6796 Forward Looking Internal hardware Suspect the speed control sensor. Check and install a new
Sensor failure sensor as required, refer to the new module/component
C1A6797 Forward Looking Sensor reduced Check for blockage in front of radar. Note: This DTC will be
Sensor visibility cleared automatically when environmental conditions allow
C1A6798 Forward Looking Speed control sensor Allow system to cool. Note: This DTC will be cleared
Sensor internal temperature automatically when environmental conditions allow
exceeded threshold
P174E81 Output Shaft Follow speed is Clear DTC and re-test

Speed/ABS W heel mis-calculated to too
Speed Correlation high a value
U000188 High Speed CAN Vehicle CAN Bus off Carry out any pinpoint tests associated with this DTC using
Communication Bus condition the manufacturer approved diagnostic system. Carry out CAN
network integrity tests using the manufacturer approved
diagnostic system
U010000 Lost Communications ECM missing message Carry out any pinpoint tests associated with this DTC using
W ith ECM/PCM "A" the manufacturer approved diagnostic system. Check ECM
for related DTCs and refer to the relevant DTC Index
U010100 Lost Communications TCM missing message Carry out any pinpoint tests associated with this DTC using
W ith TCM the manufacturer approved diagnostic system. Check TCM
for related DTCs and refer to the relevant DTC Index
U010387 Lost Communication Transmission shift Carry out any pinpoint tests associated with this DTC using
W ith Gear Shift module missing the manufacturer approved diagnostic system. Check
Module message transmission shift module for related DTCs and refer to the
relevant DTC Index
U012100 Lost Communication ABS missing message Carry out any pinpoint tests associated with this DTC using
W ith Anti-lock Brake the manufacturer approved diagnostic system. Check ABS for
System (ABS) related DTCs and refer to the relevant DTC Index
Control Module
U012800 Lost Communications Parking brake missing Carry out any pinpoint tests associated with this DTC using
W ith Park Brake message the manufacturer approved diagnostic system. Check parking
Module brake module for related DTCs and refer to the relevant DTC
Index
U015500 Lost Communications Instrument cluster Carry out any pinpoint tests associated with this DTC using
W ith Instrument missing message the manufacturer approved diagnostic system. Check
Panel Cluster (IPC) instrument cluster for related DTCs and refer to the relevant
Control Module DTC Index
U030000 Internal Control Invalid configuration Re-configure the speed control module using the
Module Software message is received manufacturer approved diagnostic system. Clear DTCs and
Incompatibility re-test. If DTC still logged, suspect incorrect speed control
module installed. Check and install a new module as
required, refer to new module/component installation note
at top of DTC Index
U030055 Internal Control RJB - at least one of Re-configure the RJB using the manufacturer approved
Module Software the car configuration diagnostic system
Incompatibility parameters is not
configured
U040100 Invalid Data ECM did not respond Check ECM for related DTCs and refer to relevant DTC Index
Received From properly to speed
ECM/PCM A control cancel or auto
brake cancel request
U040167 Invalid Data ECM did not respond Check ECM for related DTCs and refer to relevant DTC Index
Received From properly to speed
ECM/PCM A control resume request
U040181 Invalid Data Speed control inhibited Check ECM for related DTCs and refer to relevant DTC Index
Received From by ECM
ECM/PCM A
U041581 Invalid Data Stability assist fault Check ABS module for related DTCs and refer to relevant
Received From DTC Index
Anti-lock Brake
System (ABS)
Control Module
U041767 Invalid Data Parking brake module Check parking brake module for related DTCs and refer to
Received From Park did not respond relevant DTC Index
Brake Control Module properly to apply
request
U041781 Invalid Data Speed control inhibited Check parking brake module for related DTCs and refer to
Received From Park by parking brake relevant DTC Index
Brake Control Module module
U042381 Invalid Data Speed control inhibited Check instrument cluster, CJB and RJB for related DTCs and
Received From by instrument cluster refer to relevant DTC Index
Instrument Panel
Control Module
U1A1449 CAN Initialisation Internal electronic Suspect the speed control module. Check and install a new
Failure failure module as required, refer to the new module/component
U210100 Control Module Data sent from RJB is Check/amend Car Configuration File using the manufacturer
Configuration invalid approved diagnostic system, clear DTC and re-test. If DTC
Incompatible remains, re-configure RJB using manufacturer approved
diagnostic system, clear DTC and re-test. If DTC remains
check RJB for DTCs and refer to DTC Index
U300041 Control Module Internal micro controller Suspect the speed control module. Check and install a new
error module as required, refer to the new module/component
Checksum fault installation note at the top of the DTC Index
U300042 Control Module Internal RAM test fault Suspect the speed control module. Check and install a new
module as required, refer to the new module/component
U300049 Control Module Internal control module Suspect the speed control module. Check and install a new
failure module as required, refer to the new module/component
Vehicles WITHOUT Adaptive System Installed
account.

P050100 Vehicle Speed Sensor A Vehicle speed signal from Carry out CAN network integrity test using the
Range/Performance ABS not plausible manufacturer approved diagnostic system. Contact
Dealer Technical Support for further assistance
P050162 Vehicle Speed Sensor A Vehicle speed - range Check ABS/TCM for related DTCs and refer to
Range/Performance performance relevant DTC Index
P050400 Brake Switch A / B The brake pressure Carry out any pinpoint tests associated with this
Correlation reading does not agree DTC using the manufacturer approved diagnostic
with the brake light system. Refer to the electrical circuit diagrams and
switch value check brake switch circuits for short, open circuit,
high resistance
P050401 Brake Switch A / B Brake switch high fault: Carry out any pinpoint tests associated with this
Correlation - Brake lights stuck on DTC using the manufacturer approved diagnostic
- Gearshift interlock system. Refer to the electrical circuit diagrams and
inoperative check brake switch circuits for short, open circuit,
- Speed control high resistance
inoperative
- Brake lights
inoperative
- Gearshift stuck in
Park
- Reduced engine
braking
P056600 Cruise Control OFF Signal Speed control Cancel Refer to the electrical circuit diagrams and check
switch 2 stuck closed speed control switch circuits for short, open circuit.
Check for stuck switch. Check and install a new
speed control switch as required
P056700 Cruise Control DECREASE Speed control Resume Refer to the electrical circuit diagrams and check
DISTANCE Signal switch 7 stuck closed speed control switch circuits for short, open circuit.
P056800 Cruise Control INCREASE Speed control Accel Set Check and install a new speed control switch as
DISTANCE Signal Plus Switch 6 stuck closed required
P056900 Cruise Control COAST Speed control Coast Set Refer to the electrical circuit diagrams and check
Signal Minus switch 3 stuck speed control switch circuits for short, open circuit.
closed Check for stuck switch. Check and install a new
P056A00 Cruise Control INCREASE Speed control Headway Refer to the electrical circuit diagrams and check
DISTANCE Signal Plus switch 4 stuck closed speed control switch circuits for short, open circuit.
P056B00 Cruise Control DECREASE Speed control Headway Refer to the electrical circuit diagrams and check
DISTANCE Signal Minus switch 5 stuck speed control switch circuits for short, open circuit.
closed Check for stuck switch. Check and install a new
P057162 Brake Switch A Circuit Plausibility error Refer to the electrical circuit diagrams and check
brake light switch signal circuits for short, open
circuit. Check and install a new brake light switch
as required
P057501 Cruise Control Input Circuit General electrical failure Check speed control system for related DTCs and
refer to relevant DTC Index. Carry out CAN network
integrity tests using the manufacturer approved
diagnostic system
P057616 Cruise Control Input Circuit Circuit voltage below Check speed control system for related DTCs and
Low threshold refer to relevant DTC Index. Carry out CAN network
diagnostic system
P057717 Cruise Control Input Circuit Circuit voltage above Check speed control system for related DTCs and
High threshold refer to relevant DTC Index. Carry out CAN network
diagnostic system
P057800 Cruise Control Multi- One of speed control Check for stuck speed control switch, install a new
Function Input A Circuit switches stuck switch pack as required
Stuck
P05781C Cruise Control Multi- Circuit voltage out of Refer to the electrical circuit diagrams and check
Function Input A Circuit range speed control switch circuits for short, open circuit.
Stuck Check for stuck switch. Check and install a new
P05791C Cruise Control Multi- Speed control switch pack Check and install a new speed control switch pack
Function Input A Circuit internal failure as required
Range/Performance
P057929 Cruise Control Multi- Signal invalid Refer to the electrical circuit diagrams and check
Function Input A Circuit speed control switch circuits for short, open circuit.
Range/Performance Check for stuck switch. Check and install a new
P059000 Cruise Control Multi- Active speed limiter fault Check for active speed limiter fault, install a new
Function Input B Circuit transmission shift module as required
Stuck
Sensor Adjustment
General Procedures
Special Tool(s)
501-F007
Inclinometer
1. 1. CAUTION: Protect the surrounding paintwork to

avoid damage.
2. 2. NOTE: Make sure that the vehicle is standing on a

level surface.
3. 3. NOTE: Make sure that the vehicle is standing on a
level surface.
NOTE: Make sure that the vehicle is standing on a

level surface.

avoid damage.
6.
The ACC radar needed to be removed or is misaligned in its
position due to another repair operation.
7.
From the diagnostic tool menu, select: Service Alignment
Mode.
The follow indicator will now be flashing, this indicates that
the vehicle is in "service alignment" and now requires driving.
Choose a road with plenty of stationary objects, like street
lights, road signs, or barriers. Use an inside or outside lane.
Following vehicles too closely will obscure the stationary
targets from the radar, a time gap of 2 seconds is
recommended.
A straight road will produce a quicker and better result,
although the process will still operate on a curved road.
The time that the ACC module takes to align will vary,
depending on the route, speed, number of targets, and
individual module.
W hen the flashing follow indicator light extinguishes, the
ACC system is now functional, and a required vehicle speed
can now be set by the driver and the ACC system will operate
as normal.
Deactivator Switch
Removal

2.
3.
4. 4. CAUTION: Make sure that the brake pedal

remains in the rest position during this procedure.

Installation

Module
Removal

2. Refer to: Speed Control Sensor Adjustment (310-03, General

Procedures).

4.

Torque: 4 Nm
Installation
Sensor
Removal

2. Refer to: Speed Control Sensor Adjustment (310-03, General

Procedures).

avoid damage.
4. Torque: 5 Nm
NOTE: Make sure that the sensor is aligned after

installation as described in the speed control sensor
adjustment procedure.
Installation

Switch
Removal
1. Refer to: Speed Control Switch (310-03A, Removal and Installation).
Installation
1.
Climate Control System - General Information -
Air conditioning refrigerant HFC 134a
Air conditioning compressor oil ND-OIL8
Capacities
Description Grammes
Air conditioning refrigerant - All except vehicles with diesel engine 750
Air conditioning refrigerant - Vehicles with diesel engine 750
Refrigerant Oil Adding Capacities
Item Milliliters
Condenser core and desiccant bag Add 33
Desiccant bag Add 8
Evaporator Add 46
Air conditioning (A/C) compressor Drain the oil from the new compressor and replace it with the same quantity as
that drained from the compressor being replaced.
Air conditioning lines - If air conditioning Add 10 per line
has been operational.
Climate Control System - General Information - Climate Control System
For a detailed description of the Climate Control system, refer to the relevant Description and Operation sections in the
Workshop Manual. REFER to:
Air Distribution and Filtering (412-01 Climate Control, Description and Operation),
Heating and Ventilation (412-01 Climate Control, Description and Operation),
Air Conditioning (412-01 Climate Control, Description and Operation),
Control Components (412-01 Climate Control, Description and Operation),
Electric Booster Heater (412-02 Auxiliary Climate Control, Description and Operation),
Electric Booster Heater (412-02 Auxiliary Climate Control, Description and Operation),
Electric Booster Heater (412-02 Auxiliary Climate Control, Description and Operation).
vehicle.
Visual Inspection
Front End Accessory Drive (FEAD) belt Fuse(s)
Refrigerant Harness
Heater control flaps Electrical connectors
Ducting Switch(s)
DTC Index
account.

B105A01 Cabin Aspirator motor Carry out any pinpoint tests associated with this DTC using the
Temperature diagnostic circuit - short manufacturer approved diagnostic system. Refer to the
Sensor Fan to ground, open circuit electrical circuit diagrams and check aspirator motor diagnostic
Aspirator fan component circuit for short to ground, open circuit
failure
B108100 Left Temperature Left hand blend stepper Carry out any pinpoint tests associated with this DTC using the
Damper Motor motor internal or manufacturer approved diagnostic system
external fault
B108149 Left Temperature Left hand blend stepper Suspect the left hand blend stepper motor. Check and install a
Damper Motor motor internal electronic new stepper motor as required, refer to the new
failure module/component installation note at the top of the DTC Index
B108200 Right Right hand blend Carry out any pinpoint tests associated with this DTC using the
Temperature stepper motor internal manufacturer approved diagnostic system
Damper Motor or external fault
B108249 Right Right hand blend Suspect the right hand blend stepper motor. Check and install a
Temperature stepper motor internal new stepper motor as required, refer to the new
Damper Motor electronic failure module/component installation note at the top of the DTC Index
B108301 Recirculation RECIRC servo motor Carry out any pinpoint tests associated with this DTC using the
Damper Motor circuits - short to manufacturer approved diagnostic system. Refer to the
ground, power, open electrical circuit diagrams and check RECIRC servo motor circuit
circuit for short to ground, power, open circuit
B108500 Defroster Defrost stepper motor Carry out any pinpoint tests associated with this DTC using the
Damper Motor internal or external fault manufacturer approved diagnostic system
B108549 Defroster Defrost stepper motor Suspect the defrost stepper motor. Check and install a new
Damper Motor internal electronic stepper motor as required, refer to the new module/component
failure installation note at the top of the DTC Index
B108600 Air Distribution Panel/foot stepper Carry out any pinpoint tests associated with this DTC using the
Damper Motor motor internal or manufacturer approved diagnostic system
external fault
B108649 Air Distribution Panel/foot stepper Suspect the panel/foot stepper motor. Check and install a new
Damper Motor motor internal electronic stepper motor as required, refer to the new module/component
B108788 LIN Bus "A" LIN Bus power #1 Carry out any pinpoint tests associated with this DTC using the
circuit - open circuit manufacturer approved diagnostic system. Refer to the
electrical circuit diagrams and check LIN Bus power #1 circuit for
open circuit
B108888 LIN Bus "B" LIN Bus power #2 Carry out any pinpoint tests associated with this DTC using the
circuit - open circuit manufacturer approved diagnostic system. Refer to the
electrical circuit diagrams and check LIN Bus power #2 circuit for
open circuit
B11ED68 Electric Heater Event information. Clear DTC. With engine coolant temperature low, set climate
Control Module Electric heater - invalid temperature to high and re-test. If DTC remains in isolation
communication message suspect the PTC heater, check and install a new heater as
required, refer to the new module/component installation note
at the top of the DTC Index. If additional LIN related DTCs are
logged refer to the Actions for these DTCs
B11ED87 Electric Heater Electric heater - missing Carry out any pinpoint tests associated with this DTC using the
Control Module communication message manufacturer approved diagnostic system
B11ED96 Electric Heater Component internal Suspect the PTC heater, check and install a new heater as
Control Module failure required, refer to the new module/component installation note
B11ED98 Electric Heater Component or system Clear DTC. With engine coolant temperature low, set climate
Control Module over temperature temperature to high and re-test. If DTC remains suspect the
PTC heater, check and install a new heater as required, refer to
the new module/component installation note at the top of the
DTC Index
B11EE01 A/C Compressor Air conditioning Carry out any pinpoint tests associated with this DTC using the
compressor clutch manufacturer approved diagnostic system. Refer to the
solenoid circuits - short electrical circuit diagrams and check air conditioning compressor
to ground, power, open clutch solenoid circuits for short to ground, power, open circuit
circuit
B11F011 Air Intake RECIRC servo motor air Refer to the electrical circuit diagrams and check RECIRC servo
Damper Position intake feedback and 5 motor air intake feedback and 5 volt supply circuits for short to
Sensor volt supply circuits - ground
short to ground
B11F015 Air Intake RECIRC servo motor air Carry out any pinpoint tests associated with this DTC using the
Damper Position intake feedback and manufacturer approved diagnostic system. Refer to the
Sensor ground circuits - short electrical circuit diagrams and check RECIRC servo motor air
to power, open circuit intake feedback and ground circuits for short to power, open
circuit
B11F800 Left Outer Vent Left outer IP vent Carry out any pinpoint tests associated with this DTC using the
actuator internal or manufacturer approved diagnostic system.
external fault
B11F849 Left Outer Vent Left outer IP vent Suspect the left outer IP vent actuator. Check and install a new
actuator internal actuator as required, refer to the new module/component
electronic failure installation note at the top of the DTC Index
B11F900 Left Inner Vent Left inner IP vent Carry out any pinpoint tests associated with this DTC using the
external fault
B11F949 Left Inner Vent Left inner IP vent Suspect the left inner IP vent actuator. Check and install a new
actuator internal actuator as required, refer to the new module/component
B11FA00 Right Inner Vent Right inner IP vent Carry out any pinpoint tests associated with this DTC using the
external fault
B11FA49 Right Inner Vent Right inner IP vent Suspect the right inner IP vent actuator. Check and install a
actuator internal new actuator as required, refer to the new module/component
B11FB00 Right Outer Vent Right outer IP vent Carry out any pinpoint tests associated with this DTC using the
external fault
B11FB49 Right Outer Vent Right outer IP vent Suspect the right outer IP vent actuator. Check and install a
actuator internal new actuator as required, refer to the new module/component
B11FF84 A/C Refrigerant Signal below allowable This DTC can be logged by the system due to low ambient
Pressure range. A/C System temperature soak (below 3C) reducing the pressure in the
Refrigerant Pressure too refrigerant gas system. If the cabin temperature logged along
low with the DTC at the time is below 10C this could indicate low
temperature. If the air conditioning performance is satisfactory
and the in-cabin temperature is below 10C then it is likely that
the system contains a suitable amount of gas and the DTC is
being recorded as an effect of the low ambient temperature. If
this is not the case carry out any pinpoint tests associated with
this DTC using the manufacturer approved diagnostic system.
Refer to the electrical circuit diagrams and check air
conditioning pressure sensor circuits for short, open circuit.
Check for correct charge weight
B11FF85 A/C Refrigerant Signal above allowable Carry out any pinpoint tests associated with this DTC using the
Pressure range. A/C System manufacturer approved diagnostic system. Refer to the
Refrigerant pressure too electrical circuit diagrams and check air conditioning pressure
high sensor circuits for short, open circuit
B1A5911 Sensor 5 Volt Air conditioning Refer to the electrical circuit diagrams and check air
Supply pressure sensor or conditioning pressure sensor and RECIRC servo motor 5 volt
RECIRC servo motor 5 supply circuits for short to ground
volt supply circuits -
short to ground
B1A5913 Sensor 5 Volt Air conditioning Refer to the electrical circuit diagrams and check air
Supply pressure sensor 5 volt conditioning pressure sensor 5 volt supply circuit for open circuit
supply circuits - open
circuit
B1A6011 Pollution Sensor Pollution sensor Refer to the electrical circuit diagrams and check pollution
- Hydrocarbon hydrocarbon input circuit sensor hydrocarbon input circuit for short to ground
- short to ground
B1A6111 Cabin In car temperature Refer to the electrical circuit diagrams and check In car
Temperature sensor circuit - short to temperature sensor circuit for short to ground
Sensor ground
B1A6115 Cabin In car temperature Carry out any pinpoint tests associated with this DTC using the
Temperature sensor circuit - short to manufacturer approved diagnostic system. Refer to the
Sensor power, open circuit electrical circuit diagrams and check In car temperature sensor
B1A6311 Right Solar Right sun load sensor Refer to the electrical circuit diagrams and check right sun load
Sensor signal circuit - short to sensor signal circuit for short to ground
ground
B1A6411 Left Solar Sensor Left sun load sensor Refer to the electrical circuit diagrams and check left sun load
signal circuit - short to sensor signal circuit for short to ground
ground
B1A6713 Sensor Ground Sensor ground circuits - Refer to the electrical circuit diagrams and check sensor ground
open circuit circuits for open circuit
B1A6901 Humidity Sensor Humidity sensor PW M Carry out any pinpoint tests associated with this DTC using the
input circuit - short to manufacturer approved diagnostic system. Refer to the
ground, power, open electrical circuit diagrams and check humidity sensor PWM input
circuit circuit for short to ground, power, open circuit. Check and install
Sensor component a new sensor as required
failure
B1B6211 Pollution Sensor Pollution sensor NOx Refer to the electrical circuit diagrams and check pollution
- NOx input circuit - short to sensor NOx input circuit for short to ground
ground
B1B7111 Evaporator Evaporator temperature Refer to the electrical circuit diagrams and check evaporator
Temperature sensor signal circuit - temperature sensor signal circuit for short to ground
Sensor short to ground
B1B7115 Evaporator Evaporator temperature Carry out any pinpoint tests associated with this DTC using the
Temperature sensor signal circuit - manufacturer approved diagnostic system. Refer to the
Sensor short to power, open electrical circuit diagrams and check evaporator temperature
circuit sensor signal circuit for short to power, open circuit
B1B7211 LIN Bus #1 Stepper motor circuit Refer to the electrical circuit diagrams and check stepper motor
Power Supply LIN Bus #1 power circuit LIN Bus #1 power supply for short to ground
Circuit supply - short to ground
C1B1413 Sensor Supply RECIRC servo motor 5 Refer to the electrical circuit diagrams and check RECIRC servo
Voltage A volt supply circuit - motor 5 volt supply circuit for open circuit
open circuit
C1B1513 Sensor Supply RECIRC servo motor and Refer to the electrical circuit diagrams and check RECIRC servo
Voltage B EVAP sensor ground motor and EVAP sensor ground circuits for open circuit
circuits - open circuit
P053011 A/C Refrigerant Air conditioning Refer to the electrical circuit diagrams and check air
Pressure Sensor pressure sensor signal conditioning pressure sensor signal circuit for short to ground
A Circuit circuit - short to ground
P053015 A/C Refrigerant Air conditioning Carry out any pinpoint tests associated with this DTC using the
Pressure Sensor pressure sensor signal manufacturer approved diagnostic system. Refer to the
A Circuit circuit - short to power, electrical circuit diagrams and check air conditioning pressure
open circuit sensor signal circuit for short to power, open circuit
U001088 Medium Speed Bus off Carry out any pinpoint tests associated with this DTC using the
CAN manufacturer approved diagnostic system.
Communication
Bus
U030000 Internal Control Invalid configuration Re-configure the RJB using the manufacturer approved
Module Software message is received diagnostic system. Clear the DTC and retest. If the DTC is still
Incompatibility logged suspect the climate control module, refer to the new
U1A1449 CAN Internal electronic Suspect the climate control module, check and install a new
Initialisation failure module as required, refer to the new module/component
Failure installation note at the top of the DTC Index
U300055 Control Module Incorrect car Re-configure the RJB using the manufacturer approved
configuration data diagnostic system. Clear DTC and re-test. If the DTC remains
received suspect the climate control module. Check and install a new
U300087 Control Module Missing message Re-configure the RJB using the manufacturer approved
diagnostic system. Check climate control module for DTCs and
refer to the DTC Index. Carry out CAN network integrity tests
using the manufacturer approved diagnostic system. If DTC
remains suspect the climate control module. Check and install a
new module as required, refer to the new module/component
U300281 Vehicle Vehicle/component Check and install original/new module as required, refer to the
Identification mis-match. Corrupt VIN new module/component installation note at the top of the DTC
Number data being transmitted, Index
module previously
installed to other
vehicle
Climate Control System - General Information - Air Conditioning (A/C)
System Recovery, Evacuation and Charging
General Procedures
1. W ARNING: Servicing must be carried out by personnel

familliar with both vehicle system and the charging and testing
equipment. All operations must be carried out in a well
ventilated area away from open flame and heat sources.
NOTE: The receiver drier need only be changed under the

following circumstances: There is dirt in the refrigerant circuit (
eg. compressor seizure ), the system is leaking and refrigerant
has been lost to atmosphere, or the refrigerant circuit has been
open more than 24 hours, due to repair.
Refrigerant recovery.
2. Remove the dust covers from the high and low pressure
connections.
3. Connect the high and low pressure lines to the appropriate

connections.
4. Open the valves on the connections.
5. Turn the valves on the station to the correct positions.
6. Turn the process switch to the correct position.
7. Turn the main switch to 'ON'.
8. W ARNING: Refrigerant must always be recycled before

re-use to ensure that the purity of the refrigerantis high enough
for safe use in the air conditioning system. Recycling should
always be carried out with equipment which is design certified by
Underwriter Laboratory Inc. for compliance with SEA J1991. Other
equipment may not recycle refrigerant to the required level of
purity. R143a Refrigerant Recover Recycling Recharging station
must not be used with any other type of refrigerant.Refrigerant
R134a from domestic and comercial sources must not be used in
motor vehicles air conditioning systems.
Allow the system to recover the refrigerant from the system.

9. Close the valves on the refrigerant station.
10. Turn the main switch 'OFF'.
11. Close the valves on the connections.
12. Disconnect the high and low pressure connections.
13. Install the dust covers to the connectors.
14. Open the tap at the rear of the station to drain the
refrigerant oil.
15. Measure and record the quantity of refrigerant oil recovered
from the system.
16. Close the tap at the rear of the station.
17. Evacuation.
18. Remove the dust covers from the high and low pressure
connections.
19. Connect the high and low pressure lines to the appropriate
connections.
20. Open the valves on the connections.
21. Turn the valves on the station to the correct positions.
22. Turn the process switch to the correct position.
23. Turn the main switch to 'ON'.
24. Allow the station to evacuate the A/C system.
25. CAUTION: The system must be evacuated immediatley

before recharging commences. Delay between evacuation and
recharging is not permitted
Recharging
26. Close the valves on the refrigerant station.
27. Close the valve on the oil charger.
28. Disconnect the yellow line from the refrigerant station.
29. Remove the cover from the oil charger.
30. Pour the correct quantity of refrigerant oil into the oil
charger.
31. Install the cover to the oil charger.
32. Connect the yellow line to the refrigerant station.
33. Open the valve on the oil charger.
34. Move the pointer on the refrigerant gauge to mark the
position of the refrigerant drop.
35. Slowly open the correct valve on the refrigerant to allow the
vacuum to pull the refrigerant into the system.
36. Close the valve on the refrigerant station when the correct
amount of refrigerant has been drawn into the air conditioning
system.
37. Turn the main switch 'OFF'.
38. Close the valves on the connections.
39. Disconnect the high and low pressure connections.
Climate Control System - General Information - Air Conditioning (A/C)
System Flushing
General Procedures
1. WARNINGS:
Use extreme care and observe all safety precautions

related to the use of refrigerants. Due to refrigerant hazards,
always wear safety goggles and non-penetrable gloves when
working on or flushing air conditioning (A/C) systems. Failure to
When flushing the A/C system, refer to the manufacturers

equipment instructions for additional information. Failure to do
so may result in system damage or personal injury.
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 additional information, refer to the
manufacturers equipment instructions. Failure to follow this
Prior to using the A/C flushing equipment for the first time,
follow the operating instructions. Failure to follow this instruction
CAUTION: Prior to flushing, remove and discard the

desiccant sack. Depending on the equipment used, other A/C
components may have to be removed prior to flushing. For
additional information, refer to the manufacturers equipment
instructions before flushing the A/C system.
Recover the refrigerant.

For additional information, refer to Air conditioning (A/C)
System Recovery, Evacuation and Charging in this section.
2. Remove the desiccant sack.
For additional information, refer to Section 412-03 Air
Conditioning.
3. Flush the system. For additional information, refer to the
manufacturers equipment instructions.
4. Install new refrigerant lines if blocked with debris.
5. Install a new desiccant sack.
For additional information, refer to Section 412-03 Air
Conditioning.
6. 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.
7. Evacuate and charge the A/C system.
For additional information, refer to Air conditioning (A/C)
8. Carry out fluorescent dye leak detection test.
For additional information, refer to Flourescent Dye Leak
Detection in this section.
9. Check the A/C system for correct operation.
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.
4. On completion of the recovery of the contaminated

refrigerant, it will be necessary to carry out the A/C
system flushing procedure.
For additional information, refer to Air Conditioning
(AC) System Flushing in this section.
Climate Control System - General Information - Electronic Leak Detection
General Procedures
1. W ARNING: 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.
Attach an R-134a manifold gauge set or use a UL-approved

recovery/recycling device such as an R-134a A/C refrigerant
center (which meets SAE Standard J 1991). For additional
information, refer to the manufacturers equipment instructions.
Both gauges should indicate 413-551 kPa (60-80 psi) at

24C (75F) with the engine off.
If little or no pressure is indicated, carry out the air

conditioning (A/C) system recovery, evacuation and
charging procedure.
For additional information, refer to Air Conditioning (AC)
2. Use an R134-a Automatic calibration halogen leak detector to

leak test the refrigerant system. For additional information,
refer to the manufacturers equipment instructions.
3. If a leak is found, carry out the air conditioning (A/C) system
recovery procedure.
For additional information, refer to Air Conditioning (AC)
Climate Control System - General Information - Fluorescent Dye Leak
Detection
General Procedures
1. W ARNING: Eye protection glasses supplied with the

ultraviolet (UV) lamp should be used to protect eyesight from
harm.
NOTE: The air conditioning (A/C) system has an R-134a leak

trace dye wafer incorporated into the desiccant bag. 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
(due to a severe leakage for example) use proprietary tracer dye
injection equipment.
Check for leaks using ultraviolet (UV) lamp.

2. Check all components, fittings and lines of the A/C system.
3. Carry out the repair. For additional information, refer to
Section 412-03 Air Conditioning.
4. After the leak is repaired, remove any traces of leak trace dye
with a general purpose oil solvent.
5. Check the A/C system for correct operation.
6. Verify the repair by operating the system for a short time and
inspecting with the (UV) lamp.
Climate Control System - General Information - Inspection and Assembly
Requirements
General Procedures
1. Check for leaks using ultraviolet (UV) Lamp.

2. NOTE: Any time a hose or component connection leak is
observed, the component and fitting must be separated, cleaned
and a new O-ring fitted and lubricated with air conditioning
compressor oil.
For additional information, refer to Specifications in this section.
NOTE: When separating A/C joints, cap the open connections

immediately. Do not leave open to atmosphere.
O-ring seal surfaces must be free of dirt, lint, burrs and

scratches. The O-ring and connector should be lubricated with
air conditioning compressor oil.
For additional information, refer to Specifications in this
section.
Climate Control System - General Information - Manifold Gauge Set
Connection
General Procedures
1. WARNINGS:

related to the use of refrigerants. Failure to follow this
For additional information, refer to the manufacturers

equipment instructions. Failure to follow this instruction may
result in personal injury and system damage.
Install the manifold gauge set. For additional information, refer

to the manufacturers equipment instructions.
2. Carry out the repair.
3. Remove the manifold gauge set. For additional information,
refer to the manufacturers equipment instructions.
4. Carry out flourescent dye leak detection test.
5. Check air conditioning (A/C) system for correct operation.
Climate Control System - General Information - Refrigerant Oil Adding
General Procedures
CAUTION: Collect the refrigerant oil in a clean measuring cylinder.
1. 1. NOTE: This step only needs to be carried out when removing the
A/C compressor.
NOTE: Rotate the compressor shaft at least 6 to 8 turns when

draining the refrigerant oil.
Drain the refrigerant oil from the defective A/C compressor and
dispose of it.
2. 2. CAUTIONS:
The refrigerant oil top-up quantity must not exceed the

refrigerant oil fill quantity.
If other A/C components are being renewed in addition to the

A/C compressor, there is no need to top up with additional
refrigerant oil, apart from filling the compressor.
Top up with the calculated quantity of new refrigerant oil.
Refer to: Specifications (412-00 Climate Control System - General

Climate Control System - General Information - Refrigerant System Tests
General Procedures
1. WARNINGS:

related to the use of refrigerants. Failure to follow this
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 this
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 manufactures procedures and

instructions for use of equipment.
Climate Control -
Blower motor control module retaining bolts 1 - 9
Foot duct to cross car beam retaining bolt 5 - 44
Climate control assembly to cross car beam retaining bolts 9 - 80
Climate control module retaining bolts 1 - 9
Defrost vent/register blend door actuator retaining bolts 1 - 9
Evaporator pipe bracket retaining bolts 1 - 9
Evaporator housing retaining bolts 1 - 9
Footwell vent/duct blend door actuator retaining bolt 1 - 9
Heater core housing retaining bolts 2 - 18
Sunload sensor retaining bolt 2 - 18
Evaporator core pipes mounting bracket retaining bolts 1 - 9
Evaporator core pipes to thermostatic expansion valve retaining bolt 5 - 44
Thermostatic expansion valve retaining bolts 3 - 26
Climate Control - Air Distribution and Filtering - Component Location
NOTE: LHD (left-hand drive) vehicle shown, RHD (right-hand drive) vehicle similar.
Component Location
ItemDescription
1 LH (left-hand) side window vent
2 W indshield vent
3 Driver's face level duct
4 W indshield/Side window vent duct
5 Front passenger's face level duct
6 RH (right-hand) side window vent
7 Front passenger's face level register
8 Pollen filter
9 RH inner face level register
10 Front passenger's footwell duct
11 RH rear footwell duct
12 Rear face level registers
13 Rear face level duct
14 LH rear footwell duct
15 LH inner face level register
16 Driver's footwell duct
17 Driver's face level register
Climate Control - Air Distribution and Filtering - Overview
Overview
The air distribution and filtering system controls the distribution and quality of air supplied to the passenger compartment.
The system comprises of a pollen filter and a number of ducts, vents and registers.
Climate Control - Air Distribution and Filtering - System Operation and
Control Diagram
NOTE: A = Hardwired; N = Medium speed CAN (controller area network) bus; O = LIN (local interconnect network) bus; P
= Media orientated system transport (MOST) ring.
ItemDescription
1 Battery
4 Touch screen display (TSD)
6 ATC (automatic temperature control) module
7 RH (right-hand) outer face level register
9 LH (left-hand) inner face level register
10 LH outer face level register
11 Face/Feet distribution stepper motor
12 RH temperature blend stepper motor
13 W indshield (defrost) distribution stepper motor
14 LH temperature blend stepper motor
System Operation
Face Level Registers
Operation of the face level registers is controlled by the ATC module, using LIN bus messages to the integral stepper
motors. The four registers operate together in both the opening and closing phases.
The face level registers can be selected to run in one of two modes; 'automatic' or 'always open'. The mode is selected on
the climate control screen of the TSD.
Refer to: Navigation System (415-01 Information and Entertainment System, Description and Operation).
In the automatic mode, operation of the face level registers is synchronized with the engine START/STOP button. When
the engine starts the ATC module opens the registers. When the engine stops, the ATC module closes the registers.
If a face level register is fouled, when it receives an open or close request, the register concerned makes a number of
attempts to reach the requested position. If the register still does not move, it is left in the fouled position. The
remaining registers will continue to open and close as normal.
The automatic mode is disabled when the climate control system is off. The ATC module closes the registers if they are
open in the automatic mode and the climate control system is selected off.
Diagnostics
If a fault occurs with the face level registers, a DTC (diagnostic trouble code) is stored in the ATC module. The DTC can be
read using the Jaguar approved diagnostic system. The Jaguar approved diagnostic system can also initiate a self test
routine to check the operation of the face level registers.
Refer to: Climate Control System (412-00 Climate Control System - General Information, Diagnosis and Testing).
Air Ducts
The air ducts distribute air from the heater assembly to the registers and vents in the instrument panel and the center
floor console. Air ducts also direct air from the heater assembly into the front and rear footwells.
Registers and Vents

The registers control the flow and direction of air from the air ducts. The instrument panel contains four face level
registers; one at each end and two mounted centrally. For the rear seat occupants, two registers are installed in the rear
face of the center floor console. All of the registers incorporate vertical and horizontal directional vane adjustment and full
air flow adjustment down to zero.
The four face level registers in the instrument panel each contain an integral stepper motor. The stepper motors enable
the registers to rotate between the open and closed positions. In the open position, the registers have normal appearance
and functionality. In the closed position, the registers present a smooth surface flush with the surrounding instrument
panel.
The vents are fixed outlets. There are four vents in the upper surface of the instrument panel; one in each end to direct air
onto the side windows and two along the front edge to direct air onto the windshield.
Central Face Level Registers

ItemDescription
A Registers closed
B Registers open
Pollen Filter
NOTE: LHD (left-hand drive) vehicle shown, RHD (right-hand drive) vehicle similar.
ItemDescription
1 Air inlet duct
2 Pollen filter
3 Cover
The pollen filter removes odors and fine particles from fresh air entering the passenger compartment. The pollen filter is
located in the air inlet duct, in the inlet to the blower. A cover on the underside of the air inlet duct provides access to the
pollen filter for servicing.
Climate Control - Heating and Ventilation - Component Location
NOTE: RHD (right-hand drive) vehicle shown, LHD (left-hand drive) vehicle similar.
Component Location
ItemDescription
1 Ventilation outlet
2 Blower relay (on RJB (rear junction box))
3 Heater assembly
4 Blower control module
5 Blower
7 Air inlet duct
Comments:
All except 3.0L vehicles; 4.2L version shown, 2.7L diesel version similar.
Climate Control - Heating and Ventilation - Overview
Overview
The heating and ventilation system controls the temperature and flow of air supplied to the passenger compartment. The
system is a dual zone automatic system, which can provide different temperature settings for the LH (left-hand) and RH
(right-hand) sides of the passenger compartment.
Climate Control - Heating and Ventilation - System Operation and
Control Diagram
ItemDescription
1 Battery
Comments:
all except 3.0L vehicles; 4.2L version shown, 2.7L diesel version similar
5 Touch screen display (TSD)
6 Integrated control panel
7 Information control module
10 RH (right-hand) temperature blend stepper motor
11 LH (left-hand) temperature blend stepper motor
12 W indshield (defrost) distribution stepper motor
15 Blower
System Operation
Operation of the heating and ventilation system is controlled by the ATC module.
Refer to: Control Components (412-01 Climate Control, Description and Operation).
The system can be operated in automatic or manual mode, with temperature settings selected using the switches on the
integrated control panel.
When the engine is running, coolant is constantly circulated through the heater core by the engine coolant pump and the
auxiliary coolant pump. W here fitted, the auxiliary coolant pump is energized by the CJB on receipt of medium speed CAN
bus signals from the ATC module. The CJB broadcasts auxiliary coolant pump status over the medium speed CAN bus for
use by other vehicle systems.
The blower is supplied with power by the blower relay on the RJB and connected to ground via the blower control module.
The blower control module regulates the voltage across the blower motor to control blower speed. The voltage set by the
blower control module is controlled by a PWM (pulse width modulation) signal from the ATC module. The ATC module uses
a feedback signal from the blower control module to monitor blower speed.
Heater Assembly
The heater assembly controls the temperature and flow of air supplied to the air distribution ducts. The heater assembly is
mounted on the vehicle centerline, between the instrument panel and the engine bulkhead.
The heater assembly consists of a casing that contains an A/C (air conditioning) evaporator, a heater core, two air
distribution control doors and two temperature blend control doors. On 2.7L diesel vehicles, the heater assembly also
contains an electric booster heater.
Refer to: Electric Booster Heater (412-02, Description and Operation).
Mounted on the heater casing are four stepper motors. Each of the stepper motors is connected to either an air distribution
control door or a temperature blend control door.
The A/C evaporator is part of the A/C system.

Refer to: Air Conditioning (412-01 Climate Control, Description and Operation).
The heater core provides the heat source to warm the air supplied to the passenger compartment. The heater core is an
aluminum two pass, fin and tube heat exchanger, and is installed across the width of the heater housing. Two aluminum
tubes attached to the heater core extend through the engine bulkhead and connect to the engine cooling system. For
additional information, refer to:
Engine Cooling (303-03A, Description and Operation),

Engine Cooling (303-03B, Description and Operation),
Engine Cooling (303-03A Engine Cooling - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8, Description and Operation).
Air Inlet Duct

The air inlet duct connects the fresh air inlet in the engine bulkhead to the heater assembly. The air inlet duct is installed
behind the instrument panel on the passenger side.
The air inlet duct consists of a casing that contains a pollen filter, an air inlet door, a blower and a blower control module.
A recirculation air inlet is incorporated into the casing. A servo motor is mounted on the casing and connected to the air
inlet door, to allow selection between fresh and recirculated air.
The pollen filter is part of the air distribution and filtering system.
Refer to: Air Distribution and Filtering (412-01 Climate Control, Description and Operation).
The blower regulates the volume of air flowing through the air inlet duct to the heater assembly. The blower consists of an
open hub, centrifugal fan and an electric motor.
The blower control module regulates the power supply to the blower motor. The blower control module is installed in the
air inlet duct downstream of the blower, where any heat generated during operation is dissipated by the air flow.
Auxiliary Coolant Pump

On all vehicles except 3.0L, an auxiliary coolant pump is installed on the rear right side of the radiator housing, in the
return line from the heater core. The auxiliary coolant pump is an electric pump that boosts the flow of coolant through the
heater core.
Ventilation Outlets
The ventilation outlets allow the free flow of air through the passenger compartment. The outlets are installed in the LH
and RH rear quarter panels, below the rear lamps. Each ventilation outlet consists of a grille covered by a soft rubber flap,
and is effectively a non-return valve. The flaps open and close automatically depending on the pressure differential
between the air inside and outside the vehicle.
Climate Control - Air Conditioning - Component Location
NOTE: LHD (left-hand drive) 4.2L vehicle shown, other vehicles similar.
Component Location
ItemDescription
1 Evaporator
2 Thermostatic expansion valve
3 Low pressure line
4 Low pressure servicing connection
6 Receiver/Drier
7 Condenser
8 Refrigerant pressure sensor
9 High pressure line
10 High pressure servicing connection
Climate Control - Air Conditioning - Overview
Overview
The A/C (air conditioning) system transfers heat from the passenger compartment to the outside atmosphere to provide
the heater assembly with dehumidified cold air. It is a sealed, closed loop system filled with a charge weight of R134a
refrigerant as the heat transfer medium. Oil is added to the refrigerant to lubricate the internal components of the A/C
compressor.
Climate Control - Air Conditioning - System Operation and Component
Description
System Operation
General
To accomplish the transfer of heat, refrigerant is circulated around a sealed system, where it passes through two
pressure/temperature regimes. In each of the regimes the refrigerant changes state, during which process maximum heat
absorption or dissipation occurs.
The low pressure/temperature regime is from the thermostatic expansion valve, through the evaporator to the compressor.
The refrigerant decreases in pressure and temperature at the thermostatic expansion valve, then changes state from a
liquid to a vapor in the evaporator to absorb heat.
The high pressure/temperature regime is from the compressor, through the condenser and receiver drier assembly to the
thermostatic expansion valve. The refrigerant increases in pressure and temperature as it passes through the compressor,
then releases heat and changes state from a vapor to a liquid in the condenser.
Operation of the A/C (air conditioning) system is controlled by the ATC (automatic temperature control) module.
The A/C system works in conjunction with:
The air distribution and filtering system.

Refer to: Air Distribution and Filtering (412-01 Climate Control, Description and Operation).
The heating and ventilation system.
A/C System Flow Diagram

NOTE: A = Refrigerant liquid; B = Refrigerant vapor; C = Air flow.
ItemDescription
1 Evaporator
2 Thermostatic expansion valve
3 High pressure servicing connection
5 Engine cooling fan
6 Condenser
7 Receiver/Drier
8 A/C compressor
9 Low pressure servicing connection
10 Blower
A/C Compressor
ItemDescription
1 Pressure relief valve
2 Outlet port
3 Inlet port
4 Solenoid valve
6 Pulley
The A/C compressor circulates refrigerant around the system by compressing low pressure, low temperature vapor from the
evaporator and discharging the resultant high pressure, high temperature vapor to the condenser.
The A/C compressor is a permanently engaged variable displacement unit which is driven by the engine accessory drive
belt. To protect the system from excessive pressure, a pressure relief valve is installed in the outlet side of the A/C
compressor. The pressure relief valve vents excess pressure into the engine compartment.
Condenser
ItemDescription
1 RH (right-hand) end tank
2 Condenser core
3 LH (left-hand) end tank
4 Mounting brackets (4 off)
5 High pressure compressor discharge line connector block
6 High pressure liquid outlet line connector block
7 Receiver/Drier outlet pipe
8 Receiver/Drier inlet pipe
9 Receiver/Drier
The condenser transfers heat from the refrigerant to the surrounding air to convert the high pressure vapor from the
compressor into a liquid. The condenser is installed immediately in front of the radiator. Two brackets on each end tank
attach the condenser to the end tanks of the radiator.
The condenser is classified as a sub-cooling condenser and consists of a fin and tube heat exchanger core installed
between two end tanks. Divisions in the end tanks separate the heat exchanger into a four pass upper (condenser) section
and a two pass lower (sub-cooler) section.
The LH end tank provides the connections to the high pressure line from the A/C compressor and the high pressure liquid
line to the evaporator.
The RH end tank provides the connections to the receiver drier.
Receiver Drier
The receiver drier is integrated into the RH end tank of the condenser to remove solid impurities and moisture from the
refrigerant. It also provides a reservoir for liquid refrigerant to accommodate changes of heat load at the evaporator.
NOTE: The receiver drier is part of the condenser assembly and is not serviceable separately.
Refrigerant entering the receiver drier passes through a filter and a desiccant pack, then collects in the base of the unit
before flowing through the outlet pipe back to the condenser.
Refrigerant Pressure Sensor

The refrigerant pressure sensor is located in the high pressure/temperature refrigerant line between the condenser and the
thermostatic expansion valve.
Thermostatic Expansion Valve
ItemDescription
1 Metering valve
2 Housing
3 Diaphragm
4 Temperature sensor
5 Outlet passage from evaporator
6 Inlet passage to evaporator
The thermostatic expansion valve meters the flow of refrigerant into the evaporator, to match the refrigerant flow with the
heat load of the air passing through the evaporator.
The thermostatic expansion valve is a block type valve located behind the heater assembly, and attached to the inlet and
outlet ports of the evaporator. The thermostatic expansion valve consists of an aluminium housing containing inlet and
outlet passages. A ball and spring metering valve is installed in the inlet passage and a temperature sensor is installed in
the outlet passage. The temperature sensor consists of a temperature sensitive tube connected to a diaphragm. The
bottom end of the temperature sensitive tube acts on the ball of the metering valve. Pressure on top of the diaphragm is
controlled by the evaporator outlet temperature conducted through the temperature sensitive tube. The bottom of the
diaphragm senses evaporator outlet pressure.
Liquid refrigerant flows through the metering valve into the evaporator. The restriction across the metering valve reduces
the pressure and temperature of the refrigerant. The restriction also changes the liquid stream of refrigerant into a fine
spray, to improve the evaporation process. As the refrigerant passes through the evaporator, it absorbs heat from the air
flowing through the evaporator. The increase in temperature causes the refrigerant to vaporise and increase in pressure.
The temperature and pressure of the refrigerant leaving the evaporator acts on the diaphragm and temperature sensitive
tube, which regulate the metering valve opening and so control the volume of refrigerant flowing through the evaporator.
The warmer the air flowing through the evaporator, the more heat available to evaporate refrigerant and thus the greater
volume of refrigerant allowed through the metering valve.
Evaporator
The evaporator is installed in the heater assembly, between the blower and the heater matrix, to absorb heat from the
exterior or recirculated air.
Most of the moisture in the air passing through the evaporator condenses into water, which drains out of the vehicle by
passing through a drain tube to the underside of the vehicle.
Refrigerant Lines
To maintain similar flow velocities around the A/C system, the diameter of the refrigerant lines varies to suit the two
pressure/temperature regimes. Larger diameter pipes are installed in the low pressure/temperature regime and smaller
diameter pipes are installed in the high pressure/temperature regime.
Low and high pressure charging connections are incorporated into the refrigerant lines for system servicing.
Climate Control - Control Components - Component Location
NOTE: RHD (right-hand drive) vehicle shown, LHD (left-hand drive) vehicle similar.
Component Location
ItemDescription
1 Pollution sensor
Comments:
where fitted
2 Unload sensor
3 Ambient air temperature sensor
4 W indshield (Defrost) distribution stepper motor
5 Evaporator temperature sensor
6 RH (right-hand) temperature blend stepper motor
7 LH (left-hand) temperature blend stepper motor
8 Control switches
9 Humidity and temperature sensor
10 Air inlet servo motor
11 Blower
16 A/C (air conditioning) compressor solenoid valve
Climate Control - Control Components - Overview
Overview
The climate control system is controlled by the ATC (automatic temperature control) module. It controls the heating and
ventilation system and the A/C (air conditioning) system to regulate the temperature, volume and distribution of air into
the passenger compartment. The system is a fully automatic dual zone system capable of maintaining individual
temperature levels selected for the LH (left-hand) and RH (right-hand) sides of the passenger compartment, up to a
maximum differential of approximately 3 C (5.4 F). Manual overrides for the system include inlet air source, blower speed
and air distribution. These selections can be made using either the soft switches on the home and climate control screens
of the touch screen display (TSD), or the switches on the integrated control panel.
The ATC module also controls:
The rear window heater.

The windshield heater (where fitted).
The exterior mirror heaters.
The seat heaters (where fitted).
The steering wheel heater.
TSD Home Screen
TSD Climate Control Screen
Integrated Control Panel
ItemDescription
1 LH temperature switches
2 Blower switch
3 RH temperature switches
4 Automatic climate control switch
5 Recirculation switch
6 Rear window heater switch
7 W indshield heater switch
Comments:
where fitted
8 Programmed defrost switch
Climate Control - Control Components - System Operation and Component
Description
Control Diagram
ItemDescription
1 Battery
Comments:
All except 3.0L vehicles; 4.2L version shown, 2.7L diesel version similar.
6 TSD (touch screen display)
8 Evaporator temperature sensor
9 Humidity and temperature sensor
10 Sunload sensor
12 Pollution sensor
Comments:
where fitted
13 Air inlet servo motor
14 A/C (air conditioning) compressor solenoid valve
15 RH (right-hand) outer face level register
17 LH (left-hand) inner face level register
18 LH outer face level register
19 RH temperature blend stepper motor
22 LH temperature blend stepper motor
23 W indshield (Defrost) stepper motor
26 Blower
System Operation
Air Inlet Control
The source of inlet air is automatically controlled unless overridden by pressing the air recirculation switch on the
integrated control panel. During automatic control, the ATC module determines the required position of the recirculation
door from its 'comfort' algorithm and, if fitted, the pollution sensor.
The ATC module provides analogue signals to the air inlet servo motor along a hardwired connection. A potentiometer in
the motor supplies the ATC module with a position feedback signal for closed loop control.
Air Temperature Control

Cooled air from the evaporator enters the heater assembly, where temperature blend doors direct a proportion of the air
through the heater core to produce the required output air temperature.
The two temperature blend doors operate independently to enable individual temperature settings for the left and right
sides of the passenger compartment. The temperature blend doors are operated by stepper motors, which are controlled by
the ATC module using LIN bus messages.
The ATC module calculates the temperature blend stepper motor positions required to achieve the selected temperature
and compares it against the current position. If there is any difference, the ATC module signals the stepper motors to
adopt the new position.
Air temperature is controlled automatically unless maximum heating (HI) or maximum cooling (LO) is selected. When
maximum heating or cooling is selected, a 'comfort' algorithm in the ATC module adopts an appropriate strategy for air
distribution, blower speed, and air source.
Temperature control in one side of the passenger compartment can be compromised by the other side of the passenger
compartment being set to a high level of heating or cooling. True maximum heating or cooling (displayed as 'HI' or 'LO' on
the TSD) can only be selected for the driver's side of the passenger compartment. If 'HI' or 'LO' is selected for the driver's
side, the temperature for the front passenger's side is automatically set to match the driver's side.
If A/C is selected off in the automatic mode, no cooling of the inlet air will take place. The minimum output air
temperature from the system will be ambient air temperature plus any heat pick up in the air inlet path.
If the Temp. sync. soft button on the TSD is pressed, the ATC module synchronizes the temperature of the passenger side
of the passenger compartment with the driver's side.
Blower Control
When the system is in the automatic mode, the ATC module determines the blower speed required from a comfort
algorithm. W hen the system is in the manual mode, the ATC module operates the blower at the speed selected using
either the rotary control switch on the integrated control panel or the + and - soft buttons on the touch screen display
(TSD). The ATC module also adjusts blower speed to compensate for the ram effect on inlet air produced by forward
movement of the vehicle. As vehicle speed and ram effect increases, blower motor speed is reduced, and vice versa.
Air Distribution Control

Two air distribution doors are used to direct air into the passenger compartment. The doors are operated by stepper
motors, which are controlled by the ATC module using LIN bus messages.
When the A/C system is in automatic mode, the ATC module automatically controls air distribution into the passenger
compartment in line with its 'comfort' algorithm. Automatic control is overridden if any of the TSD air distribution soft
buttons are selected. Air distribution in the passenger compartment will remain as selected until the 'Auto' switch is
pressed or a different manual selection is made.
A/C Compressor Control
When A/C is selected the ATC module maintains the evaporator at an operating temperature that varies with the
passenger compartment cooling requirements. If the requirement for cooled air decreases, the ATC module raises the
evaporator operating temperature by reducing the flow of refrigerant provided by the A/C compressor. The ATC module
closely controls the rate of temperature increase to avoid introducing moisture into the passenger compartment.
If the requirement for cooled air increases, the ATC module lowers the evaporator operating temperature by increasing the
flow of refrigerant provided by the A/C compressor.
When A/C is off, the compressor current signal supplied by the ATC module holds the A/C compressor solenoid valve in the
minimum flow position, effectively switching off the A/C function.
The ATC module incorporates limits for the operating pressure of the refrigerant system. If the system approaches the high
pressure limit, the compressor current signal is progressively reduced until the system pressure decreases. If the system
falls below the low pressure limit, the compressor current signal is held at its lowest setting so that the A/C compressor is
maintained at its minimum stroke. This avoids depletion of the lubricant from the A/C compressor.
A/C Compressor Torque

The ATC module transmits refrigerant pressure and A/C compressor current values to the ECM (engine control module) over
the medium speed then high speed CAN bus, using the CJB as a gateway. The ECM uses these values to calculate the
torque being used to drive the A/C compressor. The ECM compares the calculated value with its allowable value and if
necessary forces the ATC module to inhibit the A/C compressor by transmitting the 'ACClutchInhibit' CAN message. This
forces the ATC module to reduce the drive current to the A/C compressor solenoid valve, which reduces refrigerant flow.
This in turn reduces the torque required to drive the A/C compressor.
By reducing the maximum A/C compressor torque, the ECM is able to reduce the load on the engine when it needs to
maintain vehicle performance or cooling system integrity.
Cooling Fan Control

The ATC module determines the amount of condenser cooling required from the refrigerant pressure sensor, since there is
a direct relationship between the temperature and pressure of the refrigerant. The cooling requirement is broadcast to the
ECM on the medium speed CAN bus. The ECM then controls the temperature of the condenser using the cooling fan.
Programmed Defrost
The programmed defrost DEF switch is located on the integrated control panel. When the switch is pressed, the ATC
module instigates the programmed defrost function. W hen selected, the ATC module configures the system as follows:
Automatic mode off.

A/C on.
Selected temperature unchanged.
Air inlet set to fresh air.
Air distribution set to windshield.
Blower speed set to level 6.
Windshield heater (where fitted) and rear window heater on.
The programmed defrost function can be cancelled by one of the following:
Selecting any air distribution switch on the TSD.

Pressing the AUTO switch on the integrated control panel.
A second press of the DEF button.
Switching the ignition OFF.
The blower speed can be adjusted without terminating the programmed defrost function.
Rear Window Heater

Rear window heater operation is only enabled when the engine is running. The ATC module controls operation of the rear
window heater using a relay in the RJB. When rear window heater operation is required, the ATC module broadcasts a
message to the RJB on the medium speed CAN bus. On receipt of the message, the RJB energizes the relay by providing a
ground path for the relay coil. This allows a battery feed to flow across the relay to power the rear window heater element.
There are two modes of rear window heater operation; manual and automatic.
Manual operation is activated by pressing the rear window heater switch on the integrated control panel. When the switch
is pressed, the status LED (light emitting diode) in the switch illuminates and the rear window heater element is
energized. Manual operation is discontinued when the rear window heater switch is pressed a second time, 21 minutes
have elapsed (the heating phase), or the engine stops. If manual operation is discontinued by the engine stopping, the
previous heating phase is resumed if the engine is re-started within 30 seconds.
There are two variants of automatic operation; automatic operation at the start of a journey and automatic operation
during a journey.
Automatic operation at the start of a journey is initiated if the ambient air temperature is below 5 C (41 F). In this
instance, the switch LED is illuminated and the heater element is energized for 21 minutes. Automatic operation is
discontinued if the rear window heater switch is pressed or the engine stops.
Automatic operation during a journey is initiated when low ambient air temperatures are experienced and the vehicle has
been travelling for a set period of time above a threshold speed. In this instance, no feedback is given to the driver to
inform him the rear window heater is operational (the switch LED is not illuminated). The duration of heater operation is
variable depending on the ambient air temperature, vehicle speed and the amount of time the vehicle has been travelling.
Windshield Heater (Where Fitted)
Windshield heater operation is only enabled when the engine is running. The ATC module controls operation of the
windshield heater using two relays in the EJB (engine junction box). W hen windshield heater operation is required, the ATC
module broadcasts a message to the CJB on the medium speed CAN bus. On receipt of the message, the CJB energizes
the relays by providing a ground path for both relay coils. This allows a battery feed to flow across the relays to power the
windshield left and right heater elements.
There are two modes of windshield heater operation; manual and automatic.
Manual operation is activated by pressing the windshield heater switch on the integrated control panel. When the switch is
pressed, the status LED in the switch illuminates and the windshield heater elements are energized. Manual operation is
discontinued when the windshield heater switch is pressed a second time, 5 minutes have elapsed (the heating phase), or
the engine stops. If manual operation is discontinued by the engine stopping, the previous heating phase is resumed if
the engine is re-started within 30 seconds.
There are two variants of automatic operation; automatic operation at the start of a journey and automatic operation
during a journey.
Automatic operation at the start of a journey is initiated if the ambient air temperature is below 5 C (41 F). In this
instance, the switch LED is illuminated and the heater elements are energized for 6.5 minutes. Automatic operation is
discontinued if the windshield heater switch is pressed or the engine stops.
Automatic operation during a journey is initiated when low ambient air temperatures are experienced and the vehicle has
been travelling for a set period of time above a threshold speed. In this instance, no feedback is given to the driver to
inform him the windshield heater is operational (the switch LED is not illuminated) and the duration of operation is
variable depending upon the ambient air temperature, vehicle speed and the amount of time the vehicle has been
travelling.
Exterior Mirror Heaters

Operation of the exterior mirror heaters is fully automatic and not controllable by the driver. Exterior mirror heater
operation is determined by ambient air temperature and windshield wiper status. W hen ambient air temperature reaches a
pre-determined level, the ATC module broadcasts an exterior mirror heating request to the door modules over the medium
speed CAN bus. On receipt of this message, the door modules provide feed and ground connections to both exterior mirror
heater elements.
The amount of time the exterior mirror heaters are operational increases if the windshield wipers are switched on. This
ensures the mirrors remain mist free in damp and wet conditions, where there is an increased risk of misting.
Seat Heaters (Where Fitted)

There are four seat heater settings available; off, 1, 2 and 3, which can be selected on the home and climate control
screens of the TSD. The heat setting is relayed to the vehicle occupants through a graduated display on the TSD.
Operation of the heated seats is controlled by the ATC module. W hen the ATC module receives a heating request from the
TSD, it broadcasts a message to the CJB over the medium speed CAN bus. The CJB then provides a hardwired 12 V supply
to the three heater elements in the related front seat. The heater elements, two in the seat cushion and one in the seat
squab, are wired in series. The ATC module monitors seat temperature using a temperature sensor located in each seat
cushion. The CJB provides the temperature sensors with a 5 V supply. The level of the returned voltage back to the CJB is
proportional to the seat temperature. The value of the return signal is broadcast to the ATC module, over the medium
speed CAN bus, which allows it to control the seat temperature to the required level. The ATC module will suspend or
disable operation of the seat heaters if any of the following occur:
Battery voltage exceeds 16.5 0.3 V for more than 5 seconds. Seat heating is re-enabled when battery voltage
decreases to 16.2 0.3 V.
If a short or open circuit is detected.
If the seat heat temperature rises significantly above the target temperature setting.
The graduated display on the TSD remains illuminated until the seat heaters are turned off or the engine stops. If the
engine is restarted within 30 seconds the seat heater resumes the previous heating level.
Steering Wheel Heater

The steering wheel heater has a single heat setting and is turned on/off on the home and climate control screens of the
TSD. The on/off status of the steering wheel heater is relayed to the vehicle occupants through the TSD. When the ignition
is switched off, the steering wheel heater will reset to off.
Power for the heater element is supplied by the CJB on receipt of a request from the ATC module over the medium speed
CAN bus. Temperature control for the heater element is provided by the steering wheel heater control module which
receives a temperature feedback signal from a NTC (negative temperature coefficient) thermistor located within the
steering wheel.
ATC Module
The ATC module is mounted on the outboard end of the air inlet duct, behind the front passenger side of the instrument
panel. The ATC module processes inputs from the TSD, the switches on the integrated control panel and the system
sensors. In response to these inputs, the ATC module outputs control signals to the A/C system and the heating and
ventilation system.
Two electrical connectors provide the interface between the ATC module and the vehicle wiring. The ATC module uses
hardwired inputs from the system sensors, the LIN bus to communicate with the stepper motors and the medium speed
CAN bus to communicate with other control modules on the vehicle.
A/C Compressor Solenoid Valve

The A/C compressor solenoid valve is integral with the A/C compressor. Operation of the solenoid valve is controlled by the
ATC module using a hardwired drive current of differing values. By controlling the flow of refrigerant through the
compressor, the solenoid valve can control the A/C system pressure and the evaporator operating temperature.
Refrigerant Pressure Sensor
The refrigerant pressure sensor provides the ATC module with a pressure input from the high pressure side of the
refrigerant system. The refrigerant pressure sensor is located in the refrigerant line between the condenser and the
thermostatic expansion valve.
The ATC module supplies a 5 V reference voltage to the refrigerant pressure sensor and receives a return signal voltage,
between 0 V and 5 V, related to system pressure.
The ATC module uses the signal from the pressure sensor to protect the refrigerant system from extremes of pressure. The
ATC module transmits the A/C pressure, along with the compressor drive current value, to the instrument cluster on the
medium speed CAN bus. These signals are broadcast to the ECM on the high speed CAN bus to allow it to calculate the
torque being applied to the engine by the compressor.
To protect the system from extremes of pressure, the ATC module sets the A/C compressor to the minimum flow position if
the pressure:
Decreases to 2.1 0.2 bar (31.5 3 lbf/in); the ATC module loads the A/C compressor again when the pressure
increases to 2.3 0.2 bar (33.4 3 lbf/in).
Increases to 31 1 bar (450 14.5 lbf/in); the ATC module loads the A/C compressor again when the pressure
decreases to 26 1 bar (377 14.5 lbf/in).
Evaporator Temperature Sensor

The evaporator temperature sensor is a NTC thermistor that provides the ATC module with a temperature signal from the
downstream side of the evaporator. The evaporator temperature sensor is mounted directly onto the evaporator matrix
fins.
The ATC module uses the input from the evaporator temperature sensor to control the load of the A/C compressor and thus
the operating temperature of the evaporator.
Humidity and Temperature Sensor

The humidity and temperature sensor is installed above the glovebox in the instrument panel. The sensor incorporates:
A NTC thermistor to measure temperature.

A capacitive sensor element to measure humidity.
A motor driven fan to draw air through the sensor and over the sensing elements.
The humidity sensor element is built out of a film capacitor on different substrates. The dielectric is a polymer which
absorbs or releases water proportional to the relative humidity of the air being drawn through the sensor, and thus
changes the capacitance of the capacitor. For protection, the sensor element is contained in a nylon mesh cover.
Humidity within the passenger compartment is controlled by raising and lowering the evaporator temperature. An increase
in evaporator temperature increases the moisture content of the air entering the passenger compartment. Lowering the
evaporator temperature reduces the moisture content of the air entering the passenger compartment.
Ambient Air Temperature Sensor
ItemDescription
1 LH door mirror
2 Ambient air temperature sensor
The ambient air temperature sensor is a NTC thermistor that provides the ATC module with an input of external air
temperature. The sensor is hard wired to the ECM and its signal is transmitted to the instrument cluster on the high speed
CAN bus. The instrument cluster acts as a gateway and transmits the ambient air temperature signal to the ATC module
on the medium speed CAN bus. The sensor is installed in the LH door mirror, and is accessed by removing the mirror glass,
cap and actuator.
Sunload Sensor
The sunload sensor consists of two photoelectric cells that provide the ATC module with inputs of light intensity; one as
sensed coming from the left of the vehicle and one as sensed coming from the right. The inputs are a measure of the solar
heating effect on vehicle occupants, and are used by the ATC module to adjust blower speed, temperature and distribution
to improve comfort.
The sensor is installed in the speaker grill on the upper surface of the instrument panel. Power for the sensor is provided
by a 5 V feed from the instrument cluster.
The sensor also contains the active anti-theft alarm indicator.

Refer to: Anti-Theft - Active (419-01 Anti-Theft - Active, Description and Operation).
Pollution Sensor (Where Fitted)
The pollution sensor allows the ATC module to monitor the ambient air for the level of hydrocarbons and oxidized gases
such as nitrous oxides, sulphur oxides and carbon monoxide. The sensor is attached to the center of the upper front
crossmember.
The pollution sensor is powered by an ignition controlled voltage feed from the CJB and provides the ATC module with
separate signals of hydrocarbon and oxidized gas levels. W ith a pollution sensor fitted, the ATC module can control the air
inlet source to reduce the amount of contaminants entering the passenger compartment. This function is fully automatic,
but can be overridden by manual selection of the air source using the recirculation switch on the integrated control panel.
If there is a fault with the sensor, the ATC module disables automatic operation of the recirculation door.
Climate Control - Ambient Air Temperature Sensor
Removal
1. Refer to: Exterior Mirror Cover (501-09 Rear View Mirrors, Removal
and Installation).
2.
3.
4.
5.
Installation

Climate Control - Blower Motor
Removal

2.
3.
Installation
Climate Control - Blower Motor Control Module
Removal

2. 2. CAUTION: Take extra care not to damage the

clips or screw threads. Failure to follow this instruction
may result in damage to the climate control assembly.
NOTE: RHD illustration shown, LHD is similar.
3. Torque: 1.3 Nm
Installation

Climate Control - Center Registers
Removal
CAUTION: Do not manually open the registers. Failure to follow this instruction may result in damage to the internal
components.
NOTE: The center registers must be open before carrying out this procedure. To achieve this set the registers to 'Always
Open' using the climate settings tab on the information and entertainment display. If the registers are set to 'Automatic'
mode (rotating with ignition on/off) and one or more are disconnected during an ignition cycle, a vehicle battery reset may
be required to reconnect the affected registers to the LIN BUS.
1. Set the registers to 'Always Open', using the information and

entertainment display.
2. Refer to: Passenger Side Register (412-01 Climate Control, Removal

and Installation).
3. Fully extend and lower the steering column for access.
4.
5.
6. 6. CAUTIONS:
The center registers must be open to aid access

and prevent damage to surrounding trim.
Do not manually open the registers. Failure to

follow this instruction may result in damage to the
internal components.

Installation

2. Return the registers to their original setting - 'Automatic' - using the
information and entertainment display.
Climate Control - Climate Control Assembly
Removal

2. Refer to: Instrument Panel Console (501-12 Instrument Panel and

Console, Removal and Installation).

4.
5. Torque: 5 Nm
6. Torque: 9 Nm
coolant.
Torque: 9 Nm
Installation

Climate Control - Climate Control Module
Removal

2. Refer to: Instrument Panel Console (501-12 Instrument Panel and

3. 3. CAUTIONS:
Take extra care not to damage the clips or screw

threads. Failure to follow this instruction may result in
damage to the climate control assembly.
Make sure that the component is correctly located

on the locating dowels.
Torque: 1.3 Nm
Installation

Climate Control - Defrost Vent/Register Blend Door Actuator
Removal
1. Refer to: Battery Disconnect and Connect (414-01, General

Procedures).
2. Refer to: Instrument Panel Console (501-12, Removal and

Installation).
3. 3. CAUTIONS:


Torque: 1.3 Nm
Installation

Climate Control - Driver Side Register
Removal
components.
NOTE: If the registers are set to 'Automatic' mode and one or more are disconnected during an ignition cycle, a vehicle
battery reset may be required to reconnect the affected registers to the LIN BUS.
1.
2.
3.
5.
6.
7.

Installation
Climate Control - Evaporator
Removal

2. Refer to: Thermostatic Expansion Valve (412-01 Climate Control,


Torque: 1.3 Nm
4.
5. Torque: 1.3 Nm
6.
7. 7. WARNING: Only use moderate force when
installing the sensor.
CAUTIONS:
Make sure the evaporator temperature sensor

harness does not become trapped.
Make sure that the sensor is correctly installed.
Installation

Climate Control - Floor Console Register
Removal
1. Remove both floor console side trim panels.
2.

4. Remove the 2 clips.
Installation

Climate Control - Footwell Vent/Duct Blend Door Actuator
Removal

2. Refer to: Climate Control Assembly (412-01 Climate Control,

3. 3. CAUTIONS:


Torque: 1.3 Nm
Installation

Climate Control - Heater Core
Removal
All vehicles

2. Refer to: Heater Core and Evaporator Core Housing (412-01 Climate
Control, Removal and Installation).
All vehicles

Torque: 1.3 Nm
component.
5.
6.
Installation

Climate Control - Heater Core and Evaporator Core Housing
Removal



Torque: 1.3 Nm
4.
5.
6. Torque: 2.4 Nm
Installation

Climate Control - Instrument Panel Register Trim Panel
Removal

2. Refer to: Center Registers (412-01 Climate Control, Removal and

Installation).
3.
4.
5.
6.
Installation
1. 1. CAUTION: Make sure that the clutch rib is
located between the two ribs on the car rearward (front
half), of the register housing to avoid damage on
installation.
2.
Position the locating peg.
Climate Control - In-Vehicle Temperature Sensor
Removal
1. Refer to: Glove Compartment (501-12 Instrument Panel and

2.
Installation

Climate Control - Passenger Side Register
Removal
components.
NOTE: If the registers are set to 'Automatic' mode and one or more are disconnected during an ignition cycle, a vehicle
battery reset may be required to reconnect the affected registers to the LIN BUS.
1.
2.
3.
4.
5.
6. Install the clips into the instrument panel.


passenger side register carrier.
9.
Installation

Climate Control - Pollen Filter
Removal
1.
2.
3.
Installation

Climate Control - Recirculation Blend Door Actuator
Removal


3. 3. NOTE: Make sure that the actuator is correctly

aligned to the recirculation blend door arm.
Installation

Climate Control - Sunload Sensor
Removal

2. 2. CAUTIONS:
Protect the surrounding trim to avoid damage.
Make sure that the clips are correctly located.
3.
4. 4. CAUTION: Make sure that the component is

correctly located on the locating dowels.
Torque: 2 Nm
Installation
Climate Control - Thermostatic Expansion Valve
Removal



Torque: 1.3 Nm
4. 4. CAUTIONS:
Take care not to damage the O-ring seals during

installation.
Torque: 5.3 Nm
5. 5. CAUTIONS:
Take care not to damage the O-ring seals during

installation.
Torque: 3.5 Nm
Installation

Air Conditioning -
A/C compressor retaining bolts 25 18 -
A/C compressor manifold and tube retaining bolt 9 - 80
A/C condenser core retaining studs 5 - 48
A/C condenser core supply and return lines retaining nuts 8 - 71
Power steering oil cooler retaining nuts 7 - 62
A/C desiccant bag retaining screw (vehicles fitted with petrol engines) 22 16 -
A/C desiccant bag retaining screw (vehicles fitted with diesel engines) 4 - 37
A/C pressure cutoff switch 8 - 71
Air Conditioning - Air Conditioning

REFER to: Climate Control System (412-00 Climate Control System - General Information, Diagnosis and Testing).
Air Conditioning - Air Conditioning (A/C) Compressor4.2L NA V8 -
Removal
NOTE: Removal steps may contain installation details.

Procedures).
3. NOTE: Make sure to support the vehicle with axle stands.

4.
5.
6. For additional information, refer to: Engine Mount LH (303-01A

7. NOTE: Make sure that all openings are sealed. Use new
blanking caps.
TORQUE: 9 Nm
8. TORQUE: 25 Nm
Installation
Air Conditioning - Condenser Core4.2L NA V8 - AJV8
Removal

2. Refer to: Air Conditioning (A/C) System Recovery, Evacuation and

Charging (412-00 Climate Control System - General Information,

4. Refer to: Radiator Splash Shield (501-02 Front End Body Panels,

6. Torque: 20 Nm
7. Torque: 10 Nm
8. Torque: 10 Nm
Installation

Air Conditioning - Condenser Core4.2L SC V8 - AJV8
Removal


3. Refer to: Radiator (303-03B Supercharger Cooling - 4.2L SC V8 -

4. Torque: 20 Nm
5. Torque: 20 Nm
6. 6. CAUTION: Protect the A/C condenser.
Torque: 10 Nm
Installation

Air Conditioning - Pressure Cutoff Switch
Removal

2. For additional information, refer to: Air Cleaner (303-12A
3.
4. CAUTION: Make sure the air conditioning (A/C) hose

does not turn when removing the low pressure switch.
TORQUE: 8 Nm
Installation
Instrument Cluster -
Illumination bulb. 3.0 Watt
Instrument Cluster - Instrument Cluster - Component Location
COMPONENT LOCATION
ItemDescription
1 Speedometer
2 Message Center
3 Tachometer
Instrument Cluster - Instrument Cluster - Overview
OVERVIEW
The primary task of the instrument cluster is to display current vehicle status through a series of analogue gauges,
indicator lamps, and a LCD (liquid crystal display) message center. In addition to this, the instrument cluster:
Acts as a gateway between the medium speed and high speed CAN (controller area network) bus networks
Is connected by the LIN (local interconnect network) bus to the start control unit and the steering wheel clockspring
Controls operation of the steering column adjust feature
Refer to: Steering Column (211-04 Steering Column, Description and Operation).
Acts as an interface for the passive anti-theft system.
Refer to: Anti-Theft - Active (419-01A Anti-Theft - Active, Description and Operation).
Two analogue gauges are located in the instrument cluster; the speedometer and the tachometer. The speedometer is
located on the LH (left-hand) side of the instrument cluster. The tachometer is located on the RH (right-hand) side of the
instrument cluster
and displays engine speeds up to 7000 Revolutions Per Minute (RPM) for the supercharged engine, 8000 RPM for the
naturally aspirated engines and 6000 RPM for diesel variants.
The message center is a LCD located in a central position in the cluster. The message center displays system status
information including fuel quantity remaining.
Instrument Cluster - Instrument Cluster - System Operation and
Control Diagram
NOTE: A = Hardwired; D = High speed CAN (controller area network) bus; N = Medium speed CAN bus; O = LIN (local
interconnect network) bus
ItemDescription
1 Battery
5 Sun load sensor (alarm LED (light emitting diode))
6 Servotronic valve
8 Steering column motor
9 High speed CAN bus connection to other vehicle systems
10 Engine oil pressure switch
12 Brake fluid level switch
13 LH (left-hand) steering column multifunction switch
15 Clockspring
16 RH (right-hand) steering column multifunction switch
17 Engine coolant level sensor
18 Auxiliary lighting switch
System Operation
WARNING INDICATOR FUNCTIONALITY
ItemDescription
1 LH turn signal
2 RH turn signal
3 Brake warning
4 Brake warning (NAS)
5 Forward alert
6 Automatic Speed Limiter (ASL)
7 Adaptive speed control
8 ABS (anti-lock brake system) warning
9 ABS warning (NAS)
11 Tire Pressure Monitoring System (TPMS)
12 Airbag warning
13 Front fog lamps
14 Dynamic Stability Control (DSC) warning
15 Seat belt warning
16 Side lamps
17 High beam
18 Rear fog lamps
The functionality for each of the above warning indicators is described in the following sections:
1 and 2. Turn Signal Indicators
The turn signal indicators are controlled by the CJB on receipt of medium speed CAN bus signals from the instrument
cluster.
The instrument cluster outputs a voltage to the turn signal indicator switch. The switch contains resistors of different
values. W hen the switch is operated in either the LH or RH direction, the voltage is passed to a ground connection in the
instrument cluster which detects the reduced voltage supplied via the resistors. W hen the turn signal indicator switch is
operated in the LH or RH direction, the instrument cluster detects the ground voltage and determines whether a LH or RH
selection is made.
The instrument cluster transmits a medium speed CAN message to the CJB for operation of the applicable turn signal
indicators. The message can contain a number of states for each possible switch position and also an out of range low and
high state for circuit faults and an initial value for the switch neutral position. The turn signal indicators are not subject to
the 3 second indicator check when the ignition is switched on.
The RJB (rear junction box) software controls the flash rate of the warning indicator which sends 'ON' and 'OFF' signals to
the instrument cluster which flashes the indicators in a green color. During normal operation, the warning indicator flashes
slowly, accompanied simultaneously by a sound from the instrument cluster sounder. If a fault exists, the RJB transmits a
message to the instrument cluster which responds by displaying an appropriate message in the message center.
The hazard warning indicators are controlled by the CJB on receipt of a completed ground path from the hazard warning
indicator switch. The CJB outputs a medium speed CAN message to the instrument cluster which operates both the LH and
RH turn signal indicators simultaneously. The hazard warning indicators can operate with the ignition switched off,
therefore the CAN message from the CJB will also carry a 'wake-up' message for the instrument cluster.
3. Brake Warning Indicator
This warning indicator is displayed in a red or amber color (dependant on market) as a brake symbol in all markets except
United States of America (USA) which have the word 'BRAKE' in place of the symbol. The indicator is controlled by high
speed CAN messages from the ABS module and the parking brake control module. The indicator is illuminated in a red color
for a 3 second indicator check when the ignition is switched on.
The instrument cluster monitors the fluid level in the brake fluid reservoir using a hardwired level switch. If the fluid level
falls to below a determined level, the switch contact is broken and the ABS module detects the low fluid level condition.
The instrument cluster illuminates the warning indicator and simultaneously displays a 'BRAKE FLUID LOW' message in the
message center.
NOTE: If both the brake warning indicator and the ABS warning indicator illuminate simultaneously, a major fault in the
brake system will have occurred.
The warning indicator also displays parking brake status. When the parking brake is applied, the warning indicator will be
illuminated by the instrument cluster and, if the vehicle is moving, the message 'PARK BRAKE APPLIED' will be also
displayed in the message center in response to a CAN message from the parking brake control module.
If a condition exists where the parking brake cannot be applied, the parking brake control module issues a CAN message
to the instrument cluster which flashes the warning lamp on and off and is accompanied with a message 'CANNOT APPLY
PARK BRAKE'. If a fault occurs in the parking brake system, the parking brake control module issues a CAN message to the
instrument cluster which illuminates the warning indicator and displays the message 'PARK BRAKE FAULT' in the message
center.
4. Forward Alert Indicator
The forward alert system uses the components of the adaptive speed control system to alert the driver of the presence of
a vehicle ahead. The system can be turned on and off using a switch located in the auxiliary lighting switch when the
adaptive speed control system is off. The indicator is illuminated in an amber color for a 3 second indicator check when the
ignition is switched on.
The forward alert system is controlled by the adaptive speed control module. When the switch is pressed, the forward alert
system is activated and the adaptive speed control module issues a forward alert active message on the high speed CAN
bus to the instrument cluster. The forward alert icon in the instrument cluster will illuminate in an amber color and a
'FORWARD ALERT' message will be displayed in the message center. When the button is pressed a second time, the
module issues a forward alert off CAN message. The forward alert system will be deactivated, the forward alert icon will go
off and a message 'FORW ARD ALERT OFF' will be displayed in the message center.
5. Automatic Speed Limiter (ASL) Indicator
The ASL is controlled by the ECM (engine control module). An ASL switch is located in the floor console, adjacent to the
gear selector lever. When the ASL switch is pressed, this is sensed by the ECM which issues a high speed CAN message to
the instrument cluster. The instrument cluster illuminates the ASL warning indicator in an amber color to show the driver
that ASL is active. The driver sets the required speed using the speed control SET +/- switches on the steering wheel. The
selected speed is shown by the message ' LIMITER SET XXX MPH / K/MH' in the message center. The indicator is
illuminated in an amber color for a 3 second indicator check when the ignition is switched on. ASL can be deselected by
pressing the ASL switch, by depressing the throttle pedal initiating kick-down or by pressing the 'cancel' switch on the
steering wheel. The ASL indicator will go off and the message center will display the message 'limiter cancelled' for 4
seconds. If a fault occurs in the ASL system, the ECM will send a message to the instrument cluster to illuminate the ASL
indicator and display the message 'LIMITER NOT AVAILABLE'.
6. Adaptive Speed Control Indicator
The adaptive speed control system is controlled by the adaptive speed control module. Operation of the SET +/- switches
on the steering wheel will activate the system. Operation of the switches is detected by the adaptive speed control
module. The module issues a high speed CAN message to the instrument cluster which illuminates the adaptive speed
control indicator, when the system is in 'follow mode', in an amber color and displays a 'SETSPEED XXX MPH / KM/H'
message in the message center. The indicator is illuminated in an amber color for a 3 second indicator check when the
ignition is switched on.
7. Anti-lock Braking System (ABS) Warning Indicator
The ABS warning indicator is controlled by the ABS module. If a fault in the ABS system is detected by the ABS module,
the module issues a high speed CAN message to the instrument cluster to illuminate the ABS warning indicator in an
amber color and display the message 'ABS FAULT' in the instrument cluster. The indicator is illuminated in an amber color
for a 3 second indicator check when the ignition is switched on. If a fault is present when the ignition is on, the bulb will
remain illuminated after the 3 second indicator check period.
NOTE: The 'ABS FAULT' message is not displayed in NAS markets).
NOTE: If both the ABS warning indicator and the brake warning indicator illuminate simultaneously, a major fault in the
brake system will have occurred.
On NAS vehicles, the ABS warning indicator is also used for parking brake operation. The NAS warning indicator does not
have 'ABS' on the icon and will function as described previously for the parking brake operation of the brake warning
indicator.
8. Engine Malfunction Indicator Lamp (MIL)
The MIL warning indicator is controlled by the ECM and illuminated by the instrument cluster on receipt of a message on
the high speed CAN bus from the ECM. The indicator is illuminated in an amber color for a 3 second indicator check when
the ignition is switched on.
If the MIL remains illuminated after the engine is started or illuminates when driving, a fault is present and must be
investigated at the earliest opportunity. Illumination of the MIL warning indicator alerts the driver to an OBD (on-board
diagnostic) fault which will cause excessive emissions output. This may relate to either an engine management system
fault or a transmission.
9. Tire Pressure Monitoring System (TPMS) Warning Indicator
The TPMS warning indicator is illuminated by the instrument cluster on receipt of a medium speed CAN message from the
TPMS module. The indicator is illuminated in an amber color for a 3 second indicator check when the ignition is switched
on.
If the indicator illuminates and is accompanied by the message 'TYRE PRESSURE SYSTEM FAULT' in the message center,
then a TPMS fault has occurred. If the indicator illuminates and accompanied by a different message, then a low tire
pressure has been detected, a spare wheel has been fitted or a TPMS sensor has failed.
10. Airbag Warning Indicator
The airbag warning indicator is controlled by the instrument cluster. The indicator is illuminated in an amber color for the 3
second indicator check when the ignition is switched on. The indicator remains illuminated after the 3 second period has
expired until the instrument cluster receives a turn off message on the high speed CAN bus from the RCM (restraints
control module).
11. Front Fog Lamp Indicator
The green colored front fog lamp indicator is controlled by the CJB and illuminated by the instrument cluster on receipt of a
front fog lamp on message on the medium speed CAN bus from the CJB. The indicator is illuminated for as long as the
front fog lamps are active. The front fog lamp indicator is not subject to the 3 second indicator check when the ignition is
switched on.
12. Dynamic Stability Control (DSC) Indicator
The DSC warning lamp is controlled by the ABS module and illuminated by the instrument cluster in response to messages
received on the high speed CAN bus. The indicator is illuminated in an amber color for the 3 second indicator check when
the ignition is switched on. The DSC warning indicator, are permanently illuminated in an amber color if the instrument
cluster receives a high speed CAN message from the ABS module relating to one of the following faults:
Traction control fault

Yaw control fault
Engine drag torque control fault
Panic Brake Assist (PBA) fault
Signal missing relating to either traction control active, yaw control active or DSC switch input.
The above faults will also generate an applicable DSC and ABS warning message in the message center. The DSC warning
indicator will flash at 2 Hz for if the traction control or yaw control is active when the DSC system is enabled. If the DSC
system is switched off, the warning indicator will be permanently illuminated until the DSC system is subsequently
re-activated.
13. Safety Belt Warning Indicator
The safety belt warning indicator operates for both the driver and passenger safety belts. The warning indicator is
controlled by the RCM and illuminated by the instrument cluster on receipt of high speed CAN bus messages. The safety
belt warning indicator is not subject to the 3 second indicator check when the ignition is switched on.
The operation of the passenger seat buckle switch is as described below with the exception that the instrument cluster
must receive a hardwired signal from the belt minder control module to indicate that a passenger is occupying the seat.
The safety belt warning indicator is subject to a timer. The warning indicator is activated when the following conditions
exist:
Ignition is switched on
One of the front seat belts is unbuckled
USA market only - 75 seconds has elapsed after ignition on mode is selected
Vehicle is not in reverse gear
Vehicle speed is more than 8 km/h (5 mph).
Once the above parameters are met, the instrument cluster flashes the warning indicator at 2 Hz for 10 seconds
accompanied by a simultaneous chime. After 10 seconds the chime ceases and the warning indicator is permanently
illuminated for 20 seconds. This sequence is repeated every 30 seconds until one of the following events occurs:
300 seconds has elapsed

The safety belt of the occupied front seats is fastened
The ignition is switched to off mode
The vehicle speed decreases to below 5 km/h (3 mph).
NOTE: On USA market vehicles, the warning indicator in not permanently illuminated.
The safety belt minder function cannot be disabled. The seat belt minder function can be disabled.
Refer to: Safety Belt System (501-20A Safety Belt System, Description and Operation).
14. Side Lamp Indicator
The instrument cluster controls the green colored side lamp indicator on receipt of a side lamp status message on the
medium speed CAN bus from the CJB and the auxiliary junction box. The lighting switch on the LH steering column
multifunction switch is connected to the instrument cluster. Selections using this switch are detected by the cluster which
requests the side or headlamp operation via a message to the CJB and the RJB. The CJB and the RJB responds with a side
lamp active message and the cluster illuminates the side lamp indicator. The side lamp indicator is not subject to the 3
second indicator check when the ignition is switched on.
15. High Beam Indicator
The instrument cluster controls the blue colored high beam indicator on receipt of a high beam status message on the
medium speed CAN bus from the CJB. The lighting switch on the LH steering column multifunction switch is connected to
the instrument cluster. High beam or flash selections using this switch are detected by the cluster which requests the light
operation via a CAN message to the CJB. The CJB responds with a high beam active message and the cluster illuminates
the high beam indicator. The high beam indicator is not subject to the 3 second indicator check when the ignition is
switched on.
16. Rear Fog Lamp Indicator
The amber colored rear fog lamp indicator is controlled by the auxiliary junction box and illuminated by the instrument
cluster on receipt of a rear fog lamp on message on the medium speed CAN bus from the RJB. The indicator is illuminated
for as long as the rear fog lamps are active. The rear fog lamp indicator is not subject to the 3 second indicator check
when the ignition is switched on.
SPEEDOMETER
The speedometer is driven by high speed CAN signals transmitted by the ABS module. The wheel speeds are measured by
sensors reading the rotational speed of the rear wheels from toothed targets on the hubs. An average of the two wheel
speeds are passed from the sensors to the ABS module in the form of pulsed signals. The ABS module converts these
signals into a speed output on the high speed CAN to the instrument cluster. The same speed outputs from the wheel
speed sensors are also used to calculate the distance the vehicle has travelled.
TACHOMETER
The tachometer is driven by an engine speed signal transmitted on the high speed CAN from the ECM. The signal is
derived from the CKP (crankshaft position) sensor. The signal is received by the instrument cluster microprocessor and the
output from the microprocessor drives the tachometer.
FUEL GAGE
The fuel gage is controlled by CAN messages from the RJB. The RJB reads the values output by the fuel level sensors
every 131 ms and transmits a fuel tank contents value, corrected for battery voltage, in a CAN message to the instrument
cluster. A fuel pump symbol is displayed to the left of the linear gage. An arrow above the symbol shows the driver on
which side of the vehicle the fuel filler cap is located. Above the linear fuel gage, is a LCD (liquid crystal display) area
which displays odometer and trip readouts. W hen a trip computer function is selected, these are replaced by a trip
computer display for the trip function selected.
LIQUID CRYSTAL DISPLAY

In the area above and below the message center is a LCD display. The area below the message center displays a linear
fuel gage, odometer, trip distance and trip computer readouts. The trip distance and trip computer information is derived
from information supplied on the high speed CAN bus to the instrument cluster from the ABS module and the ECM.
The area above the message center displays the transmission gear position information and speed control related
information. The transmission information is supplied on the high speed CAN bus from the TCM (transmission control
module).
NOTE: There is no engine coolant temperature gage displayed. If the engine coolant temperature increases to above a
predetermined threshold, a warning message is displayed in the message center. The message is sent from the ECM in a
high speed CAN message to the instrument cluster.
TRANSMISSION GEAR SELECTION POSITION

The gear position display shows JaguarDrive selector position or selected gear when using the Jaguar Sequential Shift. The
gear selector module transmits a CAN message to the instrument cluster for gear selector lever position. The module also
outputs a 'not in park' signal to the instrument cluster. The TCM transmits a high speed CAN message to the instrument
cluster with data containing the selected gear when in Jaguar Sequential Shift mode.
INSTRUMENT CLUSTER - WARNING INDICATOR LOCATIONS
NOTE: Other market variants of instrument cluster are similar.
EUROPEAN MARKET - DIESEL INSTRUMENT CLUSTER

ItemDescription
1 Speedometer
2 ABS indicator
3 Adaptive speed control indicator
4 Glow plug indicator
6 Tire Pressure Monitoring System (TPMS) indicator
7 Airbag warning indicator
8 Front fog lamp indicator
9 Tachometer
11 Rear fog lamp indicator
12 Dynamic Stability Control (DSC) indicator
13 High beam indicator
14 Side lamp indicator
15 Seat belt warning indicator
16 Message center
17 Automatic Speed Limiter (ASL) indicator
18 Forward alert indicator
19 Brake warning indicator
NAS MARKET - V8 NORMALLY ASPIRATED INSTRUMENT CLUSTER
ItemDescription
1 Speedometer
2 ABS indicator (NAS)
3 ABS indicator (ROW)
4 Adaptive speed control indicator
5 Tachometer
7 Tire Pressure Monitoring System (TPMS) indicator
8 Airbag warning indicator
9 Front fog lamp indicator
11 Rear fog lamp indicator
12 Dynamic Stability Control (DSC) indicator
13 High beam indicator
14 Seat belt warning indicator
15 Side lamp indicator
16 Message center
17 Automatic Speed Limiter (ASL) indicator
18 Forward alert indicator
19 Brake warning indicator (NAS)
20 Brake warning indicator (ROW)
The warning indicators are located in various positions in the instrument cluster. The indicators can be split into two
groups; instrument cluster controlled and externally controlled.
Instrument cluster controlled warning indicators are dependent on software logic within the instrument cluster for
activation. The cluster software controls the indicator illumination check at ignition on (power mode 6).
Externally controlled indicators are supplied with current from another vehicle system control module or illuminated by the
instrument cluster software on receipt of a bus message from another vehicle sub-system. The indicator illumination check
at ignition on (powermode 6) is also controlled by the sub-system module for these indicators.
MESSAGE CENTER
The message center is a LCD located in a central position in the cluster. The message center displays system status
information.
ANALOGUE GAGES
Speedometer
The analogue speedometer is located on the LH side of the instrument cluster and is available in 4 market variants:
Major scale Miles Per Hour (MPH), minor scale kilometers per hour (km/h) (ROW )
Major scale MPH, minor scale km/h (NAS)
Major scale km/h, minor scale MPH
Major scale km/h only.
Tachometer
The analogue tachometer is located on the RH side of the instrument cluster. The tachometer has different Revolutions Per
Minute (RPM) scales depending on the engine variant fitted to the vehicle as follows:
4.2L V8 Supercharged 7000 RPM

4.2L V8 Naturally aspirated 8000 RPM
3.0L V6 Naturally aspirated 8000 RPM
2.7 V6 Diesel 6000 RPM.
ELECTRONIC GAGES
Fuel Gage
The linear fuel gage has a colored bar which moves left or right depending on the tank contents. As the bar moves to the
left the fuel tank contents displayed is decreasing. A warning message is displayed in the message center when the fuel
tank contents fall to below the reserve level.
Transmission Gear Position Display
The gear position display shows the JaguarDrive selector position or the selected gear when using the Jaguar Sequential
Shift.
The applicable drive letter is highlighted to show that a selection has been made using the JaguarDrive selector.
When Jaguar Sequential Shift is selected, the letters change to numbers; 1 - 6, and the selected gear is highlighted to
emphasize the selection to the driver.
Instrument Cluster - Instrument Cluster
For a detailed description of the Instrument Cluster, refer to the relevant Description and Operation sections in the
workshop manual. REFER to: (413-01 Instrument Cluster)
Instrument Cluster (Description and Operation),

Instrument Cluster (Description and Operation),
Instrument Cluster (Description and Operation).
vehicle.
Visual Inspection
Fluid level(s) Fuse(s)
Accessory installations W iring harness
Instrument cluster
Engine Junction Box (EJB)
Symptom Chart
The instrument cluster contains a self-diagnostic mode known as engineering test mode (ETM). This can be used to show
the status of the instrument cluster inputs as well as a number of other useful features.
When in the ETM, the Message Centre displays internal data that can be cycled through. All functions except the message
centre display will continue to operate normally unless otherwise noted.
This document is to be used in conjunction with the instrument cluster ETM (see relevant section within this document)
and the Integrated Diagnostic System (IDS) facility; this does not supersede or replace the IDS facility.
Go directly to the 'Area of Concern/Symptom' that indicates the customer concern(s) and perform the actions described
within the relevant section(s):
Area of Diagnostic
Concern/Symptom Ref. No. Actions Notes
W arning lights A-1 Perform instrument cluster When this test is ended the warning lamps
Self-Diagnostic Mode/ETM test 3. currently required to be 'ON' will remain
illuminated.
Multiple warning lights B1 Check with IDS for DTCs related to .
'ON' identified vehicle system(s).
. B2 Check instrument cluster battery and Specifically check continuity of Standard
ignition wiring - refer to circuit diagrams. Corporate Protocol (SCP) and Controller Area
Network (CAN) lines.
. B3 Check instrument cluster grounds. .
. B4 Check fuses in battery junction box. .
. B5 Check for harness traps in facia. .
. B6 Perform instrument cluster Frost/ice warning illuminated in mixed red and
Self-Diagnostic Mode/ETM test 3. amber; therefore colour differs from other
warning lamps. W hen this test is ended,
warning lamps currently required to be 'ON'
will remain illuminated.
. B7 Check for open circuit/shorts in wiring to .
related warning lamp trigger (module,
sensor, switch).
Specific warning lamp C1 Check with IDS for DTCs related to .
'ON' identified vehicle system.
. C2 Check for open circuit/shorts in wiring .
related to warning lamp circuit (module,
sensor, switch) where appropriate.
Area of Diagnostic
. C3 Perform cluster Self-Diagnostic Frost/ice warning illuminated in mixed red and
Mode/ETM test 3. amber; therefore colour differs from other
warning lamps. W hen this test is ended,
warning lamps currently required to be 'ON'
will remain illuminated.
. C4 Check the specific vehicle system What is the warning lamp telling me? Does
indicated by the warning lamp this check out with the DTC logged by the
illuminated? system indicating the fault?
Fuel gauge operation D1 Perform Self-Diagnostic Mode/ETM test 0 - 9 = short circuit; gauge will show empty.
21 to establish if fuel level input to 10 254 = normal range. 255 = open circuit;
cluster is out of range or invalid. gauge will show empty. --- = missing signal;
gauge will show empty.
. D2 Check gauge function versus 0 = empty, 254 = full. 255 = invalid; gauge
Self-Diagnostic Mode/ETM test 21. will show empty.
. D3 Check for open circuit/shorts in wiring .
between the Fuel Delivery Module, Jet
Pump Module and Rear Electronic Module
(REM).
Fuel gauge reading E1 Check gauge position versus 0 = empty to 254 = full (255 invalid; gauge
Self-Diagnostic Mode/ETM test 21. will show empty). Other values percentage of
above range e.g. 127 = half.
. E2 Calculate percentage fuel level from Self-Diagnostic Mode fuel level percentage
figure obtained from Self-Diagnostic can be calculated as follows: Value from
Mode/ETM test 21 and compare to IDS Self-Diagnostic Mode test 26 254 x 100 =
vehicle fuel percentage test. % shown on gauge.
. E3 Monitor value of Self-Diagnostic Mode 0 - 9 = short circuit; gauge will show empty.
test/ETM test 21 (during test drive) to 10 254 = normal range. 255 = open circuit;
establish if input drops out of range. gauge will show empty. --- = missing signal;
gauge will show empty.
. E4 Monitor 'FUEL LEVEL' in IDS data logger Gauge function is damped so will not follow
(during test drive) to correlate gauge rapidly changing Fuel Delivery Module values.
position to vehicle reported fuel level.
Speedometer H1 Monitor Self-Diagnostic Mode/ETM test Display speed input in 1/10 mile/h, no
operation 19 (during test drive) check to establish decimal point shown, and is compensated for
if vehicle speed input to cluster is out of tire size etc. Displays ---- or INV if message
range or invalid. is not received or if received data is invalid.
Speedometer reading I1 During test drive compare speedometer Self-Diagnostic Mode displayed speed figure
position to Self-Diagnostic Mode/ETM will be approx 3% higher than speed indicated
test 19, displayed value. by speedometer. Allowed tolerance minus
nothing/+ 10% + 2.5 mile/h.
. I2 Monitor Self-Diagnostic Mode/ETM test Displays ---- if message is not received or if
19 (during test drive) to establish if received data is invalid for two seconds or
vehicle speed input to cluster drops out more.
of range or is invalid.
. I3 Check that installed wheels and tires are Non standard wheels and tires may lead to
standard Jaguar fitment. Confirm wheel speed indication inaccuracies. Incorrectly set
size in IDS, 'ADD REMOVE ACCESSORY' wheel size will result in speed indication
section. inaccuracies. Trip and odometer distance
accumulation will also be incorrect.
Tachometer operation J1 Perform Self-Diagnostic Mode/ETM test Displays ---- or INV if message is not received
20 to establish if vehicle rpm input to or if received data is invalid.
cluster out of range or invalid.
Tachometer reading K1 Check tachometer position versus Tachometer accuracy +/- 100 rpm.
Self-Diagnostic Mode/ETM test 20,
displayed value.
. K2 Monitor 'ENGINE RPM' in IDS data logger Tachometer accuracy +/- 100 rpm.
at constant engine rpm to compare
tachometer indicated engine rpm to
engine rpm reported by Engine Control
Module (ECM).
. K3 Monitor Self-Diagnostic Mode test/ETM Displays ---- or INV if message is not received
test 20, (during test drive) to establish or if received data is invalid.
if input to cluster drops out of range or
is invalid.
Gauge judder L1 Perform Self-Diagnostic Mode test/ETM .
test 2, to prove out smooth gauge
operation.
Gauge noise M1 Perform vehicle road test. Gauges .
should not be audible during operation
in drive cycle.
. M2 Benchmark noise against non-complaint .
vehicle.
Trip (fuel) computer N1 Check for consistent display (during test Displays ---- , INV or 255 if message is not
drive) of valid 'Rolling Odometer' count received, or if received data is invalid.
in Self-Diagnostic Mode/ETM test 24.
. N2 Check that installed wheels and tires are Non standard wheels and tires or incorrectly
standard Jaguar fit. Confirm fitted wheel set wheel size may lead to Odometer
size in IDS, 'ADD REMOVE ACCESSORY' increment inaccuracies. This will impact the
section. distance accumulators, which in turn affects
the rolling average, fuel economy and range
Area of Diagnostic
values. Trip distance accumulation will also
be incorrect.
. N3 Consider noting odometer value and .
resetting fuel computer system. Advise
customer to conduct brim-to-brim fuel
tank test. Use collected information to
determine if system accurate.
Column adjust O-1 Check with IDS for DTCs related to .
powered column system.
O-2 Check cluster battery supply voltage and .
ground resistance. Check for loose
connections.
O-3 Check power column motors supply .
voltage.
O-4 Check power column switch for physical .
damage.
Passive Anti-Theft P1 Check for three second prove out when .
System (PATS) vehicle start button is pressed.
indicator
. P2 Check for loose connections/wiring .
continuity.
. P3 Check ignition switch for physical .
damage.
Cluster illumination Q1 Check for loose connections/wiring .
continuity.
. Q2 Check dimmer switch operation. .
Cluster backlight R1 Is the backlight on other components .
operation inoperative.
. R2 Check dimmer switch operation. .
. R3 Check for loose connections/wiring .
continuity.
Chime/tone operation S1 Check vehicle configuration. .
. S2 Utilize lights ON, ignition OFF, door .
open warning to verify chime operation.
. S3 Check appropriate sensing circuit. .
Continuous T1 Check appropriate sensing circuit. .
chime/tone
Unexpected chime U1 Check vehicle configuration. .
operation
Message centre V1 Is the backlight 'ON' and other .
display illumination components dim?
. V2 Does the lighting level of other .
components change when dimmer
adjusted?
Message centre W 1 Perform Self-Diagnostic Mode test/ETM .
display issue tests 5 to 9, to prove out LCD display
function.
Message centre X1 Perform Self-Diagnostic Mode test/ETM .
missing lines tests 5 to 9, to prove out LCD display
function.
Message centre Y1 What is the message? .
incorrect message
. Y2 Check for open circuit/shorts in wiring to .
related warning light trigger (module,
sensor, switch).
Cluster/connectivity Z1 Check cluster battery and ignition wiring. .
. Z2 Check cluster grounds. .
. Z3 Disconnect/reconnect cluster. .
. Z4 Attempt to enter Self-Diagnostic .
Mode/ETM to prove cluster response to
inputs.
No crank AA1 Check with IDS for presence of related .
DTCs.
. AA2 Is there a Passive Anti-Theft System .
(PATS) flash code?
. AA3 Does the vehicle crank with the other .
passive key?
. AA4 Ensure only one key is in the vehicle, try If this test starts the vehicle this tends to
both keys in the Starter Control Unit indicate an issue with the keyless vehicle
(SCU). module.
. AA-5 Tried new key?
. AA6 Check battery voltage. .
. AA7 Diagnose non-start condition with IDS. .
. AA8 Attempt PATS key erase and re-learn. Ensure keys are erased from current cluster if
replacing cluster.
Crank but no-start AB1 Diagnose non-start condition with IDS. Not usually caused by cluster issue.
Incorrect configuration AC1 Attempt to configure cluster. .
Area of Diagnostic
. AC2 Ensure battery voltage is maintained .
above 12.5 volts if cluster re-configured.
1. 1. If the cause is not visually evident, verify the symptom and refer to the Self-Diagnostic Mode
Self-Diagnostic Mode
To place the cluster in engineering test mode (ETM) carry out the following steps
1. Press and hold the stalk trip cycle button, for more than five seconds but less than eight seconds, whilst briefly
pressing the vehicle START button. There is no initial display indication that the instrument cluster has entered ETM. If
ETM has successfully been entered then 'ENGINEERING TEST MODE' will be displayed in the Message Centre when the stalk
trip button is released .
2.To navigate forward through the instrument cluster Self-Diagnostic Mode tests, press the stalk trip cycle button.
3. Each push of the stalk trip cycle button will advance one step through the ETM sequence. It is not possible to move
backward through the test sequence.
4.To exit the Self-Diagnostic Mode press and hold the stalk trip cycle button for more than three seconds.
5.The Self-Diagnostic Mode is also deactivated when the ignigition switch is turned to the 'OFF' position or low battery
voltage is detected.
6.If the Self-Diagnostic Mode cannot be accessed repeat the above paying particular care to the sequence timing.
7.The ETM text is not language configurable and will be displayed in English.
Message Center Gauge/Indicator/Display

ETM Test/no. Display Tested. Range Description
1 - Self- ENGINEERING TEST . Not Applicable Establishes Self - Diagnostic
diagnostic MODE. (N/A). mode.
entry.
2 - Gauge GAUGE SWEEP. Tachometer and (N/A). All gauges go through a full up
sweep. speedometer. Gauges and down pointer sweep
display current values after smoothness check.
test.
3- Warning TELL TALE TEST. All internally controlled (N/A). Illuminates all the LED warning
lamp LED's. lamps/LED's regardless of indicators that are controlled by
software configuration. the instrument cluster. W hen
this test is exited current vehicle
warning lamps will remain
illuminated.
4 - Version PROGRAM Software Read only memory (N/A). Display's the instrument cluster
information. VERSION. (ROM) and Non volatile ROM and NVM level version and
memory (NVM) version and date or indication of ROM
ROM: XXXX date. checksum fault.
NVM: XXXX
REV: XXXX
DATE: XXXX
5 - Message LCD display in WHITE. Message center LCD display. (N/A). Activates all pixels of LCD
Center display in W hite.
display.
6 - Message LCD display in DARK Message center LCD display. (N/A). Activates all pixels of LCD
Center GREY. display in Dark Grey.
display.
7 - Message LCD display in LIGHT Message center LCD display. (N/A). Activates all pixels of LCD
Center GREY. display in Light Grey.
display.
8 - Message LCD display in four Message center LCD display. (N/A). Activates all pixels of LCD in four
Center bands black to white, bands from black to white, from
display. top to bottom. top to bottom.
9 - Message LCD display in four Message center LCD display. (N/A). Activates all pixels of LCD in four
Center bands dark to light left bands from dark to light, from
display. to right. left to right.
10 - Digital DIGITAL I/O. Cluster configuration (N/A). Display Hex coding of cluster
I/O. settings. configuration settings ports A to
A: XXXX E:XXXX H. Not defined for diagnostic
B: XXXX F:XXXX purpose.
C: XXXX G:XXXX
D: XXXX H:XXXX
11 - Analogue ANALOG INPUTS. Cluster inputs. TDB. Displays Hex coding of

Inputs. inputs 0 - 3.
#: RAW - RATIO
0:XXX - XXXX
1:XXX - XXXX 0 - Main beam / FTP
2:XXX - XXXX 1 - Master light switch
3.XXX - XXXX 2 - Power column joystick
switch
3 - DI / Hazard
#: RAW - RATIO
4:XXX - XXXX
5:XXX - XXXX 4 - Auto lamp sensor
6:XXX - XXXX 5 - battery in
7.XXX - XXXX 6 - Pedal position
7 - Display temperature

#: RAW - RATIO
8:XXX - XXXX
9:XXX - XXXX 8 - Power column Rake
10:XXX - XXXX position
11.XXX - XXXX 9 - Power column Reach
position
10 - Auxiliary switch
11 - Power column mode
switch

#: RAW - RATIO
12:XXX - XXXX
13:XXX - XXXX 12 - Not used
14:XXX - XXXX 13 -Airbag LED monitor
15.XXX - XXXX 14 - Battery voltage
15 - Low brake fluid
15- Analogue ANALOG INPUTS. Cluster inputs. TDB. Displays Hex coding of
Inputs. inputs 16- 19.
#: RAW - RATIO
16:XXX - XXXX
17:XXX - XXXX 16 - Fog light switch
18:XXX - XXXX 17 - Flick wipe switch
19.XXX - XXXX 18 - Int. wipe switch
19 - Exit delay switch

#: RAW - Ratio
20:XXX - XXXX
21:XXX - XXXX 20 - Wash wipe switch
22:XXX - XXXX 21 - Trip cycle switch
23.XXX - XXXX 22 - dimmer level
23 - Master wipe switch

#: RAW- Ratio
24:XXX - XXXX
25:XXX - XXXX 24 - Brake pad wear
26:XXX - XXXX 25 - Passenger seat belt
27.XXX - XXXX 26 - Not used
27 - On-board temp ref
18 - Analogue Cluster inputs. TDB. Displays Hex coding of

Inputs. ANALOG INPUTS. inputs 28 - 31.
#: RAW - Ratio
28:XXX - XXXX
29:XXX - XXXX 28 - On-board temp
30:XXX - XXXX 29 - Not used
31.XXX - XXXX 30 - Not used
31 - Not used
19 - SPEEDOMETER. Speedometer inputs. . Displays present .

Speedometer. Speedometer inputs
RAW: values;
MPH: Speedometer will indicate
KMH: present road speed.
DRIVER:
20 - TACHOMETER. Tachometer inputs. . Displays present received

Tachometer. Tachometer input values,
RAW: tachometer will indicate present
ACTUAL: engine RPM.
DRIVER:
21 - Fuel FUEL SYSTEM. Fuel indication system. . Displays present received fuel
system. level A/D inputs in decimal, fuel
(A) (B) gauge will indicate present
RAW : X X filtered level.
FILT: X X
PERCENT: X X
22 - Battery BATTERY Battery voltage. . Displays present received battery

voltage. VOLTAGE. input voltage values. If message
not received or invalid display
LOCAL: will be '_ _ _'.
VEHICLE:
RAW:
A/D:
23 - Rolling ROLLING Odometer and fuel gauge. 0 - 255. Displays present received
counts. COUNTS. odometer and fuel level input
values in decimal, value is a
ODO: rolling count. If either message
FUEL: not received or invalid respective
display will be ' _ _ _' .
24 - VAPS. VAPS. Variable assistance power . CURRENT is displayed in mA.
steering (VAPS) status. COMMAND is last command sent
CURRENT: to VAPS chip. STATUS is last
COMMAND: status returned from VAPS chip.
STATUS:
25 - Module MODULE STATUS. Provides status of; Ignition CONNECTED Communication (Coms) ok
status. (IGN), Dynamic Stability WAITING Coms not received, not an
IGN Control (DSC), Adaptive MISSING issue
DSC Cruise Control (ACC) and FAULTY. Coms never received
ACC Adaptive damping control Coms error .
ADCM module (ADCM) modules.
26 - Module MODULE STATUS. Provides status of; Electronic CONNECTED Communication (Coms) ok
status. park brake (EPB), Pedestrian WAITING Coms not received, not an
EPB Impact ECU (PIE), Restraints MISSING issue
PIE control module (RCM) and FAULTY. Coms never received
RCM Traction control module Coms error .
TCM (TCM), modules..
27 - Module MODULE STATUS. Provides status of; Engine CONNECTED Communication (Coms) ok
status. control module (ECM), Rear WAITING Coms not received, not an
ECM Climate Control (RCC), Driver MISSING issue
RCC Door Control (DDC) and FAULTY. Coms never received
DDC Passenger Door Control Coms error .
PDC (PDC) modules..
28 - Module MODULE STATUS. Provides status of; Keyless CONNECTED Communication (Coms) ok
status. vehicle module (KVM), WAITING Coms not received, not an
KVM Drivers seat module (DSM), MISSING issue
DSM Infotainment control module FAULTY. Coms never received
ICM (ICM) and Integrated control Coms error .
ICP panel (ICP) modules..
29 - Module MODULE STATUS. Provides status of; Front CONNECTED Communication (Coms) ok
status. smart junction box (FSJB), WAITING Coms not received, not an
FSJB Rear smart junction box MISSING issue
RSJB (RSJB), Tyre pressure FAULTY. Coms never received
TPMS monitoring system (TPMS) Coms error .
AFLS and Adaptive front lighting
system (AFLS) modules.
30 - Module MODULE STATUS. Provides status of; Passive CONNECTED Communication (Coms) ok
status. anti-theft system (PATS), WAITING Coms not received, not an
PATS Blind Spot Monitoring (BSM), MISSING issue
BSM Gear shift module (GSM) and FAULTY. Coms never received
GSM Starter Control Unit (SCU) Coms error .
SCU modules.
31- Back to GAUGE SWEEP. Tachometer and N/A. Repeats display cycle from test
test 2. speedometer. 2.
DTC Index
account.

B100811 W iper Mode Master wiper switch circuit - Refer to the electrical circuit diagrams and check master
Switch short to ground wiper switch circuit for short to ground
B100815 W iper Mode Master wiper switch circuit - Carry out any pinpoint tests associated with this DTC
Switch short to power, open circuit using the manufacturer approved diagnostic system.
Refer to the electrical circuit diagrams and check master
wiper switch circuit for short to power, open circuit
B100951 Ignition Instrument cluster power and Carry out any pinpoint tests associated with this DTC
Authorisation ground supply circuits - short, using the manufacturer approved diagnostic system.
Target SID synchronization instrument cluster power and ground supply circuits for
error following short, open circuit. Perform the Immobilisation
re-programming application from the Set-up menu using the manufacturer
CAN fault approved diagnostic system. Check CAN communications
between instrument cluster and tester
B100962 Ignition LS CAN fault Carry out any pinpoint tests associated with this DTC
Authorisation CJB ignition, power and using the manufacturer approved diagnostic system.
ground supply circuits - short, Check CAN communications between CJB and instrument
open circuit cluster. Refer to the electrical circuit diagrams and check
Instrument cluster power and CJB ignition, power and ground supply circuits for short,
ground supply circuits - short, open circuit and instrument cluster power and ground
open circuit supply circuits for short, open circuit. Check correct CJB
Incorrect CJB or instrument and instrument cluster installed. Perform the
cluster installed Immobilisation application from the Set-up menu using
Target SID synchronization the manufacturer approved diagnostic system. Check CAN
error following network for interference/EMC related issues
re-programming
B100987 Ignition CJB ignition, power and Carry out any pinpoint tests associated with this DTC
Authorisation ground supply circuits - short, using the manufacturer approved diagnostic system.
open circuit Refer to the electrical circuit diagrams and check CJB
LS CAN fault ignition, power and ground supply circuits for short, open
Instrument cluster power and circuit and instrument cluster power and ground supply
ground supply circuits - short, circuits for short, open circuit. Check CAN
open circuit communications between CJB and instrument cluster.
Low battery voltage <9 volts Check battery is in serviceable condition and fully
charged
B100A62 Fuel Pump LS CAN fault Carry out any pinpoint tests associated with this DTC
Authorisation RJB power and ground supply using the manufacturer approved diagnostic system.
circuits - short, open circuit Check CAN communications between RJB and instrument
Instrument cluster power and cluster. Refer to the electrical circuit diagrams and check
ground supply circuits - short, RJB power and ground supply circuits for short, open
open circuit circuit and instrument cluster power and ground supply
Incorrect RJB or instrument circuits for short, open circuit. Check correct RJB and
cluster installed instrument cluster installed. Perform the Immobilisation
Target SID synchronization application from the Set-up menu using the manufacturer
error following approved diagnostic system. Check CAN network for
re-programming interference/EMC related issues
B100A64 Fuel Pump Target SID synchronization Carry out any pinpoint tests associated with this DTC
Authorisation error following using the manufacturer approved diagnostic system.
re-programming Perform the Immobilisation application from the Set-up
RJB power and ground supply menu using the manufacturer approved diagnostic
circuits - short, open circuit system. Refer to the electrical circuit diagrams and check
LS CAN fault RJB power and ground supply circuits for short, open
circuit. Check CAN communications between RJB and
instrument cluster
B100A87 Fuel Pump RJB power and ground supply Carry out any pinpoint tests associated with this DTC
Authorisation circuits - short, open circuit using the manufacturer approved diagnostic system.
LS CAN fault Refer to the electrical circuit diagrams and check RJB
Instrument cluster power and power and ground supply circuits for short, open circuit
ground supply circuits - short, and instrument cluster power and ground supply circuits
open circuit for short, open circuit. Check CAN communications
Low battery voltage <9 volts between RJB and instrument cluster. Check battery is in
serviceable condition and fully charged
B100B67 Column Lock Algorithm based failure-signal If a non start issue has not been identified, clear the
Ground is incorrect after the event DTC and check vehicle starts correctly. If a non start
Authorisation Instrument cluster power and issue has been identified run the manufacturers approved
ground supply circuits - short, diagnostic system Start Authorisation Application. Carry
open circuit out any pinpoint tests associated with this DTC using the
LS CAN fault manufacturer approved diagnostic system. Refer to the
RJB power and ground supply electrical circuit diagrams and check RJB power and
circuits - short, open circuit ground supply circuits for short, open circuit and
Vehicle speed present when instrument cluster power and ground supply circuits for
attempting to power ESCL short, open circuit. Check CAN communications between
Engine speed present when RJB and instrument cluster. Check for invalid vehicle
attempting to power ESCL speed signal from ABS/instrument cluster gateway. Check
PowerMode status > 4 when for invalid engine speed signal from ECM/instrument
attempting to perform lock cluster gateway. Check for invalid signal from CJB
action
B100B87 Column Lock Instrument cluster power and Carry out any pinpoint tests associated with this DTC
Ground ground supply circuits - short, using the manufacturer approved diagnostic system.
Authorisation open circuit Refer to the electrical circuit diagrams and check RJB
LS CAN fault power and ground supply circuits for short, open circuit
RJB power and ground supply and instrument cluster power and ground supply circuits
circuits - short, open circuit for short, open circuit. Check CAN communications
between RJB and instrument cluster
B100C67 Column Lock Instrument cluster power and Carry out any pinpoint tests associated with this DTC
Supply ground supply circuits - short, using the manufacturer approved diagnostic system.
Authorisation open circuit Refer to the electrical circuit diagrams and check CJB
CJB power and ground supply and instrument cluster power and ground supply circuits
Vehicle speed present when between CJB and instrument cluster. Check for invalid
attempting to power ESCL vehicle speed signal from ABS/instrument cluster
Engine speed present when gateway. Check for invalid engine speed signal from
attempting to power ESCL ECM/instrument cluster gateway. Check for invalid signal
PowerMode status > 4 when from CJB
attempting to perform lock
action
B100C87 Column Lock Instrument cluster power and Carry out any pinpoint tests associated with this DTC
Supply ground supply circuits - short, using the manufacturer approved diagnostic system.
Authorisation open circuit Refer to the electrical circuit diagrams and check CJB
CJB power and ground supply and instrument cluster power and ground supply circuits
between CJB and instrument cluster
B100D62 Column Lock CAN fault Carry out any pinpoint tests associated with this DTC
Authorisation ESCL power and ground supply using the manufacturer approved diagnostic system.
circuits - short, open circuit Check CAN communication between Electronic Steering
Instrument cluster power and Column Lock and instrument cluster. Refer to the
ground supply circuits - short, electrical circuit diagrams and check Electronic Steering
open circuit Column Lock power and ground supply circuits for short,
Incorrect ESCL or instrument open circuit and Instrument cluster power and ground
cluster installed supply circuits for short, open circuit. Check correct
Target SID synchronization Electronic Steering Column Lock and instrument cluster
error following installed. Perform the Immobilisation application from
re-programming the Set-up menu using the manufacturer approved
Noise/EMC related error diagnostic system. Check CAN network for
interference/EMC related issues
B100D64 Column Lock Algorithm based failure-signal If the customer has not reported a non start issue, clear
Authorisation plausibility failure the DTC and check vehicle starts correctly. If a non start
CAN fault issue has been reported run the manufacturers approved
ESCL power and ground supply diagnostic system Start Authorisation Application and
circuits - short, open circuit follow the actions required for this DTC. Carry out any
Instrument cluster power and pinpoint tests associated with this DTC using the
ground supply circuits - short, manufacturer approved diagnostic system. Check CAN
open circuit communication between Electronic Steering Column Lock
and instrument cluster (check transmission out speed,
vehicle speed, engine speed, gear position and
powermode signals to Electronic Steering Column Lock).
Electronic Steering Column Lock power and ground supply
circuits for short, open circuit and Instrument cluster
power and ground supply circuits for short, open circuit.
Low voltage at ESCL < 8 volts open circuit and Instrument cluster power and ground
supply circuits for short, open circuit. Check power supply
circuit to Electronic Steering Column Lock for short, open
circuit
Low temperature < -30 open circuit and Instrument cluster power and ground
Low voltage at ESCL < 8 volts supply circuits for short, open circuit. Check power supply
Restricted bolt movement circuit to Electronic Steering Column Lock for short, open
circuit. Check steering wheel/column is not torqued up
B102487 Start Control Unit Smart card docking station Carry out any pinpoint tests associated with this DTC
failure - slave node not using the manufacturer approved diagnostic system.
responding Refer to the electrical circuit diagrams and check the
smart card docking station LIN circuit for short, open
circuit. Suspect the smart card docking station, check and
install a new docking station as required, refer to the
the DTC Index
B104611 Front Fog Lamp Fog lamp switch circuit - short Refer to the electrical circuit diagrams and check fog
Control Switch to ground lamp switch circuit for short to ground
B104615 Front Fog Lamp Fog lamp switch circuit - short Refer to the electrical circuit diagrams and check fog
Control Switch to power, open circuit lamp switch circuit for short to power, open circuit
B104811 Brake Fluid Level Brake fluid level switch circuit Refer to the electrical circuit diagrams and check brake
Switch - short to ground fluid level switch circuit for short to ground
B10A011 W iper/ W asher W ash/wipe circuit - short to Refer to the electrical circuit diagrams and check
Switch ground wash/wipe circuit for short to ground
B10A015 W iper/ W asher W ash/wipe circuit - short to Carry out any pinpoint tests associated with this DTC
Switch power, open circuit using the manufacturer approved diagnostic system.
wash/wipe circuit for short to power, open circuit
B10A611 Main Light Switch Master lighting switch circuit - Refer to the electrical circuit diagrams and check master
short to ground lighting switch circuit for short to ground
B10A615 Main Light Switch Master lighting switch circuit - Carry out any pinpoint tests associated with this DTC
short to power, open circuit using the manufacturer approved diagnostic system.
Refer to the electrical circuit diagrams and check master
lighting switch circuit for short to power, open circuit
B112B87 Steering Wheel Steering wheel module failure Carry out any pinpoint tests associated with this DTC
Module - slave node not responding using the manufacturer approved diagnostic system.
Refer to the electrical circuit diagrams and check the
clockspring LIN circuit for short, open circuit. Suspect the
clockspring, check and install a new clockspring as
B115C7A Transfer Fuel Fuel pump system fault Check for fuel system jet pump or jet pump fuel level
Pump sensor fault
B1A8515 Ambient Light Autolamp sensor circuit - Carry out any pinpoint tests associated with this DTC
Sensor short to power, open circuit using the manufacturer approved diagnostic system.
autolamp sensor circuit for short to power, open circuit
B1B0100 Key Transponder Operator only cycles one key Ensure all keys to be programmed are available. Refer to
During transponder key electrical circuit diagrams and check power and ground
programming the instrument supply circuits to all relevant modules. Replace faulty key
cluster, smartcard docking and repeat key programming. Check CAN network for
station or key loses interference/EMC related issues
power/circuit failure
Faulty key during key
programming
Unable to program
transponder key due to
noise/EMC related error
B1B0105 Key Transponder Error following SCU Carry out any pinpoint tests associated with this DTC
replacement using the manufacturer approved diagnostic system.
Smartcard docking station Perform the Immobilisation application from the Set-up
power and ground supply menu using the manufacturer approved diagnostic
circuits - short, open circuit system. Refer to the electrical circuit diagrams and check
LIN fault smartcard docking station power and ground supply
Instrument cluster power and circuits for short, open circuit and instrument cluster
ground supply circuits - short, power and ground supply circuits for short, open circuit.
open circuit Check LIN communications between smartcard docking
station and instrument cluster
B1B0151 Key Transponder LIN fault Carry out any pinpoint tests associated with this DTC
Instrument cluster power and using the manufacturer approved diagnostic system.
ground supply circuits - short, Check LIN communications between smartcard docking
open circuit station and instrument cluster. Refer to the electrical
Key fault circuit diagrams and check smartcard docking station
Smartcard docking station power and ground supply circuits for short, open circuit
power and ground supply and instrument cluster power and ground supply circuits
circuits - short, open circuit for short, open circuit. Confirm transponder key
Attempted to program a non operation. Ensure new keys are from a known source
default key
B1B0155 Key Transponder Un-programmed key inserted Confirm the correct keys are used
in SCU2
A non default key inserted
during key programming
B1B0162 Key Transponder Instrument cluster power and Carry out any pinpoint tests associated with this DTC
ground supply circuits - short, using the manufacturer approved diagnostic system.
Smartcard docking station smartcard docking station power and ground supply
power and ground supply circuits for short, open circuit and instrument cluster
circuits - short, open circuit power and ground supply circuits for short, open circuit.
Incorrect instrument cluster or Check correct instrument cluster and smartcard docking
smartcard docking station station are installed. Perform the Immobilisation
installed application from the Set-Up menu using the manufacturer
Error during or following the approved diagnostic system. Check CAN network for
W rite Target SID routine interference/EMC related issues
Transponder key fault circuit diagrams and check smartcard docking station
Error occurred during operation. Repeat transponder key programming
transponder key programming
Transponder key fault circuit diagrams and check smartcard docking station
Another key in close proximity operation. Confirm single key operation. Ensure
Instrument cluster in incorrect instrument cluster in correct mode i.e. Auto Enable, Key
programming state erase etc. Ensure new keys are from a known source.
Attempted to program a non Check for intermittent power and ground to instrument
default key cluster. Design condition - advise customer of starting
Instrument cluster Cold init sequence. Design condition - determine customer
whilst in Ignition On state, transponder key usage
without key being present in
the SCU
Race condition caused by
closing driver door and
pressing the start button
within a small time window
Passive Key search function
from last door closed and key
inserted in the SCU
Smartcard docking station circuit diagrams and check smartcard docking station
power and ground supply power and ground supply circuits for short, open circuit
circuits - short, open circuit and instrument cluster power and ground supply circuits
for short, open circuit
B1B3305 Target I.D. CAN fault Carry out any pinpoint tests associated with this DTC
Transfer ECM ignition, power and using the manufacturer approved diagnostic system.
ground supply circuits - short, Check CAN communications between ECM and instrument
open circuit cluster. Refer to electrical circuit diagrams and check ECM
Instrument cluster power and ignition, power and ground supply circuits for short, open
ground supply circuits - short, circuit and instrument cluster power and ground supply
open circuit circuits for short, open circuit. Perform the
ECM or instrument cluster Immobilisation application from the Set-up menu using
incorrectly configured the manufacturer approved diagnostic system
B1B3362 Target I.D. CAN fault Carry out any pinpoint tests associated with this DTC
Transfer ECM ignition, power and using the manufacturer approved diagnostic system.
ground supply circuits - short, Check CAN communications between ECM and instrument
open circuit cluster. Refer to electrical circuit diagrams and check ECM
Instrument cluster power and ignition, power and ground supply circuits for short, open
ground supply circuits - short, circuit and instrument cluster power and ground supply
open circuit circuits for short, open circuit. Check correct ECM and
Incorrect ECM or instrument instrument cluster installed. Perform the Immobilisation
cluster installed application from the Set-up menu using the manufacturer
Synchronisation error following approved diagnostic system. Check CAN network for
re-programming interference/EMC related issues
Instrument Cluster - Instrument Cluster
Removal
CAUTION: If a new instrument cluster is to be installed, the diagnostic tool must be connected prior to removal, the
data must then be downloaded from it and the keys (remote control handsets) set into default mode. Failure to follow this
instruction will result in permanent damage to the keys.
NOTE: If a new instrument cluster is to be installed, make sure that all keys (remote control handsets) are present.

3.
4.
5.
6.
7.

instrument cluster face.
Installation

2. Configure the instrument cluster and ignition keys using the
diagnostic tool.
Horn -
Vehicle horn retaining bolt 25 18 -
Horn - Horn
Removal

2. Torque: 7 Nm
3. Torque: 7 Nm
4. Torque: 25 Nm
Installation

Horn - Horn Switch
Removal
1. Refer to: Standard W orkshop Practices (100-00 General Information,

2. Refer to: Steering Wheel Audio Controls (415-01 Information and

Entertainment System, Removal and Installation).
3.
4.
5.
Installation
Information and Message Center - Information and Message Center -
Component Location
COMPONENT LOCATION
ItemDescription
1 Message center
Overview
OVERVIEW
The message center is a LCD (liquid crystal display) located in a central position in the instrument cluster. The message
center receives CAN (controller area network) bus, LIN (local interconnect network) bus, and hardwired signals from other
vehicle system control modules to display current vehicle status information. Depending on message importance, the
message center will be backlit in white, amber or red.
The message center will display:
Fuel level
Trip computer information
Gear selected
Speed control information
Vehicle map
Clock
Turn by turn satellite navigation
Voice control text
JaguarDrive Control system messages.
Operation of the message center is controlled by software within the instrument cluster.
System Operation
SERVICE INTERVAL INDICATOR - DIESEL MODELS ONLY
If the vehicle is within 3,200 kilometers (1,988 miles) of a service, the message center will display 'SERVICE REQUIRED IN
XXXX km or MILES'. The display reduces the 'service required in' readout by increments every 50 kilometers (30 miles). If
this distance drops below 1 km (0.6 miles), the message center will display 'SERVICE REQUIRED'.
These messages are displayed every time the vehicle enters power mode 6, for 4 seconds after the instrument cluster bulb
check routine has finished.
NOTE: The message center will display distance to next service in miles on an instrument cluster fitted with a Miles Per
Hour (MPH) speedometer unless the driver has changed the display units on the Touch Screen Display (TSD).
Reset Procedure
To re-set the service interval indicator, the following process switch presses must each be carried out within 3 seconds:
With the vehicle in power mode 0, (ignition off) press and hold the rear fog lamp switch
Allow the vehicle to enter power mode 6 (Press the start button without a foot on the brake)
Immediately release the rear fog lamp switch
Press and hold the trip computer cycle switch
Press and hold the rear fog lamp switch
Continue to hold the trip computer and rear fog lamp switches
If the process has been successful, the message center will display 'RESETTING SERVICE MODE' and then display
'SERVICE MODE RESET' after 10 seconds
Release both switches and return the vehicle ignition to off, power mode 0.
MESSAGE CENTER
The message center LCD (liquid crystal display) display has a viewable area of 126 pixels horizontal and 174 pixels
vertical. It is divided into six information display zones as follows, starting from the top:
Set speed
Transmission position
Warning /message display
JaguarDrive Optimization icon
Odometer/Trip computer information
Fuel level.
The message center is active at all times when the ignition is on and can also be active when the ignition is off,
dependant on the information to be displayed. The message center LCD illumination is controlled by the sun load light
sensor located on the instrument panel. In bright conditions, the illumination is set to maximum brightness. As the
ambient light levels drop, the illumination dims. When the lights are switched on or activated by the 'AUTO' function, the
illumination operates in the same way until a defined ambient light threshold is reached, at this point the setting of the
panel illumination dimmer in the auxiliary light switch will control the brightness.
If more than one message is active, each message is displayed for 4 seconds in the order of priority. Once all messages
have been displayed, they are again displayed in turn for 2 seconds each. W arning messages can be displayed when the
ignition is in accessory power mode 4 which is the initial ignition state when a door is opened.
Message Priority
Messages are assigned priorities which are defined by the effect on driving safety and functional ability of the vehicle.
When new messages are displayed they may be accompanied by a chime from the instrument cluster sounder. A new
message will be displayed immediately, providing the currently displayed message (if there is one) has been displayed for
at least 4 seconds. A warning indicator will be activated simultaneously with the message being displayed. If more than
one fault warning message is being displayed, the messages will cycle, in priority order, with each message being
displayed for 2 seconds.
INFORMATION DISPLAY
The transmission display is located in the upper section of the LCD. The transmission position information is sent from the
TCM (transmission control module) in a high speed CAN (controller area network) message to the instrument cluster. The
transmission has three modes of operation:
Conventional automatic operation (JaguarDrive selector in 'D' position)

Sport automatic operation (JaguarDrive selector in 'S' position)
Manual gear operation - Jaguar Sequential Shift.
The following table shows the JaguarDrive selector position and the highlighted indication displayed in the transmission
display.
JaguarDrive Selector Position Transmission Display

(P) Park P
) Reverse R
JaguarDrive Selector Position Transmission Display
(N) Neutral N
(D) Drive D
(S) Sport S
The following table shows the Jaguar Sequential Shift display. Selections are made using the steering wheel mounted
paddle switches.
Jaguar Sequential Shift Gear Selection Transmission Display

First 1
Second 2
Third 3
Fourth 4
Fifth 5
Sixth 6
The transmission may inhibit a requested up or down shift if the requested gear is outside the normal engine speed
operating range. If this occurs, the transmission display will briefly display the gear requested by the driver but will then
change to display the actual gear selection.
Speed Control and Set Speed Displays
The following table shows the possible messages which can be displayed, other visual or audible warnings and a
description of the message.
Message Other Warnings Reason Action

OVERLIMIT Amber ASL warning Displayed when vehicle speed Reduce vehicle speed to ASL set
XXX MPH indicator illuminated at exceeds the ASL set speed limit
(km/h) +4.8 km/h (+3 mph) above
limit
Amber ASL warning
indicator flashing at +24
km/h (+15 mph) above
limit
Amber ASL warning
indicator flashing and chime
emitted at +24 km/h (+15
mph) for a certain time
period
LIMITER None Displayed for 4 seconds when driver None

CANCELLED deselects ASL
LIMITER SET None Displays new speed setting for the None
XXX MPH ASL
(km/h)
LIMITER None Displayed when ASL is activated and None
STANDBY speed control is selected
LIMITER NOT None Displayed when ECM (engine control Use an approved Jaguar
AVAILABLE module) has detected a fault Diagnostic System to diagnose
fault
TOO FAST TO None Displayed when 'Resume' switch is Reduce vehicle speed to set
RESUME pressed but vehicle speed is 30 km/h speed then press 'Resume'
(18 mph) above the set speed. switch.
CRUISE None Driver has cancelled speed control or None
CANCELLED the brake pedal has been pressed.
CRUISE None Driver has pressed the accelerator WARNING: Adaptive cruise
OVERRIDE pedal, overriding the speed control braking will be disabled when
system. Message will go off when this message is displayed.
accelerator pedal is released and
speed control is active.
GAP 1 / 2 / 3 / None Displays the current set or default If required, adjust distance using
4 adaptive speed control distance. the steering wheel switches.
Displayed along with a vehicle graphic
in the LCD. Chevrons (>) denote gap
figure selected.
SETSPEED XXX None Displays the new speed input for the None
MPH (km/h) speed control
DRIVER None Immediate action required by the Apply brakes if required.
INTERVENE driver to apply the brakes if required. May also be displayed if
speed control system
loses CAN messages when
active.
CRUISE NOT None Speed control cannot be engaged. A fault has occurred in the speed
AVAILABLE control system. Diagnose fault
using an approved Jaguar
Diagnostic System.
RADAR None The adaptive speed control radar Remove obstruction or clean the
SENSOR sensor has become dirty or radar sensor.
BLOCKED obstructed.
FORWARD None Forward alert has been switched off. None
ALERT OFF No warning will be given for objects in
the vehicles forward direction.
FORWARD None Forward alert has been switched on or None
ALERT the gap settings have changed.
Warning/Message Display
Warning and information messages are displayed in the central area of the LCD. When no messages are required, an
analogue clock is present on the display. The message display language can be changed by the driver using a selection
menu on the Touch Screen Display (TSD). The following table shows the possible messages which can be displayed, other
visual or audible warnings and a description of the message.

DSC ON DSC warning indicator Displayed for a short time when the None
flashes for a short time. DSC switch is operated to activate the
DSC system.
DSC OFF DSC warning indicator Displayed for a short time when the None
illuminated. DSC switch is operated to de-activate
the DSC system.
TRAC DSC DSC warning indicator Displayed for a short time when the None
illuminated. DSC switch is operated to activate the
TRAC DSC system.
DSC NOT DSC warning indicator A fault is present in the DSC system. A fault has occurred in the DSC
AVAILABLE illuminated. system. Interrogate ABS (anti-lock
brake system) module for faults and
diagnose fault using an approved
Jaguar Diagnostic System.
BRAKE FLUID Brake warning Brake fluid level has become low and Investigate fluid loss and check brake
LOW indicator activated low level switch. system for leaks. Repair system as
illuminated. required and replenish brake fluid
Red warning reservoir.
triangle illuminated
in LCD.
ABS FAULT ABS warning A fault is present in the ABS system. A fault has occurred in the ABS
indicator Braking system will operate but ABS system. Interrogate ABS module for
illuminated. will not be available. faults and diagnose fault using an
Amber warning approved Jaguar Diagnostic System.
triangle illuminated
in LCD.
BRAKE ASSIST Amber warning triangle A fault is present in the braking A fault has occurred in the brake
FAULT illuminated in LCD. system preventing brake assist assist system. Interrogate ABS
operation. Braking system will operate module for faults and diagnose fault
but brake assist will not be available using an approved Jaguar Diagnostic
and increased effort on the brake System.
pedal may be required.
EBD FAULT Red warning triangle A fault is present in the braking A fault has occurred in the EBD
illuminated in LCD. system preventing EBD operation. system. Interrogate ABS module for
Braking system will operate but EBD faults and diagnose fault using an
will not be available. approved Jaguar Diagnostic System.
CATS SYSTEM Amber warning triangle A fault is present in the Computer A fault has occurred in the CATS
FAULT illuminated in LCD. Active Technology Suspension (CATS). system. Interrogate the CATS module
Suspension will default to the 'hard' for faults and diagnose using an
setting. approved Jaguar Diagnostic System.
PARK BRAKE None Parking brake has been applied when None
APPLIED the vehicle moving at a speed 5 km/h
(3 mph) or above.
PARK BRAKE Brake warning A fault is present in the parking brake A fault has occurred in the parking
FAULT indicator system. brake system. Interrogate the parking
illuminated. brake module for faults and diagnose
Red warning using an approved Jaguar Diagnostic
triangle illuminated System.
in LCD.
APPLY FOOT AND Amber warning triangle The battery has been disconnected or Apply foot brake and parking brake to
PARK BRAKE illuminated in LCD. power supply interrupted to the reset the parking brake module.
parking brake module.
CANNOT APPLY Brake warning A fault is present in the parking brake A fault has occurred in the parking
PARK BRAKE indicator flashing. system and the parking brake cannot brake system. Interrogate the parking
Red warning be applied. brake module for faults and diagnose
triangle illuminated using an approved Jaguar Diagnostic
in LCD. System.
NOTE: In certain
markets the brake
warning indicator
does not flash.
Odometer
CHECK TYRE Display Tire Pressure A tire pressure has decreased to below Check tires for punctures and
PRESSURE Monitoring System the warning threshold. re-inflate to correct pressures.
The odometer displays the total distance
(TPMS) warning which the vehicle has travelled. This is calculated by the instrument cluster using
wheel speed signals fromindicator
the ABS module.
illuminated.
The odometer can show 6Vehicle
characters and distances up to 999,999 miles or kilometers. The total distance travelled is
graphic
stored in a EEPROM (electrically erasable
displaying tire programmable read only memory) and the RAM (random access memory). This
ensures that the total distance is not lost if the battery is disconnected.
location.
The odometer value is passed to other vehicle system modules on the medium speed and high speed CAN bus. This is
used to record the total vehicle mileage for diagnostic purposes and when storing DTC (diagnostic trouble code)'s.
Trip computer Information Display
The instrument cluster contains software which controls the trip computer. The computer allows the driver to access
information for current fuel usage, current journey length, average speed and estimated vehicle range of fuel remaining.
The information is calculated from CAN messages from other vehicle systems, for example wheel speed signals from the
ABS module and fuel injector operating data from the ECM.
A 'Trip' button is located on the end of the LH (left-hand) multifunction switch and allows the driver to access, in
sequence, the available trip information by repeatedly pressing the button. The trip information is displayed in the
following order:
Trip distance The trip distance since the last reset is displayed
Average speed The average speed since the last reset is displayed
Average fuel consumption The average fuel consumption since the last reset is displayed
Range The range is displayed showing the distance which can be travelled until the fuel gage reads empty. If the
range display shows dashes (-), this indicates a failure with one or both of the fuel level sensors.
The trip computer has three independent memories; A, B and Auto. Memories A and B can be set independently. The Auto
memory is reset after each ignition cycle and therefore only contains information relating the current journey.
The trip information can also be accessed from the TSD located in the center console. The TSD allows the same
information available with the trip button on the multifunction switch to be displayed on the TSD, with the addition of the
option to reset the values in the A and B memories.
If the battery is disconnected, all trip data in memories A, B and Auto are erased.
Fuel Level Display
The fuel level display is a linear LCD display to show the usable fuel tank contents. The level display is active at all times
when the ignition is on. Low fuel level is displayed as a LOW FUEL LEVEL message and an amber warning triangle in the
message center.
The fuel level is obtained by fuel level sensors in the fuel tank. These are monitored by the RJB software and their output
resistance values, corresponding fuel quantity, are transmitted to the instrument cluster on the medium speed CAN bus.
The instrument cluster uses the two level sensor signals to calculate the fuel tank contents. This calculation takes into
account fuel movement in the tank to display a steady fuel quantity in the LCD.
The fuel level information is transmitted on the medium speed and high speed CAN bus for use by other vehicle system
modules.
AUDIBLE WARNINGS
The instrument cluster can generate audible warnings to alert the driver to a displayed message and change of vehicle
operating condition. The audible warning is generated by a sounder located within the instrument cluster. The audible
warnings can be generated for the warnings below and are listed in order of priority, with the first being the highest
priority:
Seatbelt reminder
EPB (High Pitch)
ACC Driver Intervene 1
Airbag fault
Key in ignition switch
ASL overspeed
ACC Driver Intervene 2
EPB (Low Pitch)
Vehicle armed (entry delay)
JaguarDrive selector not in park
Valet mode
Lights on reminder
Hood operation
Passive Entry / Passive Start (PEPS)
Memory set
Seat Belt Minder.
The audible warnings can take the form of a single chime, a number of chimes or a continuous chime. The audible warnings
are initiated by a CAN message request from the requesting sub-system control module or by the instrument cluster
software.
Information and Message Center - Information and Message Center

REFER to: Instrument Cluster (413-01 Instrument Cluster, Diagnosis and Testing).
Warning Devices - Warning Devices
For a detailed description of the Blindspot Monitoring system, refer to the relevant Description and Operation sections in
the workshop manual. REFER to: (413-09)
Blind Spot Monitoring System (Description and Operation),

Blind Spot Monitoring System (Description and Operation),
Blind Spot Monitoring System (Description and Operation).
vehicle.
NOTE: Particular attention should be paid to the following items where DTCs may not be logged:
Check for contamination (e.g. dirt, grime, frosting, ice) around the blindspot monitoring sensors and clear.
Visual Inspection
Exterior rear view mirror glass Fuse(s)
Mud or sleet contamination around rear bumper area Relay(s)
Blindspot Monitoring Modules W iring Harness
Blindspot Monitoring Modules
4. 4. If the cause is not visually evident, verify the symptom and refer to the Symptom Chart, alternatively, check for
Symptom Chart

The instrument cluster Left driver Refer to the electrical circuit diagrams and check left driver display
displays 'BSM System display alert alert LED circuit for short to power
Fault' LED circuit -
DTC B11C915 is logged short to power
within the left hand Blind
Spot Monitoring module
The Left Alert icon is
constantly illuminated
The instrument cluster Left mirror Refer to the electrical circuit diagrams and check the left mirror
displays 'BSM System ground circuit ground circuit for open circuit
Fault' - open circuit
DTC B11C915 is logged
within the left hand Blind
Spot Monitoring module
No short to power or
open circuit fault on the
driver display status LED
circuit
The instrument cluster Right mirror Refer to the electrical circuit diagrams and check the right mirror
displays 'BSM System ground circuit ground circuit for open circuit
Fault' - open circuit
DTC B11C915 is logged
within the right hand
Blind Spot Monitoring
module
No short to power or
open circuit fault on the
circuit
displays 'BSM System display status status LED circuit for short to ground. Clear DTC and re-test. If
Fault' LED circuit - DTC remains suspect the left hand Blindspot Monitoring module.
DTC U023200 is logged short to Check and install a new left hand Blindspot Monitoring module
within the right hand ground only, refer to the new module/component installation note at the
Blind Spot Monitoring Suspect left top of the DTC Index
module hand module
The left driver display failure
status LED does not
illuminate when the
vehicle is stationary, in
Park and the ignition is
on
displays 'BSM System display alert alert LED circuit for short to ground, open circuit. Clear DTC and
Fault' LED - short to re-test. If DTC remains suspect the left hand Blindspot Monitoring
DTC U023200 is logged ground, open module. Check and install a new left hand Blindspot Monitoring
within the right hand circuit module only, refer to the new module/component installation note
Blind Spot Monitoring Suspect left at the top of the DTC Index
module hand module
W hen the system is failure
powered up the left driver
display alert LED does
not illuminate during the
bulb self-checks
The instrument cluster Right driver Refer to the electrical circuit diagrams and check right driver
displays 'BSM System display status display status LED circuit for short to power. Clear DTC and
Fault' LED - short to re-test. If DTC remains suspect the right hand Blindspot
DTC U023300 is logged power Monitoring module. Check and install a new right hand Blindspot
within the left hand Blind Suspect right Monitoring module only, refer to the new module/component
Spot Monitoring module hand module installation note at the top of the DTC Index
The right driver display failure
status LED is constantly
illuminated
The instrument cluster Right driver Refer to the electrical circuit diagrams and check right driver
displays 'BSM System display status display status LED circuit for open circuit. Clear DTC and re-test. If
Fault' LED - open DTC remains suspect the right hand Blindspot Monitoring module.
DTC U023300 is logged circuit Check and install a new right hand Blindspot Monitoring module
within the left hand Blind Suspect right only, refer to the new module/component installation note at the
Spot Monitoring module hand module top of the DTC Index
W hen the system is failure
powered up the right
does not illuminate
during the bulb
self-checks
The instrument cluster Right mirror Refer to the electrical circuit diagrams and check the right mirror
displays 'BSM System ground circuit ground circuit for open circuit. Clear DTC and re-test. If DTC
Fault' - open circuit remains suspect the left hand Blindspot Monitoring module. Check
DTC U023300 is logged Suspect right and install a new left hand Blindspot Monitoring module only, refer
within the left hand Blind hand module to the new module/component installation note at the top of the
Spot Monitoring module failure DTC Index
W hen the system is
powered up both the
right driver display LEDs
do not illuminate during
the bulb self-checks
DTC Index
leads into account.
NOTE: When carrying out repair/diagnosis of the system, on removal of the front or rear bumper inspect the sensor
connectors to ensure they were correctly latched and check fly leads for signs of chaffing or trapped wires.

B11C911 Driver Display Driver Display Status LED Refer to the electrical circuit diagrams and check driver
Status LED circuit - short to ground display status LED circuit for short to ground
B11C915 Driver Display Driver Display Status LED Refer to the electrical circuit diagrams and check driver
Status LED circuit - short to power, display status LED circuit for short to power, open circuit
open circuit
B11D611 Driver Display Alert Driver Display Alert LED Refer to the electrical circuit diagrams and check driver
LED circuit - short to ground display alert LED circuit for short to ground
B11D615 Driver Display Alert Driver Display Alert LED Refer to the electrical circuit diagrams and check driver
LED circuit - short to power, display alert LED circuit for short to power, open circuit
open circuit
U001000 Medium Speed CAN No sub type information Carry out any pinpoint tests associated with this DTC using
Communication Bus the manufacturer approved diagnostic system. Check MS
CAN bus state, carry out CAN network integrity tests using
U014000 Lost Lost communication with Carry out any pinpoint tests associated with this DTC using
Communication CJB the manufacturer approved diagnostic system. Check CJB
W ith Body Control for related DTCs and correct function, refer to the relevant
Module DTC Index
Communication RJB the manufacturer approved diagnostic system. Check RJB
W ith Body Control for related DTCs and correct function, refer to the relevant
Module "B" DTC Index
Communication information and the manufacturer approved diagnostic system. Check
W ith Gateway "A" entertainment module information and entertainment module for related DTCs
and correct function, refer to the relevant DTC Index
Communication instrument cluster the manufacturer approved diagnostic system. Check
W ith Instrument instrument cluster for related DTCs and correct function,
Panel Cluster (IPC) refer to the relevant DTC Index
Control Module
Communication left hand Blindspot the manufacturer approved diagnostic system. Check left
W ith Side Obstacle Monitoring module hand Blindspot Monitoring module for DTCs and correct
Detection Control function. Refer to electrical circuit diagrams and check CAN
Module - Left network between left hand and right hand Blindspot
Monitoring modules. Clear DTC and re-test. If DTC
remains, check and install a new left hand Blindspot
Monitoring module only, refer to the new
module/component installation note at the top of the DTC
Index
Communication right hand Blindspot the manufacturer approved diagnostic system. Check left
W ith Side Obstacle Monitoring module hand Blindspot Monitoring module for DTCs and correct
Detection Control function. Refer to electrical circuit diagrams and check CAN
Module - Right network between left hand and right hand Blindspot
Monitoring modules. Clear DTC and re-test. If DTC
remains, check and install a new right hand Blindspot
Monitoring module only, refer to the new
Index
U030000 Internal Control RJB car configuration data Check RJB for related DTCs and refer to the relevant DTC
Module Software is not compatible with the Index. Clear DTCs and re-test. If DTC still logged,
Incompatibility Blindspot Monitoring re-configure the RJB using the manufacturer approved
module diagnostic system. Clear DTCs and re-test. If DTC still
logged, re-configure the Blindspot Monitoring module using
the manufacturer approved diagnostic system. Clear DTC
and re-test, if still logged suspect the Blindspot Monitoring
module. Check and install a new module as required, refer
to the new module/component installation note at the top
of the DTC Index
U041568 Invalid Data Event information Check ABS module for related DTCs and correct function,
Received From refer to the relevant DTC Index
Anti-Lock Brake
System Control
Module
U042268 Invalid Data Event information Check CJB for related DTCs and correct function, refer to
Received From the relevant DTC Index
Body Control
Module
U042368 Invalid Data Event information Check instrument cluster for related DTCs and correct
Received From function, refer to the relevant DTC Index
Instrument Panel
Control Module
U210000 Initial No configuration has been Check RJB for related DTCs and refer to the relevant DTC
Configuration Not previously set Index
Complete
U210100 Control Module Data sent from RJB is Check RJB for related DTCs and refer to the relevant DTC
Configuration invalid Index. Check/amend Car Configuration File using the
Incompatible manufacturer approved diagnostic system
U300044 Control Module Data memory failure Cycle the ignition and check if the DTC is still logged. If
DTC remains suspect the module, refer to the new
Index
U300047 Control Module Watchdog/safety Micro Cycle the ignition and check if the DTC is still logged. If
controller failure DTC remains suspect the module, refer to the new
Index
U300049 Control Module Internal electronic failure Cycle the ignition and check if the DTC is still logged. If
DTC remains suspect the module, refer to the new
Index
U300281 Vehicle Vehicle/component Check RJB has not been previously installed to other
Identification mis-match. Corrupt VIN vehicle. Install original/new module as required, refer to
Number data being transmitted, the new module/component installation note at the top of
suspect module previously the DTC Index. Check RJB for DTCs and refer to the
installed to other vehicle relevant DTC Index
U300362 Battery Voltage Mis-match in battery Carry out any pinpoint tests associated with this DTC using
voltage, of 2 volts or the manufacturer approved diagnostic system
more, between Blindspot
Monitoring module and
RJB
Parking Aid - Parking Aid - Component Location
COMPONENT LOCATION - PARKING AID
ItemDescription
1 Front parking aid sensors (4 off)
2 Parking aid switch
3 Rear parking aid sensors (4 off)
4 Parking aid module
COMPONENT LOCATION - PARKING AID CAMERA
ItemDescription
1 Touch Screen Display (TSD)
3 Parking aid camera
Parking Aid - Parking Aid - Overview
OVERVIEW
The parking aid system provides an audible warning to the driver when any obstacles are in the path of the vehicle during
a forward (if front sensors are fitted) or reversing manoeuver. The purpose of the system is to assist the driver when
parking or manoeuvring in a restricted space. It is not designed as a crash avoidance system or a replacement for visual
interpretation by the driver.
All vehicles are fitted with rear parking aid sensors. Higher specification vehicles may also be fitted with front parking aid
sensors.
A roof console mounted parking aid switch allows the driver to deactivate the parking aid system if operation is not
required.
NOTE: The switch is only fitted to vehicles with front parking aid sensors.
A parking aid camera is a standard fitment on some models and optional on others. The parking aid camera supplements
the information provided by the parking aid system by providing the driver with a visual display of the area directly behind
the vehicle.
Parking Aid - Parking Aid - System Operation and Component Description
Control Diagram
CONTROL DIAGRAM - PARKING AID
ItemDescription
NOTE:A = Hardwired; N = Medium speed CAN bus; P = MOST ring
1 Battery
4 Entertainment system control module
5 Integrated audio module
6 Audio system amplifier
7 Audio system speakers
8 RH (right-hand) outer rear sensor
9 RH inner rear sensor
10 LH (left-hand) inner rear sensor
11 LH outer rear sensor
12 LH outer front sensor
13 LH inner front sensor
14 RH inner front sensor
15 RH outer front sensor
17 Parking aid switch
CONTROL DIAGRAM - PARKING AID CAMERA
ItemDescription
NOTE:A = Hardwired; N = Medium speed CAN bus; O = LIN bus; P = MOST ring; T = Co-axial cable
1 Battery
2 BJB
3 RJB
6 Parking aid camera
System Operation
PARKING AID
The parking aid module receives and ignition power mode 6 supply from the RJB.
The parking aid module is connected to the entertainment system control module by the medium speed CAN (controller
area network) bus and the Media Orientated System Transport (MOST). The entertainment system is used by the parking
aid system to provide the driver with an audible warning. If an obstacle is sensed by the rear parking aid sensors, the rear
audio system speakers will sound. If an obstacle is sensed by the front parking aid sensors (if fitted), the front audio
system speakers will sound.
The parking aid system operates using ultrasonic signals which are transmitted by the sensors. The reflected echo from
this output is received by the sensors and used by the parking aid module to calculate the distance from an object.
When the parking aid module activates the system, the switch LED (light emitting diode) is illuminated to indicate that
the system is operating. The parking aid module then processes signals received from the sensors to determine if there is
an object with the detection range of the sensors. A parking aid screen is automatically displayed in the Touch Screen
Display. If the vehicle has a parking aid camera fitted, the camera display is automatically displayed in the TSD in
preference to the parking aid alert display. To view the parking aid sensor display, a single touch of the TSD screen will
remove the camera image display and show the parking aid alert display.
Parking Aid Alert Display
In the combined mode, the sensors emit a series of ultrasonic impulses and then switch to receiver mode to receive the
echo reflected by an obstacle within the detection range. The received echo signals are amplified and converted from an
analogue signal to a digital signal by the sensor. The digital signal is passed to the parking aid module and compared with
pre-programmed data stored in an EEPROM (electrically erasable programmable read only memory) within the module. The
module receives this data via the signal line from the sensor and calculates the distance from the object using the elapsed
time between the transmitted and received impulse. The duration of the impulse duration is determined by the module,
with the sensor controlling the frequency of the impulse output.
In receiver mode, the sensor receives impulses that were emitted by adjacent sensors. The module uses this information
to precisely determine the position and distance of the object.
If no objects are detected there are no further warning tones. If an object is detected, repeated audible tones are emitted
from either the front or rear audio speakers as appropriate. The time delay between the tones decreases as the distance
between the object and the vehicle decreases, until at approximately 250 mm (10 inches), the audible tone becomes
continuous.
If, after the initial detection of an object, there is no decrease in distance between the object and the vehicle, the audible
warning tones remain constant if the object is detected by a central sensor or stops after 3 seconds if the object is
detected by a corner sensor.
The audible tones will stop if the vehicle is moved out of reverse gear. The module continues to monitor the distance and
will resume the warning tones if a decrease in distance is detected.
The volume output of the parking aid audible tones can be adjusted by selecting the 'Vehicle Settings' menu and selecting
'Parking' from the menu on the TSD. The volume can be adjusted using the + or - selections on the TSD.
System operation is cancelled when the parking aid switch is pressed or the ignition is switched off. System operation is
also cancelled if the vehicle travels more than 50 m (164 ft) or the vehicle forward speed exceeds 30 km/h (19 mph).
The system can detect when a trailer is connected to the vehicle by a message output on the medium speed CAN bus from
the trailer module. W hen the parking aid module detects that a trailer is connected to the vehicle, the rear sensors are
disabled to prevent constant warnings due to the close proximity of the trailer.
The parking aid module also incorporates software that compensates for the effects of frost, ice or rain on the sensors. Ice
compensation occurs if the ambient temperature, received on a medium speed CAN bus message from the instrument
cluster, is less than 6C (43F).
Distance Calculation
ItemDescription
1 600 mm (24 inches
2 1800 mm (71 inches)
3 800 mm (31 inches)
An intermittent warning tone is emitted once the object is within the detection range for the particular sensor. When the
object is 250 mm (10 inches) from the sensor, the tone changes to a continuous tone.
The maximum detection range for the front sensors is 800 mm (31 inches) for the central sensors and 600 mm (23.5
inches) for the corner sensors.
The maximum detection range for the rear sensors is 1800 mm (70 inches) for the central sensors and 600 mm (23.5
inches) for the corner sensors.
PARKING AID CAMERA

The parking aid camera receives an ignition power mode 6 power supply from the RJB. It also has a LIN (local interconnect
network) bus connection from the RJB which is not used at the moment but installed for a later enhancement of the
parking aid camera.
A shielded co-axial cable connection between the camera and the Touch Screen Display (TSD) is used for the video image
transmission.
The camera receives power at all times when the ignition is in power mode 6. When reverse gear is selected, the RJB
transmits a reverse selected signal on the medium speed CAN bus message to the entertainment system control module.
This message is transferred on the MOST to the TSD which displays the parking aid camera video input from the camera in
preference to the parking aid alert screen.
If the driver does not require the camera image in the TSD, a single touch on the screen will revert the display to the
parking aid alert screen. The camera view can be reselected by pressing the 'Rear Camera' softkey on the TSD.
When reverse gear is deselected, the camera image remains on the TSD for 10 seconds after the transmission has been
put into drive 'D'. This is to prevent the TSD switching between screens if the vehicle is being manoeuvred into a parking
space. If the vehicle forward speed exceeds 16 km/h (10 mph) within the 10 second period, the camera image is removed
from the TSD.
If the TSD display is switched off, the camera image will be automatically displayed when reverse gear is selected. When
reverse gear is deselected and the 10 second period has expired, the TSD will revert back to its switched off state.
PARKING AID
Two levels of parking aid system can be fitted; a rear only system or a front and rear system.
The parking aid system provides an audible warning to the driver when any obstacles are in the path of the vehicle during
forward (if front sensors are fitted) or reverse parking manoeuvres. The system consists of four ultrasonic sensors in each
bumper, a parking aid module and a parking aid switch.
At low speeds, the parking aid module uses the ultrasonic sensors to monitor the area around the front and rear bumpers.
If an object is detected within a monitored area, the module then outputs a warning using the audio system speakers. The
sensors can detect solid objects such as posts, walls and other vehicles and can also detect less solid objects such as a
wire mesh fence. Objects very close to the ground may not be detected, but because of their low height may not cause
The parking aid system comprises the following components:
Parking aid module

Parking aid switch
Eight parking aid sensors.
The parking aid module communicates via the medium speed CAN bus with the audio system via the integrated audio
module. The audio system then outputs the applicable warning tones from the front or rear speakers when an object is
detected. The medium speed CAN bus is also used to collect vehicle data from other vehicle systems.
Parking Aid Module
The parking aid module is located on the LH side of the luggage compartment.
The parking aid module has three connectors which provide for power, ground and CAN bus connections, front parking aid
sensors and rear parking aid sensors. The medium speed CAN bus connections provide for the receipt of the following
information from other systems:
ABS (anti-lock brake system) module - Road speed signal

TCM (transmission control module) - Reverse gear engaged signal
Trailer module - Trailer attached to vehicle
Instrument cluster - Ambient temperature signal.
The module also outputs messages on the medium speed CAN bus which are received by the integrated audio module. The
integrated audio module processes these messages and converts them into Media Orientated System Transport (MOST)
signals which are passed to the audio system power amplifier. These signals are then used by the power amplifier to emit
the applicable warning tones from the front or rear audio speakers when an object is detected by the front or rear parking
aid sensors. A warning tone can also be emitted to alert the driver to a fault in the parking aid system.
The parking aid module performs self check routines and when the system is active checks the sensor wiring for short or
open circuits. If a fault is detected a code is stored in a memory in the module and if necessary either the front and/or rear
sensors can be disabled. The driver is made aware of any fault condition by the parking aid switch LED flashing and a
continuous warning tone being emitted for 3 seconds, in place of the normal short tones when the system is functioning
normally. Fault codes can be read using an approved Jaguar diagnostic system via the diagnostic socket.
Parking Aid Sensors
Four ultrasonic sensors are located in the front and rear bumpers. Each sensor comprises a sensor and a bumper insert.
The insert ensures that each sensor is correctly orientated in relation to its location in the bumper.
Each sensor has a three pin connector which mates with a bumper harness, which in turn is connected to the main body
harness. Three pins provide for power supply, ground and signal lines to and from the parking aid module.
Each sensor comprises a plastic housing which contains a piezo electric disc. The disc resonates at a frequency of 34.8kHz,
producing the ultrasonic output. The disc also receives the reflected echo signal from any objects within range.
The parking aid module controls the operation of each sensor using a digital output on the signal line. The module controls
the sensor in one of two modes; combined transmitter and receiver mode or receiver mode only.
Parking Aid Switch

The parking aid switch is located in the instrument panel switch pack, above the touch screen. The switch is the LH switch
with an integral LED.
The switch is a non-latching push switch which allows the driver to select the parking aid system on or off. W hen pressed,
the switch momentarily connects a ground to the parking aid module.
The LED indicates when the parking aid system is active. The LED is controlled by the parking aid module. The switch
allows the driver to disable the parking aid system when reverse gear is selected or to activate the parking sensors when
not in reverse gear.
If a fault exists in the parking aid system, the LED flashes continuously when reverse gear is selected or the driver selects
the parking sensors on, using the switch.
PARKING AID CAMERA

The parking aid camera is located on a bracket which is attached to the luggage compartment lid finisher.
The camera is connected to the vehicle harness by one 3 pin connector for the power, ground and LIN bus and a second
connector for the video co-axial cable.
the camera produces color images to an analogue NTSC format, with a resolution of 640 x 480 pixels and an aspect ratio of
4:3.
The image captured by the camera is mirrored to give the driver a true representation of the rear view on the TSD.
Parking Aid - Parking Aid
For a detailed description of the parking aid system, refer to the relevant Description and Operation section in the
workshop manual. REFER to: (413-13 Parking Aid)
Parking Aid (Description and Operation),

Parking Aid (Description and Operation),
Parking Aid (Description and Operation).
vehicle.
NOTE: Particular attention should be paid to the following items where DTCs may not be logged:
Check for contamination (e.g. dirt, grime, frosting, ice) around the parking aid sensors, if so refer to the parking aid
section in the vehicle handbook.
Check for the correct installation and alignment of the sensors to the bumper.
Spurious detection of the ground may occur during front system operation on an up-slope, or down slope.
Visual Inspection
Sensor installation, alignment Fuse(s)
Sensor contamination Relay(s)
Wiring Harness
Front parking aid sensor(s) and holders
Rear parking aid sensor(s) and holders
Audio system
Parking aid switch and LED
Parking aid module
DTC Index
leads into account.

B1B3601 Front right outer Front right outer Carry out pinpoint tests associated with this DTC using the
sensor sensor signal circuit - manufacturer approved diagnostic system
short to ground,
open circuit
Front right outer
sensor power supply
circuit - open circuit
B1B3612 Front right outer Front right outer Refer to electrical circuit diagrams and check front right outer
sensor sensor signal circuit - sensor signal circuit for short to power
short to power
B1B3696 Front right outer Front right outer Refer to electrical circuit diagrams and check front right outer
sensor sensor ground circuit sensor ground circuit for open circuit. Check and install new
- open circuit sensor as required
Front right outer
sensor internal
failure
B1B3801 Front right inner Front right inner Carry out pinpoint tests associated with this DTC using the
short to ground,
open circuit
Front right inner
sensor power supply
B1B3812 Front right inner Front right inner Refer to electrical circuit diagrams and check front right inner
short to power
B1B3896 Front right inner Front right inner Refer to electrical circuit diagrams and check front right inner
Front right inner
sensor internal
failure
B1B4001 Front left outer Front left outer Carry out pinpoint tests associated with this DTC using the
short to ground,
open circuit
Front left outer
sensor power supply
B1B4012 Front left outer Front left outer Refer to electrical circuit diagrams and check front left outer
short to power
B1B4096 Front left outer Front left outer Refer to electrical circuit diagrams and check front left outer
Front left outer
sensor internal
failure
B1B4201 Front left inner Front left inner Carry out pinpoint tests associated with this DTC using the
short to ground,
open circuit
Front left inner
sensor power supply
B1B4212 Front left inner Front left inner Refer to electrical circuit diagrams and check front left inner
short to power
B1B4296 Front left inner Front left inner Refer to electrical circuit diagrams and check front left inner
Front left inner
sensor internal
failure
B1B4401 Rear right outer Rear right outer Carry out pinpoint tests associated with this DTC using the
short to ground,
open circuit
Rear right outer
sensor power supply
B1B4412 Rear right outer Rear right outer Refer to electrical circuit diagrams and check rear right outer
short to power
B1B4496 Rear right outer Rear right outer Refer to electrical circuit diagrams and check rear right outer
Rear right outer
sensor internal
failure
B1B4601 Rear right inner Rear right inner Carry out pinpoint tests associated with this DTC using the
short to ground,
open circuit
Rear right inner
sensor power supply
B1B4612 Rear right inner Rear right inner Refer to electrical circuit diagrams and check rear right inner
short to power
B1B4696 Rear right inner Rear right inner Refer to electrical circuit diagrams and check rear right inner
Rear right inner
sensor internal
failure
B1B4801 Rear left outer Rear left outer Carry out pinpoint tests associated with this DTC using the
short to ground,
open circuit
Rear left outer
sensor power supply
B1B4812 Rear left outer Rear left outer Refer to electrical circuit diagrams and check rear left outer
short to power
B1B4896 Rear left outer Rear left outer Refer to electrical circuit diagrams and check rear left outer
Rear left outer
sensor internal
failure
B1B5001 Rear left inner Rear left inner Carry out pinpoint tests associated with this DTC using the
short to ground,
open circuit
Rear left inner
sensor power supply
B1B5012 Rear left inner Rear left inner Refer to electrical circuit diagrams and check rear left inner
short to power
B1B5096 Rear left inner Rear left inner Refer to electrical circuit diagrams and check rear left inner
Rear left inner
sensor internal
failure
B1B5411 Parking aid status Parking aid status Refer to the electrical circuit diagrams and test status LED
LED LED - short to ground circuit for short to ground
(detected if driven
only)
B1B5412 Parking aid status Parking aid status Refer to the electrical circuit diagrams and test status LED
LED LED - short to power circuit for short to power
(detected if not
driven only)
B1B5711 Front sensors power Front sensors power Refer to the electrical circuit diagrams and test front sensor
supply circuit supply circuit - short power supply circuit for short to ground
to ground
B1B5811 Rear sensors power Rear sensors power Refer to the electrical circuit diagrams and test rear sensor
supply circuit supply circuit - short power supply circuit for short to ground
to ground
B1C3073 Disable switch Disable switch stuck Refer to electrical circuit diagrams and check disable switch and
closed circuit for short circuit
Disable switch circuit
- short circuit
U001000 Medium speed CAN Medium speed CAN Carry out pinpoint tests associated with this DTC using the
communication Bus communication Bus manufacturer approved diagnostic system
U014000 Lost communication Logged when Carry out pinpoint tests associated with this DTC using the
with CJB subscribed CAN manufacturer approved diagnostic system
message missing
from CJB
U014200 Lost Communication Logged when Carry out pinpoint tests associated with this DTC using the
W ith Body Control subscribed CAN manufacturer approved diagnostic system. Check RJB for related
Module 'B' message missing DTCs and refer to relevant DTC Index
from RJB
U015500 Lost Communication Logged when Carry out pinpoint tests associated with this DTC using the
W ith Instrument subscribed CAN manufacturer approved diagnostic system. Check Instrument
Panel Cluster (IPC) message missing Cluster for related DTCs and refer to relevant DTC Index
Control Module from Instrument
Cluster
U030000 Internal control RJB car configuration Check RJB for related DTCs and refer to the relevant DTC Index.
module software data is not Clear DTCs and re-test. If DTC still logged, re-configure the RJB
incompatibility compatible with the using the manufacturer approved diagnostic system. Clear DTCs
parking aid module and re-test. If DTC still logged, re-configure the parking aid
module using the manufacturer approved diagnostic system.
Clear DTC and re-test, if still logged suspect the parking aid
module. Check and install a new module as required, refer to
the new module/component installation note at the top of the
DTC Index
U042200 Invalid data Logged when Check CJB for related DTCs and refer to relevant DTC Index
received from CJB subscribed CAN
message invalid from
CJB
U042300 Invalid Data Logged when Check Instrument Cluster for related DTCs and refer to relevant
Received From subscribed CAN DTC Index
Instrument Panel message invalid data
Control Module from Instrument
Cluster
U044300 Invalid Data Logged when Check RJB for related DTCs and refer to the relevant DTC Index
Received From Body subscribed CAN
Control Module "B" message invalid data
from RJB
U210000 Initial configuration No configuration has Check RJB for related DTCs and refer to the relevant DTC Index
not complete been previously set
U210100 Control module Data sent from RJB Check RJB for related DTCs and refer to the relevant DTC Index
configuration is invalid
incompatible
U300049 Control module Internal control Install a new Parking Aid module as required, refer to the new
module failure module/component installation note at the top of the DTC
Index
U300281 Vehicle Invalid VIN data Check RJB for related DTCs and refer to the relevant DTC Index.
Identification received Check RJB/parking aid module has not been previously installed
Number to other vehicle
U300316 Battery voltage Circuit voltage below Carry out pinpoint tests associated with this DTC using the
threshold manufacturer approved diagnostic system
U300317 Battery voltage Circuit voltage above Carry out pinpoint tests associated with this DTC using the
U300362 Battery voltage Mis-match in battery Carry out pinpoint tests associated with this DTC using the
voltage, of 2 volts or manufacturer approved diagnostic system
more, between
parking aid module
and RJB
Parking Aid - Front Inner Parking Aid Sensor
Removal
1. Refer to: Front Bumper Cover (501-19 Bumpers, Removal and

Installation).
2.
Installation
1. 1. CAUTION: If a new sensor is installed, only the front face

must be painted. Failure to follow this instruction may result in the
component malfunctioning.

Parking Aid - Front Outer Parking Aid Sensor
Removal

Installation).
2.
Installation
1. 1. CAUTION: If a new sensor is installed, only the front face

must be painted. Failure to follow this instruction may result in the
component malfunctioning.

Parking Aid - Parking Aid Camera
Removal
1. Refer to: Luggage Compartment Lid Moulding (501-08 Exterior Trim

and Ornamentation, Removal and Installation).
2.
Installation

Parking Aid - Parking Aid Module
Removal


3.
4.
Installation
2. If a new component has been installed, configure using Jaguar

approved diagnostic equipment.
Parking Aid - Rear Parking Aid Sensor
Removal
1. Refer to: Rear Bumper Cover (501-19 Bumpers, Removal and

Installation).
2.
Installation

Charging System - General Information - Charging System

REFER to: Battery (414-01 Battery, Mounting and Cables, Diagnosis and Testing).
Battery, Mounting and Cables - Battery and Cables - Component Location
COMPONENT LOCATION
ItemDescription
4 Battery
5 Electric booster heater megafuse
Battery, Mounting and Cables - Battery and Cables - Overview
OVERVIEW
Mounted on the battery negative terminal is a battery monitoring system module. The battery monitoring system module
is integral with the battery negative cable and is controlled by the ECM (engine control module).
CAUTION: To avoid damaging the battery monitoring system module, always use a suitable body ground point rather
than the battery negative terminal when connecting a slave power supply to the vehicle.
If a new battery is fitted to the vehicle, the battery monitoring system module will require re-calibrating using the Jaguar
approved diagnostic system.
Fitted on the battery positive terminal is a transit relay. The transit relay must be removed from the vehicle during the
Pre-Delivery Inspection (PDI). For additional information, refer to the PDI Manual.
The vehicle battery provides power to the BJB (battery junction box). The BJB contains 3 megafuses, delivering power to
the RJB (rear junction box), the CJB (central junction box) and the EJB (engine junction box). In addition to containing
fuses and relays, the RJB and RJB contain software to control a number of vehicle systems. These functions are covered in
the appropriate sections of this manual.
Battery, Mounting and Cables - Battery and Cables - System Operation and
Control Diagram
NOTE: A = Hardwired; D = High speed CAN bus; N = Medium speed CAN bus; O = LIN bus
ItemDescription
1 Battery monitoring system module
2 Battery
4 Generator/regulator
System Operation
BATTERY MONITORING SYSTEM
Periodically the battery monitoring system module will instigate a self-calibration routine. To self calibrate, the battery
monitoring system first charges the battery to its full condition.
NOTE: If the vehicle is only driven for short periods the charging process could take a number of days to complete.
Once the battery is fully charged, the battery monitoring system will discharge the battery to approximately 75% of its full
state of charge, but never lower than 12.2 V. The time taken to complete this part of the routine is dependent on the
electrical load on the vehicle.
When the second part of the routine has been successfully completed, the battery monitoring system will return the
battery to its optimum level of charge. The optimum level of charge will be between 12.6 V and 15 V, depending on
battery condition, temperature and loading.
The battery monitoring system module also monitors the battery condition with the engine switched off. If a low voltage
condition is detected the module can request the infotainment system is switched off to protect battery voltage. Once the
infotainment system has been switched off, the vehicle must be run for at least 5 minutes to charge the battery before the
infotainment system can be operated with the engine switched off.
BATTERY
The battery is located under the floor in the RH (right-hand) side of the luggage compartment.
On new vehicles the battery positive terminal is fitted with a transit relay. The transit relay must removed using the
correct process detailed in the PDI manual.
The battery negative terminal is fitted with a battery monitoring system module. The module is integral with the battery
negative cable and communicates with the RJB via a LIN (local interconnect network) bus connection. The battery condition
information is passed to the ECM which controls the generator output accordingly.
CAUTION: To avoid damage to the battery monitoring system module, always use a suitable body ground point rather
than the battery negative terminal when connecting a slave power supply. The recommended ground point is the spare
wheel securing bracket in the luggage compartment.
Failure to use the recommended ground point will lead to the setting of a DTC (diagnostic trouble code). Incorrect
information of battery condition will be retained by the battery monitoring system module due to the unmonitored current
flow into the battery. The system will however, recognize and compensate for the change in battery status after a period
of time.
If a new battery is fitted, the battery monitoring system module will require re-calibration using a Jaguar approved
diagnostic system. Replacement of the battery monitoring system module requires no action as the module will
re-calibrate automatically.
BATTERY MONITORING SYSTEM

Battery Monitoring System Module
The battery monitoring system module measures battery current and voltage, which it communicates to the RJB over a LIN
bus connection. The RJB transmits the battery information to the instrument cluster over the medium speed CAN
(controller area network)bus. The instrument cluster acts as a gateway between the medium and high speed CAN bus
networks, and transmits the battery condition information to the ECM over the high speed CAN bus. Based on the
information received from the battery monitoring system module, the ECM will control the output from the generator and
request the switching off of electrical loads if necessary. For additional information, refer to: For additional information,
refer to:
Generator (414-02A, Description and Operation),

Generator (414-02B, Description and Operation),
Generator (414-02 Generator and Regulator - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8, Description and Operation).
CAUTION: Due to the self-calibration routine, it is recommended that all power supply diagnostic testing is carried
out using the Jaguar approved diagnostic system rather than a digital multimeter
The battery monitoring system module is able to generate DTC's to help diagnose battery or generator power supply
issues. These DTC's can be read using the Jaguar approved diagnostic system. The Jaguar approved diagnostic system can
also be used to implement a battery and generator self test routine. For additional information, refer to the Diagnosis and
Testing section of the workshop manual.
If a fault is detected, the ECM will override the battery monitoring system module.
The battery monitoring system module DTC's can be used to help diagnose battery or generator power supply faults. The
DTC's are stored in both the RJB and the ECM. The Jaguar approved diagnostic system has a process for an automated
power supply diagnostic procedure. The procedure provides a menu driven process to locate a fault in a logical sequence.
The procedure uses the capability of the battery monitoring system and generator LIN bus controlled functions to provide
current flow information and will detect if the battery monitoring system or generator are functioning correctly.
Battery, Mounting and Cables - Battery
For a detailed description of the Battery, Mounting and Cables and charging system, refer to the relevant Description and
Operation sections in the Workshop Manual. REFER to:
Battery and Cables (414-01 Battery, Mounting and Cables, Description and Operation),
Generator (414-02 Generator and Regulator - 2.7L Diesel, Description and Operation),
Generator (414-02 Generator and Regulator - 3.0L, Description and Operation),
Generator (414-02 Generator and Regulator - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8, Description and Operation),
Generator (414-02 Generator and Regulator - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8, Description and Operation),
Generator (414-02 Generator and Regulator - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8, Description and Operation).
vehicle.
Visual Inspection
Front End Accessory Drive (FEAD) belt condition/tension Electrical connectors/pins
Generator drive pulley W iring harnesses
4. 4. If the cause is not visually evident refer to the Symptom Chart, alternatively, check for Diagnostic Trouble Codes
(DTCs) and refer to the DTC Index.
Symptom Chart

Battery discharged Charging/monitoring circuit Carry out automated diagnostic routine using manufacturer
fault approved diagnostic system
Battery monitoring system
failure
Generator failure
Battery failure
Quiescent current high
Generator not Charging/monitoring circuit Carry out automated diagnostic routine using manufacturer
charging fault approved diagnostic system
Generator failure
Pulley loose/failure
DTC Index
NOTE: If a module or a component is suspect and the vehicle remains under manufacturer warranty, refer to the
account.

B11D949 Vehicle Battery Internal electronic Check vehicle has correct battery type and size installed.
failure. The battery Install new as required. Using manufacturer approved
monitoring module has diagnostic system verify vehicle quiescent current draw levels
detected an internal are correct using power supply diagnostic function. Rectify as
circuit failure required. Using the Midtronics battery tester and battery care
Incorrect battery type manual check the battery is serviceable. Install new as
or size installed required. The BMS will correct a temporary battery state
High quiescent current estimation error within a reasonble adaption time. The
A temporary battery adaption time is dependant upon the driving time of the
state estimation error. vehicle and may take a number of weeks.
The battery state
estimation is performed
by the battery
monitoring system BMS
Battery failure, worn
out
Battery damaged
B11DB01 Battery Monitoring Battery monitoring Disconnect vehicle battery, re-connect after 60 seconds, clear
Module system hardware fault DTC and retest. If DTC remains install a new battery
monitoring module
B11DB87 Battery Monitoring Battery monitoring If additional DTCs B108783, B108786, B108787 are logged,
Module module connector suspect the RJB. Check and install a new RJB as required,
dis-connected/poor refer to the new module/component installation note at the
connection top of the DTC Index. If additional DTCs B108783, B108786,
Battery monitoring B108787 are NOT logged, check for good/clean contact at
module to RJB LIN battery monitoring module connector, refer to electrical
circuit - open circuit circuit diagrams and check battery monitoring module to RJB
Battery monitoring LIN circuit and battery monitoring module to battery positive
module to battery monitor circuit for open circuit. Clear DTC and repeat
positive monitor circuit automated diagnostic procedure using manufacturer approved
- open circuit diagnostic system. If DTC remains suspect the battery
Battery monitoring monitoring module, check and install a new battery
module/RJB failure monitoring module as required, refer to the new
Index
P062001 Generator Control Generator B+ or battery Carry out any pinpoint tests associated with this DTC using
Circuit terminal the manufacturer approved diagnostic system. Check for
disconnected/poor good/clean contact at generator B+ and battery terminal
connection connectors. Refer to the electrical circuit diagrams and check
Charging circuit - short, charging circuit for short, open circuit. Clear DTC and repeat
open circuit automated diagnostic procedure using the manufacturer
Generator failure approved diagnostic system. If DTC remains suspect the
generator, check and install a new generator as required,
refer to the new module/component installation note at the
P065B16 Generator Control Charging circuit - short, Carry out any pinpoint tests associated with this DTC using
Circuit open circuit the manufacturer approved diagnostic system. Refer to the
Range/Performance Quiescent current high electrical circuit diagrams and check charging circuit for short,
Battery damaged/worn open circuit. Clear DTC and repeat automated diagnostic
out procedure using the manufacturer approved diagnostic
Generator failure system. If DTC remains check battery is in fully charged and
serviceable condition using the Midtronics battery tester and
battery care manual. If ok suspect the generator, check and
install a new generator as required, refer to the new
Index
P065B17 Generator Control Charging circuit - short, Carry out any pinpoint tests associated with this DTC using
Circuit open circuit the manufacturer approved diagnostic system. Check ECM for
Range/Performance Generator/ECM failure over charging related DTCs and refer to the relevant DTC
Index. Clear DTC and re-test, if DTC remains suspect the
generator. Check and install a new generator as required,
P065C00 Generator Poor FEAD belt tension Check FEAD belt condition/contamination and for correct
Mechanical Generator pulley tension. Check generator pulley for failure. Clear DTC and
Performance loose/failure repeat automated diagnostic procedure using manufacturer
Generator failure approved diagnostic system. If DTC remains check and install
a new generator as required, refer to the new
Index
P0A1A87 Generator Control Generator to ECM LIN Check for good/clean contact at generator and ECM LIN
Module circuit - open circuit circuit connectors/pins. Refer to the electrical circuit
Generator/ECM failure diagrams and check generator to ECM LIN circuit for open
circuit. Check for ECM hardware DTCs and refer to relevant
DTC Index. Clear DTCs and repeat automated diagnostic
procedure using the manufacturer approved diagnostic
system. If DTC remains check and install a new
generator/ECM as required, refer to the new
Index
P0A3B68 Generator Over Generator Check the generator wiring and connectors for heat damage.
Temperature wiring/connectors heat Clear the DTC and repeat the automated diagnostic
damaged procedure using the manufacturer approved diagnostic
Generator failure system. If DTC remains check and install a new generator as
Battery, Mounting and Cables - Battery Disconnect and Connect
General Procedures
Disconnect
WARNING: Refer to: Battery and Battery Charging Health and Safety Precautions (100-00 General Information,
1. Obtain and record the audio unit preset radio frequencies.
2. 2. NOTE: Where fitted.

wiring harness.
4.
Connect
1. Torque: 6 Nm
2.
4. 4. NOTE: This step is only necessary when installing a new

component.
Using the Jaguar approved diagnostic equipment, reset the battery

monitoring system.
5. Refer to: Door W indow Motor Initialization (501-11 Glass, Frames

and Mechanisms, General Procedures).
6. Enter the audio unit preset radio frequencies.
7. Reset the clock to the correct time.
8. Start the engine and allow to idle until the engine reaches normal
operating temperature.

Battery, Mounting and Cables - Battery
Removal
1. Obtain and record the audio unit preset radio frequencies.
3.
4. Torque: 6 Nm
5. Torque: 6 Nm
6.
7. Torque: 13 Nm
8.
Installation
2. 2. NOTE: This step is only necessary when installing a new

component.
Using the Jaguar approved diagnostic equipment, reset the battery

monitoring system.
3. Refer to: Door W indow Motor Initialization (501-11 Glass, Frames

and Mechanisms, General Procedures).
4. Enter the audio unit preset radio frequencies.
5. Reset the clock to the correct time.
6. Start the engine and allow to idle until the engine reaches normal
operating temperature.

Generator and Regulator - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8 - Generator
- Component Location
NOTE: Generator on vehicles with supercharger shown, generator on vehicles without supercharger is the same.
Component Location
- Overview
Overview
On 4.2L vehicles (naturally aspirated and supercharged), the charging system consists of a 130 A output generator and
regulator assembly. The generator and regulator assembly generates electrical power for the vehicle electrical system and
maintains the battery in a charged state.
When the engine is running the generator produces an alternating current, which is converted to a direct current internally.
The output from the generator 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 mounted on the front right side of the engine and driven at approximately 3 times engine speed by the
accessory drive belt.
Refer to: Accessory Drive (303-05C, Description and Operation).
- System Operation and Component Description
Control Diagram
NOTE: A = Hardwired; D = High speed CAN (controller area network) bus; N = Medium speed CAN bus; O = LIN (local
interconnect network) bus.
ItemDescription
2 Battery
4 Generator and regulator
System Operation
General
The output voltage required from the generator and regulator is calculated by the battery monitoring system.
Refer to: Battery and Cables (414-01 Battery, Mounting and Cables, Description and Operation).
The battery monitoring system signals the calculated voltage to the ECM via the RJB and the instrument cluster. The ECM
then transmits the calculated voltage to the generator and regulator on the LIN bus connection.
The ECM will over-ride the voltage value requested by the battery monitoring system if it detects a fault in the generator
and regulator. The ECM also signals the instrument cluster to display a warning message if it detects a fault with the
generator and regulator.
Generator and Regulator
The regulator provides a controlled variable voltage output from the generator. Two electrical terminals are provided on the
outer casing of the generator. One terminal supplies the DC (direct current) voltage output from the generator to the
battery positive terminal. The second terminal provides the LIN bus connection between the regulator and the ECM.

REFER to: Battery (414-01 Battery, Mounting and Cables, Diagnosis and Testing).
Generator and Regulator - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8 -
Generator4.2L NA V8 - AJV8
Special Tool(s)
303-703
Removal
Installation).


6. Remove the air cleaner housing cover.
Using the special tool 303-703, rotate the accessory drive

belt tensioner counter-clockwise.
9. Release the battery positive cable protective cover.

12. Remove the right-hand engine mounting retaining nut.
13. Using a suitable hydraulic jack, raise and support the engine.
Make sure the engine mounting is raised no more than 25

mm (0.984 '').

16. Support and release the power steering rack.
17. Remove the engine mounting and bracket assembly.
18. Remove the nut and bolt.

Installation
Tighten to 21 Nm.
Generator and Regulator - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8 -
Generator4.2L SC V8 - AJV8
Removal
Procedures).


Installation).

8.
9. Release thethe
battery positive cable protective
from thecover.
10.Disconnect
Disconnect thebattery positive
generator cable
electrical connector.generator.
11. Remove the right-hand engine mounting retaining nut.
12. Using a suitable hydraulic jack, raise and support the engine.
Make sure the engine mounting is raised no more than 25

mm (0.984 '').

16. Remove the engine mounting and bracket assembly.
17. Remove the nut and bolt.
Installation
Tighten to 21 Nm.
Information and Entertainment System - General Information - Information
and Entertainment System
For a detailed description of the Information and Entertainment System, refer to the relevant Description and Operation
sections in the workshop manual. REFER to: (415-01 Information and Entertainment System)
Audio System (Description and Operation),

Speakers (Description and Operation),
Video System (Description and Operation),
Video System (Description and Operation).
vehicle.
Visual Inspection
Information and entertainment module Fuses
Audio amplifier module Loose or corroded connector(s)
Integrated audio module Information and entertainment module
Portable audio interface module Audio amplifier module
Digital audio broadcast module Integrated audio module
Integrated control panel Portable audio interface module
Touch screen display Digital audio broadcast module
Satellite radio module Integrated control panel
Television module Touch screen display
Navigation system module Satellite radio module
Telephone module Television module
Compact disc player jammed, not loading Navigation system module
Scratched/dirty compact discs Telephone module
Speakers Speakers
4. 4. If the cause is not visually evident, check for Diagnostic Trouble Codes (DTCs) and refer to the relevant DTC
Index.
DTC Index
Information and Entertainment Module
account.

B1A5949 Sensor 5 Volt Supply Internal electronic failure Suspect the information and entertainment module.
Check and install a new information and
entertainment control module as required, refer to
the new module/component installation note at the
U001000 Medium Speed CAN General failure. No sub type Clear DTC and re-test, if DTC remains check CAN
Communication Bus information network and harness integrity
U01564A Lost Communication Incorrect node installed Suspect incorrect instrument cluster installed, check
W ith Information and install correct/new instrument cluster as
Center "A" required, refer to the new module/component
U015900 Lost Communication General failure. No sub type Carry out any pinpoint tests associated with this
W ith Parking Assist information DTC using the manufacturer approved diagnostic
Control Module "A" system. Check parking aid module for related DTCs
U016300 Lost Communication General failure. No sub type Check navigation module for related DTCs and refer
W ith Navigation information to the relevant DTC Index
Control Module
U01634A Lost Communication Incorrect node installed Suspect incorrect navigation module installed, check
W ith Navigation and install correct/new module as required, refer to
Control Module the new module/component installation note at the
U018400 Lost Communication General failure. No sub type Carry out any pinpoint tests associated with this
W ith Radio information DTC using the manufacturer approved diagnostic
system. Check integrated audio module for related
U01844A Lost Communication Incorrect node installed Suspect incorrect integrated audio module installed,
W ith Radio check and install correct/new module as required,
U018600 Lost Communication General failure. No sub type Carry out the pinpoint test associated with this DTC
with Audio Amplifier information using the manufacturer approved diagnostic
"A" system. Check audio amplifier for related DTCs and
U01864A Lost Communication Incorrect node installed Suspect incorrect audio amplifier installed, check
with Audio Amplifier and install correct/new audio amplifier as required,
"A" refer to the new module/component installation
W ith Television information using the manufacturer approved diagnostic
system. Check television tuner for related DTCs and
U01914A Lost Communication Incorrect node installed Suspect incorrect television tuner module installed,
W ith Television check and install correct/new module as required,
W ith "Digital Audio information using the manufacturer approved diagnostic
Control Module A" system. Check SDARS module for related DTCs and
U01934A Lost Communication Incorrect node installed Suspect incorrect DAB/SDARS module installed,
W ith "Digital Audio check and install correct/new module as required,
Control Module A" refer to the new module/component installation
W ith Telephone information using the manufacturer approved diagnostic
Control Module system. Check telephone module for related DTCs
U01974A Lost Communication Incorrect node installed Suspect incorrect telephone module installed, check
W ith Telephone and install correct/new module as required, refer to
Control Module the new module/component installation note at the
W ith Front information using the manufacturer approved diagnostic
Controls/Display system. Check touch screen display for related
Interface Module DTCs and refer to the relevant DTC Index
U02574A Lost Communication Incorrect node installed Suspect incorrect touch screen display installed,
W ith Front check and install correct/new touch screen display
Controls/Display as required, refer to the new module/component
Interface Module installation note at the top of the DTC Index
U030051 Internal Control System programme failure. Not Re-configure the information and entertainment
Module Software programmed module using the manufacturer approved diagnostic
Incompatibility system
U1A1587 Incomplete MOST Ring Missing message Carry out the pinpoint test associated with this DTC
Reported By ICM using the manufacturer approved diagnostic system
U1A2400 MOST Ring Complete General failure. No sub type Carry out MOST network integrity tests, using the
No Communication information manufacturer approved diagnostic system.
Alternatively refer to the MOST network pinpoint
tests.
REFER to: Communications Network (418-00 Module
Communications Network, Diagnosis and Testing).
U210100 Control Module General failure. No sub type Re-configure the information and entertainment
Configuration information module using the manufacturer approved diagnostic
Incompatible system, clear DTC and re-test. If DTC remains,
check and amend the Car Configuration File using
U300055 Control Module Not configured Re-configure the information and entertainment
module using the manufacturer approved diagnostic
system. Clear DTC and re-test. If the DTC remains
suspect the information and entertainment module,
U300087 Control Module Missing message Clear DTC and re-test, if DTC remains check the RJB
for related DTCs and refer to the relevant DTC
Index
U300281 Vehicle Identification Vehicle/component mis-match. Check and install original/new information and
Number Corrupt VIN data being entertainment module as required, refer to the new
transmitted, suspect module module/component installation note at the top of
previously installed to other the DTC Index
vehicle
Audio Amplifier Module
account.

B1A0111 Speaker #1 Front left tweeter or Refer to electrical circuit diagrams and check front left tweeter
mid-range speaker speaker circuit for short to ground
circuit - short to ground
mid-range speaker speaker circuit for short to power
circuit - short to power
mid-range speaker speaker circuit for open circuit
B1A011A Speaker #1 Front left tweeter or Carry out any pinpoint tests associated with this DTC using
mid-range speaker the manufacturer approved diagnostic system
circuit - resistance
below threshold
B1A0149 Speaker #1 Internal electronic Suspect the audio amplifier module, check and install a new
B1A0211 Speaker #2 Front right tweeter or Refer to electrical circuit diagrams and check front right
mid-range speaker tweeter speaker circuit for short to ground
mid-range speaker tweeter speaker circuit for short to power
mid-range speaker tweeter speaker circuit for open circuit
B1A021A Speaker #2 Front right tweeter or Carry out any pinpoint tests associated with this DTC using
mid-range speaker the manufacturer approved diagnostic system
circuit - resistance
below threshold
B1A0311 Speaker #3 Front left woofer Refer to electrical circuit diagrams and check front left woofer
speaker circuit - short speaker circuit for short to ground
to ground
speaker circuit - short speaker circuit for short to power
to power
speaker circuit - open speaker circuit for open circuit
circuit
B1A031A Speaker #3 Front left woofer Carry out any pinpoint tests associated with this DTC using
speaker circuit - the manufacturer approved diagnostic system
resistance below
threshold
B1A0411 Speaker #4 Front right woofer Refer to electrical circuit diagrams and check front right
speaker circuit - short woofer speaker circuit for short to ground
to ground
speaker circuit - short woofer speaker circuit for short to power
to power
speaker circuit - open woofer speaker circuit for open circuit
circuit
B1A041A Speaker #4 Front right woofer Carry out any pinpoint tests associated with this DTC using
resistance below
threshold
B1A0511 Speaker #5 Rear left speaker circuit Refer to electrical circuit diagrams and check rear left speaker
- short to ground circuit for short to ground
- short to power circuit for short to power
- open circuit circuit for open circuit
B1A051A Speaker #5 Rear left speaker circuit Carry out any pinpoint tests associated with this DTC using
- resistance below the manufacturer approved diagnostic system
threshold
B1A0611 Speaker #6 Rear right speaker Refer to electrical circuit diagrams and check rear right
circuit - short to ground speaker circuit for short to ground
circuit - short to power speaker circuit for short to power
circuit - open circuit speaker circuit for open circuit
B1A061A Speaker #6 Rear right speaker Carry out any pinpoint tests associated with this DTC using
circuit - resistance the manufacturer approved diagnostic system
below threshold
B1A0711 Speaker #7 Rear left surround Refer to electrical circuit diagrams and check rear left surround
to ground
to power
circuit
B1A071A Speaker #7 Rear left surround Carry out any pinpoint tests associated with this DTC using
resistance below
threshold
B1A0811 Speaker #8 Rear right surround Refer to electrical circuit diagrams and check rear right
speaker circuit - short surround speaker circuit for short to ground
to ground
speaker circuit - short surround speaker circuit for short to power
to power
speaker circuit - open surround speaker circuit for open circuit
circuit
B1A081A Speaker #8 Rear right surround Carry out any pinpoint tests associated with this DTC using
resistance below
threshold
B1A0911 Speaker #9 Center speaker circuit - Refer to electrical circuit diagrams and check center speaker
short to ground circuit circuit for short to ground
short to power circuit for short to power
open circuit circuit for open circuit
B1A091A Speaker #9 Center speaker circuit - Carry out any pinpoint tests associated with this DTC using
resistance below the manufacturer approved diagnostic system
threshold
B1A1011 Speaker #10 Left subwoofer speaker Refer to electrical circuit diagrams and check left subwoofer
circuit - short to ground speaker circuit for short to ground
circuit - short to power speaker circuit for short to power
circuit - open circuit speaker circuit for open circuit
B1A101A Speaker #10 Left subwoofer speaker Carry out any pinpoint tests associated with this DTC using
circuit - resistance the manufacturer approved diagnostic system
below threshold
B1A1111 Speaker #11 Right subwoofer Refer to electrical circuit diagrams and check right subwoofer
to ground
to power
circuit
B1A111A Speaker #11 Right subwoofer Carry out any pinpoint tests associated with this DTC using
resistance below
threshold
U200398 Fibre Optic Component or system Clear DTC and allow system to cool, monitor for re-occurrence
Communication Bus over temperature of DTC
U300005 Control module - Software Re-configure the audio amplifier as an existing control
system incompatibility module, using the manufacturer approved diagnostic system
programming The version of the
failures Local Configuration file
does not match that
expected
U300042 Control module - General memory failure Re-configure the audio amplifier as an existing control
general memory module, using the manufacturer approved diagnostic system.
failure Clear DTC, cycle ignition and read DTCs. If DTC returns,
suspect audio amplifier module and install a new module.
Refer to the new module/component installation note at the
U300044 Control module - Data memory failure Re-configure the audio amplifier as an existing control
data memory module, using the manufacturer approved diagnostic system.
failure Clear DTC, cycle ignition and read DTCs. If DTC returns,
suspect audio amplifier module and install a new module.
Refer to the new module/component installation note at the
U300055 Control Module Incorrect car Check/up-date Car Configuration File using the manufacturer
configuration data approved diagnostic system
received
U300087 Control Module Missing message Check CJB 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
diagnostic system
U300316 Battery Voltage Circuit voltage below Carry out any pinpoint tests associated with this DTC using
threshold the manufacturer approved diagnostic system
U300317 Battery Voltage Circuit voltage above Carry out any pinpoint tests associated with this DTC using
threshold the manufacturer approved diagnostic system
Integrated Audio Module
account.

B1B6915 12 Volt supply Antenna power supply circuit Carry out any pinpoint tests associated with this DTC
circuit - short to battery, high using the manufacturer approved diagnostic system
resistance
B1B6911 12 Volt supply Antenna power supply circuit Carry out any pinpoint tests associated with this DTC
circuit - short to ground using the manufacturer approved diagnostic system. to
the electrical circuit diagrams and test the antenna power
supply circuit for short to ground
B1D1916 Compact Disc Unit Circuit voltage below Suspect the integrated audio module, check and install a
threshold new module as required, refer to the new
Index
B1D1977 Compact Disc Unit Commanded position not Suspect the integrated audio module, check and install a
reachable new module as required, refer to the new
Index
B1D1993 Compact Disc Unit No operation Suspect the integrated audio module, check and install a
new module as required, refer to the new
Index
B1A0111 Speaker #1 Front driver speaker circuits - Carry out any pinpoint tests associated with this DTC
short to ground using the manufacturer approved diagnostic system. Refer
to the electrical circuit diagrams and test front driver
speaker circuits for short to ground
B1A0112 Speaker #1 Front driver speaker circuits - Carry out any pinpoint tests associated with this DTC
short to power using the manufacturer approved diagnostic system. Refer
to the electrical circuit diagrams and test front driver
speaker circuits for short to power
B1A011A Speaker #1 Front driver speaker circuits - Carry out any pinpoint tests associated with this DTC
resistance below threshold using the manufacturer approved diagnostic system
B1A011B Speaker #1 Front driver speaker circuits - Carry out any pinpoint tests associated with this DTC
resistance above threshold using the manufacturer approved diagnostic system
B1A011C Speaker #1 Front driver speaker circuits - Suspect the integrated audio module. Check and install a
voltage out of range. Power new module as required, refer to the new
IC failure internal to the module/component installation note at the top of the DTC
integrated audio Index
B1A0211 Speaker #2 Front passenger speaker Carry out any pinpoint tests associated with this DTC
circuits - short to ground using the manufacturer approved diagnostic system. Refer
to the electrical circuit diagrams and test front passenger
B1A0212 Speaker #2 Front passenger speaker Carry out any pinpoint tests associated with this DTC
circuits - short to power using the manufacturer approved diagnostic system. Refer
to the electrical circuit diagrams and test front passenger
B1A021A Speaker #2 Front passenger speaker Carry out any pinpoint tests associated with this DTC
circuits - resistance below using the manufacturer approved diagnostic system
threshold
B1A021B Speaker #2 Front passenger speaker Carry out any pinpoint tests associated with this DTC
circuits - resistance above using the manufacturer approved diagnostic system
threshold
B1A021C Speaker #2 Front passenger speaker Suspect the integrated audio module. Check and install a
circuits - voltage out of new module as required, refer to the new
range. Power IC failure module/component installation note at the top of the DTC
internal to the integrated Index
audio
B1A0311 Speaker #3 Rear left speaker circuits - Carry out any pinpoint tests associated with this DTC
to the electrical circuit diagrams and test rear left
B1A0312 Speaker #3 Rear left speaker circuits - Carry out any pinpoint tests associated with this DTC
to the electrical circuit diagrams and test rear left
B1A031A Speaker #3 Rear left speaker circuits - Carry out any pinpoint tests associated with this DTC
B1A031B Speaker #3 Rear left speaker circuits - Carry out any pinpoint tests associated with this DTC
B1A031C Speaker #3 Rear left speaker circuits - Suspect the integrated audio module. Check and install a
B1A0411 Speaker #4 Rear right speaker circuits - Carry out any pinpoint tests associated with this DTC
to the electrical circuit diagrams and test rear right
to the electrical circuit diagrams and test rear right
B1A041A Speaker #4 Rear right speaker circuits - Carry out any pinpoint tests associated with this DTC
B1A041C Speaker #4 Rear right speaker circuits - Suspect the integrated audio module. Check and install a
B1A5613 Antenna Antenna circuit - open circuit Carry out any pinpoint tests associated with this DTC
using the manufacturer approved diagnostic system. Refer
to the electrical circuit diagrams and check antenna circuit
for open circuit
B1D7811 Auxiliary Input Auxiliary input circuit - short Carry out any pinpoint tests associated with this DTC
to ground using the manufacturer approved diagnostic system. Refer
to the electrical circuit diagrams and test Auxiliary input
B1D7812 Auxiliary Input Auxiliary input circuit - short Carry out any pinpoint tests associated with this DTC
to power using the manufacturer approved diagnostic system. Refer
circuits for short to power
B1D7813 Auxiliary Input Auxiliary input circuit - high Carry out any pinpoint tests associated with this DTC
resistance using the manufacturer approved diagnostic system. Refer
circuits for high resistance
B1D7911 Microphone Input Microphone input circuit - Carry out any pinpoint tests associated with this DTC
to the electrical circuit diagrams and test microphone
input circuits for short to ground
input circuits for short to power
high resistance using the manufacturer approved diagnostic system. Refer
input circuits for high resistance
B113411 Phone Input Phone input circuit - short to Refer to the electrical circuit diagrams and test phone
ground input circuits for short to ground
B113412 Phone Input Phone input circuit - short to Refer to the electrical circuit diagrams and test phone
power input circuits for short to power
B113413 Phone Input Phone input circuit - high Refer to the electrical circuit diagrams and test phone
resistance input circuits for high resistance
U210000 Initial Car configuration data not Check RJB for related DTCs and refer to the relevant DTC
Configuration Not received Index
Complete
U210100 Control Module Incorrect car configuration Check RJB for related DTCs and refer to the relevant DTC
Configuration data received Index. Check/amend Car Configuration File using the
Incompatible manufacturer approved diagnostic system
U300049 Control Module Internal electronic failure Suspect the integrated audio module, install a new
U300055 Control Module Incorrect car configuration Re-configure the RJB using the manufacturer approved
data received diagnostic system. Clear DTC and re-test. If the DTC
remains suspect the integrated audio module, refer to the
new module/component installation note at the top of the
DTC Index
U300087 Control Module Missing message Re-configure the RJB using the manufacturer approved
diagnostic system. Check integrated audio module for
DTCs and refer to the DTC Index. Check CAN network
integrity using the manufacturer approved diagnostic
system
U300098 Control Module Component or system over Check for additional DTCs and refer to DTC Index. Clear
temperature DTC and re-test/monitor condition
U300362 Battery Voltage Mis-match in battery voltage, Carry out any pinpoint tests associated with this DTC
of 2 volts or more, between using the manufacturer approved diagnostic system
integrated audio module and
RJB
Portable Audio Interface Module
account.

U300044 Control Module internal failure Suspect the portable audio interface module. Check and
Module install a new module as required, refer to the new
Index
U300045 Control Module internal failure Suspect the portable audio interface module. Check and
Module install a new module as required, refer to the new
Index
U300055 Control Module configuration/programming Re-program the portable audio interface module, clear DTC
Module failure and re-test. If DTC remains carry out MOST tests and test
USB cable for open, short circuit, clear DTC and re-test. If
DTC remains suspect the portable audio interface module,
check and install a new module as required, refer to the
new module/component installation note at the top of the
DTC Index
U300362 Battery Mis-match in battery voltage, of 2 Carry out any pinpoint tests associated with this DTC
Voltage volts or more, between portable using the manufacturer approved diagnostic system
audio interface module and RJB
Digital Audio Broadcast Module
account.

B11A411 L-Band DAB L-Band antenna If DTCs: B11A411, B11A511, U300044, U30004A, U300098, U300362
Antenna circuit - short to ground have logged at the same time with invalid snapshot data carry out a DTC
clear and re-read to ensure the DTCs have not re-logged. If the DTC
B11A411 does relog (without the other DTCs) carry out any pinpoint tests
associated with this DTC using the manufacturer approved diagnostic
system. Refer to electrical circuit diagrams and check DAB L-Band
antenna circuit for short to ground
B11A415 L-Band DAB L-Band antenna Carry out any pinpoint tests associated with this DTC using the
Antenna circuit - short to power, manufacturer approved diagnostic system. Refer to electrical circuit
open circuit diagrams and check DAB L-Band antenna circuit for short to power, open
circuit
B11A511 Band 3 DAB Band 3 antenna If DTCs: B11A411, B11A511, U300044, U30004A, U300098, U300362
Antenna circuit - short to ground have logged at the same time with invalid snapshot data carry out a DTC
clear and re-read to ensure the DTCs have not re-logged. If the DTC
B11A511 does relog (without the other DTCs) carry out any pinpoint tests
associated with this DTC using the manufacturer approved diagnostic
system. Refer to electrical circuit diagrams and check DAB Band 3
antenna circuit for short to ground
B11A515 Band 3 DAB Band 3 antenna Carry out any pinpoint tests associated with this DTC using the
Antenna circuit - short to power, manufacturer approved diagnostic system. Refer to electrical circuit
open circuit diagrams and check DAB Band 3 antenna circuit for short to power, open
circuit
U300004 Control Module System internal failure Clear the DTC and perform a system function check. If the DTC relogs
and the system do not function correctly suspect the digital audio
broadcast module. Check and install a new module as required
U300044 Control Module System internal failure If DTCs: B11A411, B11A511, U300044, U30004A, U300098, U300362
data memory have logged at the same time with invalid snapshot data carry out a DTC
failure clear and re-read to ensure the DTCs have not re-logged.
U30004A Control Module Incorrect component If the DTCs: B11A411, B11A511, U300044, U30004A, U300098, U300362
installed have logged at the same time with invalid snapshot data carry out a DTC
clear and re-read to ensure the DTCs have not re-logged. If the DTC does
re-log check/up-date Car Configuration File using manufacturer approved
diagnostic system
U300055 Control Module Incorrect Car Check/up-date Car Configuration File using manufacturer approved
Configuration File data diagnostic system
received
U300087 Control Module Missing message Check RJB for related DTCs and refer to relevant 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 diagnostic
system
U300098 Control Module Component or system If DTCs: B11A411, B11A511, U300044, U30004A, U300098, U300362
over temperature have logged at the same time with invalid snapshot data carry out a DTC
clear and re-read to ensure the DTCs have not re-logged.
U300362 Battery Mis-match in battery If DTCs: B11A411, B11A511, U300044, U30004A, U300098, U300362
Voltage voltage, of 2 volts or have logged at the same time with invalid snapshot data carry out a DTC
more, between digital clear and re-read to ensure the DTCs have not re-logged. If only DTC
audio broadcast module U300362 is logged carry out any pinpoint tests associated with this DTC,
and RJB check power supply circuits to Digital Audio Broadcast module and Rear
Junction Box.
account.

B101223 Heated Windshield Button stuck Check for stuck down/jammed button. Check and install a
Switch down/jammed new integrated control panel as required
Integrated control
panel failure
B101323 Heater Rear Defog Button stuck Check for stuck down/jammed button. Check and install a
Integrated control
panel failure
B101423 Recirculation Switch Button stuck Check for stuck down/jammed button. Check and install a
down/jammed new integrated control panel as required
Integrated control
panel failure
B101523 Screen On/Off Switch Button stuck Check for stuck down/jammed button. Check and install a
Integrated control
panel failure
B101623 Status Switch Button stuck Check for stuck down/jammed button. Check and install a
Integrated control
panel failure
B101723 Left Temperature Button stuck Check for stuck down/jammed button. Check and install a
Decrease Switch down/jammed new integrated control panel as required
Integrated control
panel failure
B101823 Right Temperature Button stuck Check for stuck down/jammed button. Check and install a
Decrease Switch down/jammed new integrated control panel as required
Integrated control
panel failure
B101923 Left Temperature Button stuck Check for stuck down/jammed button. Check and install a
Increase Switch down/jammed new integrated control panel as required
Integrated control
panel failure
B101A23 Right Temperature Button stuck Check for stuck down/jammed button. Check and install a
Increase Switch down/jammed new integrated control panel as required
Integrated control
panel failure
B101B23 Defrost Switch Button stuck Check for stuck down/jammed button. Check and install a
Integrated control
panel failure
B101C23 Seek Up Switch Button stuck Check for stuck down/jammed button. Check and install a
Integrated control
panel failure
B101D23 Seek Down Switch Button stuck Check for stuck down/jammed button. Check and install a
Integrated control
panel failure
B101E23 Air Conditioning Mode Button stuck Check for stuck down/jammed button. Check and install a
Integrated control
panel failure
B101F23 Eject Switch Button stuck Check for stuck down/jammed button. Check and install a
Integrated control
panel failure
B102023 Load Switch Button stuck Check for stuck down/jammed button. Check and install a
Integrated control
panel failure
B102123 Source Switch Button stuck Check for stuck down/jammed button. Check and install a
Integrated control
panel failure
B102223 Audio On/Off Switch Button stuck Check for stuck down/jammed button. Check and install a
Integrated control
panel failure
B11A923 Tone Button Button stuck Check for stuck down/jammed button. Check and install a
Integrated control
panel failure
B121F23 Climate Switch Button stuck Check for stuck down/jammed button. Check and install a
Integrated control
panel failure
U001088 Medium Speed CAN Bus off Carry out any pinpoint tests associated with this DTC
Communication Bus using the manufacturer approved diagnostic system
U014000 Lost Communication Missing message from Carry out any pinpoint tests associated with this DTC
W ith Body Control CJB using the manufacturer approved diagnostic system
Module
W ith Body Control RJB using the manufacturer approved diagnostic system
Module "B"
U015500 Lost Communication Missing message from Carry out any pinpoint tests associated to this DTC using
W ith Instrument Panel instrument cluster the manufacturer approved diagnostic system
Cluster (IPC) Control
Module
W ith Information Center information and using the manufacturer approved diagnostic system
"A" entertainment control
module
U030000 Internal Control Module Invalid car Re-configure the integrated control panel as new. Clear
Software Incompatibility configuration data DTC and re-test, if DTC remains suspect the integrated
received control panel. Check and install a new integrated control
panel as required, refer to the new module/component
U300041 Control Module Checksum error, Suspect the integrated control panel, check and install a
internal module failure new integrated control panel as required, refer to the new
Index
Touch Screen Display (TSD)
account.

B100E25 Video Input 'A' ODST Only - TV video Carry out any pinpoint tests associated with this DTC using the
synch mis-match manufacturer approved diagnostic system
B100F25 Video Input 'B' ODST Only - Reverse Carry out any pinpoint tests associated with this DTC using the
Camera video synch manufacturer approved diagnostic system
mis-match
U1A0101 Communication ODST Only - cable from Carry out any pinpoint tests associated with this DTC using the
Link navigation module not manufacturer approved diagnostic system. Check electrical
correctly installed harness from navigation module is correctly installed
U1A0115 Communication TSD to navigation Carry out any pinpoint tests associated with this DTC using the
Link module circuit - short manufacturer approved diagnostic system. Refer to the electrical
to power, open circuit circuit diagrams and check TSD to navigation module circuit for
U1A4B48 Control Module Supervision software Re-configure the TSD using the manufacturer approved
Processor B failure diagnostic system
U300044 Control Module EEPROM, External RAM Suspect the TSD, check and install a new TSD as required, refer
access failure to the new module/component installation note at the top of
the DTC Index
U300048 Control Module Supervision software Re-configure the TSD using the manufacturer approved
failure diagnostic system
U30004B Control Module Touch panel backlight - Allow the system to cool, clear the DTC and check/monitor
high temperature system for re-occurrence. If DTC re-occurs suspect the TSD.
detected Check and install a new TSD as required, refer to the new
U300055 Control Module Incorrect Car Check/amend Car Configuration File using the manufacturer
Configuration approved diagnostic system
Parameters received
U300087 Control Module Car Configuration File Check RJB for related DTCs and refer to relevant DTC Index.
not received Check CAN and MOST networks, carry out the CAN and MOST
network tests using the manufacturer approved diagnostic
system
U300098 Control Module TSD internal Allow the system to cool, clear the DTC and check/monitor
temperature over limit system for re-occurrence. If DTC re-occurs suspect the TSD.
Check and install a new TSD as required, refer to the new
U300316 Battery Voltage Circuit voltage below Carry out any pinpoint tests associated with this DTC using the
U300317 Battery Voltage Circuit voltage above Carry out any pinpoint tests associated with this DTC using the
Satellite Radio Module
account.
B1A8911 Satellite Satellite antenna circuit - Carry out any pinpoint tests associated with this DTC using
Antenna short to ground the manufacturer approved diagnostic system. Refer to the
electrical circuit diagrams and check satellite antenna circuit
for short to ground
Antenna short to power the manufacturer approved diagnostic system. Refer to the
for short to power
Antenna open circuit the manufacturer approved diagnostic system. Refer to the
for open circuit
U300004 Control System internal failure Suspect the satellite radio module, check and install a new
Module module as required, refer to the new module/component
U30004A Control Incorrect component installed Suspect the satellite radio module, check and install a new
U300055 Control Vehicle not configured for Check/amend the Car Configuration File using the
Module satellite radio system manufacturer approved diagnostic system
U300087 Control Missing message Suspect the satellite radio module, check and install a new
U300098 Control Component or system over Clear DTC and re-test. Check/monitor condition for
Module temperature re-occurrence
U300362 Battery Mis-match in battery voltage, Carry out any pinpoint tests associated with this DTC using
Voltage of 2 volts or more, between the manufacturer approved diagnostic system
satellite radio module and RJB
Television Module
account.

B1A5611 Antenna Antenna circuit - Carry out any pinpoint tests associated with this DTC using the
short to ground manufacturer approved diagnostic system. Refer to electrical circuit
diagrams and check antenna circuit for short to ground
short to power manufacturer approved diagnostic system. Refer to electrical circuit
diagrams and check antenna circuit for short to power
open circuit manufacturer approved diagnostic system. Refer to electrical circuit
diagrams and check antenna circuit for open circuit
B1D5511 Antenna#2 Antenna#2 circuit - Carry out any pinpoint tests associated with this DTC using the
short to ground manufacturer approved diagnostic system. Refer to electrical circuit
diagrams and check antenna#2 circuit for short to ground
short to power manufacturer approved diagnostic system. Refer to electrical circuit
diagrams and check antenna#2 circuit for short to power
open circuit manufacturer approved diagnostic system. Refer to electrical circuit
diagrams and check antenna#2 circuit for open circuit
B1D5611 Antenna #3 Antenna#3 circuit - Carry out any pinpoint tests associated with this DTC using the
Circuit short to ground manufacturer approved diagnostic system. Refer to electrical circuit
Circuit short to power manufacturer approved diagnostic system. Refer to electrical circuit
Circuit open circuit manufacturer approved diagnostic system. Refer to electrical circuit
Circuit short to ground manufacturer approved diagnostic system. Refer to electrical circuit
Circuit short to power manufacturer approved diagnostic system. Refer to electrical circuit
Circuit open circuit manufacturer approved diagnostic system. Refer to electrical circuit
B1D5811 Television Television output Carry out any pinpoint tests associated with this DTC using the
Output circuit - short to manufacturer approved diagnostic system. Refer to electrical circuit
ground diagrams and check television output circuit for short to ground
Output circuit - short to manufacturer approved diagnostic system. Refer to electrical circuit
power diagrams and check television output circuit for short to power
Output circuit - open circuit manufacturer approved diagnostic system. Refer to electrical circuit
diagrams and check television output circuit for open circuit
U300049 Control Internal electronic Suspect the television module, check and install a new module as
Module failure required, refer to the new module/component installation note at the
U300316 Battery Circuit voltage Carry out any pinpoint tests associated with this DTC using the
Voltage below threshold manufacturer approved diagnostic system
U300317 Battery Circuit voltage Carry out any pinpoint tests associated with this DTC using the
Voltage above threshold manufacturer approved diagnostic system
Information and Entertainment System - General Information - Cellular
Phone
For a detailed description of the Cellular Phone System, refer to the relevant Description and Operation sections in the
workshop manual.
vehicle.
Visual Inspection
Microphone Electrical connectors
Bluetooth antenna Wiring harness for damage or corrosion
Fuses
4. 4. If the cause is not visually evident, verify the symptom and refer to the Symptom Chart, alternatively check for
Diagnostic Trouble Codes (DTCs) and refer to the relevant DTC Index.
Symptom Chart
Symptom Action
Unable to pair GO to Pinpoint Test A.
Not Auto Connecting GO to Pinpoint Test B.
No Audio to 3rd Party GO to Pinpoint Test C.
No Audio from 3rd Party GO to Pinpoint Test D.
No Audio GO to Pinpoint Test E.
DTC Index
account.

B1A5613 Antenna Bluetooth antenna circuit - Refer to the electrical circuit diagrams and check blue tooth
open circuit antenna circuit for open circuit
B1D7984 Microphone Input Signal amplitude < Refer to the electrical circuit diagrams and test microphone
minimum input circuit for short/open circuit. Check integrated audio
module for related DTCs and refer to relevant DTC Index
U1A0088 Private Bluetooth phone module Suspect the module. Check and install a new telephone
Communication internal communications module as required, refer to the new module/component
Network failure installation note at the top of the DTC Index
U210000 Initial Initial configuration not Re-configure the RJB using the manufacturer approved
Configuration Not complete diagnostic system. If DTC remains, carry out CAN network
Complete integrity tests using the manufacturer approved diagnostic
system
U210100 Control Module Configuration incompatible Re-configure the RJB using the manufacturer approved
Configuration diagnostic system. If DTC remains, suspect the telephone
Incompatible module. Check and install a new telephone module as
U300044 Control Module Data memory failure Re-configure the telephone module. If the DTC remains,
suspect the telephone module. Check and install a new
telephone module as required, refer to the new
Index
U300045 Control Module Program memory failure Re-configure the telephone module. If the DTC remains,
suspect the telephone module. Check and install a new
telephone module as required, refer to the new
Index
U300055 Control Module Incorrect car configuration Re-configure the RJB using the manufacturer approved
data received diagnostic system. Clear DTC and re-test. If the DTC
remains suspect the telephone module. Check and install a
new module as required, refer to the new
Index
U300098 Control Module Component or system over Check for additional DTCs and refer to DTC Index. Clear
temperature DTC and re-test/monitor condition for re-occurrence
U300362 Battery Voltage Mis-match in battery Carry out any pinpoint tests associated with this DTC using
voltage, of 2 volts or the manufacturer approved diagnostic system
more, between telephone
module and RJB
Pinpoint Tests
PINPOINT TEST A : UNABLE TO PAIR

CONDITIONS
A1: 'NO PHONE FITTED' DISPLAY
NOTE: Prior to continuing with any diagnosis, ensure that the Customer telephone and level of software is included on
the JLR approved list, the telephone battery is fully charged and in a serviceable condition, the bluetooth function is
activated and the telephone handset is placed within the vehicle cabin area.
1 Carry out checks to determine if 'No Phone Fitted' is shown on vehicle display.
Is 'No Phone Fitted' displayed?
Yes
GO to A2.
No
Locate the connected telephone and if not Customer telephone, disconnect from the system.
A2: TELEPHONE BLUETOOTH DEVICE SEARCH
1 Carry out Bluetooth device search using Customer handset.
Is 'Jaguar' identified in Bluetooth device list?
Yes
Select device from list, then continue with diagnosis.GO to A3.
No
Carry out further Bluetooth device search, to a maximum of 4 times, waiting approximately 20 seconds
between searches. If 'Jaguar' still not identified in Bluetooth device list, set ignition status to OFF,
wait approximately 30 seconds and set ignition status to ON. Carry out further Bluetooth device
search, to a maximum of 4 times, waiting approximately 20 seconds between searches. If 'Jaguar' still
not identified in Bluetooth device list, contact your local in market support for further assistance.
A3: TELEPHONE HANDSET ERROR
1 Check for any error shown on the telephone handset when 'Jaguar' is selected from the Bluetooth
device list.
W as an error immediately shown on the telephone handset?
Yes
W ait approximately 10 seconds then re-attempt selection, to a maximum of 4 times, waiting
approximately 10 seconds between each attempt. If error still being displayed, contact your local in
market support for assistance.
No
Enter PIN '1313' then continue with diagnosis.GO to A4.
A4: PIN ENTRY STATUS
1 Check for successful PIN entry.
W as PIN entry successful?
Yes
GO to A5.
No
W ait approximately 10 seconds then re-attempt PIN entry, to a maximum of 4 times, waiting
approximately 10 seconds between each attempt. If PIN entry is still un-successful, contact your local
in market support for assistance.
A5: 'NO PHONE FITTED' DISPLAY
1 Carry out checks to determine if 'No Phone Fitted' is still shown on vehicle display.
Is 'No Phone Fitted' still displayed?
Yes
From the telephone handset, select the connect option for the 'Land Rover' device identified in the
Bluetooth device list. If 'No Phone Fitted' is still displayed, suspect a telephone handset fault. Carry
out Pinpoint test again using known good telephone handset.
No
The telephone is paired and connected to the system. No further action is required for this symptom.
PINPOINT TEST B : NOT AUTOMATICALLY CONNECTING

CONDITIONS
B1: BLUETOOTH MODULE PAIRED DEVICE LIST
the JLR approved list, the telephone battery is fully charged and in a serviceable condition, the bluetooth and auto
connect functions are activated and the telephone handset is placed within the vehicle cabin area.
1 Carry out checks to determine if the Customer telephone is shown in the Bluetooth Module paired
device list.
Is the Customer telephone in the Bluetooth Module paired device list?
Yes
GO to B2.
No
Carry out Unable to Pair Pinpoint Test.GO to A.
B2: CUSTOMER HANDSET PAIRED DEVICE LIST
1 Carry out checks to determine if the Bluetooth Module is shown in the Customer telephone paired
device list.
Is the Bluetooth Module in the Customer telephone paired device list?
Yes
GO to B3.
No
Carry out Unable to Pair Pinpoint Test.GO to A.
B3: CUSTOMER TELEPHONE IN POSITION 1
1 Carry out checks to determine if the Customer telephone is in position 1 in the Bluetooth Module
paired device list.
Is the Customer telephone in position 1?
Yes
GO to B4.
No
Advise Customer that auto connection will only be attempted with the device that is shown in
position 1 in Bluetooth Module paired device list.
B4: CHECK FOR DTC B1A56-13
1 Using Manufacturer approved diagnostic system, check for DTC B1A56-13.
Is DTC B1A56-13 logged?
Yes
Carry out remedial actions as outlined in DTC Index. If symptom remains, contact your local in
market support for assistance.
No
GO to B5.
B5: BLUETOOTH CONNECTION
1 Carry out checks to determine if Bluetooth connection icon is shown on Customer Bluetooth
telephone screen but shows 'No Phone Fitted' on vehicle screen.
Is Bluetooth connection icon shown on the Customer handset but 'No Phone Fitted' displayed on vehicle
screen?
Yes
GO to B9.
No
GO to B6.
B6: 'LAND ROVER' AUTHORISATION
NOTE: Some handsets may require operator intervention to manually authorise connection.
1 Carry out checks to determine if 'Land Rover' is authorised in the Customer Bluetooth telephone
device list menu.
Is 'Land Rover' authorised in the Customer Bluetooth telephone device list menu?
Yes
GO to B7.
No
Advise customer that 'Land Rover' needs to be authorised in the Customer Bluetooth telephone
device list menu, or operator intervention may be required to manually authorise connection.
B7: SEARCH FOR DEVICES SCREEN
1 Select the search for devices button on the vehicle display.
Does pressing the search for devices button bring up the searching screen on the vehicle display?
Yes
Contact your local in market support for assistance.
No
GO to B8.
B8: CYCLE IGNITION AND CHECK SEARCH FOR DEVICES SCREEN
1 Lock vehicle (wait 60s) before unlocking and turning Ignition status back to ON.
Does pressing the search for devices button bring up the searching screen on the vehicle display?
Yes
No further action required for this Symptom. Possible intermitent fault.
No
B9: PAIRED DEVICE
1 Check Customer telephone paired device list to establish which device the Customer telephone is
connected to.
Is the Customer telephone connected to the vehicle?
Yes
Lock vehicle (wait 60s) before unlocking and turning Ignition status back to ON. If Not Automatically
Connecting, contact you local in market support for assistance.
No
Using the Customer telephone controls, disconnect from the currently connected device and delete
from paired device list. Lock vehicle (wait for 60s) before unlocking and turning Igition status to ON.
If Not Automatically Connecting, contact your local in market support for assistance.
PINPOINT TEST C : NO AUDIO TO THIRD PARTY

C1: MICROPHONE DIAGNOSTIC TROUBLE CODES (DTCS)
the JLR approved list, the telephone battery is fully charged and in a serviceable condition, the telephone is placed within
the vehicle cabin area and is connected to the vehicle via bluetooth.
1 Using the Manufacturer approved diagnostic system, check for any logged microphone DTCs in
Audio Front Control module.
Is DTC B1D79-01 logged?
Yes
Carry out diagnosis of electrical failure as advised in Action column of DTC Index.
No
PINPOINT TEST D : NO AUDIO FROM THIRD PARTY

D1: 'IN CALL' DISPLAY
1 Carry out checks to determine if 'In Call' is shown on the vehicle display.
Is vehicle display showing 'In Call'?
Yes
No
Call has ended. No further action is required for this symptom.
PINPOINT TEST E : NO AUDIO

E1: AUDIO FROM THIRD PARTY
1 Establish from Customer feedback/symptom if there is Audio from the Third Party.
Is there Audio from the Third Party?
Yes
GO to E2.
No
Refer to the 'No Audio From Third Party' Pinpoint test.GO to D.
E2: AUDIO TO THIRD PARTY
1 Establish from Customer feedback/symptom if there is Audio to the Third Party.
Is there Audio to the Third Party?
Yes
GO to E3.
No
Refer to the 'No Audio To Third Party' Pinpoint test.GO to C.
E3: CD OR RADIO AUDIO
1 Establish from Customer feedback/symptom if there is Audio from the CD or Radio.
Is there Audio from the CD or Radio?
Yes
GO to E4.
No
Suspect MOST ring fault, refer to electrical circuit diagrams and check/rectify MOST ring as
necessary.
E4: TELEPHONE HANDSET AUDIO
1 Establish from Customer feedback/symptom if there is Audio from the telephone handset.
Is there Audio from the telephone handset?
Yes
Ensure vehicle is parked. Disconnect and reconnect handset. If issue not resolved, contact your
local in market support for assistance.
No
Contact you local in market support for assistance.
Information and Entertainment System - General Information - Navigation
System
For a detailed description of the Navigation System, refer to the relevant Description and Operation sections in the
workshop manual. REFER to: (415-01 Information and Entertainment System)
Navigation System (Description and Operation),

Video System (Description and Operation).
vehicle.
Visual Inspection
Information and entertainment module Fuses
Audio amplifier module Loose or corroded connector(s)
Integrated audio module Information and entertainment module
Portable audio interface module Audio amplifier module
Digital audio broadcast module Integrated audio module
Integrated control panel Portable audio interface module
Touch screen display Digital audio broadcast module
Satellite radio module Integrated control panel
Television module Touch screen display
Navigation system module Satellite radio module
Telephone module Television module
Compact disc player jammed, not loading Navigation system module
Scratched/dirty compact discs Telephone module
Speakers Speakers
Index.
DTC Index
Navigation System Module
account.

B1A8911 Satellite Satellite antenna circuit Check satellite antenna connections. Refer to the electrical circuit
Antenna - short to ground diagrams and check satellite antenna circuit for short to ground
B1A8913 Satellite Satellite antenna circuit Check satellite antenna connections. Refer to the electrical circuit
Antenna - open circuit diagrams and check satellite antenna circuit for open circuit
B1A891B Satellite Satellite antenna - Suspect navigation module. Check and install a new navigation
Antenna circuit resistance above system module as required, refer to the new module/component
threshold installation note at the top of the DTC Index
B1D5514 Antenna #2 TMC/VICS FM antenna Check TMC/VICS FM antenna connections. Refer to the electrical
circuit - open circuit circuit diagrams and check TMC/VICS FM antenna circuit for open
circuit
B1D5614 Antenna #3 VICS antenna circuit - Check VICS antenna connections. Refer to the electrical circuit
Circuit open circuit diagrams and check VICS antenna circuit for open circuit
U200531 Vehicle Missing vehicle speed Check ABS module and Instrument Cluster for speed related DTCs
Speed message and refer to relevant DTC Index
U300049 Control Internal electronic Suspect the navigation module. Check and install a new navigation
Module failure system module as required, refer to the new module/component
U300055 Control Incorrect car Using the manufacturer approved diagnostic system check/amend
Module configuration data the Car Configuration File parameter in block 2, byte 127 to match
received vehicle market/specification. If the DTC remains check navigation
system module part number and ensure the correct component is
installed to vehicle market/specification
U300087 Control Missing message Re-configure the RJB using the manufacturer approved diagnostic
Module system. Check navigation module for DTCs and refer to the DTC
Index. Check CAN network integrity using the manufacturer
U300098 Control Component or system Check for additional DTCs and refer to DTC Index. Clear DTC and
Module over temperature re-test/monitor condition for re-occurrence
U300317 Battery Circuit voltage above Carry out any pinpoint tests associated with this DTC using the
Voltage threshold manufacturer approved diagnostic system
U300362 Battery Mis-match in battery Carry out any pinpoint tests associated with this DTC using the
Voltage voltage, of 2 volts or manufacturer approved diagnostic system
more, between
navigation module and
RJB
Touch Screen Display (TSD)
account.

B100E25 Video Input 'A' ODST Only - TV video Carry out any pinpoint tests associated with this DTC using the
synch mis-match manufacturer approved diagnostic system
B100F25 Video Input 'B' ODST Only - Reverse Carry out any pinpoint tests associated with this DTC using the
Camera video synch manufacturer approved diagnostic system
mis-match
U1A0101 Communication ODST Only - cable from Carry out any pinpoint tests associated with this DTC using the
Link navigation module not manufacturer approved diagnostic system. Check electrical
correctly installed harness from navigation module is correctly installed
U1A0115 Communication TSD to navigation Carry out any pinpoint tests associated with this DTC using the
Link module circuit - short manufacturer approved diagnostic system. Refer to the electrical
to power, open circuit circuit diagrams and check TSD to navigation module circuit for
U1A4B48 Control Module Supervision software Re-configure the TSD using the manufacturer approved
Processor B failure diagnostic system
U300044 Control Module EEPROM, External RAM Suspect the TSD, check and install a new TSD as required, refer
access failure to the new module/component installation note at the top of
the DTC Index
U300048 Control Module Supervision software Re-configure the TSD using the manufacturer approved
failure diagnostic system
U30004B Control Module Touch panel backlight - Allow the system to cool, clear the DTC and check/monitor
high temperature system for re-occurrence. If DTC re-occurs suspect the TSD.
detected Check and install a new TSD as required, refer to the new
U300055 Control Module Incorrect Car Check/amend the Car Configuration File using the manufacturer
Configuration approved diagnostic system
Parameters received
U300087 Control Module Car Configuration File Check RJB for related DTCs and refer to relevant DTC Index.
not received Check CAN and MOST networks, carry out the CAN and MOST
network tests using the manufacturer approved diagnostic
system
U300098 Control Module TSD internal Allow the system to cool, clear the DTC and check/monitor
temperature over limit system for re-occurrence. If DTC re-occurs suspect the TSD.
Check and install a new TSD as required, refer to the new
U300316 Battery Voltage Circuit voltage below Carry out any pinpoint tests associated with this DTC using the
U300317 Battery Voltage Circuit voltage above Carry out any pinpoint tests associated with this DTC using the
Information and Entertainment System -
Description Nmlb-ft lb-in
Audio antenna unit to "D" pillar retaining bolts 9 - 80
Digital Radio antenna pod retaining nuts 5 - 48
Amplifier retaining nuts 7 - 62
Information and entertainment display retaining bolts 2 - 17
Information and entertainment display mounting bracket to Information and entertainment display retaining 3 - 26
bolts
Information and entertainment module retaining bolts 3 - 26
Instrument panel speaker retaining screws 2 - 18
Steering wheel audio control switch retaining screws 3 - 26
Subwoofer amplifier retaining nuts 7 - 62
Subwoofer speaker retaining bolts 6 - 53
Information and Entertainment System - Audio System - Component
Location
ItemDescription
1 IAM (integrated audio module)
2 Touch-screen
3 ICP (integrated control panel)
4 ICM (information control module)
5 Roof pod antenna module (DAB band L and satellite radio receiver antennas)
6 RF filter
7 DAB (digital audio broadcasting) radio receiver (Optional - Europe only)
8 Satellite radio digital receiver (Optional - NAS only)
9 Power amplifier (Not fitted to the Jaguar Sound System)
10 RF filter
11 Diversity antenna module (AM/FM and DAB band III antennas)
12 Portable audio interface console (Optional)
13 Portable audio module (Optional)
14 Steering wheel remote audio controls
Information and Entertainment System - Audio System - Overview
OVERVIEW
The audio system is available in three versions.
Jaguar Sound System

Jaguar 320W Premium Sound System
Bowers & Wilkins 440W Surround Sound System
The audio systems are instrument panel mounted and combine the radio tuner with a slot loading single or 6 disc CD
(compact disc) player. All units have AM/FM diversity reception, through the diversity antenna module, which receives
signals from antennas located in the heated rear window. The audio systems have various levels of user control through
the Touch-screen, ICP (integrated control panel) and steering wheel control panel. The Jaguar Sound System (base audio
unit) with single CD player is only compatible with standard CD's. All other versions of CD player are compatible with
standard CDs and CDs with MP3 or W MA (windows media audio) files.
A portable audio module allows for the connection of a range of portable audio devices to the cars audio system. The
portable audio module is controlled through the IAM (integrated audio module) and Touch-screen with play back through
the cars speaker system. The introduction of this system allows the user to import their personal portable media player to
interface with the car, including iPod and other MP3 players, or USB mass storage devices such as memory sticks. MP3
players can also be controlled through the Touch-screen if they are configured as mass storage devices. Details of how to
do this will be contained in the manufacturers instructions.
The chosen audio device can be plugged into the car using an interface panel located in the floor console between the
front seats. The interface includes a 3.5mm auxiliary jack-plug socket, a 12-volt power supply, a dedicated iPod connector
with charging function, plus a USB2 connector which allows connectivity for a wide variety of USB devices. The USB port
also provides a charging function although it does not support a USB hub. The maximum charging current supplied is
500ma. The user can connect an iPod and USB device at the same time, changing the source via the Touch-screen. The non
selected source will still charge.
The Jaguar Sound System is the basic audio system which comprises of an IAM (integrated audio module) with no external
amplifier and 8 speakers.
The Jaguar 320W Premium Sound System has the addition of an AUD 8 power amplifier and a 9 speaker system.
The Bowers & Wilkins 440w Surround Sound System additions include an AUD 12 power amplifier, a Dolby Pro-Logic 2 7.1
Surround Sound System, and 14 speakers.
DAB (digital audio broadcasting) is available for most European markets and gives access to digital radio channels for
better sound quality and enhanced functionality depending on local service availability. The DAB (digital audio
broadcasting) module is located in the luggage compartment. The system receives reception signals from the following
sources to ensure optimum signal strength.
DAB band L antenna located in the roof pod antenna module

DAB band III antenna located in the heated rear window.
For NAS vehicles the digital format adopted is satellite radio which specifically links to the Sirius network. The system
operates in the S-band frequency range, and as a result of the use of satellite transmission, has the ability to provide CD
quality audio broadcasts over very large areas (typically continents). The satellite radio receiver is located in the luggage
compartment. The system receives reception signals from the satellite radio antenna located in the roof pod module.
Primary user control of the audio system is via the ICP (integrated control panel) and the Touch-screen which are located
in the center of the instrument panel. Control signals from the ICP (integrated control panel) are relayed on the medium
speed CAN (controller area network) bus to the ICM (information control module). The ICM (information control module)
relays the control signals to the rest of the audio system on the MOST (media oriented systems transport) ring. The ICM
(information control module) is the timing master for the MOST (media oriented systems transport) ring and also hosts a
gateway function between the medium speed CAN bus and the MOST (media oriented systems transport) ring. Audio
output signals on the Jaguar 320W Premium Sound System and Bowers & Wilkins 440W Surround Sound System are sent
on the MOST (media oriented systems transport) ring from the IAM (integrated audio module) to the power amplifier for
speaker output.
Information and Entertainment System - Audio System - System Operation
Control Diagram
NOTE: A = Hardwired; N = Medium Speed CAN (controller area network) bus; O = LIN bus; P = MOST ring; T = Coaxial
ItemDescription
1 Battery
7 Portable audio module
8 Clock spring
10 Portable audio interface panel
11 Microphone
12 Touch-screen
13 Power amplifier
14 Diversity antenna module
16 DAB receiver/Satellite Radio receiver (Note: There is no co-axial link from the diversity antenna module to the
satellite radio receiver)
17 Roof pod
ItemDescription
1 Navigation computer (Optional)
2 DAB (digital audio broadcasting) radio receiver (Optional - Europe only)
3 Satellite Radio digital receiver (Optional - NAS only)
4 Telephone control module (Optional)
5 Touch-screen
6 TV tuner (Optional)
7 Power amplifier (Not fitted to the Jaguar Sound System)
9 Portable audio module (Optional)
System Operation
AUDIO SYSTEM OPERATION
The components of the audio/infotainment system are all connected on the MOST (media orientated systems transport)
ring. The MOST (media orientated systems transport) ring is a fibre optic communications bus for multimedia applications.
Audio and control information is passed around the MOST (media orientated systems transport) ring and can be picked up
by any of the systems units. For example, radio station tuning/selection input by the vehicle user into the Touch-screen is
sent along the MOST (media orientated systems transport) ring and collected by the IAM (integrated audio module) which
then selects the requested radio station.
MOST (media orientated systems transport) technology uses a plastic optical fibre which forms a network connecting the
audio and multimedia system components. Each component in the ring is connected to the plastic optical fibre through a
device known as a FOT (fibre optical transceiver). Each FOT (fibre optical transceiver) has two optical connections; one
connection is sensitive to light and is the input, the second connection forms the light source and is the output. The
system operates by connecting the output from one FOT (fibre optical transceiver) to the input of another FOT (fibre
optical transceiver).
The light signals are sent in one direction only and are formed in the following way:
Electrical signals are converted into an electrical current

The current then drives an LED (light emitting diode) in the FOT (fibre optical transceiver) to produce a high
intensity red light
The LED transmits the light through a fibre optic cable
A photo diode in the FOT (fibre optical transceiver) at the opposite end of the fibre optic cable detects the light.
The following components may be connected to the MOST ring dependant on the vehicle equipment level:
IAM (integrated audio module)

Touch-screen
ICM (information control module)
DAB (digital audio broadcasting) radio receiver (Optional - Europe only)
Satellite radio digital receiver (Optional - NAS only)
Power amplifier (Not fitted to the Jaguar Sound System)
Portable audio module (Optional)
Telephone control module (Optional)
Navigation computer (Optional)
TV tuner (Optional)
NOTE: Do not view the red light directly
MOST is a synchronous network. A timing master supplies the clock information and all other devices on the network
synchronize their operation to this clock. The timing master for the MOST (media orientated systems transport) network on
this vehicle is the ICM (information control module). This unit also controls and manages the MOST (media orientated
systems transport) ring and the system components.
An Optical Bus tester is used in conjunction with the Jaguar diagnostic system to diagnose the MOST (media orientated
systems transport) system. The Optical Bus tester emits a visible, high intensity red light which can be connected into the
ring at any point to test the ring integrity. Disconnecting a MOST (media orientated systems transport) connector will
reveal if the high intensity red light is visible.
If a break occurs in the MOST (media orientated systems transport) ring fault codes are stored in the ICM (information
control module) which can be retrieved using the Jaguar diagnostic system equipment.
With reference to the audio system information and signal transfer the instrument cluster is the gateway between the high
and medium speed CAN bus communication protocols. The ICM (information control module) is the gateway between
medium speed CAN and the MOST (media orientated systems transport) systems.
A typical example of information transfer is vehicle speed information from the ABS (anti-lock brake system) module used
to control the automatic volume control function. The vehicle speed information from the ABS module is sent on the high
speed CAN network and collected by the instrument panel gateway. The signal is passed to the medium speed CAN
network and onto the ICM (information control module) gateway. The ICM (information control module) calculates the
volume adjustment required. The corrected audio volume level signal is sent on the MOST (media orientated systems
transport) network to the IAM (integrated audio module) or Power amplifier (dependant on vehicle equipment level) for
output to the speaker system.
AUDIO SYSTEM GATEWAY FUNCTIONS

With reference to the audio system information and signal transfer the instrument cluster is the gateway between the high
and medium speed CAN bus communication protocols. The ICM is the gateway between medium speed CAN and the MOST
systems.
A typical example of information transfer is vehicle speed information from the ABS (anti-lock brake system) module used
to control the automatic volume control function. The vehicle speed information from the ABS module is sent on the high
speed CAN network and collected by the instrument panel gateway. The signal is passed to the medium speed CAN
network and onto the ICM gateway. The ICM calculates the volume adjustment required. The corrected audio volume level
signal is sent on the MOST network to the IAM or Power amplifier (dependant on vehicle equipment level) for output to the
speaker system.
AUDIO SYSTEM USER CONTROLS

Touch-Screen
ItemDescription
1 Touch-screen
2 Home menu button
3 Touch-screen on/off button
The Touch-screen forms the basis of the audio system. It communicates with the rest of the audio/infotainment system on
the MOST ring and allows control of the audio system and other infotainment systems from a single point.
The Touch-screen communicates with the IAM on the MOST ring and provides the primary user interface and display of the
audio system controls. No configuration procedure is required if the touch-screen is replaced.
Calibration of the Touch-screen using the Jaguar approved diagnostic equipment enables updates to be downloaded as
new technology becomes available or any fault concerns require software updates.
The touch-screen provides user control of the following systems:
System Functions
Audio Radio display AM/FM or DAB, auxiliary and portable audio, digital TV or CD (compact disc)
Climate Air conditioning, distribution, seats, heated steering wheel, automatic air recirculation
control
Telephone Digit dialer, phone book, last ten calls (made, received, missed)
Navigation Destination, stored locations, navigation setup, route options
Vehicle Security, parking, valet mode, trip computer, clock, brightness, contrast, system settings, vehicle settings,
display settings
ItemDescription
1 Touch-screen
2 CD load
3 CD load and eject slot
4 Seek up
5 Settings button
6 Audio system on/off and volume control
7 Audio source
8 Seek down
9 Eject
The ICP duplicates many of the touch-screen audio user control features. Any volume setting made whilst in audio, TV,
phone, navigation or voice activation mode will be memorized for that system. The ICP communicates with the ICM on the
medium speed CAN. The ICM converts control/command signals from the ICP and then distributes the information onto the
MOST system to the audio system and other information and entertainment systems.
No configuration procedure is required if the ICP is replaced. There is no option to calibrate the ICP using the Jaguar
Steering W heel Controls
ItemDescription
1 Volume adjustment
2 Change pre-set radio stations or CD tracks
3 Select audio source
4 Audio mute control/JaguarVoice control
Additional control of the audio system is available in the form of steering wheel mounted switches which are located on
the left hand side of the steering wheel. The four switches provide for volume adjustment, change pre-set radio stations or
CD tracks, select audio source and finally audio mute control. The mute control is also used for JaguarVoice control.
The steering wheel audio control switches are hardwired through the clock spring to the ICM. The ICM processes the
analogue signals from the switches into digital signals. The digital signals are then passed from the ICM onto the MOST
system to control the requested audio functions.
AVC (automatic volume control) controls the audio volume in relation to vehicle speed. As vehicle speed increases the
audio level is adjusted to compensate for extra road and vehicle noise. There are three settings for AVC:
Low
Medium
High
Setting of the AVC level is made using the audio controls. The default setting is medium.
The vehicle speed signal is used to enable the ICM to calculate the volume adjustment required. The vehicle speed signal
is received over the CAN. The signal is an average of the four wheel speed sensor signals. Should an invalid speed signal
be received the AVC will not alter the output volume.
INTEGRATED AUDIO MODULE
The IAM is located in the center console behind the ICP faceplate, and combines the radio tuner and CD player. The head
unit controls which of the two sources is routed to the speakers. All tuner versions have AM/FM reception. Each audio
system features auto-store, with a press and hold function to store selected channels as pre-sets. The standard search
facility finds the nine strongest channels currently available, while search and manual tuning allow channels to be stored
as above.
The Jaguar Sound System IAM uses an internal amplifier which directly drives the system speakers. The Jaguar 320W
Premium Sound System and Bowers & W ilkins 440W Surround Sound System differs from the Jaguar Sound System with the
addition of an external amplifier. Audio output signals from the IAM are sent on the MOST system to the external amplifier
which drives the system speakers.
Depending on audio specification the slot-loading CD unit is either a single-disc type or six-disc auto-changer. The system
automatically detects the CD format of the source (standard CD, MP3 or WMA files) and offers a full range of options,
presenting folders on the touch-screen, listed by albums and tracks, to browse as on a PC. Both versions have mix and
repeat functions and the six-disc version displays disc names.
The IAM communicates on the MOST system with the rest of the audio system. If the IAM is replaced it must be configured
as a new module using the Jaguar approved diagnostic equipment.
Calibration of the IAM using the Jaguar approved diagnostic equipment enables updates to be downloaded as new
technology becomes available or any fault concerns require software updates.
Audio Antennas
ItemDescription
1 Single TV antenna module
2 RF filter
4 Heated rear window
5 Heated rear window upper section
6 Heated rear window lower section
7 Triple TV antenna module
8 RF filter
The diversity antenna module, located on the left hand side of the heated rear window, receives signals from four
antennas located in the heated rear window, where one antenna is dedicated as an AM antenna.
The diversity tuning system ensures that the strongest signals are used by the radio system to ensure the best possible
FM reception. Using the three remaining receiving antennas serves to eliminate multipath signal distortion. Typically, the
signal from the antenna with the least noise is chosen, and the other antennas are ignored.
The diversity antenna module is an interface between the antenna aerials in the heated rear window and audio system
modules/tuners. It provides antenna signals to the AM/FM tuner in the IAM, to the DAB receiver and to the VICS (vehicle
information and communication systems) or TMC (traffic message channel) in the navigation computer.
There are three different types of diversity antenna module fitted depending on the vehicle market and infotainment
equipment specification:
AM/FM with one co-axial output

AM/FM and VICS/TMC with two co-axial outputs
AM/FM, VICS/TMC and DAB band III with three co-axial outputs
The diversity antenna module receives a power supply from the IAM.
Vehicle or other component generated electromagnetic interference may cause unwanted disturbances in the radio and TV
reception signals. The disturbance may interrupt, obstruct, or otherwise degrade or limit the effective performance of the
circuit. It frequently affects the reception of AM radio in urban areas and can also affect FM radio and television reception,
although to a lesser extent.
The RF filters, which act as RF isolators, are located on both sides of the heated rear window and are used to reduce the
electromagnetic interference. The left hand side RF filter is connected across the heated rear window power supply and
used to separate the DC (direct current) interference from the RF signals. The right hand side RF filter is used in
conjunction with the TV antenna module (if fitted). If the TV system is not fitted the filter is linked directly to ground.
INFORMATION CONTROL MODULE
The ICM is located beneath the IAM in the center console. The unit performs a range of infotainment and some climate-
control functions.
The ICM, which is the timing master of the MOST system; supplies clock information to all other devices on the network
which synchronize their operation to this clock.
The unit also controls and manages the MOST ring and provides the allocations of channels, system power management,
functionality and co-ordination of the other system components.
The system becomes operational when the vehicle is unlocked and a 'wake up' signal is received by the ICM on the
medium speed CAN. The ICM 'wakes up' all the control modules on the MOST system ready for immediate operation by the
vehicle user.
If the ICM is replaced it must be configured as a new module using the Jaguar approved diagnostic equipment.
Calibration of the ICM using the Jaguar approved diagnostic equipment enables updates to be downloaded as new
technology becomes available or any fault concerns require software updates.
PORTABLE AUDIO MODULE
The portable audio module, located under the left hand front seat, allows for the connection, control and playback of a
range of portable audio devices through the cars audio system.
No configuration procedure is required if the portable audio module is replaced. Calibration of the portable audio module
using the Jaguar approved diagnostic equipment enables updates to be downloaded as new technology becomes available
or any fault concerns require software updates.
ItemDescription
1 iPod connection
2 USB connection
3 Auxiliary connection
The chosen audio device is plugged into the car using the interface panel located in the center console between the front
seats. Vehicles with the optional iPod function are supplied with a bespoke iPod lead in the vehicle delivery pack .
A menu option is available through the Touch-screen audio section when selecting a portable audio device for operation
through the vehicle audio system.
After the connection of an iPod or USB mass storage device the Touch-screen is used to operate and search the connected
device. Due to safety regulations, the normal control interfaces of either the iPod or USB device are disabled when it is
plugged into the interface panel.
NOTE: Some MP3 players have their own file system that is not supported by this system. To use the MP3 player it must
be set to USB Removable Device or Mass Storage Device mode. The manufacturer's information should include details of
this procedure. Only music that has been added to the device in this mode can be played via the vehicle's portable audio
system.
Conversely, connection of any devices through the auxiliary connection cannot be controlled through the touch-screen and
are controlled through the device itself.
NOTE: The system will support devices with a storage capacity up to 256 GB which is approximately 65,000 audio tracks.
The wiring link harness between the portable audio module and interface panel consists of hardwired and digital
connections for data and signal exchange. The MOST carries the communication signals and information between the
portable audio module to the IAM and touch-screen. Audio output to the speaker system is controlled by the IAM or power
amplifier depending on the audio system specification.
POWER AMPLIFIER
The audio system has three amplification options dependant on the audio system specification:
IAM internal amplifier

Alpine AUD 8
Alpine AUD 12
The power amplifier is located in the left hand side of the luggage compartment and is connected to the audio system via
the MOST bus. Speaker connections are hardwired.
If the power amplifier is replaced it must be configured as a new module using the Jaguar diagnostic equipment.
Calibration of the power amplifier using the Jaguar approved diagnostic equipment enables updates to be downloaded as
new technology becomes available or any fault concerns require software updates.
DIGITAL AUDIO BROADCASTING

DAB is a digital radio network designed to provide reliable, multi-service broadcasting for reception by mobile, portable
and fixed receivers.
DAB provides a clear signal with minimal interference, hiss or fading. After a channel (or station) has been tuned and
stored, it does not need retuning.
NOTE: Radio signals travel in a straight line so large obstacles, such as tall buildings, can shield the vehicle from the
signal causing temporary loss of reception (known as dead spots).
Digital radio is transmitted from regional terrestrial transmitters. Some local digital radio channels are not available
outside the range of a transmitter. To receive new local channels during vehicle movement around a country, the auto-tune
function is used to build new channel lists.
NOTE: When the vehicle DAB radio is first used the system will not receive any digital stations until the auto-tune
function has been completed.
Digital radio channels are organized into groups called ensembles (also known as multiplexes). Some individual channels
may also provide a number of subchannels. For example, if several sports events are being held simultaneously, the
channel may temporarily choose to broadcast each different event on a separate subchannel.
DAB is broadcast across Europe, Canada and parts of Asia. System transmission is via a terrestrial network, on two
separate broadcasting bands:
DAB band-L
DAB band III
The DAB system requires additional components to be added to the audio system. DAB antennas and a receiver are fitted
to allow reception of the service.
Operation of the DAB system is the same as the radio operation with selections made through the touch-screen and ICP to
access and navigate the system functions.
The DAB receiver is a dedicated tuner which is controlled by the ICM on the MOST ring. The receiver processes the signals
from the DAB antennas. Information is transmitted on the MOST ring and processed by the ICM. The processed information
is sent out to the power amplifier or IAM (with internal amplifier) and broadcast through the speaker system.
No configuration procedure is required if the DAB receiver is replaced. Calibration of the DAB receiver using the Jaguar
approved diagnostic equipment enables updates to be downloaded as new technology becomes available or any fault
concerns require software updates.
Digital Audio Broadcasting Antennas
ItemDescription
1 Roof pod
The DAB band III antenna is located in the heated rear window and is part of the diversity antenna module circuit. The two
antenna circuits each have a co-axial connection to the DAB module.
DAB signals are transmitted on either DAB band III (174 - 240 MHz) or DAB band-L (1452 - 1492 MHz). Some countries
may only use the band III signals, while others may only use the band-L signals. Some countries use both frequency
ranges within the same geographical area. The type of DAB signal received depends on the vehicle market location.
The DAB antennas are designed with 50 ohm output impedance. The DAB receiver is fitted with 50 ohm fakra II connectors
to ensure compatibility with the antenna. For optimum performance 50 ohm low loss coaxial cable is used between the
antenna and receiver.
SATELLITE RADIO (NAS VEHICLES ONLY)
The digital radio format adopted for NAS vehicles is satellite radio. Satellite service providers transmit a signal from their
up-link facility (which is the original point of transmission of data, voice or other information through an antenna system)
to a satellite where the signal is then down linked to both the terrestrial repeater network and the individual satellite car
radios. The radio switches between the satellite signal and the repeater network signal depending on the strength of the
signal at any given time.
The Sirius satellite system comprises:
Satellites
Ground repeaters
Up-link ground stations
Radio receiver systems
The Sirius satellite radio system uses three satellites on an inclined elliptical orbit. This ensures that each satellite spends
approximately 16 hours a day over the continent of the USA, with at least one satellite over the country at any one time.
The satellites beam their signals down to the ground where the signal is picked up by receivers or is transmitted to
repeater stations to cover built up areas where the signal is obscured. The satellite service comprises over 100 channels of
digital entertainment which is provided by subscription requiring a monthly payment.
Operation of the satellite radio system is the same as the radio operations with selections made through the Touch-screen
and ICP to access and navigate the system functions.
The satellite radio receiver is a dedicated tuner which is controlled by the ICM on the MOST ring. The receiver filters the
signals from the satellite radio antenna. Information is transmitted on the MOST ring and processed by the ICM. The
processed information is sent out to the power amplifier or IAM (with internal amplifier) and broadcast through the speaker
system.
No configuration procedure is required if the satellite radio receiver is replaced. Calibration of the satellite radio receiver
using the Jaguar approved diagnostic equipment enables updates to be downloaded as new technology becomes available
or any fault concerns require software updates.
Satellite Radio Antenna
The satellite radio antenna is located in the roof pod and is shared with the navigation system GPS (global positioning
system) antenna where fitted. The roof pod is located externally in a central position towards the rear of the roof.
Similar to the DAB system the satellite radio antenna is designed with 50 ohm output impedance. The satellite radio
receiver is fitted with 50 ohm fakra II connectors to ensure compatibility with the antenna. For optimum performance 50
ohm low loss coaxial cable is used between the antenna and receiver.
The antenna is designed to receive one of two signals, using the strongest signal with the least distortion to process for
audio output. For example, if the vehicle drives into a tunnel, the signal received will change from a satellite signal to a
repeater station signal maintaining the strongest signal.
Information and Entertainment System - Speakers - Component Location
ItemDescription
1 LH (left-hand) front tweeter speaker (All models)
2 Front center speaker (Bowers & Wilkins 440W Surround Sound System only)
3 RH (right-hand) front tweeter speaker (All models)
4 RH front mid-range speaker (Bowers & W ilkins 440W Surround Sound System only)
5 RH front mid-bass speaker (All models)
6 RH rear tweeter speaker (All models)
7 RH rear mid-bass speaker (All models)
8 RH rear full range speaker (Bowers & W ilkins 440W Surround Sound System only)
9 Subwoofer enclosure (Not fitted to Jaguar Sound System)
10 LH rear full range speaker (Bowers & W ilkins 440W Surround Sound System only)
11 LH rear mid-bass speaker (All models)
12 LH rear tweeter speaker (All models)
13 LH front mid-bass speaker (All models)
14 LH front mid-range speaker (Bowers & W ilkins 440W Surround Sound System only)
Information and Entertainment System - Speakers - Overview
Overview
The vehicle has three levels of audio system available:
Jaguar Sound System

Jaguar Premium Sound System
Bowers & Wilkins Surround Sound System
The Jaguar Sound System has 8 speakers, comprising an identical mid-bass and tweeter combination in each door. All
speaker domes in this system are of standard textile construction. The speakers are driven directly by the IAM (integrated
audio module) internal amplifier.
The Jaguar 320W Premium Sound System has 9 speakers including mid-bass and tweeters in the doors, adding a
sub-woofer in the spare wheel well. The speakers are driven by an Alpine AUD 8 amplifier located in the LH (left-hand)
side of the luggage compartment.
The Bowers & Wilkins 440W Surround Sound System uses an Alpine AUD 12 amplifier, a Dolby Pro-Logic 2 7.1 Surround
Sound System and has 14 speakers. This layout adds a mid-range speaker to each front door while retaining a mid-bass
and tweeter in each rear door. It also adds an instrument panel center speaker, 2 surround-effect speakers in the rear
parcel shelf, and has the luggage compartment-mounted sub-woofer as the Jaguar 320W Premium Sound System. The
speakers are driven by an AUD 12 power amplifier located in the luggage compartment.
The main speakers on the Jaguar 320W Premium Sound System and the Bowers & Wilkins 440W Surround Sound System
are identified by the bright yellow Kevlar constructed domes which are visible through the speaker grilles. The tweeter
speaker domes are an aluminum construction. The sub-woofer speakers are a textile dome construction.
Information and Entertainment System - Speakers - System Operation and
Control Diagram
NOTE: A = Hardwired
CONTROL DIAGRAM - JAGUAR SOUND SYSTEM
ItemDescription
1 Battery
5 RH (right-hand) rear mid-bass speaker
6 RH rear tweeter speaker
7 RH front mid-bass speaker
8 RH front tweeter speaker
9 LH (left-hand) front mid-bass speaker
10 LH front tweeter speaker
11 LH rear tweeter speaker
12 LH rear mid-bass speaker
CONTROL DIAGRAM - JAGUAR 320W PREMIUM SOUND SYSTEM
ItemDescription
1 Battery
2 BJB
3 RJB
4 Power amplifier
5 RH rear mid-bass speaker
9 Subwoofer enclosure
10 LH front mid-bass speaker
CONTROL DIAGRAM - BOWERS & WILKINS 440W SURROUND SOUND SYSTEM
ItemDescription
1 Battery
2 BJB
3 RJB
4 Power amplifier
5 RH rear full range speaker
6 RH rear mid-bass speaker
9 RH front mid-range speaker
11 Front center speaker
12 Subwoofer enclosure
13 LH front mid-bass speaker
14 LH front mid-range speaker
18 LH rear full range speaker
System Operation
The Jaguar Sound System has 8 speakers, comprising an identical mid-bass and tweeter combination in each door. All
speaker domes in this system are of standard textile construction. The speakers are driven directly by the IAM (integrated
audio module) internal amplifier.
The Jaguar 320W Premium Sound System has 9 speakers including mid-bass and tweeters in the doors, adding a
sub-woofer in the spare wheel well. The speakers are driven by an Alpine AUD 8 amplifier located in the LH side of the
luggage compartment.
The Bowers & Wilkins 440W Surround Sound System uses an Alpine AUD 12 amplifier, a Dolby Pro-Logic 2 7.1 Surround
Sound System and has 14 speakers. This layout adds a mid-range speaker to each front door while retaining a mid-bass
and tweeter in each rear door. It also adds an instrument panel center speaker, 2 surround-effect speakers in the rear
parcel shelf, and has the luggage compartment-mounted sub-woofer as the Jaguar 320W Premium Sound System. The
speakers are driven by an AUD 12 power amplifier located in the luggage compartment.
The main speakers on the Jaguar 320W Premium Sound System and the Bowers & Wilkins 440W Surround Sound System
are identified by the bright yellow Kevlar constructed domes which are visible through the speaker grilles. The tweeter
speaker domes are an aluminum construction. The sub-woofer speakers are a textile dome construction.
Information and Entertainment System - Cellular Phone - Component
Location
ItemDescription
2 Touch-screen
4 Microphone
5 Steering wheel controls
6 Navigation Computer
7 Power amplifier
8 Speakers
9 Telephone control module
Information and Entertainment System - Cellular Phone - Overview
Authoring Template
OVERVIEW
The cellular phone system uses the customers own Bluetooth capable handset in conjunction with the vehicle
information and entertainment system. The telephone control module is located under the left-hand front seat, and has a
Bluetooth antenna integrated into the unit. Telephone handsets must be paired with the telephone control module,
requiring input of a PIN (personal identification number) before they can be used with the vehicle system. Once paired, any
phone can be docked to the car without re-entering a PIN (personal identification number). In addition to this, the last
connected device will dock automatically the next time it is placed in the vehicle and the ignition is in power mode
(ignition on).
The system has the ability to pair and dock telephone handsets from the telephones themselves. By supplying a fixed PIN
(personal identification number), a user will be able to use their telephone or other telephone related Bluetooth device
and pair with it without using the touch screen. This enables devices such as Blackberry's and other secure PDA's (personal
digital assistants) to pair and dock with the vehicle system.
Up to 5 telephone handsets can be paired with the vehicle, but only 1 telephone can be used at a time. The Touch-screen
displays phone functionality, including dialing, and (if compatible) the handsets phone book. The Touch-screen also
displays the phone's signal strength and battery meter (if supported by the phone). These functions allow the user to view
the displays on the Touch-screen and not have to use the handset.
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.
The system allows the driver to make, receive and end phone calls using the Touch-screen, steering wheel switches and
voice recognition system (if fitted).
Phone dialing is achieved using one of the following methods:
Dialing a number using the Touch-screen keypad

Selecting a number from the handsets (automatically or manually downloaded) phonebook on the Touch-screen
Selecting a number from the handsets (automatically or manually downloaded) phonebook in the instrument cluster
message center
Selecting from the handsets (downloaded) call register, typically the last 10 calls made, received and missed
The telephone control module is connected to the information and entertainment system on the MOST (media oriented
systems transport) ring. This allows audio and control signals to be routed to and from the telephone control module.
Information and Entertainment System - Cellular Phone - System Operation
Control Diagram
NOTE: A = Hardwired; N = Medium Speed CAN (controller area network) bus; O = LIN bus; P = MOST ring
ItemDescription
1 Touch-screen
2 Power amplifier
3 Speakers
5 Microphone
6 Telephone control module
7 Clock spring
8 Steering wheel controls
11 Navigation computer
System Operation
PRINCIPLES OF OPERATION
Primary user control of the phone system is via the Touch-screen and JaguarVoice control switch. Selection of
'phone/comms' on the Touch-screen home menu sends a control signal to the telephone control unit on the MOST (media
orientated systems transport) ring, opening the phone submenu options.
When making an outgoing phone call using the JaguarVoice function the ICM (information control module) processes the
analogue signal from the switch into a digital signal. The digital signal is passed from the ICM (information control
module) onto the MOST (media orientated systems transport) system to the JaguarVoice control unit which is integral with
the navigation computer.
The navigation computer sends an instruction via MOST (media orientated systems transport) to the IAM (integrated audio
module) to turn on the microphone facility.
The voice command signals are relayed from the IAM (integrated audio module) via the MOST (media orientated systems
transport) ring to the navigation computer for processing.
The processed voice command is relayed on the MOST (media orientated systems transport) ring from the navigation
computer to the phone control module.
Speech output information is transferred from the phone control module via the Bluetooth connection to the cell phone.
Incoming calls are received from the Bluetooth phone by the phone control module. The information is processed by the
phone control module and transferred on the MOST (media orientated systems transport) ring to the power amplifier or IAM
(integrated audio module) for audio output through the vehicles audio speaker system.
A number of responses by the telephone and voice systems are reinforced by messages appearing in the instrument cluster
message center display. Information is relayed to the message center from the phone control module and navigation
computer on the MOST (media orientated systems transport) ring to the ICM (information control module).
The ICM (information control module) is the gateway from the MOST (media orientated systems transport) ring to the
medium speed CAN. The ICM (information control module) transfers the message center information onto the medium
speed CAN which is received and processed for display on the instrument cluster message center.
Users can pair & dock their handset using their phone or the touch screen. If there is no phone already docked with the
system, a user can use their phone to search for Bluetooth Devices. If the vehicles Bluetooth system has been successfully
discovered, the phone will display "Jaguar" as a device to pair & connect to. Using this method requires the user to enter
the Jaguar PIN of 1313. Alternatively, after accessing the phone menu from the Touch-screen home menu, selecting
Search New searches for the Bluetooth enabled handsets within range, displays their identities on screen, and allows
the user to pair and dock the phone ready for use, using a random four-digit security code displayed on screen. The system
will normally try to dock (automatically) to the last phone docked, but if a different Bluetooth enabled phone enters the
car it will become available on the screens list of handsets once the search has been completed.
Once a phone is paired and docked a digit dial screen is displayed, including phonebook options. W ith a Bluetooth
compatible handset and software version there is the option, through the settings menu, to automatically download the
contents of the handsets phonebook to the vehicle system. Because there is no industry standard for arranging the
phonebook, the downloaded lists from individual handsets may vary.
Cell phone handset manufacturers continually update hardware and software to standard specifications laid down by the
Bluetooth Special Interest Group (SIG), which defined how Bluetooth would work in an automotive environment.
However, because different makes and models may use different software, not all handsets are fully compatible with
Jaguar, but through testing individual handset models Jaguar has produced a list of compatible handsets and the
appropriate software version for Jaguar Bluetooth connectivity. Referral to the list also describes how to check the
software version of each individual cell phone manufacturer. This list must be consulted by users, sales & service teams to
confirm whether customer's handsets are compatible or not.
Jaguar is continually validating compatible handset and software combinations. The most up-to-date compatibility list will
always be available on-line from Jaguar.
NOTE: To achieve full Bluetooth handset functionality it is crucial that the phone software level matches the version
detailed in the list of compatible handsets.
The upgraded hands free profile of this system allows the display of the network signal strength, network operator and
phone battery level indication on the vehicle display. Also, if applicable, the phone handset will show a "car" or "headset"
symbol to indicate it is in handsfree profile.
BLUETOOTH
Bluetooth is a short-range RF (radio frequency) technology that operates at 2.4 GHz and is capable of transmitting voice
and data wirelessly. The effective range of Bluetooth devices is 32 feet (10 meters) with a data transfer rate of 1 Mbps.
Bluetooth is essentially a wireless connection which operates with the user's own mobile handset, does not have to be
fixed into the car and is designed to function without an external aerial. The handset can be located anywhere within the
cabin, even in a bag, or jacket pocket. It could work from the luggage compartment, although the signal could be
compromised. The handset can be charged from the 12 volt power socket or USB (if supported) while in use.
Touch-Screen
The Touch-screen communicates with the telephone control module on the MOST (media orientated systems transport) ring
and provides the primary user interface and display of the phone system.
ItemDescription
1 Touch-screen
3 Home menu button
The following functions are available on the phone menu:
Digit dial
Phone book
Last ten calls (made, received, missed)
Voicemail
Steering Wheel Controls
ItemDescription
1 Volume adjustment
2 Scroll up/down to next/previous memory location.
3 Audio source (Long press for instrument cluster message center phonebook access)
4 JaguarVoice button. Briefly press to initiate or end a call. This is also used for voice control functions
Additional control of the phone system is available in the form of steering wheel mounted switches which are located on
the left hand side of the steering wheel. The switches provide for volume adjustment, scroll up/down to next/previous
memory location, instrument cluster message center phonebook access and finally JaguarVoice/call control.
The steering wheel control switches are hardwired through the clock spring to the ICM (information control module). The
ICM (information control module) processes the analogue signals from the switches into digital signals. The digital signals
are then passed from the ICM (information control module) onto the MOST (media orientated systems transport) system
for control unit processing and operation of the requested functions.
JaguarVoice
JaguarVoice enables activation of several voice activated functions of the infotainment and climate control systems
without the need to touch any controls manually. The following systems include JaguarVoice functionality;
Navigation system
Phone system
Climate control system
Vehicle display system
Vehicle notepad
The 'notepad' facility allows voice notes to be recorded. Nametags for phone dialing and navigation locations allow the
system to be personalized and there is a help and tutorial function to provide advice on using the system.
The system allows the vehicle user to concentrate fully on driving the vehicle, without any need to divert their eyes from
the road ahead in order to check information read outs on the vehicle instrument panel information units. The voice control
system also feeds back audible information to the vehicle user.
JaguarVoice is a key component of the phone system, allowing hands free control and use of the Bluetooth enabled
phone.
The system is controlled by the voice button on the left hand side of the steering wheel. Voice commands are picked by
the dedicated microphone. When giving a voice command audible feedback will be heard through the vehicles audio
speakers. Received call voice/speech is also broadcast on the vehicle audio speaker system. All speakers are used for
voice/speech output with the exception of the front center speaker (only fitted on the Bowers & W ilkins 440W Surround
Sound System) due to echo return picked up by the microphone.
ItemDescription
1 JaguarVoice button
Efficient operation of JaguarVoice is reliant on the user understanding some of the following basic operating conditions;
Face forwards, sitting in a normal driving position

After pressing the voice button, always wait for the end of the audible tone before speaking.
Speak naturally, as if you were talking to a passenger or on the phone without pausing between words
When the system asks for more information, always wait for the end of the tone before responding
Always say numbers correctly
Excessive noise, for example while driving with windows open, may cause voice command mis-recognition. If it is
too noisy to use the phone, it is likely that voice commands will not be recognized
Most accents are understood without difficulty, but if the system does not recognize the command it will respond "SORRY"
and allow two more attempts to say the command.
Voice feedback is given in the same language as the command recognition. It is possible to change the language of the
speech control system.
Information and Entertainment System - Navigation System - Component
Location
ItemDescription
2 Touch-screen
4 Microphone
5 Roof pod antenna module (GPS antenna)
6 RF filter
8 Power amplifier
9 RF filter
10 Diversity antenna module (VICS/TMC antenna)
12 VICS (vehicle information and communication system) beacon antenna - Japan only
Information and Entertainment System - Navigation System - Overview
Authoring Template
OVERVIEW
The navigation system provides audible and visual route guidance information to enable the driver to reach a desired
destination. The system allows the driver to choose the desired route using minor or major roads and will present 3 routes
to the driver based on user preferences. Directions to hospitals, museums, monuments and hotels are also available. The
navigation computer uses map information stored on a DVD (digital versatile disc) to determine the best route for the
journey and provide the driver with details of directions and approaching junctions.
The navigation system has various levels of user control through the Touch-screen and JaguarVoice system. System
volume adjustment can be made using the ICP (integrated control panel), Touch-screen and steering wheel controls.
There are 3 navigation system variants specific to various markets. On all systems the GPS (global positioning system)
signal is received by the GPS (global positioning system) antenna located in the roof pod antenna module.
The European navigation system includes the TMC (traffic messaging channel) function, which receives traffic information
from an FM antenna integrated into the heated rear window. On a pre-selected route the system will offer re-routing
options depending on traffic conditions.
The Japanese navigation system includes the VICS (vehicle information and communication systems) function. The VICS
(vehicle information and communication systems) supplies information to enable the navigation computer to re-route the
navigation guidance or to inform the vehicle driver of traffic conditions in the vehicles vicinity. Information is provided to
the system through an FM antenna integrated into the heated rear window and a VICS beacon located in the LH upper side
of the instrument panel.
The NAS (North American specification) variant does not include any additional traffic information systems.
The navigation system is primarily controlled from the Touch-screen which is located in the center of the instrument panel.
Control signals from the Touch-screen are sent on the MOST (media oriented systems transport) ring to the navigation
computer. The navigation computer uses a dedicated GVIF (gigabit video interface) bus to transmit video signals to the
Touch-screen.
Depending upon the audio system version fitted the navigation audio output signals are sent on the MOST (media oriented
systems transport) ring to the IAM (integrated audio module) or the power amplifier for speaker output.
Information and Entertainment System - Navigation System - System
Control Diagram
NOTE: A = Hardwired; D = High Speed CAN bus; N = Medium Speed CAN bus; O = LIN bus; P = MOST ring; Q = GVIF; T
= CoAxial
ItemDescription
3 Touch-screen
4 Power amplifier
5 Speakers
7 Microphone
9 VICS (vehicle information and communication system) beacon antenna - Japan only
10 Roof pod antenna module (GPS (global positioning system) antenna)
11 Diversity antenna module (VICS/TMC antenna)
14 Clock spring
System Operation
Authoring Template
INTRODUCTION TO THE GLOBAL POSITIONING SYSTEM

The system used to calculate the current position of the vehicle is called the GPS. The system utilizes satellites which are
owned by the United States Department of Defense. A total of 24 satellites circular orbit the earth every 12 hours at a
height of 20,000 km (12500 miles), and between 5 and 11 of these satellites can be seen from a single point at any given
time. The orbits are tilted to the earth's equator by 55 degrees to ensure coverage of polar regions. Each satellite
transmits radio signals to provide information about the satellite position i.e. latitude, longitude, altitude, almanac data
and an accurate time signal generated by an on-board atomic clock. Each satellite contains four atomic clocks.
The vehicle needs to receive data from at least four different satellites to give a three dimensional fix on its current
position.
As the vehicle moves, this information is continually being updated. The computer determines which satellites are 'visible'
to the system and their current position and relationship to each other. Using this information the computer can account
for positional deviations of the satellites and compensate to enhance the accuracy of the navigation system.
The GPS signal is also known as the PPS (precision positioning signal).
PPS (precision positioning signal) predictable accuracy is:
22 meters horizontal accuracy

27.7 meters vertical accuracy
200 nanoseconds time accuracy
The navigation system receives GPS information via the GPS antenna. The GPS signals are used by the navigation
computer to calculate the vehicles position. Once the driver has input a desired destination the navigation computer can
calculate a route, based on the driver's pre-determined preferences or the default settings in the navigation computer.
The navigation system is accessed from the Touch-screen home menu.
Navigation is initiated by the driver inputting a destination. This can be achieved by:
Entering an address using the Touch-screen

Entering a post code
Choosing a previous destination
Choosing a point of interest from the map disc database
Choosing the home location
Choosing a memory stored location
The driver is then guided to the destination by a scrolling map display and voice guidance. The display can be varied by
scale and display type.
In addition to the standard navigation system there are two market dependant systems that supply extra information to
the navigation system and the driver. These are:
TMC (traffic message channel) (Europe only)

VICS (vehicle information and communication system) (Japan only)
The TMC (traffic message channel) is a function of the FM (frequency modulation)RDS (radio data system). The system
broadcasts real-time traffic and weather information. Data messages are received and decoded by the TMC (traffic
message channel) integral receiver and processed by the navigation computer. TMC (traffic message channel) messages
can be filtered by the navigation computer so that only those relevant to the current journey are displayed, allowing the
navigation system to offer dynamic route guidance - alerting the driver of a problem on the planned route and calculating
an alternative route to avoid the incident. All TMC (traffic message channel) events on the map can be viewed not just the
ones on the calculated route.
TMC (traffic message channel) traffic information systems conform to a global standard that has been adopted by traffic
data gatherers, information service providers, broadcasters and vehicle/receiver manufacturers.
All TMC (traffic message channel) receivers use the same list of event codes, while the location database (on the map
disc) contains both a country-specific set of location codes for the strategic European road network.
TMC (traffic message channel) traffic data is currently broadcast in many European countries.
The VICS (vehicle information and communication system) is broadcast in the Japanese market.
The VICS (vehicle information and communication system) supplies information to enable the navigation computer to
re-route the navigation guidance or to inform the vehicle driver of traffic conditions in the vehicles vicinity. Information is
provided to the system through 3 routes:
RF (radio frequency) transmission

Infra-red transmission
FM multiplex transmissions
The RF (radio frequency) transmissions are generally transmitted from road side beacons mainly on expressways. The
information transmitted is as follows:
Traffic congestion
Travel time to next intersection
Traffic conditions in surrounding areas and expressway turn offs
Traffic accidents
Speed limits
Lane regulations
Tire change
Parking availability at expressway service areas and parking areas
Infra-Red transmissions are transmitted from road side beacons on major trunk roads. The information transmitted is:
Traffic congestion and travel time

Traffic accidents
Breakdowns
Road works restrictions
Parking availability
FM transmissions are broadcast as part of the FM multiplex broadcasting system from NHK FM stations. Information
transmitted is:
Traffic congestion and travel time for wide areas

Traffic accidents, road works, speed limits and lane restrictions for a wide area
Parking availability information
The traffic data is split from the normal FM transmissions by the diversity antenna module.
Selection of 'Navigation' on the Touch-screen home menu and subsequent sub-menu selection sends a control request
signal to the navigation computer on the MOST (media orientated systems transport) ring. The requested control
information is processed by the navigation computer.
If voice guidance is operational the voice signal information is relayed from the navigation computer on the MOST (media
orientated systems transport) ring to either the IAM (integrated audio unit) or Power Amplifier, dependant on equipment
level, for output on the speaker system. The navigation audio output is through the front speakers whilst the background
audio, for example radio or CD (compact disc), is played at a reduced volume on the rear speakers.
The GPS signal is available to the navigation system at all times when the vehicle ignition is switched on.
Navigation user voice commands are made using the JaguarVoice system. The ICM (information control module) processes
the analogue signal from the JaguarVoice switch into a digital signal. The digital signal is passed from the ICM
(information control module) onto the MOST (media orientated systems transport) system to the JaguarVoice control unit
which is integral with the navigation computer.
The navigation computer sends an instruction via the MOST (media orientated systems transport) ring to the IAM
(integrated audio module) to turn on the microphone facility.
The microphone is hardwired to the IAM (integrated audio module). The spoken voice command signals are relayed from
the IAM (integrated audio module) via the MOST (media orientated systems transport) ring to the navigation computer for
processing.
The processed voice command is relayed from the navigation computer to the Touch-screen.
Traffic data from TMC (traffic message channel) or VICS (vehicle information and communication system) is processed by
the navigation computer, distributed to the Touch-screen with any supporting voice instruction relayed through the MOST
(media orientated systems transport) ring to either the IAM (integrated audio unit) or Power Amplifier, dependant on
equipment level, for output on the speaker system.
A number of actions, when using the navigation voice system, are reinforced by messages appearing in the instrument
cluster message center display. Information is relayed to the message center from the navigation computer on the MOST
(media orientated systems transport) ring to the ICM (information control module).
The ICM (information control module) is the gateway from the MOST (media orientated systems transport) ring to the
medium speed CAN (controller area network). The ICM (information control module) transfers the message center
information onto the medium speed CAN which is received and processed for display on the instrument cluster message
center.
NAVIGATION COMPUTER
The navigation computer is located in the left hand side of the luggage compartment.
The navigation computer incorporates the following:
GPS receiver
VICS (vehicle information and communication system) receiver (Japan only)
TMC (traffic message channel) receiver (Europe only)
JaguarVoice control module
The navigation computer contains a solid state piezo gyro which measures the motion of the vehicle around its vertical
axis. The gyro operates on the principle known as the coriolis force. The coriolis force is the force that appears to
accelerate a body moving away from its rotational axis against the direction of rotation of the axis.
Using inputs from the ABS module, the GPS antenna and the gyro sensor, the computer calculates the vehicle's current
position, direction and speed.
The navigation computer houses the DVD (digital versatile disc) drive. The drive is used to read map data from region
specific DVD's. The number of DVD's issued per region varies depending on the amount of information available. The
regions are as follows:
Europe (2 versions, Western Europe and W hole of Europe)

NAS (North American specification)
Japan, Middle East, Australia and South Africa
A button, located adjacent to the DVD slot, is provided to eject the DVD from the unit. Prior to ejecting the disc the slot
protection has to be slid to the side. If the ignition is on, or the entertainment system is in 1-hour mode, one press of the
button will eject the DVD.
The navigation computer uses non-volatile memory to store settings and configuration information when it is powered
down. This process takes place just before the computer turns off.
No configuration procedure is required if the navigation computer is replaced. There is no option to calibrate the navigation
computer using the Jaguar approved diagnostic equipment; however in some regions a software download, contained in
the DVD disc, is required before the navigation system becomes operational.
MICROPHONE
A single microphone is used for hands-free operation using the JaguarVoice system. The microphone has an integrated
noise suppression system for hands-free use. The microphone is a standard directional type and is located in the front roof
overhead console. The microphone is hardwired to the IAM (integrated audio module). When replacing the microphone
extra care must be taken to make sure it is fitted into its securing clips for correct positioning and orientation.
GPS Antenna
The GPS antenna passes signals from the GPS satellites to the navigation computer for processing. The antenna is located
in the roof pod and is shared with the DAB (digital audio broadcasting) band L antenna or satellite radio antenna where
fitted. The roof pod is located externally in a central position towards the rear of the roof.
The GPS antenna is designed with 50 ohm output impedance. The navigation computer is fitted with 50 ohm fakra II
connectors to ensure compatibility with the antenna. For optimum performance 50 ohm low loss coaxial cable is used
between the antenna and navigation computer.
It is possible for the GPS antenna to lose the signal from the GPS satellites;
In hilly or tree lined areas

Built up areas with tall buildings
In multi storey car parks
In garages
In tunnels
On bridges
During heavy rain or thunderstorms
When the signal is lost the navigation computer will continue to give guidance using memory mapped data from the DVD
map until the signal is restored.
TMC/VICS FM Antenna
Data messages for both TMC (traffic message channel) and VICS (vehicle information and communication system) are
received through the FM antennas and diversity antenna module located in the heated rear window.
VICS Beacon Antenna (Japan Only)

The VICS (vehicle information and communication system) beacon antenna receives infra red and RF (radio frequency)
traffic data signals from road side transmitters. The antenna is connected to the navigation computer which incorporates a
VICS (vehicle information and communication system) receiver.
Touch Screen Display
The Touch-screen is the control interface for the following vehicle systems;
System Functions
Audio Radio display AM/FM or DAB (digital audio broadcast), auxiliary and portable audio, digital TV or CD
Climate Air conditioning, distribution, seats, heated steering wheel, automatic air recirculation
control
Telephone Digit dialer, phone book, last ten calls (made, received, missed)
Navigation Destination, stored locations, navigation setup, route options
Vehicle Security, parking, valet mode, trip computer, clock, brightness, contrast, system settings, vehicle settings,
display settings
The screen is a touch sensitive 7 inch LCD (liquid crystal display) VGA screen containing 800 x 480 pixels in a 15:9 format.
The screen processes its own video for system operation but receives the navigation graphics from the navigation
computer.
ItemDescription
1 Volume adjustment
2 Scroll wheel (No navigation functionality)
3 Audio source (No navigation functionality)
4 JaguarVoice control
Additional control of the navigation system is available in the form of steering wheel mounted switches which are located
on the left hand side of the steering wheel. 2 switches are used for navigation functions;
Volume adjustment
JaguarVoice control
JaguarVoice enables operation of several voice activated functions of the infotainment and climate control systems without
the need to touch any controls manually. The following systems include JaguarVoice functionality;
Navigation system
Phone system
Climate control system
Vehicle display system
Vehicle notepad
The 'notepad' facility allows voice notes to be recorded. Nametags for phone dialing and navigation locations allow the
system to be personalized and there is a help and tutorial function to provide advice on using the system.
The system allows the vehicle user to concentrate fully on driving the vehicle, without any need to divert their eyes from
the road ahead in order to check information read outs on the vehicle instrument panel information units. The voice control
system also feeds back audible information to the vehicle user.
JaguarVoice is a key component of the navigation system, allowing hands free control when issuing navigation commands.
The system is controlled by the voice button on the left hand side of the steering wheel. Voice commands are picked up by
a dedicated microphone. W hen giving a voice command audible feedback will be heard through the vehicles audio
speakers.
ItemDescription
1 JaguarVoice button
Efficient operation of JaguarVoice is reliant on the user understanding some of the following basic operating conditions;
Face forwards, sitting in a normal driving position

After pressing the voice button, always wait for the end of the tone before speaking.
Speak naturally, as if you were talking to a passenger or on the phone without pausing between words
When the system asks for more information, always wait for the end of the tone before responding
Always say numbers correctly
Excessive noise, for example while driving with windows open, may cause voice command mis-recognition. For
example if it is too noisy to use the phone, it is likely that voice commands will not be recognized.
Most accents are understood without difficulty, but if the system does not recognize the command it will respond "SORRY"
and allow two more attempts to say the command.
Voice feedback is given in the same language as the command recognition. It is possible to change the language of the
speech control system.
Information and Entertainment System - Video System - Component
Location
ItemDescription
2 Touch-screen
4 Microphone
5 Triple TV (television) antenna module
6 RF filter
7 Single TV (television) antenna module
8 Power amplifier
9 TV (television) tuner
10 RF filter
12 Steering wheel remote controls
Information and Entertainment System - Video System - Overview
OVERVIEW
The Television system combines digital and analogue reception. The digital element is similar to the home based freeview
system, and displays information such as current channel detail. The Japanese market uses the analogue signal as the
digital format is not compatible.
For legal reasons, the Touch-screen Television image can only be displayed when the vehicle is at rest, however the
system is configured not to constantly switch on and off in stop-start traffic. It is possible to listen to Television sound as
the vehicle is moving.
Information and Entertainment System - Video System - System Operation
Control Diagram
NOTE: A = Hardwired; N = Medium Speed CAN (controller area network) bus; O = LIN bus; P = MOST ring; T = CoAxial; I
= Composite video signal
ItemDescription
2 TV (television) tuner
3 Touch-screen
4 Microphone
6 Speakers
7 Power amplifier
8 Clock spring
9 Steering wheel remote controls
System Operation
The Television system has various levels of user control through the Touch-screen, ICP (integrated control panel) and
steering wheel control panel. The system includes nine analogue and nine digital channel pre-sets. As with the audio
system, the user can search up or down and store by a long press of the selected channel button. The system offers a
choice of screen aspect ratios similar to a typical domestic receiver, giving options between the standard 4:3 format, wide
screen 16:9 format and zoom to fill the screen.
To provide the strongest possible signal the Television tuner receives signals from 4 antenna sources located in the
heated rear window. Unlike domestic systems this system gives a more progressive picture loss if the signal is lost. The
signal loss is indicated to the user by a loss of reception screen message.
The Television system is primarily controlled from the Touch-screen and the ICP (integrated control panel) which are
located in the center of the instrument panel. Control signals from the Touch-screen display are sent on the MOST (media
oriented systems transport) ring to the Television tuner. The Television tuner uses a dedicated CVBS (composite video
signal) bus to transmit video signals to the Touch-screen.
Control signals from the ICP (Integrated control panel) are relayed on the medium speed CAN bus to the ICM (information
control module). The ICM (information control module) relays the control signals to the Television tuner on the MOST
(media oriented systems transport) ring. The ICM (information control module) is the timing master for the MOST (media
oriented systems transport) ring and also hosts a gateway function between the medium speed CAN bus and the MOST
(media oriented systems transport) ring.
Depending upon the audio system version fitted the Television tuner audio output signals are sent on the MOST (media
oriented systems transport) ring to the IAM (integrated audio module) or the power amplifier for speaker output.
TELEVISION TUNER
The television tuner is a DVB-T (digital video broadcasting - terrestrial) receiver and consists of a 'front end' which is made
up of a tuner and a demodulator. Following pre-filtering, the tuner converts the signal from the antenna to an intermediate
frequency. In the demodulator, the signal is first converted to a basic frequency, so that a signal from a transponder can
be forwarded to the MPEG decoder as a transport stream. The transport stream usually contains several television
channels along with relevant auxiliary services such as teletext, subtitles and electronic program guides.
NOTE: Not all digital features such as text and programme listings are currently available.
Control signals from the Touch-screen display are sent on the MOST (media oriented systems transport) ring to the
television tuner. The television tuner uses the dedicated CVBS (composite video signal) bus to transmit its video signals
to the Touch-screen. The CVBS (composite video signal) system utilizes a single wire transmission system and is limited in
bandwidth to less than 6MHz.
No configuration procedure is required if the television tuner is replaced. Calibration of the television tuner using the
Jaguar approved diagnostic equipment enables updates to be downloaded as new technology becomes available or any
fault concerns require software updates.
Television Antennas
ItemDescription
2 RF filter
4 Heated rear window
5 Heated rear window upper section
6 Heated rear window lower section
8 RF filter
The television tuner receives digital and analogue television signals through 4 antennas located in the heated rear
window. 3 of the antennas are connected to the triple antenna amplifier/module located on the RH (right-hand) side of the
heated rear window. A fourth antenna is connected to the single antenna amplifier/module located on the LH (left-hand)
side of the heated rear window.
The combination of signals from several antennas is known as 'diversity' reception. For example using two or more
antennas can reduce the signal error rate by 50%, which is of critical importance for mobile receivers.
Vehicle or other component generated electromagnetic interference may cause unwanted disturbance in the television
reception signals. The disturbance may interrupt, obstruct, or otherwise degrade or limit the effective performance of the
circuit.
Double coil RF (radio frequency) filters, which act as RF (radio frequency) isolators, are located on both sides of the heated
rear window and are used to reduce any electromagnetic interference. The LH side RF (radio frequency) filter is connected
across the heated rear window power supply and used to separate the DC (direct current) interference from the RF (radio
frequency) signals. The positive filter is present on all vehicle types and markets.
The right hand side double coil RF (radio frequency) filter is only used in conjunction with the television antenna modules
and is connected across the heated rear window ground circuit. If a television system is not fitted a filter is used which is
linked directly to ground.
Touch-Screen
ItemDescription
1 Touch-screen
3 Home menu button
The Touch-screen is the primary user interface for the television system. From the 'Home' screen menu television is a
sub-menu of 'Audio'. The Touch-screen communicates with the television tuner. Video signals to the Touch-screen are
transmitted from the television tuner.
ItemDescription
1 Touch-screen
2 Seek up button
3 Settings button
4 On/off and volume control
5 Source button
6 Seek down button
The ICP (integrated control panel) duplicates many of the Touch-screen television user control features. The ICP
(integrated control panel) communicates with the television system through the medium speed CAN and MOST (media
orientated systems transport) bus systems.
ItemDescription
1 Volume adjustment
2 Change pre-set TV (television) stations
3 Select source
4 Audio mute control/JaguarVoice control
Additional control of the television system is available in the form of steering wheel mounted switches which are located
on the left hand side of the steering wheel. The 4 switches provide for volume adjustment, change pre-set television
stations, select media source and finally audio mute control. The mute control is also used for JaguarVoice control.
Information and Entertainment System - Information and Entertainment
System
For additional information. REFER to: (415-00 Information and Entertainment System - General Information)
Information and Entertainment System (Diagnosis and Testing),

Cellular Phone (Diagnosis and Testing),
Navigation System (Diagnosis and Testing).
Information and Entertainment System - Audio Unit
Removal

2. Refer to: Audio and Climate Control Assembly (415-01 Information

and Entertainment System, Removal and Installation).
3. 3. CAUTIONS:
Cover fiber optic cable connectors to minimize

dust ingress and avoid bending the cables in a radius of
less than 30 mm.

Torque:
Retaining screws 3 Nm
Retaining nuts 5 Nm
Installation
1. 1. NOTE: New units must be configured using the Programmable

Module Installation Routine in the diagnostic tool.

Information and Entertainment System - Audio Unit Antenna Amplifier
Removal

2. Refer to: C-Pillar Trim Panel (501-05 Interior Trim and

3. Torque: 10 Nm
4.
Installation

Information and Entertainment System - Audio and Climate Control
Assembly
Removal
1. Remove both floor console side trim panels.
2. Torque: 4 Nm
Installation

Information and Entertainment System - Front Door Speaker
Removal
1. Refer to: Front Door Trim Panel (501-05, Removal and Installation).
2.
Installation

Display
Removal

2. Refer to: Center Registers (412-01 Climate Control, Removal and

Installation).
3. Torque: 2 Nm
4. 4. CAUTION: Cover fiber optic cable connectors to

minimize dust ingress and avoid bending the cables in
a radius of less than 30 mm.
Torque: 3 Nm
Installation

Module
Removal

2. Refer to: Audio Unit (415-01 Information and Entertainment System,

3. Torque: 3 Nm
Installation
1. 1. NOTE: New units must be configured using the Programmable

Module Installation Routine in the diagnostic tool.

Information and Entertainment System - Instrument Panel Speaker
Removal

2. Refer to: Instrument Panel Speaker Grille (501-05 Interior Trim and
3. Torque: 2 Nm
4.
Installation

Information and Entertainment System - Rear Door Speaker
Removal
1. Refer to: Rear Door Trim Panel (501-05 Interior Trim and
2.
Installation

Information and Entertainment System - Steering Wheel Audio Controls
Removal
Refer to: Standard W orkshop Practices (100-00 General Information,

2. Refer to: Driver Air Bag Module (501-20B Supplemental Restraint

System, Removal and Installation).
3. Refer to: Upshift Paddle Switch (307-05 Automatic

Installation).
4. Refer to: Downshift Paddle Switch (307-05 Automatic

Installation).
5. Torque: 3 Nm
6. Torque: 3 Nm
7. Torque: 6 Nm
8.
9.
Installation

Information and Entertainment System - Subwoofer Amplifier
Removal


3. Torque: 7 Nm
4. Torque: 7 Nm
5.
Torque: 7 Nm
7. Torque: 7 Nm
Installation

Information and Entertainment System - Subwoofer Speaker
Removal

2.
3. Torque: 6 Nm
4. Torque: 6 Nm
Installation
Exterior Lighting -
Item Specification
Low beam headlamp bulb - Vehicles with conventional headlamps - non Federal H7
Low beam headlamp bulb - Vehicles with conventional headlamps - Federal H11
Low beam headlamp bulb - Vehicles with xenon headlamps D1S
High beam headlamp bulb H7
Cornering lamp bulb H8
Side repeater lamp bulb W Y5W
Side marker lamp bulb - Federal W 5W
Front turn signal lamp bulb - non Federal PY21W
Front turn signal lamp bulb - Federal 3457 AK
Rear turn signal lamp bulb PY19W
Front side/parking lamp bulb W 5W halogen cool blue
Reversing lamp bulb PS19W
Exterior Lighting - Exterior Lighting - Component Location
ItemDescription
1 Front height sensor
2 Headlamp leveling module
3 Rain/light sensor
4 Rear height sensor
5 Light switch - LH (left-hand) steering column multifunction switch
7 Side marker lamp (NAS only) (2 off)
8 Front turn signal indicator (2 off)
9 Halogen or xenon headlamp projector module (2 off)
10 Cornering/Static bending lamp (where fitted) (2 off)
11 Headlamp telescopic power washer (2 off)
12 Front side lamp (2 off)
13 High beam only halogen lamp (2 off)
14 High Mounted Stop Lamp (HMSL) LED (light emitting diode)'s
15 License plate lamps (2 off)
16 Rear fog lamp (2 off)
17 Rear turn signal indicator (2 off)
18 Reverse lamp (2 off)
19 Side lamp/stop lamp LED's (2 off)
20 Side marker LED's (All markets) (2 off)
21 Side repeater lamp (2 off)
Exterior Lighting - Exterior Lighting - Overview
OVERVIEW
The lighting systems are controlled by the EJB (engine junction box), RJB (rear junction box) and the CJB (central junction
box). The two boxes contain fuses, relays and microprocessors to control the power supply and functionality of the lighting
systems.
Driver lighting selections using the LH (left-hand) steering column multifunction switch or the auxiliary lighting switch are
passed to the CJB via the instrument cluster.
The lighting system has an 'auto' lights function which is controlled by the CJB on receipt of signals from the rain/light
sensor located at the top of the windscreen. The exterior lights are turned on or off in response to ambient light signals
from the rain/light sensor on a LIN (local interconnect network) bus connection to the CJB . The auto lights can also be
activated when the windshield wipers are activated by signals from the rain sensor, which is located at the top of the
windshield or when the driver activates the wipers in the fast wipe position.
Two levels of headlamp specification are available; halogen or xenon. In certain markets the headlamps feature a
cornering lamp or a static bending lamp which illuminates the area at the side of the vehicle when turning into driveways
for example. North American Specification (NAS) vehicles have a side marker lamp installed in the headlamp assembly.
Replacement of any of the headlamp bulbs requires removal of the headlamp assembly.
The tail lamp comprises two separate lamp assemblies. The turn signal indicator, side and stop lamps and reverse lamps
are located in each rear fender tail lamp assembly. The rear fog lamps are located in separate units attached to the
luggage compartment lid. A side marker lamp is fitted to the rear fender tail lamp assembly and is fitted in all markets.
Two systems of headlamp leveling are available; manual leveling which is only available on halogen headlamps and static
dynamic leveling which is available on xenon headlamps. The manual system uses a thumbwheel rheostat to adjust the
vertical alignment of the headlamps to compensate for differing vehicle loading. The static dynamic system uses height
sensors fitted to the front and rear suspension and a headlamp leveling module which periodically monitors the vehicle
attitude and adjusts the headlamp vertical alignment accordingly.
Exterior Lighting - Exterior Lighting - System Operation and Component
Description
Control Diagram
XENON HEADLAMPS - CONTROL DIAGRAM
ItemDescription
A = Hardwired; D = High speed CAN bus; N = Medium speed CAN bus
1 Battery
5 Medium speed CAN (controller area network) bus to other vehicle systems
7 Front height sensor
8 Rear height sensor
9 RH (right-hand) headlamp assembly
10 LH (left-hand) headlamp assembly
11 Lighting control switch - LH steering column multifunction switch
HALOGEN HEADLAMPS - CONTROL DIAGRAM
ItemDescription
A = Hardwired; N = Medium speed CAN bus
1 Battery
2 BJB
3 CJB
4 EJB
6 RH headlamp assembly
7 LH headlamp assembly
SIDE LAMPS/TURN SIGNAL INDICATORS/FOG LAMPS - CONTROL DIAGRAM
ItemDescription
A = Hardwired; N = Medium speed CAN bus; O = LIN bus
1 Battery
2 BJB - Megafuse
3 Stop lamp switch
7 RH licence plate lamp
8 LH licence plate lamp
9 LH fog lamp
10 RH fog lamp
11 High mounted stop lamp
12 RH tail lamp assembly
13 LH tail lamp assembly
14 RH door mirror side repeater
15 LH door mirror side repeater
16 RH front door module
18 LH front door module
20 Rain/light sensor
22 RH headlamp assembly - side lamp and side marker lamp (if fitted)
23 CJB
24 LH headlamp assembly - side lamp and side marker lamp (if fitted)
System Operation
CENTRAL JUNCTION BOX (CJB) AND REAR JUNCTION BOX (RJB)
The CJB is an integrated unit which controls body functions and power distribution. The CJB is located on the RH 'A' pillar.
The RJB also controls body functions and power distribution and is located in the RH side of the luggage compartment.
Central Junction Box
The CJB receives inputs from the following switches via the instrument cluster and the medium speed CAN bus:
LH Steering column multifunction switch

- Side lamp position
- Headlamp position
- Automatic (AUTO) position
- Timer delay positions
- Turn signal indicators
- Headlamp flash and main beam positions.
The CJB receives direct inputs from the following components:
Stop lamp switch

Rain/light sensor.
The CJB provides power supplies to the following lamps:
LH and RH front side lamps

LH and RH front side marker lamps (if fitted)
LH and RH static bending lamp (if fitted)
LH and RH low beam headlamp
LH and RH high beam headlamp.
Rear Junction Box
The RJB provides power supplies to the following lamps:
LH and RH tail lamps

LH and RH stop lamps
LH and RH front turn signal indicators
LH and RH rear turn signal indicators
LH and RH licence plate lamps
LH and RH side marker lamps
High mounted stop lamp
Rear fog lamps
Reverse lamps.
The RJB also provides a power supply to the LH and RH door modules. The door modules use the power supply to activate
the turn signal indicator side repeater lamps located in the door mirrors, on receipt of a medium speed CAN bus message
from the RJB.
Circuit Protection
The CJB and the RJB provide circuit protection for their respective lighting circuits. The exterior lighting circuits are
protected by Field Effect Transistors (FET's). The FET's can detect overloads and short circuits and respond to heat
generated by increased current flow caused by a short circuit.
On a normal conventionally protected circuit this would cause a fuse to blow. The FET's respond to the heat increase and
disconnect the power supply to the affected circuit. When the fault is rectified or the FET has cooled, the FET will reset
and operate the circuit normally. If the fault persists the FET will cycle, disconnecting and reconnecting the power supply.
The CJB and the RJB store fault codes which can be retrieved using a Jaguar approved diagnostic system. The fault code
will identify that there is a fault on a particular output circuit which will assist with fault diagnosis and detection.
Alarm Indications
The exterior lighting system is used for alarm arm and disarm requests to show alarm system status.
When the driver locks and arms the vehicle, a visual indication of a successful lock and arm request is displayed to the
driver by a single flash of the hazard flashers. If the vehicle is superlocked, then the hazard flashers will flash a second
time (200 ms off and 200 ms on) to confirm the superlock request.
If the alarm is activated, the hazard flashers are operated for 10, 30 second cycles of 200 ms on and 200 ms off, with a 10
second delay between each cycle.
NOTE: On North American Specification (NAS) vehicles, the delay between the cycle when the alarm is activated is 60
seconds.
Lights on Warning
When the ignition is in the off power mode 0 or accessory power mode 4 and the lighting control switch is in the side lamp
or headlamp position, a warning chime will sound if the driver's door is opened. This indicates to the driver that the
exterior lights have been left switched on.
The chime is generated from the instrument cluster sounder on receipt of a lights on signal, a driver's door open signal and
an ignition off power mode 0 or accessory power mode 4 signal via a medium speed CAN bus signal from the CJB.
Headlamp Timer
The RJB controls the headlamp timer function which allows the headlamps to remain on for a period of time after leaving
the vehicle. This is a driver convenience feature which illuminates the driveway after leaving the vehicle.
To operate the timer function the lighting control switch must be in one of the three headlamp timer positions when the
ignition status is changed from ignition on power mode 6 to the off power mode 0. The timer function will then be initiated
and the low beam headlamps will be illuminated for the selected timer period.
NOTE: If the lighting switch is in the AUTO position, the headlamp timer will not function when the ignition is changed
to off power mode 0.
When the lighting control switch is in the autolamp exit delay position, the lighting control switch reference voltage flows
through 4 of the resistors. The returned signal voltage is detected by the instrument cluster which outputs a message on
the medium speed CAN bus to the RJB that autolamps has been selected.
Depending on the selected exit delay position, the reference voltage to the autolamp exit delay switch is routed through 3,
2 or 1 resistors which is detected by the instrument cluster. The cluster outputs a message on the medium speed CAN bus
to the RJB that autolamp exit delay period has been selected at 30, 60 or 120 seconds respectively.
Crash Signal Activation
When a crash signal is transmitted from the RCM (restraints control module), the RJB activates the hazard flashers. The
hazard flashers continue to operate until the ignition is in the off power mode 0 or accessory power mode 6. Once this
ignition state has occurred, the RCM will cease to transmit the crash signal.
LIGHTING CONTROL SWITCH

The instrument cluster outputs 2 reference voltages to the rotary lighting control switch; one feed being supplied to the
light selection function of the switch and the second feed being supplied to the auto headlamp exit delay function. The
switch position is determined by instrument cluster by the change in returned signal voltage which is routed through up to
4 resistors in series depending on the selection made.
OFF - W hen the lighting control switch is in the off position, the reference voltage flows through 1 of the resistors. The
the CJB that no lighting selection is made. The reference voltage to the auto headlamp exit delay switch is routed through
4 resistors which is detected by the instrument cluster which outputs a message on the medium speed CAN bus to the CJB
that auto headlamp or exit delay has not been selected.
SIDE LAMPS - When the lighting control switch is in the side lamp position, the reference voltage flows through 2 of the
resistors. The returned signal voltage is detected by the instrument cluster which outputs a message on the medium
speed CAN bus to the CJB to activate the side lamps. The reference voltage to the autolamp exit delay switch is routed
through 4 resistors which is detected by the instrument cluster which outputs a message on the medium speed CAN bus to
the CJB that auto headlamp or exit delay has not been selected.
HEADLAMPS - When the lighting control switch is in the headlamp position, the reference voltage flows through 3 of the
resistors. The returned signal voltage is detected by the instrument cluster which outputs a message on the medium
speed CAN bus to the CJB to activate the headlamps. The reference voltage to the auto headlamp exit delay switch is
routed through 4 resistors which is detected by the instrument cluster which outputs a message on the medium speed CAN
bus to the CJB that auto headlamp or exit delay has not been selected.
AUTOLAMPS - When the lighting control switch is in the auto headlamp position, the reference voltage flows through 4 of
the resistors. The returned signal voltage is detected by the instrument cluster which outputs a message on the medium
speed CAN bus to the CJB to activate the autolamp function. The reference voltage to the autolamp exit delay switch is
routed through 4 resistors which is detected by the instrument cluster which outputs a message on the medium speed CAN
bus to the CJB that auto headlamp has been selected.
AUXILIARY LIGHTING SWITCH

Headlamp Leveling Rotary Thumbwheel (Halogen headlamps only)
A power supply is passed to the headlamp leveling thumbwheel from the ignition relay in the EJB. Depending on the
position of the thumbwheel, the voltage passes through 1, 2 or 3 resistors connected in series. The voltage through the
resistors is passed to the headlamp leveling motor controller in each headlamp. The received voltage is determined as a
request for the appropriate level position and the controller powers the headlamp level motors to the applicable position
for each headlamp.
Rear Fog Lamp Switch
The instrument cluster supplies a reference voltage and return to the rear fog lamp switch. The fog lamp switch is a
non-latching, momentary switch.
When the fog lamp switch is off the reference voltage is passed through a 1Kohm resistor. The voltage through the
resistor is returned to the instrument cluster that determines that no request for fog lamp operation has been made.
When the driver presses the fog lamp switch, the reference voltage is passed through a 330 ohm resistor. The change is
return voltage is sensed by the instrument cluster which determines fog lamp operation has been requested. The
instrument cluster transmits a medium speed CAN bus signal to the RJB providing the lighting control switch is in the
correct position. The RJB reacts to the message and provides a power supply to the 3 LED (light emitting diode)'s in each
rear fog lamp. A fog lamp warning lamp in the instrument cluster will also be illuminated when the fog lamps are
operating.
The RJB will only activate the rear fog lamps if the headlamps are selected on or are active with auto headlamp activation.
When the headlamps are turned off the fog lamps are also turned off. When the headlamps are next switched on, the fog
lamps will not be activated until the driver requests fog lamp operation.
NOTE: The fog lamps do operate when DRL (daytime running lamps) are active.
HEADLAMP LEVELING
Manual Headlamp Leveling - Halogen headlamps only
A power supply is passed to the headlamp leveling motor in each headlamp from the ignition relay in the EJB. W hen a
signal voltage is received from the headlamp leveling rotary thumbwheel, the headlamp leveling motor controller in each
headlamp uses the power supply to operate the motors and move the headlamp to the requested position.
Static Dynamic Headlamp Leveling - Xenon headlamps only
The headlamp leveling module receives a power supply from the ignition relay in the EJB. The same power supply is also
supplied to the headlamp leveling motor in each headlamp assembly. The front and rear height sensors are connected to
the headlamp leveling module and receive a power and ground from the module. Each sensor has a signal line to the
headlamp leveling module to return height information to the module. The module uses the height signals from the
sensors to calculate the vehicle attitude and supplies a signal to each motor to power the headlamp to the required
position.
EXTERIOR BULB TYPE/RATING
The following table shows the bulbs used for the exterior lighting system and their type and specification.
NOTE: The tail lamps, side marker lamps, stop lamps, high mounted stop lamp and rear fog lamps are illuminated by
LED's and are non-serviceable components.
Bulb Type Rating

Halogen headlamp - Projector module low/high beam - Not NAS H7 55W
Halogen headlamp - Projector module low/high beam - NAS only H11 60W
Xenon headlamp - Projector module low/high beam - All markets D1S 35W
High beam only (halogen) - High/low beam (xenon) - All markets H7 55W
Front side lamps - all markets W5W Halogen cool blue (HCB) 5W
Front turn signal indicators - Not NAS PY21W 21W
Front turn signal indicators - NAS only 3457AK 27W
Rear turn signal indicators - All markets PSY19W 19W
Turn signal indicator side repeaters - All markets WY5W 5W
Reverse lamps - All markets PS19W 19W
Licence plate lamps - All markets W5W 5W
LIGHTING CONTROL SWITCH
ItemDescription
1 Off position
2 Side lamp position
3 High beam position
5 Headlamp flash/high beam off position
7 Headlamp position
8 AUTO headlamp position
9 Headlamp timer 120 second delay position
10 Headlamp timer 60 second delay position
11 Headlamp timer 30 second timer delay position
The lighting control switch is located on the LH steering column multifunction switch. The lighting control switch is a rotary
control with positions for the following lighting functions:
Off
Side lamps
Headlamps
AUTO headlamps
Headlamp timer (3 time period selections).
The LH steering column multifunction switch also provides for the following functions:
Low beam headlamps

High beam headlamps
Headlamp flash
LH and RH turn signal indicators
Trip computer function button.
The switch has a turn signal indicator lane change function. If the switch is gently pushed to either turn signal indicator
position and then released, the applicable turn signal indicators will flash 3 times and then will be automatically cancelled.
If a turn signal indicator bulb fails, the green turn signal warning indicator in the instrument cluster will flash at twice the
normal rate and the audible ticking from the instrument cluster sounder will also be at twice the normal rate.
AUXILIARY LIGHTING SWITCH

NOTE: RHD (right-hand drive) switch shown
ItemDescription
1 Headlamp leveling rotary thumbwheel (halogen headlamps only)
2 Instrument panel illumination dimmer thumbwheel
3 Luggage compartment lid release switch
4 Forward alert switch (if fitted)
5 Rear fog lamp switch
The auxiliary lighting switch is located in the instrument panel, adjacent to the steering column. The switch has a rear fog
lamp switch and a rotary thumbwheel to adjust headlamp leveling on vehicles with halogen headlamps. The auxiliary
lighting switch also has a forward alert switch (if fitted) and a rotary thumbwheel for instrument panel illumination
dimming.
The rear fog lamp switch is a non-latching switch which provides a momentary signal to the instrument cluster. The fog
lamps can only be activated if the ignition is in power mode 6 and the headlamp or auto headlamps are selected on. If the
fog lamp switch is pressed when the fog lamps are operating, they will be switched off. If the lighting control switch is
moved to the side lamp or off position or if the auto headlamps turns off the headlamps the rear fog lamps will be
extinguished. If the headlamps are subsequently turned on the rear fog lamp operation will not be active and the rear fog
lamp switch must be pressed to activate the lamps.
HEADLAMP ASSEMBLY
Two types of headlamp are available; xenon or halogen. The headlamp is secured in the front of the vehicle with three
bolts; one outboard bolt is screwed into the front upper cross member, one inboard bolt in the front upper body gusset and
one bolt located at the rear of the headlamp assembly which locates in the front fender reinforcing panel. Bulb
replacement requires the removal of the 3 bolts and the headlamp assembly.
The rear of the headlamp has removable panels which allow access to the bulbs for replacement. A large cover can be
rotated counter-clockwise for removal allows access the headlamp low beam halogen or xenon D1S bulb. Another large
removable cover can be rotated for removal to provide access to the high beam bulb, side lamp bulb and cornering/static
bending lamp bulb (if fitted).
The headlamps have 2 adjustment screws on the rear which allow for the manual setting of the vertical and horizontal
alignment.
On NAS vehicles, the headlamp is regarded as 'Visual Optically Left' aiming. The adjustment screws must be turned equal
amounts to maintain the correlation in the vertical axis only. There is no horizontal adjustment. Refer to the Service Repair
Procedures manual for headlamp alignment data and procedures.
Each headlamp has an integral 16 pin connector which provides inputs and outputs for the various functions of the
headlamp assembly.
ItemDescription
1 Xenon control module (not fitted on halogen low beam headlamps)
2 Turn signal indicator
3 Side marker lamp (NAS only)
4 Projector module - Low beam headlamp(Halogen) Low/High beam headlamp (xenon)
5 Cornering/static bending lamp (if fitted)
6 Side lamp
7 High beam headlamp
8 Power wash jets trim cover
9 Headlamp powerwash
10 Side marker lamp bulb (NAS only)
11 Turn signal indicator bulb
12 Headlamp adjuster screw (2 off)
13 Cover - Low beam headlamp projector module bulb
14 Mounting collar
15 Xenon igniter unit and bulb
16 Xenon igniter electrical connector
17 Cornering/static bending lamp bulb (if fitted)
18 Side lamp bulb
19 High beam headlamp bulb
20 Cover - Side lamp, cornering/static bending lamp (if fitted) and high beam headlamp bulbs
Bi-Xenon Headlamp
The bi-xenon headlamp uses a projector lens, similar to the halogen headlamp. The projector module comprises an
ellipsoidal lens and a reflector. The projector reflector collects the light produced by the halogen bulb and projects the
light into a focal plane containing a shield. The contour of the shield is projected onto the road by the lens. A complex
surface reflector is used for the halogen fill in high beam lamp. This type of reflector is divided into separate parabolic
segments, with each segment having a different focal length. The low and high beam bulbs are quartz halogen H7, with a
rating of 55W. The bulbs are retained in the headlamp unit with conventional wire retaining clips.
A tourist lever mechanism is located on the right hand side of the projector module. This mechanism moves a flap to blank
off a portion of the beam spread to enable the vehicle to be driven in opposite drive hand markets without applying
blanking decals to the headlamp lens. The beam is changed by removing the access cover at the rear of the lamp assembly
and moving a small lever located near the bulb holder, at the side of the projector.
NOTE: The tourist lever is not fitted to NAS vehicles.
WARNING: The Xenon system generates up to 30000 volts and contact with this voltage could lead to fatality. Make
sure that the headlamps are switched off before working on the system.
The following safety precautions must be adhered to when working on the xenon low beam headlamp system:
DO NOT attempt any procedures on the xenon headlamps when the lights are switched on.
Handling of the D1S xenon bulb must be performed using suitable protective equipment; for example gloves and
goggles. The glass part of the bulb must not be touched.
Xenon bulbs must be disposed of as hazardous waste.
Only operate the bulb in a mounted condition in the projector module installed in the headlamp.
The xenon headlamp is known as 'bi-xenon' because it operates as both a low and high beam headlamp unit. The xenon
lamp, or High Intensity Discharge (HID) lamp as they are sometimes referred to, comprises an ellipsoidal lens with a
solenoid controlled shutter to change the beam output from low to high beam.
NOTE: If the lighting control switch is in the 'off' position, both the xenon lamp and the halogen high beam lamp will
operate when the high beam 'flash' function is operated.
The xenon headlamp system is controlled by the CJB using a control module for each headlamp and an igniter. The control
modules and the igniters provide the regulated power supply required to illuminate the bulbs through their start-up phases
of operation.
The xenon headlamp is a self contained unit located within the headlamp assembly. The unit comprises a reflector, an
adaptor ring, the lens, a shutter controller and the xenon bulb, which together forms an assembly known as the projector
module. The reflector is curved and provides the mounting point for the xenon bulb. The bulb locates in a keyway to ensure
the correct alignment in the reflector and is secured by a plastic mounting ring. The bulb is an integral component of the
igniter and is electrically connected by a connector located in the igniter unit.
The shutter controller is a solenoid which operates the shutter mechanism via a lever. The shutter is used to change the
beam projection from low beam to high beam and vice versa.
The xenon bulbs illuminate when an arc of electrical current is established between 2 electrodes within the bulb. The
xenon gas sealed in the bulb reacts to the electrical excitation and the heat generated by the current flow to produce the
characteristic blue/white light.
To operate at full efficiency, the xenon bulb goes through 3 full stages of operation before full output for continuous
operation is achieved. The 3 phases are; start-up phase, warm-up phase and continuous phase.
In the start-up phase, the bulb requires an initial high voltage starting pulse of up to 30000 volts to establish the arc. This
is produced by the igniter. The warm-up phase begins once the arc is established. The xenon control module regulates the
supply to the bulb to 2.6A which gives a lamp output of 75W. During this phase, the xenon gas begins to illuminate
brightly and the environment within the bulb stabilizes, ensuring a continual current flow between the electrodes. When
the warm-up phase is complete, the xenon control module changes to continuous phase. The supply voltage to the bulb is
reduced and the operating power required for continual operation is reduced to 35W . The process from start-up to
continuous phase is completed in a very short time.
The xenon control modules (one per headlamp) receive an operating voltage from the CJB when the headlamps are
switched on. The modules regulate the power supply required through the phases of start-up.
The igniters (one per headlamp) generate the initial high voltage required to establish the arc. The igniters have integral
coils which generate high voltage pulses required for start-up. Once the xenon bulbs are operating, the igniters provide a
closed circuit for the regulated power supply from the control modules.
Halogen Low/high Beam Headlamp
The halogen low/high beam headlamp uses a projector lens, similar to the xenon headlamp. The projector module
comprises an ellipsoidal lens and a reflector. The projector reflector collects the light produced by the halogen bulb and
projects the light into a focal plane containing a shield. The contour of the shield is projected onto the road by the lens.
The low/high beam bulbs are quartz halogen and are retained in the headlamp unit with conventional wire retaining clips.
A tourist lever mechanism is located on the right hand side of the projector module. This mechanism moves a flap to blank
off a portion of the beam spread to enable the vehicle to be driven in opposite drive hand markets without applying
blanking decals to the headlamp lens. The beam is changed by removing the access cover at the rear of the lamp assembly
and moving a small lever located near the bulb holder, at the side of the projector.
Halogen High Beam Headlamp - Xenon and Halogen

The xenon and halogen headlamps use a complex surface reflector for the halogen fill in high beam lamp only lighting unit,
which is of the same design on both headlamp types. This type of reflector has the reflector divided into separate
parabolic segments, with each segment having a different focal length.
The high beam headlamp bulbs are quartz halogen and are retained in the headlamp unit with conventional wire retaining
clips.
Cornering Lamps
NOTE: The cornering lamps are not fitted to NAS vehicles.
The cornering lamps are an optional feature designed to illuminate the direction of travel when cornering at low speeds.
The design of the lens projects a spread of light from the vehicle at approximately 45 degrees to the vehicle axis. The
cornering lamp is incorporated into the headlamp assembly and shares the same housing as the low beam headlamp. The
cornering lamp uses a 35W Halogen H8 bulb which is permanently located in an integral holder which is connected on the
headlamp housing. The holder is located in an aperture in the headlamp housing and rotated to lock. The bulb is
accessible via a removable cover on the base of the headlamp housing.
The cornering lamps are controlled by the LH steering column multifunction switch with the lighting control switch in the
headlamp position and the ignition in power mode 6. The cornering lamps are supplied power via the ignition circuit to
ensure that they do not function with the headlamp delay feature. The cornering lamps are deactivated if the vehicle
speed exceeds 25 mph (40 km/h). Only one cornering lamp will illuminate at any one time. If the left hand turn signal
indicators are selected on, the left hand cornering lamp will be illuminated and vice versa, providing the vehicle speed and
lighting control switch positions are correct.
Static Bending Lamps
NOTE: The static bending lamps are not fitted to NAS vehicles.
The static bending lamps are designed to illuminate the direction of travel when cornering at low speeds. The static
bending lamp functionality, which is controlled by the CJB and the headlamp leveling module, operates using inputs from
the steering angle sensor and vehicle speed information from the ABS (anti-lock brake system) module. The static bending
lamp is incorporated into the headlamp assembly and shares the same housing as the low beam headlamp. The design of
the lens projects a spread of light from the vehicle at approximately 45 degrees to the vehicle axis. The static bending
lamp uses a 35W Halogen H8 bulb which locates in a holder which is connected via wires to the main connector on the
headlamp housing. The holder is located in an aperture in the headlamp housing and rotated to lock. The bulb is
accessible via a removable cover at the rear of the headlamp housing.
The static bending lamps operate with a steering angle sensor CAN bus signal which is received by the CJB. The CJB
monitors this signal and vehicle speed and activates the static bending lamp bulb. W hen the operation parameters of the
lamp are reached, the CJB fades the static bending lamp bulb on using a PW M (pulse width modulation) voltage over a
period of approximately 2 seconds. When the lamp is switched off, the CJB fades the bulb off by decreasing the PW M
voltage in a linear manner depending on steering angle and vehicle speed. The cornering lamps can only be active for a
maximum of 3 minutes.
NOTE: Static bending lamps only operate when the transmission is in DRIVE or in SPORT.
Turn Signal Indicators
The turn signal indicator lamp is incorporated into the outer part of the headlamp assembly. The turn signal indicator lamp
uses a PY21W bayonet orange colored bulb in ROW markets, a S8W 27/7W wedge bulb is used in NAS markets. The bulb
is fitted into a holder which connects with contacts in the headlamp housing. The holder is fitted into an aperture in the
headlamp housing and rotated to lock into position.
When active, the turn signal indicator lamps will flash at a frequency cycle of 380ms on and 380ms off. If a bulb fails, the
remaining turn signal lamps bulbs continue to flash at normal speed. The turn signal indicators in the instrument cluster
will flash at double speed to indicate the bulb failure to the driver.
Side Lamps
The side lamp is located between the headlamp projector module and the high bean headlamp. The side lamp uses a W 5W
wedge fitting bulb which locates in a holder which connected via wires to the main connector on the headlamp housing.
The holder is a push fit into a receptacle in the headlamp housing. The bulb is accessible by removal of the inner cover on
the rear of the headlamp housing. Access to the bulb requires removal of the headlamp from the vehicle. The side lamps
are operated by selecting side lamps or headlamps on the lighting control switch. The side lamps are functional at all
times and are dependant on a particular ignition mode status. The side lamps will also be illuminated when the lighting
control switch is in the AUTO position and a 'lights on' signal is received by the CJB from the rain/light sensor
Side Marker Lamps (NAS only)
The side marker lamp is located in the outer part of the headlamp assembly. The side marker lamp uses a W5W wedge
fitting bulb. The bulb is fitted into a holder which connects with contacts in the headlamp housing. The holder is fitted into
an aperture which connects with contacts in the headlamp housing. The side marker lamp is active at all times when the
side lamps are active.
AUTOMATIC HEADLAMP OPERATION

The automatic headlamp function is a driver assistance system. The driver can override the system operation by selection
of side lamp or headlamp on if the ambient light conditions require front and rear lighting to be active. The automatic
headlamp system uses a light sensor and the CJB, which are connected via a LIN (local interconnect network) bus to
control the headlamp functionality. The light sensor is incorporated in the rain/light sensor located on the inside of the
windshield, below the rear view mirror. The wiper system also uses the rain/light sensor for automatic wiper operation.
The light sensor measures the ambient light around the vehicle in a vertical direction and also the angular light level from
the front of the vehicle. The rain/light sensor uses vehicle speed signals, wiper switch position and the park position of the
front wipers to control the system. The automatic headlamp operation uses ambient light levels which are monitored by
photodiode incorporated in the rain/light sensor. The rain/light sensor sends a lights on/off request to the CJB on the LIN
bus, which responds by switching on the low beam headlamps, front side lamps and rear tail lamps. The automatic
headlamps are activated under the following conditions:
Twilight
Darkness
Rain
Snow
Tunnels
Underground or multistoried car parks.
Operation of the automatic headlamps requires the ignition to be in ignition mode 6, the lighting control switch to be in
the 'AUTO' position and a lights on request signal from the light sensor. If the rain sensor signal activates the fast speed
wipers, the low beam headlamps are activated, providing the lighting control switch is in the 'AUTO' position.
HEADLAMP LEVELING
Headlamp leveling provides for the adjustment of the vertical aim of the headlamps. The leveling system is primarily
required to minimise glare to other road users when a heavy load is in the rear of the vehicle. Two systems of headlamp
leveling are available; manual and static dynamic.
Manual Headlamp Leveling
The manual system uses a thumbwheel rheostat to adjust the vertical alignment of the headlamps to compensate for
differing vehicle loading. The rotary thumbwheel is located on the auxiliary lighting switch, adjacent to the illumination
dimmer thumbwheel. Three positions are available to adjust the headlamps to a position to prevent glare to other road
users.
Static Dynamic Headlamp Leveling
The static dynamic headlamp leveling system uses the following components:
Front and rear vehicle height sensors

Two headlamp leveling, vertical adjustment motors
Headlamp leveling module
Ignition in mode 6
Vehicle speed information from ABS module.
The static dynamic system uses height sensors fitted to the front and rear suspension and a headlamp leveling module
which periodically monitors the vehicle attitude and adjusts the headlamp vertical alignment accordingly.
Static dynamic headlamp leveling is controlled by a headlamp leveling module located in the lower instrument panel,
behind the glovebox.
The height sensors are both located on the RH side of the vehicle. The front sensor is attached to the front suspension
lower arm with a strap and to the front sub frame with a bracket and 2 bolts. The rear sensor is attached to the rear
suspension upper control arm with a cable tied clip and to the rear sub frame with a bracket and 2 bolts. Each sensor has 3
connections to the headlamp leveling module; power, ground and signal.
DAYTIME RUNNING LAMPS (DRL)

Refer to DRL section for details.
Refer to: Daytime Running Lamps (DRL) (417-04 Daytime Running Lamps (DRL), Description and Operation).
REAR LAMP ASSEMBLY

The rear lamp assembly is a 2 piece unit, with one part located in the rear quarter panel and the second part attached to
the luggage compartment lid. The outer rear lamp assembly is located in a recess in the vehicle body. The lamp is secured
with 2 studs inboard studs on the lamp body which are secured to the vehicle body with 2 nuts. A third outboard stud and
nut secures a clip to the vehicle body. To remove the lamp assembly, only the 2 inboard nuts require removal. The
outboard nut retains a sliding clip in position on the vehicle body. To remove the rear lamp assembly, remove the 2
inboard nuts and slide the lamp rearwards to release the outboard clip.
The inner rear lamp is located in a recess in the luggage compartment lip and secured with a clip.
ItemDescription
1 Nut (3 off)
2 Reverse lamp bulb and holder
3 Rear lamp electrical connector
4 Turn signal indicator bulb and holder
5 Securing clip
6 Rear fog lamp electrical connector
7 Rear fog lamp LED's and Printed Circuit Board (PCB)
8 Side marker LED's (4 off - all markets)
9 Reverse lamp
10 Turn signal indicator lamp
11 Side lamp/stop lamp LED's (24 off)
12 Rear fog lamp LED's (3 off)
Rear Stop and Side Lamp
The turn signal indicator, side and stop lamps and reverse lamps are located in each outer rear lamp assembly. The side
lamps and stop lamps use 24 LED's. The 24 LED's are illuminated at a higher intensity than the side lamp when the stop
lamp switch is operated by pressing the brake pedal. A side marker lamp is fitted to the outer rear lamp assembly and is
fitted in all markets. The side marker lamp also uses 4 LED's and are active at all times when the side lamps are selected
on.
The stop lamps can also be activated by the adaptive speed control system. A signal from the adaptive speed control
module is sent via the high speed CAN bus to the RJB which activates the stop lamps until an off message is received.
Turn Signal Indicator
The turn signal indicator lamp uses a Phillips Hypervision glass filament bulb. The bulb is located in a holder which has
contacts which mate with contacts on lamp body. The holder locates in the lamp body and is rotated to lock.
If a bulb fails, the remaining turn signal indicator lamps continue to flash at the normal speed. The applicable turn signal
indicator in the instrument cluster will flash at double speed to indicate the bulb failure to the driver.
Reverse Lamp
The reverse lamp also uses a Phillips Hypervision glass filament bulb. The bulb is located in a holder which has contacts
which mate with contacts on lamp body. The holder locates in the lamp body and is rotated to lock.
The reverse lamps are activated on receipt of a reverse selected message sent on the medium speed CAN bus to the RJB.
Rear Fog Lamp
The rear fog lamps are located in separate units attached to the luggage compartment lid. The rear fog lamps each use 3
high intensity LED's. The fog lamp locates in a recess in the luggage compartment lid has a seal to prevent the ingress of
water into the luggage compartment. The lamp is secured in the recess with a metal securing clip. The rear fog lamp is
activated using a button located on the auxiliary lighting switch in the instrument panel.
LICENCE PLATE LAMPS

Two licence plate lamps are located in the luggage compartment lid trim finisher. One is located adjacent to the
emergency luggage compartment lid release key barrel cover and the other is adjacent to the rear view camera (if fitted).
The licence plate lamps are active at all times when the side lamps are operating. Each lamp can be removed from the
finisher by inserting a wide, flat screwdriver blade or similar tool in a slot between the lamp lens and the finisher and
gently levering the lamp from the surround. The bulb is a push fit in a holder which in turn is a press fit in the lamp
housing.
HIGH MOUNTED STOP LAMP

The high mounted stop lamp is located at the bottom of the rear windshield. The lamp is secured to a bezel in the parcel
shelf with 2 screws.
The high mounted stop lamp uses 12, red colored LED's which illuminate through a clear lens. The high mounted stop lamp
functionality is the same as that described for the stop lamps.
TURN SIGNAL INDICATOR SIDE REPEATER LAMPS

The turn signal indicator side repeaters are located in each door mirror. On vehicles from 10MY the lamp is an LED unit
which illuminates in an orange color. The LED unit is secured to the mirror bezel with 2 screws and is connected to the
mirror wiring harness with a 2 pin connector.
The side repeaters have the same functionality and operate in conjunction with the front and rear turn signal indicators
and the hazard warning flashers.
HAZARD FLASHERS
The hazard flashers are activated by a non-latching switch located in the switch pack located in the center of the
instrument panel. The hazard flashers operate at all times when selected and operate independent of the ignition mode.
When the hazard flashers are selected on by the driver, a ground path is momentarily completed to the CJB which
activates the front and rear and side repeater turn signal indicators. A second press of the switch is sensed by the CJB and
the hazard flasher are deactivated. When the hazard flashers are active, they override any request for turn signal indicator
operation.
The hazard flashers can also be activated by a crash signal from the RCM.
Refer to: Air Bag and Safety Belt Pretensioner Supplemental Restraint System (SRS) (501-20B Supplemental Restraint
System, Description and Operation).
Exterior Lighting - Headlamps
For a detailed description of the exterior lighting system, refer to the relevant Description and Operation section in the
workshop manual. REFER to: (417-01 Exterior Lighting)
Exterior Lighting (Description and Operation),

Exterior Lighting (Description and Operation),
Exterior Lighting (Description and Operation).
Safety Information
W ARNINGS:
The Xenon Headlamp system generates up to 28,000 volts. Make sure that the headlamps are switched off before
working on the system. Failure to follow this instruction may lead to fatality.
The following safety precautions must be followed when working on the Xenon Headlamp System:
DO NOT attempt any procedures on the Xenon Headlamps or circuits when the system is energized.
Handling of the xenon bulb must be performed using suitable protective equipment, e.g. gloves and goggles. The
glass part of the bulb must not be touched.
Only operate the lamp in a mounted condition in the reflector.
All safety procedures and precautions must be followed to prevent personal injury.
CAUTION: Xenon bulbs must be disposed of as hazardous waste.
There are instructions on the correct procedures for Xenon Headlamp System repairs in the manual, refer to section 100-00
- General Information, Standard W orkshop Practices of the workshop manual.
vehicle.
Visual Inspection
Electrical
Headlamp Leveling Module (HLM)
Bulb(s)
Photocell(s)
Ballast
W iring harness/electrical connectors
Fuse(s)
4. 4. If the cause is not visually evident, check for Diagnostic Trouble Codes (DTCs) and refer to DTC Index.
Symptom Chart

Low beam lamp(s) Bulb failure Check the bulb and fuse condition (see visual inspection). Check the
inoperative Fuse(s) blown headlamp circuits. Check the lighting control switch function. Check the
Circuit fault left-hand steering column multifunction switch operation. Refer to the
Lighting control switch electrical guides. Check for DTCs indicating a headlamp or related
fault circuit fault.
High beam lamp(s)
Left-hand steering
inoperative
column multifunction
switch fault
Low beam lamp(s) Incorrect bulb rating Check the bulb condition and rating. Check the tourist lever is set
dim Tourist lever set in the correctly. Check the headlamp circuits. Check the lighting control switch
wrong position function. Check the left-hand steering column multifunction switch
Circuit fault function. Refer to the electrical guides.
High beam lamp(s) Lighting control switch
dim fault
Left-hand steering
switch fault
Low beam lamp(s) Circuit fault Check the headlamp circuits. Check the lighting control switch function.
stuck on Lighting control switch Check the left-hand steering column multifunction switch operation.
fault Check the headlamp timer function. Refer to the electrical guides.
Left-hand steering Check for DTCs indicating a headlamp circuit fault
High beam lamp(s)
switch fault
stuck on
Headlamp timer
function fault
Headlamp low/high Circuit fault Check the headlamp circuits. Check the left-hand steering column
beam switching Left-hand steering multifunction switch operation. Check the xenon lamp shutter
function inoperative column multifunction mechanism operation. Refer to the electrical guides. Check for DTCs
switch fault indicating a headlamp circuit fault
Xenon lamp shutter
mechanism fault
W arning lamp(s) Fuse(s) blown Check the fuse(s) (see visual inspection). Check the lighting control
inoperative Lighting control switch switch function. Check the left-hand steering column multifunction
fault switch function. Check the warning lamp circuits. Refer to the electrical
Left-hand steering guides. Check for DTCs indicating an instrument cluster or CAN system
column multifunction fault.
switch inoperative
Circuit fault
Instrument cluster
fault
Headlamp W et - Condensation Check for outstanding Technical Service Bulletins (TSBs) relating to
Internal W ater Ingress 'Headlamp Internal Condensation'. Carry out the instructions in the
service bulletin to determine if the fault is related to condensation or
water ingress.
DTC Index
account.
NOTE: Prior to installation/replacement of the Headlamp Assembly carry out all relevant internal visual and mechanical
checks for correct cable location and termination including: checks for corroded, bent or backed out pins or terminals,
incorrectly inserted connectors and harness damage due to chaffing or incorrect routing.
NOTE: If the control module has been removed and reinstalled, carry out a DTC code clear, cycle the ignition state to off,
then on. This will erase any DTCs that have been logged during the module installation procedure
Headlamp Leveling Module (HLM)

B1041-04 Leveling Control - Module internal failure Suspect Headlamp Leveling Module internal fault. Replace as
System Internal required, refer to the new module/component installation
Failures note at the top of the DTC Index
B1041-54 Leveling Control - NOTE: This DTC will NOTE: Sensor calibration routine must be carried out with
Missing calibration normally be logged when a the vehicle unladen.
new module has been
installed. Calibrate the Headlamp Leveling sensors using the
manufacturer approved diagnostic system, carry the out
Leveling sensor routine 'Headlamp Control Module System Calibration' from
calibration routine not the 'Module programming and configuration - Setup and
carried out Configuration - Lighting'
B10AE-11 Headlamp Leveling Headlamp Leveling Refer to the electrical circuit diagrams and check the
Motor - Circuit short Motor Control circuit Headlamp Leveling Motor Control circuit for short to ground
to ground short to ground
B10AE-12 Headlamp Leveling Headlamp Leveling Refer to the electrical circuit diagrams and check the
Motor - Circuit short Motor Control circuit Headlamp Leveling Motor Control circuit for short to power
to battery short to power
B10AE-64 Headlamp Leveling Signal plausibility Refer to the electrical circuit diagrams and check the
Motor - Signal failure voltage out of Headlamp Leveling Motor circuits for failure. Disconnect one
plausibility failure range headlamp connector, clear DTC and re-test. If DTC cleared,
suspect Headlamp Leveling Module or circuits to the
disconnected side. If DTC remains, reconnect first headlamp
and disconnect second, clear DTC and re-test. If DTC
cleared, suspect Headlamp Leveling Module or circuits to the
disconnected side. If DTC remains, suspect common circuits
of the failure. Refer to the electrical circuit diagrams and
check as required
B1A59-11 Sensor 5 Volt Supply Headlamp Leveling Refer to electrical circuit diagrams and check the Headlamp
- Circuit short to sensor 5 volt supply Leveling Sensor 5 volt supply circuit for short to ground
ground circuit short to ground
B1A59-12 Sensor 5 Volt Supply Headlamp Leveling Refer to electrical circuit diagrams and check the Headlamp
- General Electrical sensor 5 volt supply Leveling Sensor 5 volt supply circuit for short to power
Failure circuit short to power
C1A04-11 Right Front Height Right Front Height Refer to the electrical circuit diagrams, and check the Right
Sensor - Circuit short Sensor circuit short to Front Height Sensor circuit for short to ground
to ground ground
C1A04-15 Right Front Height Right Front Height Check the Right Front Height Sensor connector for security.
Sensor - Circuit short Sensor circuit short to Refer to the electrical circuit diagrams, and check Right Front
to battery or open power or open circuit Height Sensor circuit for short to power or open circuit
C1A04-64 Right Front Height Sensor (PW M) Signal NOTE: This DTC may be logged if the vehicles wheels have
Sensor - Signal out of range been raised from the floor
plausibility failure
Check the location, security and mechanical operation of the
Height Sensor. Refer to the electrical circuit diagrams, and
check Front Right Height Sensor signal circuit for fault
C1A06-11 Right Rear Height Right Rear Height Refer to the electrical circuit diagrams, and check Right Rear
Sensor - Circuit short Sensor circuit short to Height Sensor circuit for short to ground
to ground ground
C1A06-15 Right Rear Height Right Rear Height Check the Right Rear Height Sensor connector for security.
Sensor - Circuit short Sensor circuit short to Refer to the electrical circuit diagrams, and check Right Rear
to battery or open power or open circuit Height Sensor circuit for short to power or open circuit
C1A06-64 Right Rear Height Sensor (PW M) Signal NOTE: This DTC may be logged if the vehicles wheels have
Sensor - Signal out of range been raised from the floor
plausibility failure
Check the location, security and mechanical operation of the
Height Sensor. Refer to the electrical circuit diagrams, and
check Right Rear Height Sensor signal circuit for fault
U0001-88 High Speed CAN CAN Bus Off Carry out the CAN Network Integrity test using the
Communication Bus - CAN Bus Circuit fault manufacturer approved diagnostic system
Bus off
U0100-00 Lost Communication Lost communication Check the Engine Control Module for stored DTCs. Using the
With ECM/PCM "A" - with the Engine manufacturer approved diagnostic system, complete the CAN
No sub type Control Module Network Integrity test. Refer to the electrical circuit
information CAN network fault diagrams and check the CAN network between the Headlamp
Leveling Module and the Engine Control Module
U0101-00 Lost Communication Lost communication Check the Transmission Control Module for stored DTCs.
with TCM - No sub with the Transmission Using the manufacturer approved diagnostic system,
type information Control Module complete the CAN Network Integrity test. Refer to the
CAN network fault electrical circuit diagrams and check the CAN network
between the Headlamp Leveling Module and the
Transmission Control Module
U0121-00 Lost Communication Lost communication Check the Anti-lock Brake System Module for stored DTCs.
With Anti-Lock Brake with the Anti-lock Using the manufacturer approved diagnostic system,
System (ABS) Brake System Module complete the CAN Network Integrity test. Refer to the
Control Module - No CAN network fault electrical circuit diagrams and check the CAN network
sub type information between the Headlamp Leveling Module and the Anti-lock
Brake System Module
U0155-00 Lost Communication Lost communication Check the Instrument Cluster for stored DTCs. Using the
With Instrument with the Instrument manufacturer approved diagnostic system, complete the CAN
Panel Cluster (IPC) Panel Cluster (IPC) Network Integrity test. Refer to the electrical circuit
Control Module - No Control Module diagrams and check the CAN network between the Headlamp
sub type information CAN network fault Leveling Module and the Instrument Cluster
U0300-00 Internal Control Car Configuration File NOTE: The Car Configuration File (CCF) parameters
Module Software (CCF) information required are (Vehicle type)(Headlamp type)(Gearbox type)
Incompatibility - No incompatible to and (Dayrunning light)
sub type information Headlamp Leveling
Module Check/amend the Car Configuration File (CCF) using the
manufacturer approved diagnostic system. Confirm the latest
Strategy and Calibration software is installed in the
Headlamp Leveling Module, using the manufacturer approved
diagnostic system update the Headlamp Leveling Module
software as required. If DTC returns suspect an internal fault
with the Headlamp Leveling Module check and install a new
U0415-00 Invalid Data NOTE: Steering Angle NOTE: The steering wheel center (straight ahead) position
Received From Sensor not calibrated is recalculated each ignition cycle
Anti-Lock Brake
System (ABS) Invalid data received Check the Anti-lock Brake System Module for related DTCs
Control Module - No from ABS module and refer to relevant DTC Index.
sub type information
U0443-00 Invalid Data Invalid signal from the Check the Auxiliary Junction Box for related DTCs and refer
Received From Body Auxiliary Junction Box to the relevant DTC Index. Carry out the CAN Network
Control Module "B" - Auxiliary Junction Box Integrity test using the manufacturer approved diagnostic
No sub type fault system
information
U2100-00 Initial Configuration Car Configuration File NOTE: The Car Configuration File (CCF) parameters
Not Complete - No (CCF) information not required are (Vehicle type)(Headlamp type)(Gearbox type)
sub type information received completely and (Dayrunning light)
Using the manufacturer approved diagnostic system, clear

the stored DTC then cycle the Ignition State to off, wait 30
seconds, return the Ignition state to on and check for stored
DTCs, if the DTC reoccurs check other modules for related
stored DTCs. If no other modules have related DTCs confirm
the security and condition of the Headlamp Leveling Module
circuit connections. If no other DTCs are stored and the
circuit is correct suspect an internal fault with the Headlamp
Leveling Module check and install a new module as required,
U2101-00 Control Module Car Configuration File NOTE: The Car Configuration File (CCF) parameters
Configuration (CCF) information required are (Vehicle type)(Headlamp type)(Gearbox type)
Incompatible - No incompatible to and (Dayrunning light)
sub type information Headlamp Leveling
Module Re-configure the Car Configuration File (CCF) as required
using the manufacturer approved diagnostic system. Clear
DTC and re-test. If the DTC remains suspect the Headlamp
Leveling Module, refer to the new module installation note
U3002-81 Vehicle Identification The stored Vehicle Check the correct Headlamp Leveling Module is installed to
Number - Invalid Identification Number vehicle specification. Refit original or replace the module as
serial data received is not the same as the required. Refer to the new module/component installation
Central Broadcast note at the top of the DTC Index
Vehicle Identification
Number
The Headlamp Leveling
Module has previously
been installed to
another vehicle
U3003-16 Battery Voltage - The power supply to Suspect Battery or Charging fault. Check the battery
Circuit voltage below the Module has been condition and state of charge. Check the vehicle charging
threshold below 9 Volts for more system. Refer to the relevant workshop manual section.
than 1000 milliseconds Clear the DTC, cycle ignition state to off then on, if DTC
returns refer to the electrical circuit diagrams and check
power and ground circuit to the Headlamp Leveling Module
U3003-17 Battery Voltage - The power supply to Suspect Charging fault. Check the battery condition and
Circuit voltage above the Module has been state of charge. Check the vehicle charging system. Refer to
threshold above 16 Volts for the relevant workshop manual section
more than 1000
milliseconds
U3003-62 Battery Voltage - Difference in battery Check other modules for related stored DTCs. Refer to the
Signal compare voltage, of 2 volts or electrical circuit diagrams and check power and ground
failure more, between the voltages at the Headlamp Leveling Module
central broadcast
voltage (via CAN Bus)
and Headlamp Leveling
Module
Exterior Lighting - Approach Lamp
Removal
1. Refer to: Exterior Mirror Glass (501-09 Rear View Mirrors, Removal
and Installation).
2.
3.
Installation

Exterior Lighting - Headlamp Assembly
Removal
1. 1. NOTE: Turn the steering wheel to full LH lock.
2.
3.
4.
Installation
1.
2.
3. Torque: 5 Nm
4. Torque: 5 Nm
Exterior Lighting - Headlamp Leveling Front Sensor
Removal


2. Remove the headlamp leveling sensor.
Disconnect the height sensor link.
Remove the 2 bolts.

Remove the height sensor link.

Remove the bracket.
Remove the 2 Allen bolts.
Installation
Install the bracket.
Tighten to 5 Nm.
2. Install the height sensor link.

3. Install the headlamp leveling sensor.
Tighten to 25 Nm.
Connect the height sensor link.

Exterior Lighting - Headlamp Leveling Rear Sensor
Removal


2. Remove the headlamp leveling sensor.
Disconnect the height sensor link.
Release and disconnect the electrical connector.
Remove the 2 bolts.

Remove the bracket.
Remove the 2 Allen bolts.
Installation
Install the bracket.
Tighten to 5 Nm.
2. Install the headlamp leveling sensor.
Tighten to 25 Nm
Install the height sensor link.

Exterior Lighting - High Mounted Stoplamp
Removal

2.
Installation

Exterior Lighting - Rear Fog Lamp
General Equipment
Spatula
Removal
1. Refer to: Luggage Compartment Lid Moulding (501-08 Exterior Trim

2. 2. CAUTIONS:
Protect the surrounding paintwork to avoid

damage.
Take extra care not to damage the edges of the

component.
General Equipment: Spatula
Installation

Exterior Lighting - Rear Lamp Assembly
Removal
1. Refer to: Loadspace Scuff Plate Trim Panel (501-05 Interior Trim and
Torque: 3 Nm
edges of the component.

Installation

Exterior Lighting - Side Turn Signal Lamp
Removal
1. Refer to: Exterior Mirror Cover (501-09 Rear View Mirrors, Removal
and Installation).
2.
3.
Installation

Interior Lighting - Interior Lighting - Component Location
INTERIOR LIGHTING COMPONENT LOCATION
ItemDescription
1 Glovebox lamp
2 Door casing LED (light emitting diode) illumination
3 Approach lamp
4 Vanity mirror illumination
5 Overhead console
6 Vanity mirror illumination
7 Rear overhead console
8 Luggage compartment lamp
9 Approach lamp
10 Door casing LED illumination
11 Footwell lamps
Interior Lighting - Interior Lighting - Overview
OVERVIEW
Interior lighting is provided to enable the safe entry and departure from the vehicle for the driver and passengers in low
ambient light conditions, without any manual switching of the lights.
NOTE: The term interior lamps also includes the door mirror approach lamps.
The interior lamps are controlled by the CJB (central junction box) and the RJB (rear junction box) and have 2 modes of
operation: manual and automatic. The front interior lamps in the front overhead console are operated using the
'JaguarSense' system. The system uses capacitive proximity sensor technology for the switch operation which is integral
with the overhead console. The rear overhead console interior lamps have conventional switches.
In the manual mode the interior lamps can be switched on and off with the JaguarSense system. Positioning your hand
adjacent to each lamp in the front overhead console will switch interior lamps on or off and completely disable the interior
lamp system. In the automatic mode the interior lamp functionality is controlled by the CJB and the RJB and reacts to the
vehicle being locked or unlocked and opening the vehicle doors.
In manual mode the interior lamps can be operated by placing your finger(s) close to, or touch, the surface of the
appropriate lamp. The courtesy light and map reading lamps can be operated manually by the 'JaguarSense' system. When
in automatic mode, the courtesy lamp functionality is also controlled by the CJB and the RJB and reacts to the vehicle
being locked or unlocked and opening the vehicle doors. To deactivate or activate automatic illumination, touch the front
courtesy lamp for approximately 2 seconds
The driver's and passenger door approach lamps are controlled by the driver's door module and the passenger door module
respectively and operate with the automatic mode. The door modules receive a power supply from the RJB and receive
information to illuminate the approach lamps on the medium speed CAN (controller area network) bus from the RJB and
the CJB.
Interior Lighting - Interior Lighting - System Operation and Component
Description
Control Diagram
CONTROL DIAGRAM (SHEET 1 OF 2)
ItemDescription
A = Hardwired; N = Medium speed CAN Bus
1 Battery
2 BJB (battery junction box) - Megafuse
3 BJB - Megafuse
5 Driver's door mirror approach lamp
6 Driver's door module
7 Passenger door mirror approach lamp
8 Passenger door module
9 LH (left-hand) rear door latch
10 RH (right-hand) rear door latch
11 LH front door latch
12 RH front door latch
14 LH front door handle LED (light emitting diode) illumination
15 RH front door handle LED illumination
CONTROL DIAGRAM (SHEET 2 OF 2)
ItemDescription
A = Hardwired
1 Battery
2 BJB - Megafuse
3 BJB - Megafuse
4 RJB
5 Glovebox lamp
6 Glovebox lamp switch
7 LH footwell lamp
8 RH footwell lamp
9 LH vanity mirror
10 RH vanity mirror
11 LH rear interior lamp
12 RH rear interior lamp
13 CJB
14 Ambience lighting LED's
15 LH map reading lamp
16 Courtesy lamp
17 RH map reading lamp
System Operation
JUNCTION BOXES
Inputs
The CJB receives the following inputs which affect the operation of the interior lamps:
Ignition mode
Lock/unlock
Luggage compartment lid latch switch
Door latch switches.
Outputs
The RJB outputs the following for the interior lighting system:
Luggage compartment lamp power supply

Driver and passenger door module power supplies
Fade on and off grounds for front and rear overhead console interior lamps and footwell lamps
PWM (pulse width modulation) power output for the ambience lighting.
Interior Lamp Time-Out
The interior lamps are controlled by a timer within the CJB which allows a 60 second delay period for the lamps to remain
active after the ignition mode has been changed to off power mode 0 or the vehicle has been unlocked. The interior lamp
fade off is controlled by the RJBvia a delayed power off relay in the CJB. The following interior lamps are subject to the
delay period:
Front overhead console interior lamp

Rear interior lamps
Footwell lamps
Door mirror approach lamps.
The timer delay is activated when the CJB receives one of the following signals:
An unlock signal from the Smart Key via the keyless vehicle module.
Ignition mode is changed from the crank power mode 9 or ignition power mode 6 to the accessory power mode 4 to
the off power mode 0.
If a second occurrence of the above actions occurs within the timer period, the timer will be rest and the delay period timer
will restart.
The timer delay is deactivated when the CJB receives one of the following signals:
A lock signal from the Smart Key via the keyless vehicle module
Ignition mode is changed from the off power mode 0 to the accessory power mode 4 or ignition power mode 6
The CJB receives a door opened signal (even if that door is subsequently closed).
Battery Saver
The battery saver provides an automatic shut-off of the interior lamps after a period of 15 minutes in order to prevent
excessive power drain on the battery.
When the ignition mode is changed from the ignition power mode 6 or accessory power mode 4 to the off power mode 0,
the CJB starts a timer which de-energizes a delayed power off relay in the CJB, removing the power supply to the interior
lamps after a period of 15 minutes, switching off all or any interior lamps which have remained on for any reason.
Once the timer has expired and the lamps are off, any one of the following will 'wake up' the battery saver and the interior
lamps will function again. The timer will be restarted as soon as an input is received by the CJB from one of the following:
Ignition mode changed from off power mode 0 to accessory power mode 4, ignition power mode 6 or crank power
mode 9.
Any door, including the luggage compartment lid is opened
An unlock request is received from the Smart Key via the keyless vehicle module
Overhead console interior lamp is switched on via the JaguarSense function.
INTERIOR LAMPS
When the interior lighting system switches the interior lamps on, the CJB ramps the lamps up to full power over a period
of 1.3 seconds. When the system switches the lamps off, after the time-out period has expired, the CJB fades the lamps
off over a period of 2.6 seconds.
The interior lighting system will illuminate the interior lamps when one of the following events occurs:
The CJB receives an unlock signal from the Smart Key via the keyless vehicle module
Any door is opened including the luggage compartment lid
The ignition mode is changed from ignition power mode 6 or accessory power mode 4 to off power mode 0.
The interior lighting system will turn off the interior lamps when one of the following events occurs:
Once the time-out timer delay has expired since the lamps were either activated or the last door is closed and the
vehicle is not locked
The ignition is in off power mode 0 and an external lock is requested (using either the door lock buttons or the
Smart Key) with all doors closed
The ignition mode is changed from the off power mode 0 or the accessory power mode 4 to the ignition power mode
6
The last door is closed and the vehicle is externally locked, on receipt of an unlock request from the Smart Key or
door handle operation detected when the time-out timer is still active.
DELIVERY MODE
Delivery mode is set at the factory on vehicles to minimize battery drain. The mode enables the switching off of
non-critical electrical components, including the interior lighting system. The delivery mode feature is cancelled by the
dealer during the Pre-Delivery Inspection using an approved Jaguar diagnostic system.
CRASH ILLUMINATION
When a crash signal is received from the RCM (restraints control module), the CJB activates the interior lamps once the
vehicle speed has reduced to 5 km/h (3.1 mph). The hazard flashers are also activated and the doors are prevented from
being locked. The lamps remain on until the crash signal is removed, they cannot be switched off using the JaguarSense
feature. The crash signal is removed by completing one ignition on and off cycle.
INTERIOR BULB TYPE/RATING
The following table shows the bulbs used for the interior lighting system and their type and specification.
NOTE: The front overhead console and the front door ambience lighting is illuminated by LED's and are non-serviceable
components.
Bulb Type Rating

Front overhead console - interior lamp W6WX 6W
Front overhead console - LH/RH map reading lamps W6WX 6W
Rear interior lamps W6WX 10W
Sunvisor lamps TS1.3W 1.3W
LH/RH footwell lamps W5W 5W
Glovebox lamp W5W 5W
LH/RH door mirror approach lamps W5W 5W
Luggage compartment lamp S10W 10W
JUNCTION BOXES
The CJB is an integrated unit located on the RH 'A' pillar, below the instrument panel. The CJB contains fuses, relays and
number of microprocessors which control the power supply and functionality of the interior lighting system and other
vehicle systems.
The RJB is located on the RH side of the luggage compartment. The RJB contains fuses, relays and microprocessors which
in conjunction with the CJB control the interior lighting system and other vehicle systems.
Circuit Protection
The CJB and the RJB provide circuit protection for all interior lamp circuits. The lamps are protected by fuses in the CJB and
the RJB.
FRONT OVERHEAD CONSOLE

ItemDescription
1 LH map reading lamp bulb
2 Interior lamp bulb
3 RH map reading lamp bulb
4 Printed Circuit Board (PCB) - JaguarSense
5 Ambience lighting LED's
6 RH map reading lamp
7 Interior lamp
8 LH map reading lamp
The overhead console is located near the windshield in the head lining. The console can be removed by carefully levering
out the rear edge of the housing to release 2 spring clips, and then pulling the console rearwards to release 2 locating
tabs. Removal of the console is required to replace any of the interior or map reading lamp bulbs.
The interior lamps and air bag off warning lamp in the front overhead console are common to all vehicles. The overhead
console can also contain security system intrusion detection module and volumetric sensors, sunroof switch and a voice
activation microphone depending on vehicle specification and market.
The interior lamp can operated manually using the JaguarSense feature to switch the lamp on and off. The lamp is also
controlled as part of the automatic interior lighting system.
The map reading lamps only operate manually using the JaguarSense feature to activate the lamps.
The interior and map reading lamp bulbs are located in holders which locate in a PCB. The PCB also provides for the
operation of the ambience lighting LED's, the air bag off warning lamp and the JaguarSense proximity sensors which are
integral with the PCB.
The overhead console also contains 2 LED's for the ambience lighting system. The ambience lighting is part of the lighting
control switch functionality and is subject to the setting of the instrument panel illumination dimmer control in the
auxiliary lighting switch. The ambience lighting provides very limited illumination of the instrument panel and floor console
when the vehicle is being driven without affecting the driver's visibility.
REAR OVERHEAD CONSOLE

ItemDescription
1 Lamp body
2 Lamp lens
3 Interior lamp bulbs
4 LH lamp switch
5 RH lamp switch
6 Bulb holders
The rear overhead console is located in the head lining, at the rear of the vehicle. The console can be removed by carefully
levering the lamp lens from the body. This releases 2 tabs which are integral with the lens allowing the body to removed
from the aperture in the head lining.
the lamp comprises the lamp body and lens and 2 separate lamps with 2 switches to operate each lamp individually.
The rear interior lamps can operated manually using the 2 switches located on the lamp body. The lamp is also controlled
as part of the automatic interior lighting system.
The bulbs are located in bulb holders which locate in a PCB connected to each switch. Removal of the rear overhead
console is required to replace the bulbs.
GLOVEBOX LAMP
The glovebox lamp is located in the top of the glovebox housing in the instrument panel. The lamp is located in a cover on
the outside, upper surface of the housing and projects the light into the top of the glovebox.
The lamp is operated by a switch located at the rear of the glovebox housing. The switch protrudes into the housing and is
operated by the rear face of the glovebox lid tray when the glovebox is opened or closed.
The bulb is located in a holder which is fitted into the side of the glovebox lamp cover. Replacement of the bulb requires
the removal of the glovebox housing.
The glovebox lamp is active at all times when the interior lamps are active and will illuminate only when the glovebox is
opened.
FOOTWELL LAMPS
The footwell lamps are located under the instrument panel. Each lamp comprises a bulb and holder which is part of the
instrument panel wiring harness. The bulb and holder is located in a hole in the front footwell air ducts. The footwell lamps
are active at all times when the interior lamps are active.
LUGGAGE COMPARTMENT LAMP

The luggage compartment lamp is located in the luggage compartment trim, in a central position below the rear screen.
The lamp comprises a molded lens and housing and two electrical contacts which locate the bulb.
The lamp is accessible be removed by levering one end from the trim panel to gain access to the bulb. The lamp is active
at all times when the interior lamps are active.
VANITY MIRROR LAMPS

Four vanity mirror lamps are fitted, two in each vanity mirror. The lamps are illuminated when the mirror cover is raised.
The vanity mirror lamps operate at all times when the interior lamps are active.
The vanity mirrors use low voltage, 1.2W festoon type bulbs.
DOOR MIRROR APPROACH LAMPS

A door mirror approach lamp is located on the underside of each exterior door mirror.
The approach lamps are active at all times when the interior lamps are active.
Interior Lighting - Interior Lighting
For a detailed description of the interior lighting system, refer to the relevant Description and Operation sections in the
workshop manual. REFER to: (417-02 Interior Lighting)
Interior Lighting (Description and Operation),

Interior Lighting (Description and Operation),
Interior Lighting (Description and Operation).
vehicle.
Visual Inspection
Bulbs Fuses/relays (refer to electrical guide)
Wiring harness
Correct engagement of electrical connectors
Loose or corroded connections
DTC Index
account.

B116511 Left Front Left front puddle lamp Refer to the electrical circuit diagrams and test left front
Puddle Lamp control circuit - short to puddle lamp control circuit for short to ground
Output ground
B116515 Left Front Left front puddle lamp Carry out any pinpoint tests associated with this DTC using
Puddle Lamp control circuit - short to the manufacturer approved diagnostic system. Refer to the
Output power, open circuit electrical circuit diagrams and test left front puddle lamp
B116611 Right Front Right front puddle lamp Refer to the electrical circuit diagrams and test right front
Puddle Lamp control circuit - short to puddle lamp control circuit for short to ground
Output ground
B116615 Right Front Right front puddle lamp Carry out any pinpoint tests associated with this DTC using
Puddle Lamp control circuit - short to the manufacturer approved diagnostic system. Refer to the
Output power, open circuit electrical circuit diagrams and test right front puddle lamp
B111E11 Boot/Trunk Luggage compartment lamp Carry out any pinpoint test associated with this DTC using
Lamps control circuit - short to the manufacturer approved diagnostic system. Refer to the
ground electrical circuit diagrams and check luggage compartment
lamp control circuit for short to ground
B111E15 Boot/Trunk Luggage compartment lamp Carry out any pinpoint test associated with this DTC using
Lamps control circuit - short to the manufacturer approved diagnostic system. Refer to the
power, open circuit electrical circuit diagrams and check luggage compartment
lamp control circuit for short to power, open circuit
B112412 Lamp Fade Interior lamp fade control Refer to the electrical circuit diagrams and check interior
Control circuit - short to power lamp fade control circuit for short to power
B113C12 Hazard Switch Hazard switch illumination Refer to the electrical circuit diagrams and check hazard
Illumination control circuit - short to switch illumination control circuit for short to power
power
B1A8596 Ambient Light Light sensor internal Check and install a new sensor as required
Sensor electronic failure
U201012 Switch Switch/interior illumination Refer to the electrical circuit diagrams and check
Illumination PW M supply circuit - short switch/interior illumination PWM supply circuit for short to
to power power
U201014 Switch Switch/interior illumination Refer to the electrical circuit diagrams and check
Illumination PW M supply circuit - short switch/interior illumination PWM supply circuit for short to
to ground, open circuit ground, open circuit
Daytime Running Lamps (DRL) - Daytime Running Lamps (DRL) - Overview
OVERVIEW
DRL (daytime running lamps) use the full intensity low beam headlamps which are permanently illuminated when the
vehicle is being driven.
Two DRL systems are available depending on market requirements.

Daytime Running Lamps (DRL) - Daytime Running Lamps (DRL) - System
System Operation
CENTRAL JUNCTION BOX (CJB)
The CJB (central junction box) controls the operation of the DRL (daytime running lamps). The DRL are activated once the
CJB detects an ignition on power mode 6 signal.
The CJB also monitors the lighting control switch and the auto lamps feature and overrides the DRL if required.
DAYTIME RUNNING LAMPS - CANADA
The DRL for this market use full intensity low beam headlamps. The side marker lamps, tail lamps and license plate lamps
will be on, but instrument cluster illumination will be off. DRL are active when the following parameters are met:
PARK is not selected on the electronic transmission selector

Electronic Parking Brake (EPB) is off
Power mode 6 (ignition on) detected by the CJB
The CJB receives an engine running signal
The lighting control switch is in the off or side lamps position.
NOTE: If the lighting control switch is moved to the headlamp position, 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. W hen the
transmission is in PARK, DRL are turned off. This is to reduce battery discharge during long periods of engine idling in cold
climate conditions. W hen the electronic transmission selector is moved from the PARK position, normal DRL functionality is
restored.
DAYTIME RUNNING LAMPS - 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:
Power mode 6 (ignition on) detected by the CJB

The CJB receives an engine running signal
The lighting control switch is in the off position.
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.
If the lighting control switch is moved to the side lamp or headlamp positions, DRL are deactivated and normal side lamp
and headlamp functionality is operational.
AUTOMATIC HEADLAMPS
On vehicles fitted with the automatic headlamps feature, DRL are overridden if the lighting control switch is in the 'Auto'
position and the CJB receives a signal from the rain/light sensor to activate the exterior lights.
When the CJB receives a signal to de-activate the automatic headlamps feature the DRL function is restored providing the
parameters for DRL activation are met.
Module Communications Network - Communications Network - Overview
OVERVIEW
A number of different types of communication network are incorporated into the vehicle wiring harnesses for the
transmission of commands and information between control modules. The configuration installed on a particular vehicle
depends on the model and equipment level.
NOTE: The control diagrams shown later in this section are schematics reflecting communications networks fitted to LH
(left-hand) vehicles only. For detailed layouts of the various communications networks fitted to LHD (left-hand drive) and
RHD (right-hand drive) vehicles, refer to the Electrical Guide.
The communications networks available on the vehicle are shown in the table below.
Network Baud Rate

LIN (local interconnect network) bus 9.6 kbits/s
Medium speed CAN (controller area network) bus 125 kbits/s
High speed CAN bus 500 kbits/s
Media Orientated System Transport (MOST) ring 24 mbits/s
Module Communications Network - Communications Network - System
Control Diagram
NOTE:
CONTROL DIAGRAM - LIN BUS - SHEET 1 OF 2
ItemDescription
O = LIN (local interconnect network) bus
2 Battery backed sounder
3 Intrusion detection module
4 Rain/Light sensor
7 Rear view camera
9 Generator
10 Driver's door switch pack
11 Rear door control module
12 Driver's door control module
14 Electronic transmission selector
15 Driver's seat module
16 Driver's seat switch pack
17 Rear door control module
18 Front passenger door control module
19 Clockspring
20 Audio and telephone steering wheel switches
CONTROL DIAGRAM - LIN BUS - SHEET 2 OF 2
ItemDescription
O = LIN bus
2 Stepper motor - Windshield defrost
3 Stepper motor - Face/feet distribution
4 Stepper motor - LH (left-hand) temperature blend
5 Stepper motor - RH (right-hand) temperature blend
6 Electric booster heater
7 Stepper motor - RH outer face level vent
8 Stepper motor - RH inner face level vent
9 Stepper motor - LH inner face level vent
10 Stepper motor - LH outer face level vent
CONTROL DIAGRAM - MEDIUM SPEED CAN BUS
ItemDescription
N = Medium speed CAN (controller area network) bus
2 RJB
4 RH blind spot monitoring module
6 Front seat climate control module
7 Information control module
8 ATC module
9 CJB
13 Front passenger door control module
14 Tire Pressure Monitoring System (TPMS) module
15 Driver's door control module
16 LH blind spot monitoring module
CONTROL DIAGRAM - HIGH SPEED CAN BUS
ItemDescription
D = High speed CAN bus
3 Diagnostic socket
6 Occupant classification system control module
9 ECM
10 TCM
12 Electric park brake module
CONTROL DIAGRAM - MOST RING
ItemDescription
P = MOST ring
2 Software download socket
4 Portable audio interface
5 Bluetooth telephone module
7 Multi-media module
8 DAB/SDARS receiver
9 Television (TV) tuner
System Operation
OPERATION
Refer to the relevant system section for details of system operation.
DESCRIPTION
Refer to the relevant system section for details of system description.
Module Communications Network - Communications Network
For a detailed description of the Communications Network, refer to the relevant Description and Operation sections in the
Communications Network (418-00, Description and Operation),

Communications Network (418-00 Module Communications Network, Description and Operation),
Communications Network (418-00 Module Communications Network, Description and Operation).
vehicle.
Visual Inspection
Electrical
Fuses (refer to electrical guide)
W iring harness
Correct engagement of electrical connectors
Loose or corroded connections
Routing of fibre optic harnesses
Correct engagement of optical connectors
Correct placement of optical connectors (ring order)
Correct assembly of optical connectors (backout, etc)
Damage to fibre (chafing, abrasion, kinking, cuts, etc)
CAN Network Integrity Checks
In the event that one or more control modules are not communicating on either the Medium Speed (MS) or High Speed (HS)
CAN Buses, checks can be performed to confirm the integrity of the CAN harness.
The following information is applicable to HS and MS CAN Buses accessible via the J1962 diagnostic connector.
Module Connections to the CAN Harness
Modules are connected to the CAN harness either in a 'loop' or 'spur' configuration. In the 'loop' type configuration the CAN
harness loops into the module (via two connector pins) and then loops out of the module (via another two connector pins).
In the 'spur' type configuration, a harness spur is spliced into the main 'backbone' of the CAN harness and the module is
connected to the harness spur via two connector pins.
CAN Harness Architecture
For a detailed description of the CAN Networks and architecture, refer to the relevant Description and Operation section in
the Workshop Manual. REFER to:
Communications Network (418-00, Description and Operation),

Communications Network (418-00 Module Communications Network, Description and Operation),
Communications Network (418-00 Module Communications Network, Description and Operation).
IDS Vehicle Integrity Test
If a control module is suspected of non-communication, the Network Integrity test application available on the
manufacturer approved diagnostic system can be used to confirm if communication is possible between the control
modules on the vehicle and the manufacturer approved diagnostic system (via the J1962 diagnostic connector ). The
results from the test can be used to determine if either a single module or multiple modules are failing to communicate.
CAN Terminating Modules
If the Network Integrity test indicates that one or more module on one of the CAN networks (HS or MS) are failing to
communicate, there are several checks that can be made. The first step is to identify if both of the CAN terminating
modules on each individual CAN Bus are communicating. If both CAN terminating modules for each individual CAN Bus are
communicating (identified via the Network Integrity test), then it can be confirmed that the main 'backbone' of the CAN
harness is complete. The main 'backbone' of the CAN harness consists of all the modules connected to the CAN harness
via a 'loop' configuration and also includes the two terminating modules.
Communication with both CAN terminating modules via the Network Integrity test confirms the physical integrity of the
main 'backbone' of the CAN harness (and the harness spur to the J1962 diagnostic connector). This means that there is no
requirement to check the resistance of the CAN Network. This is because the standard check for 60 ohms across the CAN
High and CAN Low lines will not provide any additional information regarding the physical condition of the CAN harness,
beyond what has already been determined from the Network Integrity test.
Non-Communication of a Terminating Module
If a Network Integrity test reveals a terminating module is failing to communicate it can indicate a break in the main
'backbone' of the CAN harness. The first checks should always be to confirm the power and ground supplies to the
non-communicating module are correct. Providing these are correct, the resistance between the CAN High and CAN Low
lines at the J1962 connector can be checked to determine the integrity of the main 'backbone' of the CAN harness. After
disconnecting the battery a reading of 120 ohms would indicate an open circuit in the main 'backbone' of the CAN harness.
Alternatively, a reading of 60 ohms would indicate that there is no open circuit fault with the main 'backbone' of the CAN
harness.
It is worth noting that even if one of the terminating modules is disconnected from the CAN harness, communications
between the modules still connected may still be possible. Therefore communication between the manufacturer approved
diagnostic system and the connected modules may also be possible.
Locating CAN Harness Open Circuits
In the case where multiple modules, including a terminating module, are failing to communicate, having first confirmed the
power and ground supplies are correct, the approximate location of the open circuit can be identified from analysis of the
Network Integrity test results and reference to the relevant CAN network circuit diagrams. For example, if an open circuit
existed in a certain position on the CAN harness, any module positioned on the Network between the J1962 connector and
the open circuit should return a response during the Network Integrity test. No responses would be returned from any
modules past the open circuit fault in the Network.
CAN Harness 'Spur' Type Configuration Circuits
If, after the initial checks (Network Integrity test using the manufacturer approved diagnostic system, and power and
ground supplies to the module have been checked and confirmed as correct), a module that is connected to the CAN
harness via a 'spur' type configuration is suspected of not communicating, then the physical integrity of the CAN harness
'spur' can be checked.
This is most easily undertaken by individually checking the continuity of the CAN High and CAN Low lines between the
non-communicating module connector (with the module disconnected) and the J1962 diagnostic connector.
'Lost Communications' DTCs
As well as the methods described so far in this document, which can be used to determine the location of an open circuit
in the CAN harness, 'Lost Communications' DTCs can also be used for this purpose.
For example, if a global DTC read were to be carried out, only DTCs stored in the modules that the manufacturer approved
diagnostic system could communicate with would be displayed. If there were an open circuit fault in a certain position on
the CAN harness, the modules that could display DTCs would all be prior to the open circuit on the Network, and these
modules should display 'Lost Communications' DTCs with all the modules located on the Network past the open circuit
fault.
NOTE: Additional DTCs may also be logged along with the 'Lost Communications' DTCs.
DTC Index
account.

B00D511 Restraint System PAD lamp supply circuit - short Refer to the electrical circuit diagrams and check PAD
Passenger Disable to ground lamp supply circuit for short to ground
Indicator
B00D512 Restraint System PAD lamp supply circuit - short Refer to the electrical circuit diagrams and check PAD
Passenger Disable to power lamp supply circuit for short to power
Indicator
B00D513 Restraint System PAD lamp supply circuit - open Refer to the electrical circuit diagrams and check PAD
Passenger Disable circuit lamp supply circuit for open circuit
Indicator
B100951 Ignition Faulty instrument cluster Check ignition, power and ground supplies to CJB and
Authorisation Target SID re-synchronisation instrument cluster. Re-synchronize ID by re-configuring
error following programming the instrument cluster as a new module. Check CAN
CAN fault communications between instrument cluster and tester
B100962 Ignition Low speed CAN fault Check CAN communications between CJB and
Authorisation CJB fault instrument cluster. Check ignition, power and ground
Instrument cluster fault supplies to CJB and instrument cluster. Confirm correct
Incorrect module installed module is installed. Re-synchronise ID by
(CJB/Instrument cluster) re-configuring the instrument cluster as a new module.
Target SID synchronisation Check CAN network for interference/EMC related issues
B100963 Ignition CJB fault Check Power and Ground supplies to CJB and
Instrument cluster fault between CJB and instrument cluster. Check battery is
battery care manual
B100964 Ignition CJB fault Check power and ground supplies to CJB and
Instrument cluster fault between CJB and instrument cluster
B102B67 Passive Key CJB fault Check power and ground supplies to CJB and RKE
Low speed CAN fault module. Check CAN communications between CJB and
Remote Keyless Entry (RKE) RKE module. Re-synchronise ID by re-configuring the
module fault RKE module as a new module
W rite target SID
re-programming
B102B87 Passive Key CJB fault Check power and ground supplies to CJB, RKE module
Low speed CAN fault and receiver. Check CAN communications between CJB
RKE module fault and instrument cluster. Check key fob battery. Confirm
Key fob battery low/battery vehicle surroundings, move vehicle. Check CAN network
contact issue for interference/EMC related issues. Disconnect battery,
Interference from other RF then re-connect - confirm operation by re-programming
signal keys. Check serial circuit between receiver and RKE
EMC/noise module. Confirm spare key works. Refer to the
Receiver fault electrical circuit diagrams and test circuits to all 3
Receiver not programmed antennas. Check whereabouts of key
correctly
module)
Key fault
Confirm placement of key
within vehicle
B108413 Boot/Trunk Motor Trunk latch open signal circuit Refer to the electrical circuit diagrams and check trunk
Close Switch - open circuit latch open signal circuit for open circuit
B108783 LIN Bus "A" Checksum of the received LIN Check operation of rain/light sensor by covering sensor
frame from battery backed or applying water to screen, install a new sensor as
sounder, roof header console, required
and/or rain/light sensor is
incorrect
B108788 LIN Bus "A" Bus off. Battery backed Carry out any pinpoint tests associated with this DTC
sounder, roof header console, using the manufacturer approved diagnostic system.
and/or rain/light sensor LIN Refer to the electrical circuit diagrams and check
circuit - short to ground, power battery backed sounder, roof header console, and
rain/light sensor LIN circuit for short to ground, power
power short to power
B109512 W iper On/Off W iper On/Off relay control Carry out any pinpoint tests associated with this DTC
Relay circuit - short to power using the manufacturer approved diagnostic system.
Refer to the electrical circuit diagrams and check wiper
On/Off relay control circuit for short to power
B109514 W iper On/Off W iper On/Off relay control Refer to the electrical circuit diagrams and check wiper
Relay circuit - short to ground, open On/Off relay control circuit for short to ground, open
circuit circuit
B109612 W iper High/Low W iper Fast/Slow relay control Carry out any pinpoint tests associated with this DTC
Relay circuit - short to power using the manufacturer approved diagnostic system.
Refer to the electrical circuit diagrams and check wiper
Fast/Slow relay control circuit for short to power
B109614 W iper High/Low W iper Fast/Slow relay control Refer to the electrical circuit diagrams and check wiper
Relay circuit - short to ground, open Fast/Slow relay control circuit for short to ground, open
circuit circuit
B109712 Heated Windshield Heated windshield relay Carry out any pinpoint tests associated with this DTC
Relay control circuit - short to power using the manufacturer approved diagnostic system.
heated windshield relay control circuit for short to
power
B109714 Heated Windshield Heated windshield relay Refer to the electrical circuit diagrams and check
Relay control circuit - short to heated windshield relay control circuit for short to
ground, open circuit ground, open circuit
B10A612 Main Light Switch Master light switch signal from Refer to the electrical circuit diagrams and check
roof header console circuit - master light switch signal from roof header console
B10A623 Main Light Switch Master light switch signal from Carry out any pinpoint tests associated with this DTC
roof header console signal using the manufacturer approved diagnostic system.
stuck low. Switch is read as Refer to the electrical circuit diagrams and check
ON for too long a time master light switch signal from roof header console for
short to ground
B10AD09 Rain Sensor Component failures Carry out any pinpoint tests associated with this DTC
Suspect the rain/light sensor, check and install a new
sensor as required
B10AD11 Rain Sensor Rain/light sensor power circuit Carry out any pinpoint tests associated with this DTC
- short to ground using the manufacturer approved diagnostic system.
rain/light sensor power circuit for short to ground
B10AD96 Rain Sensor Component internal failure Suspect the rain/light sensor, check and install a new
sensor as required
Signal short to ground wake-up signal circuit for short to ground
Signal short to power wake-up signal circuit for short to power
Signal open circuit wake-up signal circuit for open circuit
B10F111 Key In Switch Keyless vehicle module, key IN Carry out any pinpoint tests associated with this DTC
status circuit - short to ground using the manufacturer approved diagnostic system.
keyless vehicle module, key IN status circuit for short
to ground
B10F112 Key In Switch Keyless vehicle module, key IN Refer to the electrical circuit diagrams and check
status circuit - short to power keyless vehicle module, key IN status circuit for short
to power
B10F113 Key In Switch Keyless vehicle module, key IN Refer to the electrical circuit diagrams and check
status circuit - open circuit keyless vehicle module, key IN status circuit for open
circuit
B10F211 Sunroof Control Sunroof enable signal circuit - Carry out any pinpoint tests associated with this DTC
short to ground using the manufacturer approved diagnostic system.
sunroof enable signal circuit for short to ground
B10F212 Sunroof Control Sunroof enable signal circuit - Refer to the electrical circuit diagrams and check
short to power sunroof enable signal circuit for short to power
B10F213 Sunroof Control Sunroof enable signal circuit - Refer to the electrical circuit diagrams and check
open circuit sunroof enable signal circuit for open circuit
B10F311 Left Front Position Left front side lamps circuit - Carry out any pinpoint tests associated with this DTC
Light short to ground using the manufacturer approved diagnostic system.
Refer to the electrical circuit diagrams and check left
front side lamps circuit for short to ground
B10F315 Left Front Position Left front side lamps circuit - Carry out any pinpoint tests associated with this DTC
Light short to power, open circuit using the manufacturer approved diagnostic system.
front side lamps circuit for short to power, open circuit
B10F411 Right Front Right front side lamps circuit - Carry out any pinpoint tests associated with this DTC
Position Light short to ground using the manufacturer approved diagnostic system.
Refer to the electrical circuit diagrams and check right
front side lamps circuit for short to ground
B10F415 Right Front Right front side lamps circuit - Carry out any pinpoint tests associated with this DTC
Position Light short to power, open circuit using the manufacturer approved diagnostic system.
front side lamps circuit for short to power, open circuit
B10F812 Accessory socket Accessory socket 'A' relay Carry out any pinpoint tests associated with this DTC
'A' relay control circuit - short to power using the manufacturer approved diagnostic system.
accessory socket 'A' relay control circuit for short to
power
B10F814 Accessory socket Accessory socket 'A' relay Refer to the electrical circuit diagrams and check
'A' relay control circuit - short to accessory socket 'A' relay control circuit for short to
B10F912 Accessory socket Front powerpoint, trailer tow Refer to the electrical circuit diagrams and check front
'B' relay connector, road pricing powerpoint, trailer tow connector, road pricing
connector, sunblind power connector, sunblind power supply circuits for short to
supply circuits - short to power power
B10F914 Accessory socket Front powerpoint, trailer tow Refer to the electrical circuit diagrams and check front
'B' relay connector, road pricing powerpoint, trailer tow connector, road pricing
connector, sunblind power connector, sunblind power supply circuits for short to
supply circuits - short to ground, open circuit
B10F993 Accessory socket Front powerpoint, trailer tow Carry out any pinpoint tests associated with this DTC
'B' relay connector, road pricing using the manufacturer approved diagnostic system.
connector, sunblind power Refer to the electrical circuit diagrams and check front
supply circuits - short to powerpoint, trailer tow connector, road pricing
power, ground, open circuit connector, sunblind power supply circuits for short to
power, ground, open circuit
B10FA93 Delayed Power Off ADRC ECM, roof header Carry out any pinpoint tests associated with this DTC
relay console lamp, glove box lamp , using the manufacturer approved diagnostic system.
RH/LH footwell lamps, JAG Refer to the electrical circuit diagrams and check ADRC
Sense glove box module, ECM, roof header console lamp, glove box lamp , RH/LH
RH/LH sunvisor lamps, rear footwell lamps, JAG Sense glove box module, RH/LH
dome lamps switched power sunvisor lamps, rear dome lamps switched power
circuits - short to power, open circuits for short to power, open circuit
circuit
and FPDB ignition control circuit for short to ground
circuit - open circuit using the manufacturer approved diagnostic system.
and FPDB ignition control circuit for open circuit
B110011 O2 sensor heater FPDB O2 sensor heater relay Carry out any pinpoint tests associated with this DTC
relay control circuit - short to ground using the manufacturer approved diagnostic system.
Refer to the electrical circuit diagrams and check FPDB
O2 sensor heater relay control circuit for short to
ground
B113D12 Sunroof Global Roof opening panel global Carry out any pinpoint tests associated with this DTC
Open/Close open/close control circuit - using the manufacturer approved diagnostic system.
Control short to power Refer to the electrical circuit diagrams and check roof
opening panel global open/close control circuit for short
to power
B113D14 Sunroof Global Roof opening panel global Refer to the electrical circuit diagrams and check roof
Open/Close open/close control circuit - opening panel global open/close control circuit for short
Control short to ground, open circuit to ground, open circuit
Authorisation signal circuit - short to ground using the manufacturer approved diagnostic system.
ground
B114211 Ignition Status 1 Ignition supply 1 circuits - Carry out any pinpoint tests associated with this DTC
B114311 Ignition Status 2 Ignition supply 2 circuits - Carry out any pinpoint tests associated with this DTC
B114411 Heated Steering Heated steering wheel supply Carry out any pinpoint tests associated with this DTC
W heel Supply circuit - short to ground using the manufacturer approved diagnostic system.
heated steering wheel supply circuit for short to ground
B114511 Glovebox Locking Glovebox latch locking motor Carry out any pinpoint tests associated with this DTC
Motor circuit - short to ground using the manufacturer approved diagnostic system.
glovebox latch locking motor circuit for short to ground
B114512 Glovebox Locking Glovebox latch locking motor Refer to the electrical circuit diagrams and check
Motor control circuit - short to power glovebox latch locking motor control circuit for short to
power
B114513 Glovebox Locking Glovebox latch locking motor Refer to the electrical circuit diagrams and check
Motor control circuit - open circuit glovebox latch locking motor control circuit for open
circuit
B114612 Passive sounder Security passive sounder Refer to the electrical circuit diagrams and check
Supply control circuit - short to power security passive sounder control circuit for short to
power
B114614 Passive sounder Security passive sounder Refer to the electrical circuit diagrams and check
Supply control circuit - short to security passive sounder control circuit for short to
B115811 Front Passenger Front passenger seat heater Carry out any pinpoint tests associated with this DTC
Seat Heater Sensor sensor circuit - short to ground using the manufacturer approved diagnostic system.
Refer to the electrical circuit diagrams and check front
passenger seat heater sensor circuit for short to ground
B115813 Front Passenger Front passenger seat heater Carry out any pinpoint tests associated with this DTC
Seat Heater Sensor sensor circuit - open circuit using the manufacturer approved diagnostic system.
passenger seat heater sensor circuit for open circuit
B115911 Driver Seat Heater Driver seat heater sensor Carry out any pinpoint tests associated with this DTC
Sensor circuit - short to ground using the manufacturer approved diagnostic system.
Refer to the electrical circuit diagrams and check driver
seat heater sensor circuit for short to ground
B115913 Driver Seat Heater Driver seat heater sensor Carry out any pinpoint tests associated with this DTC
Sensor circuit - open circuit using the manufacturer approved diagnostic system.
seat heater sensor circuit for open circuit
B115A11 Front Passenger Front passenger seat heater Carry out any pinpoint tests associated with this DTC
Seat Heater supply circuit - short to ground using the manufacturer approved diagnostic system.
passenger seat heater supply circuit for short to ground
B115A15 Front Passenger Front passenger seat heater Carry out any pinpoint tests associated with this DTC
Seat Heater supply circuit - short to power, using the manufacturer approved diagnostic system.
open circuit Refer to the electrical circuit diagrams and check front
passenger seat heater supply circuit for short to power,
open circuit
B115B11 Driver Seat Heater Driver seat heater supply Carry out any pinpoint tests associated with this DTC
seat heater supply circuit for short to ground
B115B15 Driver Seat Heater Driver seat heater supply Carry out any pinpoint tests associated with this DTC
circuit - short to power, open using the manufacturer approved diagnostic system.
circuit Refer to the electrical circuit diagrams and check driver
seat heater supply circuit for short to power, open
circuit
B117513 Driver Door Ajar Driver door ajar switch signal Refer to the electrical circuit diagrams and check driver
Switch circuit - open circuit door ajar switch signal circuit for open circuit
B117613 Passenger Door Passenger door ajar switch Refer to the electrical circuit diagrams and check
Ajar Switch signal circuit - open circuit passenger door ajar switch signal circuit for open circuit
B117712 Screenwash Level Screenwash level switch signal Refer to the electrical circuit diagrams and check
Switch circuit - short to power screenwash level switch signal circuit for short to
power
B11C013 Driver Side Rear Left rear door ajar switch Refer to the electrical circuit diagrams and check left
Door Ajar Switch signal circuit - open circuit rear door ajar switch signal circuit for open circuit
B11C113 Passenger Side Right rear door ajar switch Refer to the electrical circuit diagrams and check right
Rear Door Ajar signal circuit - open circuit rear door ajar switch signal circuit for open circuit
Switch
B122223 Master Lock/Unlock Master lock or unlock switch Refer to the electrical circuit diagrams and check
Switch digital input circuit - signal master lock and unlock switch digital input circuits for
stuck low short to ground, open circuit
B123711 Gear Shift Module Transmission shift module Carry out any pinpoint tests associated with this DTC
Early W ake-up wake-up control circuit - short using the manufacturer approved diagnostic system.
to ground Refer to the electrical circuit diagrams and check
transmission shift module wake-up control circuit for
short to ground
B123712 Gear Shift Module Transmission shift module Refer to the electrical circuit diagrams and check
Early W ake-up wake-up control circuit - short transmission shift module wake-up control circuit for
to power short to power
B123713 Gear Shift Module Transmission shift module Refer to the electrical circuit diagrams and check
Early W ake-up wake-up control circuit - open transmission shift module wake-up control circuit for
B123E13 Crank Enable OK to crank signal circuit - Refer to the electrical circuit diagrams and check OK to
open circuit crank signal circuit for open circuit
B1A8596 Ambient Light Light sensor internal electronic Check and install a new sensor as required
Sensor failure
B1C4513 Front W iper Park W indshield wiper motor park Refer to the electrical circuit diagrams and check
Position Switch switch signal circuit - open windshield wiper motor park switch signal circuit for
B1C4523 Front W iper Park Signal stuck low Refer to the electrical circuit diagrams and check front
Position Switch wiper park position switch input circuit for short, open
circuit
B1C7812 Powerwash Relay Powerwash relay control circuit Refer to the electrical circuit diagrams and check
- short to power powerwash relay control circuit for short to power
B1C7814 Powerwash Relay Powerwash relay control circuit Refer to the electrical circuit diagrams and check
- short to ground, open circuit powerwash relay control circuit for short to ground,
open circuit
B1C7911 Front W asher Screenwash pump control Refer to the electrical circuit diagrams and check
Pump circuit - short to ground screenwash pump control circuit for short to ground
B1C7913 Front W asher Screenwash pump control Carry out any pinpoint tests associated with this DTC
Pump circuit - open circuit using the manufacturer approved diagnostic system.
screenwash pump control circuit for open circuit
B1C9812 Left Corner Lamp Left front corner lamp control Refer to the electrical circuit diagrams and check left
Circuit circuit - short to power front corner lamp control circuit for short to power
B1C9814 Left Corner Lamp Left front corner lamp control Refer to the electrical circuit diagrams and check left
Circuit circuit - short to ground, open front corner lamp control circuit for short to ground,
B1C9912 Right Corner Lamp Right front corner lamp control Refer to the electrical circuit diagrams and check right
Circuit circuit - short to power front corner lamp control circuit for short to power
B1C9914 Right Corner Lamp Right front corner lamp control Refer to the electrical circuit diagrams and check right
Circuit circuit - short to ground, open front corner lamp control circuit for short to ground,
B1D0011 Left Low Beam Left dip beam control circuit - Carry out any pinpoint tests associated with this DTC
dip beam control circuit for short to ground
B1D0012 Left Low Beam Left dip beam control circuit - Refer to the electrical circuit diagrams and check left
short to power dip beam control circuit for short to power
B1D0013 Left Low Beam Left dip beam control circuit - Refer to the electrical circuit diagrams and check left
open circuit dip beam control circuit for open circuit
B1D0111 Right Low Beam Right dip beam control circuit - Carry out any pinpoint tests associated with this DTC
dip beam control circuit for short to ground
B1D0112 Right Low Beam Right dip beam control circuit - Refer to the electrical circuit diagrams and check right
short to power dip beam control circuit for short to power
B1D0113 Right Low Beam Right dip beam control circuit - Refer to the electrical circuit diagrams and check right
open circuit dip beam control circuit for open circuit
B1D0211 Left High Beam Left high beam control circuit - Refer to the electrical circuit diagrams and check left
Circuit short to ground high beam control circuit for short to ground
Circuit short to power high beam control circuit for short to power
Circuit open circuit high beam control circuit for open circuit
B1D0311 Right High Beam Right high beam control circuit Refer to the electrical circuit diagrams and check right
Circuit - short to ground high beam control circuit for short to ground
Circuit - short to power high beam control circuit for short to power
Circuit - open circuit high beam control circuit for open circuit
B1D1711 Battery Backed Battery backed sounder Refer to the electrical circuit diagrams and check
Sounder inclination sensor control battery backed sounder inclination sensor control circuit
circuit - short to ground for short to ground
B1D1811 Volumetric Sensor Intrusion sensor module Carry out any pinpoint tests associated with this DTC
supply circuit - short to ground using the manufacturer approved diagnostic system.
intrusion sensor module supply circuit for short to
ground
B1D2711 Heater Coolant Heater coolant pump control Carry out any pinpoint tests associated with this DTC
Pump circuit - short to ground using the manufacturer approved diagnostic system.
Refer to the electrical circuit diagrams and check heater
coolant pump control circuit for short to ground
B1D2713 Heater Coolant Heater coolant pump control Carry out any pinpoint tests associated with this DTC
Pump circuit - open circuit using the manufacturer approved diagnostic system.
Refer to the electrical circuit diagrams and check heater
coolant pump control circuit for open circuit
B1D9796 Tilt Sensor Component internal failure Suspect the battery backed sounder, check and install
a new battery backed sounder as required
P057112 Brake Switch A Footbrake switch circuit - short Refer to the electrical circuit diagrams and check
Circuit to power footbrake switch circuit for short to power
P080111 Reverse Inhibit Electrochromic rear view Carry out any pinpoint tests associated with this DTC
Control Circuit mirror, reverse inhibit circuit - using the manufacturer approved diagnostic system.
short to ground Refer to the electrical circuit diagrams and check
electrochromic rear view mirror, reverse inhibit circuit
for short to ground
P080112 Reverse Inhibit Electrochromic rear view Refer to the electrical circuit diagrams and check
Control Circuit mirror, reverse inhibit circuit - electrochromic rear view mirror, reverse inhibit circuit
short to power for short to power
P080113 Reverse Inhibit Electrochromic rear view Refer to the electrical circuit diagrams and check
Control Circuit mirror, reverse inhibit circuit - electrochromic rear view mirror, reverse inhibit circuit
open circuit for open circuit
P085013 Park/Neutral Park/Neutral signal circuit - Refer to the electrical circuit diagrams and check
Switch Input open circuit Park/Neutral signal circuit for open circuit
Circuit
P162413 Anti-theft System RJB anti-theft signal circuit - Refer to the electrical circuit diagrams and check RJB
open circuit anti-theft signal circuit for open circuit
P254F13 Engine Hood Hood ajar switch signal circuit Refer to the electrical circuit diagrams and check hood
Switch - open circuit ajar switch signal circuit for open circuit
Circuit/Open
U001988 Low Speed CAN Bus OFF Carry out any pinpoint tests associated with this DTC
Communication using the manufacturer approved diagnostic system.
Bus
U014200 Lost No sub type information Carry out any pinpoint tests associated with this DTC
W ith Body Control
Module "B"
W ith Instrument
Panel Cluster (IPC)
Control Module
W ith Information
Center "A"
W ith HVAC Control
Module
U016800 Lost No sub type information Check power and ground supplies to vehicle security
Communication module
W ith Vehicle
Security Control
Module
W ith "Door Control
Module A"
W ith "Door Control
Module B"
W ith Remote
Function Actuation
U023100 Lost No sub type information Check power and ground supplies to rain sensing
Communication module. LIN circuit fault
W ith Rain Sensing
Module
U030000 Internal Control No sub type information Suspect the CJB. Check and install a new CJB as
Module Software required, refer to the new module/component
Incompatibility installation note at the top of the DTC Index
U100000 Solid State Driver No sub type information Check CJB for additional load related DTCs and refer to
Protection Active - remedial actions for those DTCs
Driver Disabled
U1A1449 CAN Initialisation Internal electronic failure Suspect the CJB. Check and install a new CJB as
Failure required, refer to the new module/component
U200813 Sensor Cluster Instrument cluster security Refer to the electrical circuit diagrams and check
signal circuit - open circuit instrument cluster security signal circuit for open circuit
U201012 Switch Illumination Switch/interior illumination Refer to the electrical circuit diagrams and check
PW M supply circuit - short to switch/interior illumination PWM supply circuit for short
power to power
U201014 Switch Illumination Switch/interior illumination Refer to the electrical circuit diagrams and check
PW M supply circuit - short to switch/interior illumination PWM supply circuit for short
ground, open circuit to ground, open circuit
U210000 Initial RJB configuration (parameters) Re-configure the RJB using the manufacturer approved
Configuration Not failure diagnostic system
Complete
U300049 Control Module Internal electronic failure Suspect the CJB. Check and install a new CJB as
U300055 Control Module Not configured Re-configure the RJB using the manufacturer approved
diagnostic system. Check the correct CJB is installed to
vehicle market/specification. Install a new/correct CJB
U300087 Control Module Missing message Carry out CAN network integrity test using the
manufacturer approved diagnostic system. Refer to the
electrical circuit diagrams and check CAN network
between RJB and CJB for short, open circuit. Check RJB
and then CJB for related DTCs and refer to the relevant
DTC Index
U300281 Vehicle Invalid serial data received Suspect the CJB has previously been installed to
Identification another vehicle. Check and install the original or a new
Number CJB
U300317 Battery Voltage Circuit voltage above threshold Carry out any pinpoint tests associated with this DTC
U300362 Battery Voltage Mis-match in battery voltage, Carry out any pinpoint tests associated with this DTC
of 2 volts or more, between using the manufacturer approved diagnostic system.
CJB and RJB
Rear Junction Box (RJB)
account.

P046011 Fuel Level Sensor Fuel level sensor A Carry out any pinpoint test associated with this DTC using the
A Circuit analogue input circuit - manufacturer approved diagnostic system. Refer to the
short to ground electrical circuit diagrams and check fuel level sensor A
P046015 Fuel Level Sensor Fuel level sensor A Carry out any pinpoint test associated with this DTC using the
A Circuit analogue input circuit - manufacturer approved diagnostic system. Refer to the
short to power, open electrical circuit diagrams and check fuel level sensor A
circuit analogue input circuit for short to power, open circuit
P057112 Brake Switch A Footbrake switch digital Refer to the electrical circuit diagrams and check footbrake
Circuit input signal circuits - switch digital input signal circuits for short to power
short to power
P123012 Fuel Pump Low High Side output not Refer to the electrical circuit diagrams and check fuel pump
Speed driven - Diagnosis delivery module for short to power
Malfunction feedback indicates
(VLCM) output is short to power
P123014 Fuel Pump Low High Side output not Refer to the electrical circuit diagrams and check fuel pump
Speed driven - Diagnosis delivery module for short to ground, open circuit
Malfunction feedback indicates
(VLCM) output is short to
P123093 Fuel Pump Low High Side output not Carry out any pinpoint test associated with this DTC using the
Speed driven - Diagnosis manufacturer approved diagnostic system. Refer to the
Malfunction feedback indicates electrical circuit diagrams and check fuel pump delivery
(VLCM) output is at open load or module for short to power, open circuit
short to power
P134611 Fuel Level Sensor Fuel level sensor B Carry out any pinpoint test associated with this DTC using the
B Circuit analogue input circuit - manufacturer approved diagnostic system. Refer to the
short to ground electrical circuit diagrams and check fuel level sensor B
P134615 Fuel Level Sensor Fuel level sensor B Carry out any pinpoint test associated with this DTC using the
B Circuit analogue input circuit - manufacturer approved diagnostic system. Refer to the
short to power, open electrical circuit diagrams and check fuel level sensor B
P162413 Anti-theft System Anti-theft signal circuit Refer to the electrical circuit diagrams and check anti-theft
from CJB - open circuit signal circuit from CJB for open circuit
C111A11 Right Stop Lamp Right stomp lamp control Carry out any pinpoint test associated with this DTC using the
circuit - short to ground manufacturer approved diagnostic system. Refer to the
electrical circuit diagrams and check right stomp lamp control
C111A12 Right Stop Lamp Right stomp lamp control Refer to the electrical circuit diagrams and check right stomp
circuit - short to power lamp control circuit for short to power
C111A13 Right Stop Lamp Right stomp lamp control Refer to the electrical circuit diagrams and check right stomp
circuit - open circuit lamp control circuit for open circuit
C111B11 Left Stop Lamp Left stomp lamp control Carry out any pinpoint test associated with this DTC using the
electrical circuit diagrams and check left stomp lamp control
C111B13 Left Stop Lamp Left stomp lamp control Refer to the electrical circuit diagrams and check left stomp
C112011 Reversing lamp Reverse lamp control Carry out any pinpoint test associated with this DTC using the
electrical circuit diagrams and check reverse lamp control
C112012 Reversing lamp Reverse lamp control Refer to the electrical circuit diagrams and check reverse lamp
circuit - short to power control circuit for short to power
C112013 Reversing lamp Reverse lamp control Refer to the electrical circuit diagrams and check reverse lamp
circuit - open circuit control circuit for open circuit
Authorisation Low speed CAN fault communications between RJB and instrument cluster. Check
Instrument cluster fault power and ground supplies to instrument cluster
B100A62 Fuel Pump Low speed CAN fault Check CAN communications between RJB and instrument
Authorisation RJB fault cluster. Check power and ground supplies to RJB and
Instrument cluster fault instrument cluster. Confirm correct module installed.
Incorrect module Re-synchronise ID by re-configuring the RJB as a new module.
installed (RJB/Instrument Check CAN network for interference/EMC related issues
cluster)
W rite target SID
synchronisation error
B100A63 Fuel Pump RJB fault Check power and ground supplies to RJB and instrument
Authorisation Low speed CAN fault cluster. Check CAN communications between RJB and
B102612 Steering Column Steering column lock Refer to the electrical circuit diagrams and check steering
Lock ground circuit - short to column lock ground circuit for short to power
power
B108783 LIN Bus "A" The checksum of the Check the battery monitoring system and rear parking aid
received LIN frame is system for DTCs and refer to relevant DTC Index
incorrect
B108786 LIN Bus "A" The header of the LIN Carry out any pinpoint test associated with this DTC using the
message received is manufacturer approved diagnostic system. Check the battery
incorrect monitoring system and rear parking aid system for DTCs and
refer to relevant DTC Index
B108788 LIN Bus "A" Battery monitoring Carry out any pinpoint test associated with this DTC using the
system LIN circuit - short manufacturer approved diagnostic system. Refer to the
to ground, power electrical circuit diagrams and check battery monitoring
system LIN circuit for short to ground, power
B108A23 Start Button Start/Stop switch digital Carry out any pinpoint test associated with this DTC using the
input signal circuit - manufacturer approved diagnostic system. Refer to the
stuck low electrical circuit diagrams and check Start/Stop switch digital
B10A111 Trailer Tow Trailer tow detection Carry out any pinpoint test associated with this DTC using the
Detection digital input circuit - manufacturer approved diagnostic system. Refer to the
short to ground electrical circuit diagrams and check trailer tow detection
digital input circuit for short to ground
B10AF12 Blower Fan Relay High Side output not Refer to the electrical circuit diagrams and check blower motor
driven - Diagnosis supply circuit for short to power
feedback indicates
output is short to power
B10AF14 Blower Fan Relay High Side output not Refer to the electrical circuit diagrams and check blower motor
driven - Diagnosis supply circuit for short to ground, open circuit
feedback indicates
output is short to
B10AF93 Blower Fan Relay High Side output not Carry out any pinpoint test associated with this DTC using the
driven - Diagnosis manufacturer approved diagnostic system. Refer to the
feedback indicates electrical circuit diagrams and check blower motor supply
output is at open load or circuit for short to power, open circuit
short to power
B10DD11 Airbag Deployed Airbag deployed digital Carry out any pinpoint test associated with this DTC using the
short to ground electrical circuit diagrams and check airbag deployed digital
B10DD15 Airbag Deployed Airbag deployed digital Carry out any pinpoint test associated with this DTC using the
short to power, open electrical circuit diagrams and check airbag deployed digital
circuit input signal circuit for short to power, open circuit
B10DD38 Airbag Deployed Signal frequency incorrect Check the RCM for related DTCs and refer to the relevant DTC
Index
B10DE11 Low Fuel Warning Diesel run-dry switch Carry out any pinpoint test associated with this DTC using the
Switch analogue input circuit - manufacturer approved diagnostic system. Refer to the
short to ground electrical circuit diagrams and check diesel run-dry switch
B10DE15 Low Fuel Warning Diesel run-dry switch Carry out any pinpoint test associated with this DTC using the
Switch analogue input circuit - manufacturer approved diagnostic system. Refer to the
short to power, open electrical circuit diagrams and check diesel run-dry switch
B111211 Park Aid Ignition Parking aid ignition Carry out any pinpoint test associated with this DTC using the
supply circuit - short to manufacturer approved diagnostic system. Refer to the
ground electrical circuit diagrams and check parking aid ignition
supply circuit for short to ground
B111212 Park Aid Ignition Parking aid ignition Refer to the electrical circuit diagrams and check parking aid
supply circuit - short to ignition supply circuit for short to power
power
B111511 High Mounted High mounted stop lamp Carry out any pinpoint test associated with this DTC using the
Stop Lamp control circuit - short to manufacturer approved diagnostic system. Refer to the
Control ground electrical circuit diagrams and check high mounted stop lamp
B111611 Left Tail Lamp Left hand tail lamp Carry out any pinpoint test associated with this DTC using the
control circuit - short to manufacturer approved diagnostic system. Refer to the
ground electrical circuit diagrams and check left hand tail lamp
B111711 Right Tail Lamp Right hand tail lamp Carry out any pinpoint test associated with this DTC using the
control circuit - short to manufacturer approved diagnostic system. Refer to the
ground electrical circuit diagrams and check right hand tail lamp
B111A11 Number Plate Right hand or left hand Carry out any pinpoint test associated with this DTC using the
Lamps number plate lamp manufacturer approved diagnostic system. Refer to the
control circuits - short to electrical circuit diagrams and check right hand and left hand
ground number plate lamp control circuits for short to ground
B111A12 Number Plate Right hand or left hand Refer to the electrical circuit diagrams and check right hand
Lamps number plate lamp and left hand number plate lamp control circuits for short to
control circuits - short to power
power
B111A13 Number Plate Right hand or left hand Refer to the electrical circuit diagrams and check right hand
Lamps number plate lamp and left hand number plate lamp control circuits for open
control circuits - open circuit
circuit
B111D12 Boot/Trunk Motor Luggage compartment lid Carry out any pinpoint test associated with this DTC using the
Open latch actuator control manufacturer approved diagnostic system. Refer to the
circuit - short to power electrical circuit diagrams and check luggage compartment lid
latch actuator control circuit for short to power
B111D14 Boot/Trunk Motor Luggage compartment lid Carry out any pinpoint test associated with this DTC using the
Open latch actuator control manufacturer approved diagnostic system. Refer to the
circuit - short to ground, electrical circuit diagrams and check luggage compartment lid
open circuit latch actuator control circuit for short to ground, open circuit
B111E11 Boot/Trunk Luggage compartment Carry out any pinpoint test associated with this DTC using the
Lamps lamp control circuit - manufacturer approved diagnostic system. Refer to the
short to ground electrical circuit diagrams and check luggage compartment
B111E12 Boot/Trunk Luggage compartment Refer to the electrical circuit diagrams and check luggage
Lamps lamp control circuit - compartment lamp control circuit for short to power
short to power
B111E13 Boot/Trunk Luggage compartment Refer to the electrical circuit diagrams and check luggage
Lamps lamp control circuit - compartment lamp control circuit for open circuit
open circuit
B112312 Restraints High Side output not Carry out any pinpoint test associated with this DTC using the
Ignition Relay driven - diagnosis manufacturer approved diagnostic system. Refer to the
feedback indicates electrical circuit diagrams and check restraints ignition relay
output is short to power output for short to power
output is short to output for short to ground, open circuit
output is at open load or output for open load or short to power
short to power
B112411 Lamp Fade Interior lamp fade control Refer to the electrical circuit diagrams and check interior lamp
Control circuit - short to ground fade control circuit for short to ground
B112412 Lamp Fade Interior lamp fade control Refer to the electrical circuit diagrams and check interior lamp
Control circuit - short to power fade control circuit for short to power
B113C12 Hazard Switch Hazard switch Refer to the electrical circuit diagrams and check hazard
Illumination illumination control switch illumination control circuit for short to power
B113C14 Hazard Switch Hazard switch Refer to the electrical circuit diagrams and check hazard
Illumination illumination control switch illumination control circuit for short to ground, open
circuit - short to ground, circuit
open circuit
B113E12 External External luggage Refer to the electrical circuit diagrams and check external
Boot/Trunk compartment lid release luggage compartment lid release switch digital input circuit
Release Switch switch digital input for short to power
B113E23 External External luggage Carry out any pinpoint test associated with this DTC using the
Boot/Trunk compartment lid release manufacturer approved diagnostic system. Refer to the
Release Switch switch digital input electrical circuit diagrams and check external luggage
circuit - signal stuck low compartment lid release switch digital input circuit for short
to ground
B11D949 Vehicle Battery Vehicle battery Check battery is in fully charged and serviceable condition
damaged/worn out using the Midtronics battery tester and the battery care
manual
B11DB49 Battery Internal electronic failure Suspect the battery monitoring module. Check and install a
Monitoring new module as required, refer to the new module/component
Module installation note at the top of the DTC Index
B11DB87 Battery Battery monitoring Carry out any pinpoint test associated with this DTC using the
Monitoring module connector manufacturer approved diagnostic system. If additional DTCs
Module dis-connected/poor B108783, B108786, B108787 are logged, suspect the RJB.
connection Check and install a new RJB as required, refer to the new
Battery monitoring module/component installation note at the top of the DTC
module to RJB LIN circuit Index. If additional DTCs B108783, B108786, B108787 are
- open circuit NOT logged, check for good/clean contact at battery
Battery monitoring monitoring module connector, refer to electrical circuit
module to battery diagrams and check battery monitoring module to RJB LIN
positive monitor circuit - circuit and battery monitoring module to battery positive
open circuit monitor circuit for open circuit. Clear DTC and repeat
Battery monitoring automated diagnostic procedure using manufacturer approved
module/RJB failure diagnostic system. If DTC remains suspect the battery
monitoring module, check and install a new battery
monitoring module as required, refer to the new
Index
B123A11 Left Front Turn Left front turn signal Refer to the electrical circuit diagrams and check left front
Indicator lamp control circuit - turn signal lamp control circuit for short to ground
short to ground
Indicator lamp control circuit - turn signal lamp control circuit for short to power
short to power
Indicator lamp control circuit - turn signal lamp control circuit for open circuit
open circuit
B123B11 Right Front Turn Right front turn signal Refer to the electrical circuit diagrams and check right front
short to ground
short to power
open circuit
B124711 Left Rear Turn Left rear turn signal lamp Refer to the electrical circuit diagrams and check left rear turn
Indicator control circuit - short to signal lamp control circuit for short to ground
ground
Indicator control circuit - short to signal lamp control circuit for short to power
power
Indicator control circuit - short to signal lamp control circuit for open circuit
power, open circuit
B124811 Right Rear Turn Right rear turn signal Refer to the electrical circuit diagrams and check right rear
short to ground
short to power
open circuit
B126113 Fuel Flap/Door Fuel filler flap digital Refer to the electrical circuit diagrams and check fuel filler
Release Switch input signal circuit - open flap digital input signal circuit for open circuit
circuit
B1A7911 Rear Fog Lamp Rear fog lamp control Carry out any pinpoint test associated with this DTC using the
electrical circuit diagrams and check rear fog lamp control
B1A7912 Rear Fog Lamp Rear fog lamp control Refer to the electrical circuit diagrams and check rear fog
circuit - short to power lamp control circuit for short to power
B1A7913 Rear Fog Lamp Rear fog lamp control Refer to the electrical circuit diagrams and check rear fog
B1C5512 Horn Relay Horn control circuit - Refer to the electrical circuit diagrams and check horn control
B1C5514 Horn Relay Horn control circuit - Refer to the electrical circuit diagrams and check horn control
short to ground, open circuit for short to ground, open circuit
circuit
B1C8312 Rear Defog Relay High Side output not Refer to the electrical circuit diagrams and check heated rear
driven - diagnosis window power supply circuit for short to power
feedback indicates
output is short to power
B1C8314 Rear Defog Relay High Side output not Refer to the electrical circuit diagrams and check heated rear
driven - diagnosis window power supply circuit for short to ground, open circuit
feedback indicates
output is short to
B1C8393 Rear Defog Relay High Side output not Carry out any pinpoint test associated with this DTC using the
driven - diagnosis manufacturer approved diagnostic system. Refer to the
feedback indicates electrical circuit diagrams and check heated rear window
output is at open load or power supply circuit for open load and short to power
short to power
B1C9112 Fuel Flap/Door Fuel filler flap locking Refer to the electrical circuit diagrams and check fuel filler
Lock Relay Coil motor control circuit - flap locking motor control circuit for short to power
Circuit short to power
B1C9114 Fuel Flap/Door Fuel filler flap locking Refer to the electrical circuit diagrams and check fuel filler
Lock Relay Coil motor control circuit - flap locking motor control circuit for short to ground, open
Circuit short to ground, open circuit
circuit
B1D3512 Hazard Switch Hazard warning lamp Refer to the electrical circuit diagrams and check hazard
switch digital input warning lamp switch digital input circuit for short to power
B1D3523 Hazard Switch Hazard warning lamp Carry out any pinpoint test associated with this DTC using the
switch digital input manufacturer approved diagnostic system. Refer to the
circuit - signal stuck low electrical circuit diagrams and check hazard warning lamp
switch digital input circuit for short to ground
U001988 Low Speed CAN Bus off Carry out any pinpoint test associated with this DTC using the
Communication manufacturer approved diagnostic system
Bus
U014000 Lost No sub type information Carry out any pinpoint test associated with this DTC using the
With Body
Control Module
With Instrument
Panel Cluster
(IPC) Control
Module
With Parking
Assist Control
Module "A"
With HVAC
Control Module
With Remote
Function
Actuation
U030046 Internal Control Calibration/parameter Suspect the RJB. Check and install a new RJB as required,
Module Software memory failure refer to the new module/component installation note at the
Incompatibility top of the DTC Index
U100000 Solid State Driver No sub type information Carry out any pinpoint test associated with this DTC using the
Protection Active manufacturer approved diagnostic system
-Driver Disabled
U1A1449 CAN Initialisation Internal electronic failure Suspect the RJB. Check and install a new RJB as required,
Failure refer to the new module/component installation note at the
U300049 Control Module Internal electronic failure Suspect the RJB. Check and install a new RJB as required,
U300055 Control Module Not configured Re-configure the RJB using the manufacturer approved
diagnostic system
Module Communications Network - Central Junction Box (CJB)
Removal
All vehicles

2. Refer to: Cowl Side Trim Panel (501-05 Interior Trim and
3.
All vehicles
4.
5.
Installation
2. Configure the CJB using the diagnostic tool.

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: W here 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)

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: W here 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.
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
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
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
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

W iring Harness Repair Kit 418-S065 1
Pre-Terminated W iring Harness(s) 418-066 to 418-103 10 each
inclusive
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 418-106 1
spacers
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
W ire 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
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 related 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.

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
Electrical connector terminal type Pin or socket Extractor tip Anti-backout tip
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.
W here 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.
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:
W hen using a heat source make sure that it is localised and causes no damage to surrounding materials.
W here 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
Stripping Insulation
Spice Correctly Located

Wiring Harnesses - Wiring Harness Repair
General Procedures
1. For additional information, refer to: Wiring Harness (418-02

W iring Harnesses, Description and Operation).
Wiring Harnesses - Engine Wiring HarnessTDV6 2.7L Diesel
Special Tool(s)
303-021
303-1129
Engine Lifting Brackets
303-703
General Equipment
Powertrain Jack
Removal
1. Refer to: Specifications (414-01 Battery, Mounting and Cables, Specifications).
2. Refer to: Cowl Vent Screen (501-02 Front End Body Panels, Removal and Installation).
3. 3. NOTE: Some variation in the illustrations may occur, but the essential
Torque: 25 Nm
4.
5. Refer to: Air Cleaner (303-12A Intake Air Distribution and Filtering - TDV6 2.7L Diesel,
6. Torque: 4 Nm
7.
8.
9. Refer to: Exhaust Gas Recirculation (EGR) Valve Outlet Tube (303-08A Engine
Emission Control - TDV6 2.7L Diesel, Removal and Installation).
11.
12. Torque: 10 Nm
13.
14. Torque: 22 Nm
16. Special Tool(s): 303-021, 303-1129
17.
18. Torque: 47 Nm
20. Torque: 63 Nm
21. Raise the engine.
General Equipment: Powertrain Jack

22.
23. Torque: 110 Nm
24. 24. CAUTIONS:
Make sure the alignment mark on the steering gear pinion seal
protection cover is central to the steering gear pinion casting.
Do not turn the steering wheel with the steering column lower
shaft disconnected as damage to the clockspring and steering wheel
switches may occur.
Make sure that a new bolt is installed.
Torque: 35 Nm
25.
26. 26. CAUTION: Make sure to support the steering gear.
Torque: 100 Nm
27.
29. Torque: 12 Nm
30. Torque: 47 Nm
31.
32. Torque: 63 Nm
33. 33. NOTE: Component illustrated, removed for clarity.
Torque: 110 Nm
34. Torque: 48 Nm
35. Lower the engine.
General Equipment: Powertrain Jack
36.
37.
38. Torque: 10 Nm
39. Torque: 25 Nm
40.
41.
42.
44.
45.
46.
47.
48. Release the engine wiring harness from below the vaccum hoses.
49.
50.
51. Release the engine wiring harness from the RH side of the engine.
52. Position the RH engine wiring harness on top of the engine.
53. Torque: 25 Nm
54.
55.
56.
57. Release the engine wiring harness from the LH side of the engine.
58.
59. Torque: 6 Nm
60.
61. Torque: 10 Nm
62.
63.
64.
65. Release the engine wiring harness from beneath the fuel pipes.
66.
67. Torque: 10 Nm
68.
69. Remove the engine wiring harness.
Installation
1. To install reverse the removal procedure.

Wiring Harnesses - Luggage Compartment Lid Wiring Harness
Removal
1. Remove the luggage compartment lid trim panel.
Refer to: Luggage Compartment Lid Trim Panel (501-05 Interior Trim
2.
3.
Installation

Anti-Theft - Active - Anti-Theft - Active - Component Location
Component Location
ItemDescription
1 Alarm indicator
2 Latch mechanism - front door
4 Latch mechanism - rear door
5 Central locking Radio Frequency (RF) receiver
6 Luggage compartment lid latch mechanism
8 Latch mechanism - rear door
9 Latch mechanism - front door
10 Start control unit
12 Passive sounder
13 Hood latch mechanism
14 Vehicle horn
Anti-Theft - Active - Anti-Theft - Active - Overview
Overview
The active anti-theft system is available with three different levels of vehicle protection depending on market
specification:
Hinged panel sensing

Hinged panel and intrusion sensing
Hinged panel, intrusion and inclination sensing.
The CJB (central junction box) automatically arms and disarms the active anti-theft system when it functions the central
locking system.
Refer to: Handles, Locks, Latches and Entry Systems (501-14 Handles, Locks, Latches and Entry Systems, Description and
Operation).
Depending on market specification two modes of protection are used: perimeter mode and volumetric mode.
Perimeter mode
Perimeter mode, monitors the security of the hinged panels, which include:
all doors,
luggage compartment lid, and
engine compartment lid.
When perimeter mode is active, the CJB monitors the panel ajar switches in the latch mechanisms of the hinged panels.
Volumetric mode
In volumetric mode the CJB monitors the interior of the vehicle for movement using an ultrasonic sound wave sensor.
If the battery backed sounder incorporates an inclination sensor the vehicle will also be monitored for unauthorised tilting;
for example towing or jacking.
Anti-Theft - Passive - Anti-Theft - Passive - Component Location
Component Location
ItemDescription
2 Radio frequency receiver
5 Low frequency antennae (3 off)
Anti-Theft - Passive - Anti-Theft - Passive - Overview
Overview
The PATS (passive anti-theft system) prevents the vehicle's engine from being started by unauthorized persons.
Engine starting is prevented by inhibiting the fuel, engine (spark, injectors and crank) and ignition systems from operating.
This is achieved by using a uniquely coded Smart Key and an encoded data exchange between multiple control modules.
The system is automatic and requires no input from the driver.
The engine start system is initiated when the encoded data between the Smart Key and vehicle control modules is
verified. The engine can then be started when the drive selector is in the 'Park' position, and the start/stop switch and the
brake pedal are pressed simultaneously.
Anti-Theft - Passive - Anti-Theft - Passive - System Operation and
Control Diagram
NOTE: A = Hardwired; D = High speed CAN; N = Medium speed CAN; O = LIN bus
ItemDescription
1 Battery
2 Drive selector
4 ABS (anti-lock brake system)
7 Low frequency antenna - front
8 Low frequency antenna - center
9 Low frequency antenna - rear
14 Megafuse (250 amp)
System Operation
The passive start function prevents the vehicle from being started by unauthorized persons. It does this by immobilizing
the ignition, fuel and engine crank functions. The system is automatic and requires no input from the driver.
At the request of the CJB, the keyless vehicle module prompts each of the Low Frequency (LF) antennae to output a
signal. When the Smart Key is in the vehicle cabin, it detects the LF signals and responds with a Radio Frequency (RF)
data-identification signal back to the keyless vehicle module via the RF receiver.
If the data received matches that stored in the keyless vehicle module it continues the passive start process by
communicating a 'Smart Key valid signal to the CJB via the medium speed CAN (controller area network) bus.
Once the CJB receives the authorization and confirms a response with an internal calculation, it passes the result to the
instrument cluster on the medium speed CAN bus.
Before the instrument cluster sends a mobilization signal to the ECMit will exchange encrypted data with:
The electric steering lock mechanism to authorize unlocking the steering column.
The RJB to authorize fuel pump operation. Once the RJB receives the authorization and confirms the response with
an internal calculation, it will enable the FPDM (fuel pump driver module).
The CJB to authorize the ignition status. If the drive selector is in the park position and the driver presses the
brake pedal and simultaneously presses the start/stop switch, the CJB interprets this as an engine crank request.
Before the engine crank request is allowed, the CJB compares a brake pressure signal received from the ABS
module. The brake pressure signal is compared to an internally stored threshold value within the CJB. If the signal
is greater than the stored threshold value, a crank request signal is sent to the ECM on the high speed CAN bus.
Once these factors have been confirmed, and the vehicle is in 'Park', the engine can be started by pressing the brake pedal
and the Stop/Start button simultaneously.
NOTE: If the keyless vehicle module fails to locate the Smart Key, the message 'SMART KEY NOT FOUND PLEASE INSERT
IN SLOT' will appear in the instrument cluster message center. When inserted the start control module will read the
transponder within the Smart Key. If the transponder identification is valid, authorization will be transmitted to the
instrument cluster on the LIN (local interconnect network) bus.
NOTE: When the vehicle is delivered from the factory the passive start function is inhibited. In this condition the vehicle
can only be started by placing the Smart Key in the start control module. The system should be switched on during the
Pre-Delivery Inspection (PDI) using the Jaguar approved diagnostic system. For additional information, refer to the PDI
Manual.
Start Control Module
The start control module is used if the keyless vehicle module is unable to authorise the Smart Key.
If the keyless vehicle module is unable to identify the Smart Key, for example if the Smart Key battery voltage is low or
there is local RF interference, the transponder within the Smart Key can be read in the conventional manner. The driver will
be alerted to this by a chime and a message in the instrument cluster message center 'SMART KEY NOT FOUND PLEASE
INSERT IN SLOT'.
Once inserted the start control module will read the transponder within the Smart Key. If the transponder identification is
valid, authorization will be transmitted to the instrument cluster on the LIN bus.
NOTE: Inserting the Smart Key into the start control module will not charge the Smart Key battery. The battery is
non-chargeable and must be replaced if defective.
A message 'REMOVE SMART KEY' will be displayed if the Smart Key is still in the start control module and the driver's door
is opened.
Low Frequency Antenna

Three Low Frequency (LF) antennae for the passive start system are positioned in specific locations in the vehicle; refer to
Component Location graphic.
NOTE: On vehicles with the passive entry system, five additional antennae are used; one integrated into the rear
bumper and one in each door handle assembly. These are only used by the passive entry system and have no function in
the passive start system.
The keyless vehicle module transmits an LF signal via the antennae which is received by the Smart Key. The Smart Key
then responds by transmitting a Radio Frequency (RF) signal which is received by the RF receiver and passed to the
keyless vehicle module for authorization.
Keyless Vehicle Module

The keyless vehicle module controls signal transmissions to and from the Smart Key and provides authorization to allow
the vehicle to be started. The module has a medium speed CAN connection to the CJB for authorizing vehicle starting.
Radio Frequency Receiver

The Radio Frequency (RF) receiver transmission is received from the Smart Key to enable key identification.
Anti-Theft - Passive - Anti-Theft - Passive
For a detailed description of the Anti-Theft - Passive system, refer to the relevant Description and Operation sections in
the workshop manual. REFER to: (419-01B Anti-Theft - Passive)
Anti-Theft - Passive (Description and Operation),

Anti-Theft - Passive (Description and Operation),
Anti-Theft - Passive (Description and Operation).
Anti-theft - Passive
The best method to confirm the correct operation of the Passive Anti-Theft System (PATS) is to check the LED (located in
the center of the instrument panel). The LED should illuminate solid for 3 seconds, when the ignition status is set to ON,
and then extinguish. This validates all PATS functions (i.e. the key transponder matches a stored key code, the
challenge/response sequence between the respective modules was successful resulting in the EMS being enabled).
Ignition fails to operate
Check that the smart key is located within the vehicle interior, and that it is the correct one for the vehicle.
Insert the smart key into the start control unit (located at out board side of driver instrument panel lower panel), this is
an alternative method to allow Ignition On/Engine Start.
Check that the start button circuit to the CJB is not open circuit or short circuit to power.
Check that the Low Speed CAN network is not malfunctioning, i.e. open circuit or short circuit. This would mean that the
remote keyless entry module, Central Junction Box (CJB) and instrument cluster would be unable to communicate.
Engine fails to crank
If a PATS fault is detected, the LED will flash for 60 seconds at 4Hz with a 50% duty cycle. At the end of this period, the
LED will flash a 2 digit code; this code is repeated 10 times. The meaning of these fault codes along with the frequency of
flashing is given in the accompanying table. As a general rule a fault code of 16 or less will cause the vehicle not to crank.
Additionally, the manufacturer approved diagnostic system should be used to check the instrument cluster, CJB & ECM for
Diagnostic Trouble Codes (DTCs).
One potential occurrence for failing to crank could be due to the P & N start switch (input to the ECM).
Check the Crank Request output from the CJB to ECM is not short circuit to ground or open circuit.
Check the Starter Relay circuit.
NOTE: On petrol engine variants, due to Smart Start, both sides of Relay Coil are switched directly from ECM (If
conditions correct). On diesel engine variants the low side only is switched directly from the ECM.
Check that the Steering Column Lock correctly operates and the steering wheel can turn freely.
Check that the High Speed CAN network is not malfunctioning, i.e. the CAN circuit is open or short circuit. This would mean
that the instrument cluster and ECM would be unable to communicate resulting in no Challenge being performed to enable
the ECM. This would be supported by LED Flash Code 24, see PATS Fault Code Table.
Also check the CAN network between the ABS module and the CJB. The CJB uses the CAN_BrakePressureTMC signal to
determine if the brake pedal has been pressed in order to allow an engine crank. The CJB uses a value of 0x05, if the CJB
sees a value less than this, it will not enable the Crank Request Output.
Engine cranks but will not start
If the Engine is cranking it means that the ECM has passed the authorisation required with the Instrument Cluster. If this
authorisation failed, the ECM would not engage the starter relay. This could be confirmed by verifying the PATS LED prove
out (illuminated solid for 3 seconds) or by reading DTCs from the instrument cluster and ECM.
In this case, the fuel pump circuit should be verified. The Fuel Pump Delivery Module (FPDM), which is supplied via the RJB
(authentication required with the instrument cluster) and controlled by the ECM, supplies the fuel pump.
In all cases of suspected non-start issues, the most logical failure modes should be eliminated first. i.e.
Check all relevant supplies and grounds to the relevant modules listed herein.
Note any unusual behaviour from other systems/functionality.
Note any functions that are not operating as expected.
PATS Fault Codes
For the various PATS modes/faults listed in the table , the instrument cluster will store a DTC and indicate this to the
customer during the detection period defined in the 'when logged' column, by illuminating the indicator as described for 60
seconds and then flashing the LED 10 times as appropriate. The indication will stop immediately the ignition status is set
to OFF any time during the fault indication sequence. Up to 4 DTCs could be stored per key read sequence (1-10 read
attempts). No DTCs will be stored until all retry attempts are complete. Only the highest priority fault code will be flashed.
To determine the fault code from the LED: The LED will flash initially ten times with 1.5 seconds between. The LED will
remain OFF for 2.5 seconds then flash a number of times with 0.5 seconds between (the number of times the LED flashes
represents the first digit of the code), the LED will remain OFF for 1.5 seconds then flash a number of times with 1.5
seconds between (the number of times the LED flashes represents the second digit of the code).
The PATS LED will be commanded on as shown under 'indication'. Normal PATS operations are complete within 400ms of
the ignition switch transition from OFF to ON or START, worst case for ECM communication problems will be less than 2
seconds. If PATS is not complete during the 2 seconds the ECM will terminate PATS and await the next ignition ON or
START event. PATS faults will be indicated via the LED as soon as possible and will terminate the LED prove out. At
ignition OFF all previous flashing will cease and the perimeter anti-theft system will control the LED when the vehicle is
locked and armed.
PATS Fault Code Table

LED
Ignition Fault
Mode of Operation/Fault When Logged Status DTC Code Indication
Prove out N/A Transition N/A N/A 3 Seconds of steady
from OFF to illumination
ON
Perimeter Anti-theft Control N/A OFF - N/A N/A Off or 0.5Hz flashing
Vehicle at 5% duty cycle
locked and 20% until Off
armed
Start Control Unit already programmed Key Insert Any B1B0105 N/A No Indication
Start Control Unit status = invalid response Key Insert Any B1B0167 N/A No Indication
Start Control Unit programming error Key Insert Any B1B0151 N/A No Indication
Start Control Unit challenge response error Key Insert OFF B1B0162 N/A No Indication
Key Programming timer expired or Key Auth Timer Key Insert Any B1B0187 N/A No Indication
expired
Transponder challenge response error Key Insert Any B1B0164 N/A No Indication
Transponder keys stored below minimum number B&A/Dealer Any B1B0100 N/A No Indication
required
Transponder not programmed B&A/Dealer Any B1B0155 N/A No Indication
If the instrument cluster sends a 'theft' key EMS CAN OFF to ON B1B3364 16 60 seconds of 4Hz
status to the ECM or the ECM returns a status communication flashing at 50% duty
message containing the data 'Disabled/Theft', the cycle followed by fault
instrument cluster will set this DTC code 16 flashing 10
times
During manufacturing a Target ID is transferred B&A/Dealer OFF to ON B1B3305 22 60 seconds of steady
from the ECM when requested by the instrument indication followed by
cluster. The instrument cluster stores this unique fault code 22 flashing
vehicle number in EEPROM. If this ID fails to 10 times
store in EEPROM correctly, the instrument cluster
will set this DTC
If the status message received from the ECM Challenge/Response OFF to ON B1B3362 23 60 seconds of steady
contains the data challenge response error, the indication followed by
instrument cluster will set this DTC fault code 23 flashing
10 times
After the instrument cluster has transmitted its Idle message OFF to ON B1B3387 24 60 seconds of steady
first PATS idle message, it will start a 2 second missing indication followed by
timer running. If the PATS sequence does not fault code 24 flashing
complete (Cluster received the Enable msg) 10 times
within this time period the instrument cluster will
set this DTC
2. 2. If the cause is not visually evident, verify the symptom and refer to the manufacturer approved diagnostic
system.
Anti-Theft - Active - Anti-Theft - Active - System Operation and Component
Description
Control Diagram
NOTE: A = Hardwired; N = Medium speed CAN; O = LIN bus
ItemDescription
1 Battery
5 Vehicle horn
7 Central locking - Radio Frequency (RF) receiver
8 Engine compartment lid - latch mechanism
9 Passive sounder
11 Alarm indicator
13 Start control unit
14 Luggage compartment lid - latch mechanism
15 Door latch mechanism - LH (left-hand) rear
16 Door latch mechanism - RH (right-hand) rear
17 Door latch mechanism - RH front
18 Door latch mechanism - LH front
19 Door module - LH rear
20 Door module - RH rear
21 Door module - RH front
22 Door module - LH front
System Operation
Anti-Theft - Active
The active anti-theft system is available with three different levels of vehicle protection depending on market
specification:
Hinged panel sensing

Hinged panel and intrusion sensing
Hinged panel, intrusion and inclination sensing.
The system is controlled by software in the CJB and RJB and indicates a trigger condition:
Visually, using the direction indicators, and

Audibly, using the vehicle horn and either a passive or active sounder to indicate a trigger condition.
The passive sounder takes the form of an anti-theft disc horn located at the rear of the engine compartment on the LH
side. The active sounder takes the form of a battery backed sounder located in the same position.
Depending on market specification, the battery backed sounder may be fitted with an inclination sensor. Both types of
battery backed sounder are visually identical and can only be identified by their part number. Both are also intelligent
units, and communicate to the CJB over a LIN (local interconnect network) bus connection.
Monitoring of the hinged panels is carried out using switches located in each door latch assembly, the engine-
compartment-lid latch assembly, and the luggage-compartment-lid latch assembly. The condition of the switches is
monitored by the CJB.
Monitoring of front door lock status is carried out using switches located in the door latch mechanisms. The condition of
the switches is monitored by the front door modules and transmitted to the CJB over the medium speed CAN (controller
area network) bus.
Monitoring of the cabin interior is carried out using an intrusion detection module mounted behind the roof console. The
intrusion detection module comprises an ultrasonic sound wave sensor to determine if there is movement within the cabin.
Information from the intrusion detection module is communicated to the CJB over a LIN bus connection.
CAUTIONS:
The intrusion detection module electrical connections, particularly those to the sensors mounted in the roof console,
are very delicate and must be handled with care.
The intrusion detection module is an electro-statically sensitive part and should only be handled in an electro-
statically controlled environment.
When armed, the active anti-theft system can be triggered in one of the following ways:
A door ajar switch indicates a door has been opened.

The engine compartment lid or luggage compartment lid ajar switches indicate that either has been opened.
Either front door latch mechanism indicates a door has been unlocked.
The emergency key blade is used to open either the LH front door or luggage compartment.
The CJB or RJB are disconnected (this may result in only a partial trigger).
An attempt is made to start the engine without a valid signal from the Smart Key.
The battery backed sounder is disconnected (partial trigger only).
The vehicle battery is disconnected on a vehicle fitted with a battery backed sounder (partial trigger only).
The inclination sensor detects a change in vehicle attitude.
The intrusion detection module detects movement within the cabin.
Door Modules
The door modules provide the interface between the door latch-motors, the door latch-switches and the CJB. The door
modules provide door switch status information and enable the door latch-motors on request from the CJB or the keyless
vehicle module.
Keyless Vehicle Module

The keyless vehicle module interfaces with the Central locking, Radio Frequency (RF) receiver and collects RF signal
information which is transmitted from the Smart Key. This information is translated into commands which are passed on
the medium speed CAN bus to the:
CJB,
RJB,
door modules, and
instrument cluster.
The keyless vehicle module also monitors:
2 interior antennae,
1 luggage compartment antenna,
a rear bumper antenna, and
4 door handle antennae if the passive entry system is fitted.
On vehicles with passive entry, the additional fast latch motors are controlled via the keyless vehicle module and the
locking status is passed to the CJB on the medium speed CAN bus.
Instrument Cluster
The instrument cluster controls the alarm indicator, and in conjunction with the ECM (engine control module), the engine
immobilization. The ECM controls the engine crank and fuel functions and the instrument cluster processes the valid
transponder information.
Alarm Indicator
The alarm indicator is a LED (light emitting diode) located in the body of the sunload/light sensor. W hen the ignition is off
the indicator gives a visual indication of the active anti-theft system to show if the alarm system is active or not active.
Operation of the alarm indicator is controlled by the instrument cluster which varies the flash rate of the LED to indicate
the system status of the alarm and the immobilization systems.
When the ignition is on, the indicator provides a visual indication of the status of the passive anti-theft (engine
immobilization) system. If the immobilization system is operating correctly, the LED will be illuminated for 3 seconds at
ignition on and then extinguish. If a fault exists in the immobilization system, the LED will be either permanently
illuminated or flashing for 60 seconds. This indicates that a fault exists and fault code has been recorded. After the 60
second period the LED will flash at different frequencies which indicate the nature of the fault.
Passive Anti-Theft Horn

The passive anti-theft horn is hardwired to the CJB which activates the horn when the alarm is triggered.
Battery Backed Sounder

Operation of the battery backed sounder is controlled by the CJB on the LIN bus. The sounder is also connected with a
permanent battery supply via the CJB. An integral, rechargeable battery powers the sounder if the battery power supply
from the CJB is interrupted.
Dependant on vehicle, a incitation sensor is incorporated into the battery backed sounder, to monitor vehicle attitude, see
Inclination Sensor.
Inclination Sensor
The CJB monitors the inclination sensor and will activate the alarm system if the vehicle is being raised.
Intrusion Detection Module

The intrusion detection module comprises an ultrasonic sound wave sensor which monitors the vehicle's interior.
The intrusion detection module is activated with volumetric mode which in turn is enabled when the vehicle is double
locked. The vehicle can be locked and alarmed with the module de-activated if a pet is to be left in the vehicle for example
by single-locking the active anti-theft system. The intrusion detection modules can also be de-activated by deselecting the
'Alarm Sensors' option in the 'Vehicle Settings' screen on the Touch Screen Display.
NOTE: The Touch Screen method of de-activation of the intrusion detection module is only for one arm cycle, it will revert
to active once the engine is next started.
When the volumetric mode is active and the vehicle battery voltage falls below 9 volts, the CJB will ignore any inputs from
the intrusion detection module to prevent false alarm activation.
Anti-Theft - Active - Anti-Theft - Active
For a detailed description of the anti-theft - active system, refer to the relevant Description and Operation sections in the
workshop manual. REFER to: (419-01A Anti-Theft - Active)
Anti-Theft - Active (Description and Operation),

Anti-Theft - Active (Description and Operation),
Anti-Theft - Active (Description and Operation).
vehicle.
Visual Inspection
Door latch micro switches Fuse(s)
Hood ajar switch Electrical
Passive anti-theft alarm horn (if installed) connector(s)
Battery backed sounder (if installed) or battery backed sounder with tilt sensor (if Wiring Harness
installed)
Vehicle horns
Index.
NOTE: For Remote Keyless Entry system failures.

REFER to: Remote Keyless Entry (RKE) Module (419-10 Multifunction Electronic Modules, Diagnosis and Testing).
DTC Index

B108783 LIN Bus "A" Checksum of the received LIN Check operation of rain/light sensor by covering sensor
frame from battery backed or applying water to screen, install a new sensor as
sounder, roof header console, required
and/or rain/light sensor is
incorrect
B108788 LIN Bus "A" Bus off. Battery backed Carry out any pinpoint tests associated with this DTC
sounder, roof header console, using the manufacturer approved diagnostic system.
and/or rain/light sensor LIN Refer to the electrical circuit diagrams and check battery
circuit - short to ground, power backed sounder, roof header console, and rain/light
sensor LIN circuit for short to ground, power
B10EB11 Driver door double Driver door double locking Refer to the electrical circuit diagrams and test driver
locking motor motor control circuit - short to door double locking motor control circuit for short ground
ground
B10EB15 Driver door double Driver door double locking Carry out any pinpoint tests associated with this DTC
locking motor motor control circuit - short to using the manufacturer approved diagnostic system.
power, open circuit Refer to the electrical circuit diagrams and test driver
door double locking motor control circuit for short to
power or open circuit
B10EC11 Passenger door Passenger door double locking Refer to the electrical circuit diagrams and test
double locking motor control circuit - short to passenger door double locking motor control circuit for
motor ground short ground
B10EC15 Passenger door Passenger door double locking Carry out any pinpoint tests associated with this DTC
double locking motor control circuit - short to using the manufacturer approved diagnostic system.
motor power, open circuit Refer to the electrical circuit diagrams and test
passenger door double locking motor control circuit for
short to power or open circuit
B10ED11 Rear door driver Rear door driver side double Refer to the electrical circuit diagrams and test rear door
side double locking motor control circuit - driver side double locking motor control circuit for short
locking motor short to ground ground
B10ED15 Rear door driver Rear door driver side double Carry out any pinpoint tests associated with this DTC
side double locking motor control circuit - using the manufacturer approved diagnostic system.
locking motor short to power, open circuit Refer to the electrical circuit diagrams and test rear door
driver side double locking motor control circuit for short
power, open circuit
B10EE11 Rear door Rear door passenger side Refer to the electrical circuit diagrams and test rear door
passenger side double locking motor control passenger side double locking motor control circuit for
double locking circuit - short to ground short ground
motor
B10EE15 Rear door Rear door passenger side Carry out any pinpoint tests associated with this DTC
passenger side double locking motor control using the manufacturer approved diagnostic system.
double locking circuit - short to power, open Refer to the electrical circuit diagrams and test rear door
motor circuit passenger side double locking motor control circuit for
short power, open circuit
B10F111 Key In Switch Keyless vehicle module, key Carry out any pinpoint tests associated with this DTC
IN status circuit - short to using the manufacturer approved diagnostic system.
ground Refer to the electrical circuit diagrams and check keyless
vehicle module, key IN status circuit for short to ground
B10F112 Key In Switch Keyless vehicle module, key Refer to the electrical circuit diagrams and check keyless
IN status circuit - short to vehicle module, key IN status circuit for short to power
power
B10F113 Key In Switch Keyless vehicle module, key Refer to the electrical circuit diagrams and check keyless
IN status circuit - open circuit vehicle module, key IN status circuit for open circuit
B110811 Driver door central Driver door central locking Refer to the electrical circuit diagrams and test driver
locking motor motor control circuit - short to door central locking motor control circuit for short ground
ground
B110815 Driver door central Driver door central locking Carry out any pinpoint tests associated with this DTC
door central locking motor control circuit for short to
power, open circuit
B110A11 Rear door driver Rear driver door central locking Refer to the electrical circuit diagrams and test rear
side central motor control circuit - short to driver door central locking motor control circuit for short
locking motor ground ground
side central motor control circuit - short to driver door central locking motor control circuit for short
locking motor power, open circuit to power, open circuit
B117513 Driver Door Ajar Driver door ajar switch signal Refer to the electrical circuit diagrams and check driver
Switch circuit - open circuit door ajar switch signal circuit for open circuit
B11C013 Driver Side Rear Left rear door ajar switch Refer to the electrical circuit diagrams and check left
Door Ajar Switch signal circuit - open circuit rear door ajar switch signal circuit for open circuit
B11C113 Passenger Side Right rear door ajar switch Refer to the electrical circuit diagrams and check right
Rear Door Ajar signal circuit - open circuit rear door ajar switch signal circuit for open circuit
Switch
B122223 Master Master lock or unlock switch Refer to the electrical circuit diagrams and check master
Lock/Unlock digital input circuit - signal lock and unlock switch digital input circuits for short to
Switch stuck low ground, open circuit
B1D1711 Battery Backed Battery backed sounder Refer to the electrical circuit diagrams and check battery
Sounder inclination sensor control backed sounder inclination sensor control circuit for
circuit - short to ground short to ground
B1D1811 Volumetric Sensor Intrusion sensor module Carry out any pinpoint tests associated with this DTC
supply circuit - short to ground using the manufacturer approved diagnostic system.
intrusion sensor module supply circuit for short to
ground
B1D9796 Tilt Sensor Component internal failure Suspect the battery backed sounder, check and install a
new battery backed sounder as required
P162413 Anti-theft System RJB anti-theft signal circuit - Refer to the electrical circuit diagrams and check RJB
open circuit anti-theft signal circuit for open circuit
P254F13 Engine Hood Hood ajar switch signal circuit Refer to the electrical circuit diagrams and check hood
Switch - open circuit ajar switch signal circuit for open circuit
Circuit/Open
Anti-Theft - Active - Anti-Theft Alarm Horn
Removal

Installation).
4. Remove the pedestrian protection actuator.
Reposition the pedestrian protection hood actuator.

6. Remove the anti-theft alarm horn.
Installation
Tighten to 7 Nm.
3. Tighten to 8 Nm.
Navigation System - Navigation System Antenna
Removal
1. Remove the interior lamp lens.
2. Release the interior lamp.
4. Remove the global positioning sensor (GPS) antenna.

3. CAUTION: Make sure that the latch is pressed before
Installation
disconnecting the electrical connector.
Release and disconnect the 2 electrical connectors.
Remove the 2 nuts.
Remove the reinforcement plate.

Tighten to 6 Nm.
Navigation System - Navigation System Module
Removal
Procedures).
2. Remove the LH luggage compartment side trim panel.
Installation).
3. Release the navigation system module.
4. Remove the navigation system module.
Installation
Cellular Phone - Bluetooth Module
Removal
Procedures).
2. Remove the front seat.
3. Lift the carpet for access.

5. Remove the bluetooth module.
Installation
Tighten to 10 Nm.
Multifunction Electronic Modules -
Rear electronic module retaining bolts 10 7 89
Multifunction voice activated module retaining bolts 10 7 89
Front electronic module retaining bolts 10 7 89
Multifunction Electronic Modules - Module Controlled Functions -
Component Location
COMPONENT LOCATION - LIN BUS (Sheet 1 of 2)
ItemDescription
NOTE: LHD (left-hand drive) vehicle shown
4 Steering wheel switches
5 Rain/light sensor
7 Passenger side rear door module
8 Driver's door switches
11 Rear view camera
12 Driver's side rear door module
14 Driver's seat switches
17 Clockspring
20 Generator
COMPONENT LOCATION - LIN BUS (Sheet 2 of 2)
ItemDescription
NOTE: LHD vehicle shown
2 RH (right-hand) outer face level vent
3 RH inner face level vent
4 LH (left-hand) inner face level vent
5 LH outer face level vent
6 Electric booster heater
7 Stepper motor - LH temperature blend
8 Stepper motor - windshield defrost
9 Stepper motor - RH temperature blend
10 Stepper motor - face/feet
COMPONENT LOCATION - MEDIUM SPEED CAN BUS
ItemDescription
1 CJB
2 ATC module
4 Audio system control panel
6 RJB
7 RH blind spot monitoring module
10 LH blind spot monitoring module
14 Tire Pressure Monitoring System (TPMS) control module
16 Climate seat module
COMPONENT LOCATION - HIGH SPEED CAN BUS
ItemDescription
1 ECM - V8 shown
2 Headlamp leveling control module
7 Electronic Parking Brake (EPB) module
11 Pedestrian protection control module
13 TCM
COMPONENT LOCATION - MOST
ItemDescription
4 Digital Audio Broadcast (DAB)/Satellite Digital Audio Radio System (SDARS)
5 Multimedia module
7 Television (TV) tuner
8 Portable audio interface
9 Blue tooth phone module
10 Software download socket
Multifunction Electronic Modules - Module Controlled Functions - Overview
OVERVIEW
The vehicle electrical system comprises a number of control modules which are interconnected via several network
systems.
The following network systems are used on the vehicle:
High speed CAN (controller area network) bus

Medium speed CAN bus
LIN (local interconnect network) bus
K Bus
Media Orientated Systems Transport (MOST) ring.
Multifunction Electronic Modules - Module Controlled Functions - System
System Operation
MODULE CONTROLLED FUNCTIONS
Refer to the relevant section for details of system operation.
MODULES, SYSTEMS AND FUNCTION
The CJB (central junction box) is the 'gateway' for the network systems which allows information to be exchanged between
networks.
The entertainment system components are connected on a fiber optic MOST ring. The MOST ring can send and receive
information to/from the other network systems via a 'gateway' in the Integrated Control Module.
The following table shows each vehicle control module, the network system to which it is connected, its function and
location in the vehicle.
Module Network System Function Vehicle Location

Instrument cluster High speed CAN Receives data from other vehicle systems to Instrument panel.
(controller area provide information to the driver. Also functions as
network) bus the gateway for the bus systems.
Steering column High speed CAN Controls the locking and unlocking of the steering Upper steering column.
bus column.
Diagnostic socket High speed CAN Allows the transfer of vehicle information using a In the lower instrument
bus Jaguar approved diagnostic system or other panel on the driver's side,
diagnostic tool. adjacent to the start control
module.
RCM (restraints control High speed CAN Controls the deployment of the supplementary At rear of floor console.
module) bus restraint components.
TCM (transmission High speed CAN Controls automatic transmission operation. Inside the transmission and
control module) bus accessible via the fluid pan.
ECM (engine control High speed CAN Controls engine management and fuel system Rear of the engine
module) bus operation. compartment on the
bulkhead.
ABS (anti-lock brake High speed CAN Controls all aspects of the braking system Rear of the engine
system) bus compartment on the
bulkhead.
Headlamp leveling High speed CAN Controls the static dynamic headlamp leveling In the lower instrument
module bus function. panel, behind the glovebox.
Occupant classification High speed CAN Detects when a passenger is in the front Below the front passenger
system control module bus passenger seat and can determine their size and seat.
(NAS only) weight.
Adaptive damping High speed CAN Controls the adjustment of the dampers. Below the front passenger
control module bus seat.
Electronic Parking High speed CAN Controls the application and release of the In the luggage
Brake (EPB) module bus electronic parking brake. compartment, above the RH
(right-hand) wheel arch.
Pedestrian protection High speed CAN Controls and monitors the pedestrian protection LH (left-hand) 'A' pillar.
module bus system.
Adaptive speed control High speed CAN Controls the vehicle's road speed in relation to Behind the instrument panel
module bus other vehicles when in speed control mode. on the driver's side.
Electronic transmission High speed CAN Allows the driver to electronically select the In the floor console.
selector bus required automatic transmission mode. Transmits
driver selections to the TCM.
Jaguar Drive control High speed CAN Controls the Jaguar Drive function and Integral with the electronic
module bus communicates with other system modules. transmission selector
software in the floor
console.
CJB Medium speed Controls body functions and power distribution. On RH 'A' pillar.
CAN bus
Diagnostic socket Medium speed Allows the transfer of vehicle information using a In the lower instrument
CAN bus Jaguar approved diagnostic system or other panel on the driver's side,
diagnostic tool. adjacent to the start control
module.
Passenger door module Medium speed Controls window and locking functions. In the front passenger door.
CAN bus
Parking aid module Medium speed Controls the parking aid system. In the LH side of the
CAN bus luggage compartment,
adjacent to the keyless
vehicle module.
Driver's seat module Medium speed Controls driver's seat positioning and also memory Below the driver's seat.
CAN bus functions of other personalized functions.
Instrument cluster Medium speed Receives data from other systems to provide driver In the instrument panel.
CAN bus information.
Driver's door module Medium speed Controls window and locking functions. In the driver's door.
CAN bus
ATC (automatic Medium speed Contains controls for the heating and air On the end of the air
temperature control) CAN bus conditioning systems. conditioning evaporator and
module blower assembly.
Information control Medium speed Contains controls for the entertainment systems. In the instrument panel
module CAN bus below the integrated control
panel.
Integrated control Medium speed Contains controls for the entertainment systems In the instrument panel.
panel CAN bus and gateway between audio system and other
vehicle systems.
Front seat climate Medium speed Controls the temperature requirements of the Below the RH front seat.
control module CAN bus driver and passenger front seats.
LH blind spot Medium speed Controls the operating parameters of the system Behind the outer part of the
monitoring module CAN bus and provides driver indications and fault rear bumper, rearward of the
monitoring. rear wheel.
RH blind spot Medium speed Controls the operating parameters of the system Behind the outer part of the
monitoring module CAN bus and provides driver indications and fault rear bumper, rearward of the
monitoring. rear wheel.
Keyless vehicle module Medium speed Allows the vehicle to be opened and closed In the LH side of the
CAN bus without the use of a key. luggage compartment,
adjacent to the parking aid
module.
RJB (rear junction box) Medium speed Controls body functions and power distribution. RH of luggage compartment.
CAN bus
Tire pressure Medium speed Monitors the vehicle tires to warn of deflation. Below the rear of the floor
monitoring control CAN bus console.
module
TCM K Bus Data transfer between TCM and diagnostic socket. Inside the transmission and
NOTE: Only fitted to early build vehicles. accessible by removal of the
fluid pan.
Driver's side rear door LIN (local Controls window and locking operation. In the driver's side rear
module interconnect door.
network)
Passenger side rear LIN Controls window and locking operation. In the passenger side rear
door module door.
Driver's door module LIN Memory/adjustment functions for seat, steering In the driver's door.
column and mirrors and door security functions.
Passenger front door LIN Memory/adjustment functions for seat, steering In the passenger door.
module column and mirrors and door security functions.
Driver's door switches LIN Transmit driver selections to the driver's door In the driver's door panel.
module.
ECM LIN Receives a load signal from the generator. In the engine compartment
on the bulkhead.
Generator LIN Provide load signal to the ECM. On the LH side at the front
of the engine.
Driver's seat module LIN Control position of driver's seat. Below the driver's seat on
the floor pan.
Driver's seat switches LIN Provide driver selection inputs to the driver's seat On the outside of the trim
module. panel on the driver's seat.
Air quality sensor LIN Measures quality of air entering the vehicle At the front of the vehicle,
interior. behind the air intake grill.
W indshield (defrost) LIN Moves flaps within the heater assembly to direct On the heater assembly.
stepper motor air flow to the windshield.
Face/feet stepper LIN Moves flaps within the heater assembly to direct On the heater assembly.
motor air flow to instrument panel vents and/or footwell.
LH temperature blend LIN Moves flaps within the heater assembly to control On the heater assembly.
stepper motor temperature in LH side footwell.
RH temperature blend LIN Moves flaps within the heater assembly to direct On the heater assembly.
stepper motor air flow to RH side footwell.
Electric booster heater LIN Controls operation of the electric booster heater. Inside the heater assembly.
LH outer face level LIN Controls the operation of the face level vent In the instrument panel.
vent stepper motor.
LH inner face level LIN Controls the operation of the face level vent In the instrument panel.
vent stepper motor.
RH inner face level LIN Controls operation of the face level vent stepper In the instrument panel.
vent motor.
RH outer face level LIN Controls operation of the face level vent stepper In the instrument panel.
vent motor.
ATC module LIN Controls operation of the climate system In the instrument panel.
functions.
Steering wheel audio LIN Converts analogue signals from steering wheel On the steering wheel.
switches switches into digital messages.
Steering wheel LIN Passes digital messages from the steering wheel Behind the steering wheel,
clockspring audio switches to the instrument cluster. on the upper steering
column.
Instrument cluster LIN Receives digital signals from other vehicle On the driver's side of the
systems. instrument panel.
Battery backed sounderLIN Activated by CJB when alarm trigger is received. In the LH side of the engine
compartment, near the
bulkhead.
CJB LIN Controls body functions and power distribution. On the RH 'A' pillar.
RJB LIN Controls body functions and power distribution. On the RH of the luggage
compartment.
Battery monitoring LIN Monitors the condition and charge of the vehicle On the vehicle battery
system module battery. positive terminal in the
luggage compartment.
Intrusion detection LIN Detects movement in the vehicle interior and In the front overhead
module activates the anti-theft system. console.
Rain/light sensor LIN Detects ambient light levels and moisture on the On the inside of the
windscreen for operation of the automatic windshield behind the
headlamps and wiper systems. interior rear view mirror.
Start control module LIN Used to identify the Smart Key - component of the In the lower instrument
keyless start system. panel on the driver's side.
Rear view camera LIN Passes digital images data from the rear view In the luggage compartment
camera to the RJB lid trim finisher.
Driver's window switch LIN Controls operation of the driver's window. In the driver's door trim
panel.
Electronic transmission LIN Sends selector position to the TCM. In the floor console.
selector
TCM LIN Receives selector position information to control Inside the transmission and
the transmission. accessible by removal of the
fluid pan.
Information control Media Oriented Contains controls for the entertainment system In the instrument panel
module System Transport and gateway between audio system and other below the integrated control
(MOST) vehicle systems. panel.
Integrated control MOST Contains controls for the entertainment system. In the instrument panel.
panel
Digital Audio Broadcast MOST Receives digital radio broadcasts. In the LH side of the
(DAB) receiver (SDARS luggage compartment,
NAS only) above the keyless vehicle
module.
Bluetooth phone MOST Controls operation of the Bluetooth phone Below the LH front seat,
module system. adjacent to the portable
audio module.
Amplifier/tuner MOST Provides amplification for the entertainment In the LH side of the
systems and reception of radio RF broadcasts. luggage compartment.
Navigation computer MOST Reads map data from a DVD (digital versatile disc) In the LH side of the
to calculate and display visual route guidance luggage compartment.
information via the TSD and audible guidance via
the amplifier to the driver.
Touch Screen Display MOST Provides the driver interface to the entertainment, In the center of the
(TSD) navigation and driver personalization functions. instrument panel.
TV tuner MOST Controls the reception of television signals and In the LH side of the
audio/visual inputs. luggage compartment.
Portable Audio Module MOST Controls the auxiliary inputs for additional audio Below the LH front seat,
inputs via the portable audio interface. adjacent to the Bluetooth
phone module.
MOST diagnostic MOST Allows for diagnostic fault detection of the MOST Below the air ducting in the
connector ring. floor console.
Refer to Communications Network section for further details.
Refer to: Communications Network (418-00 Module Communications Network, Description and Operation).
Multifunction Electronic Modules - Driver Door Module (DDM)

For a detailed description of the multifunction electronic control modules, refer to the relevant Description and Operation
sections in the workshop manual. REFER to: (419-10 Multifunction Electronic Modules)
Module Controlled Functions (Description and Operation),

Module Controlled Functions (Description and Operation).
vehicle.
Visual Inspection
Electrical
Fuse(s)
W iring Harness
DTC Index

locking motor motor control circuit - short to door double locking motor control circuit for short
ground ground
double locking motor control circuit - short to passenger door double locking motor control circuit
motor ground for short ground
passenger door double locking motor control circuit
for short to power or open circuit
B10ED11 Rear door driver Rear door driver side double Refer to the electrical circuit diagrams and test rear
side double locking locking motor control circuit - door driver side double locking motor control circuit
motor short to ground for short ground
side double locking locking motor control circuit - using the manufacturer approved diagnostic system.
motor short to power, open circuit Refer to the electrical circuit diagrams and test rear
door driver side double locking motor control circuit
for short power, open circuit
B10EE11 Rear door Rear door passenger side Refer to the electrical circuit diagrams and test rear
passenger side double locking motor control door passenger side double locking motor control
double locking circuit - short to ground circuit for short ground
motor
double locking circuit - short to power, open Refer to the electrical circuit diagrams and test rear
motor circuit door passenger side double locking motor control
circuit for short power, open circuit
B110811 Driver door central Driver door central locking Refer to the electrical circuit diagrams and test driver
locking motor motor control circuit - short to door central locking motor control circuit for short
ground ground
door central locking motor control circuit for short to
power, open circuit
side central locking motor control circuit - short to driver door central locking motor control circuit for
motor ground short ground
side central locking motor control circuit - short to driver door central locking motor control circuit for
motor power, open circuit short to power, open circuit
B116311 Left Mirror Heater Left mirror heater control circuit Refer to the electrical circuit diagrams and test left
Output - short to ground mirror heater control circuit for short to ground
B116315 Left Mirror Heater Left mirror heater control circuit Carry out any pinpoint tests associated with this DTC
Output - short to power, open circuit using the manufacturer approved diagnostic system.
Refer to the electrical circuit diagrams and test left
mirror heater control circuit for short to power, open
circuit
B116411 Right Mirror Heater Right mirror heater control Refer to the electrical circuit diagrams and test right
Output circuit - short to ground mirror heater control circuit for short to ground
B116415 Right Mirror Heater Right mirror heater control Carry out any pinpoint tests associated with this DTC
Output circuit - short to power, open using the manufacturer approved diagnostic system.
circuit Refer to the electrical circuit diagrams and test right
circuit
B116511 Left Front Puddle Left front puddle lamp control Refer to the electrical circuit diagrams and test left
Lamp Output circuit - short to ground front puddle lamp control circuit for short to ground
B116515 Left Front Puddle Left front puddle lamp control Carry out any pinpoint tests associated with this DTC
Lamp Output circuit - short to power, open using the manufacturer approved diagnostic system.
circuit Refer to the electrical circuit diagrams and test left
front puddle lamp control circuit for short to power,
open circuit
B116611 Right Front Puddle Right front puddle lamp control Refer to the electrical circuit diagrams and test right
B116615 Right Front Puddle Right front puddle lamp control Carry out any pinpoint tests associated with this DTC
open circuit
B117C07 Rear Power Window Mechanical failure Check rear window mechanism for mechanical failure
Up
B117C72 Rear Power Window Actuator stuck open Suspect the rear door module. Check and install a
Up new module as required, refer to the new
DTC Index
B117C73 Rear Power Window Actuator stuck closed Suspect the rear door module. Check and install a
DTC Index
B117C92 Rear Power Window Performance or incorrect Refer to the electrical circuit diagrams and check rear
Up operation door module power and ground supplies
B117D72 Rear Power Window Actuator stuck open Suspect the rear door module. Check and install a
Down new module as required, refer to the new
DTC Index
B117D73 Rear Power Window Actuator stuck closed Suspect the rear door module. Check and install a
DTC Index
B117E07 Front Power Mechanical failure Check front window mechanism for mechanical failure
W indow Up
B117E72 Front Power Actuator stuck open Suspect the DDM. Check and install a new DDM as
W indow Up required, refer to the new module/component
B117E73 Front Power Actuator stuck closed Suspect the DDM. Check and install a new DDM as
B117F72 Front Power Actuator stuck open Suspect the DDM. Check and install a new DDM as
W indow Down required, refer to the new module/component
B117F73 Front Power Actuator stuck closed Suspect the DDM. Check and install a new DDM as
B118929 Front W indow Front window hall position Carry out any pinpoint tests associated with this DTC
Position Sensor sensor - signal invalid using the manufacturer approved diagnostic system
B118A29 Rear Window Rear window hall position Carry out any pinpoint tests associated with this DTC
B11D183 LIN Bus Circuit "C" Value of signal protection Suspect driver switchpack. Check and install a new
calculation incorrect driver switchpack as required, refer to the new
DTC Index
B11D186 LIN Bus Circuit "C" Signal invalid Suspect driver switchpack. Check and install a new
driver switchpack as required, refer to the new
DTC Index
B11D187 LIN Bus Circuit "C" Missing message Suspect driver switchpack. Check and install a new
DTC Index
B11F611 Driver Folding Mirror Driver folding mirror motor Refer to the electrical circuit diagrams and check
Motor control circuit - short to ground driver folding mirror motor control circuit for short to
ground
B11F615 Driver Folding Mirror Driver folding mirror motor Carry out any pinpoint tests associated with this DTC
Motor control circuit - short to power, using the manufacturer approved diagnostic system.
driver folding mirror motor control circuit for short to
power, open circuit
B1A9883 LIN Bus Circuit #1 Value of signal protection Refer to the electrical circuit diagrams and check LIN
calculation incorrect circuit between DDM and rear door module for
short/open circuits
B1A9886 LIN Bus Circuit #1 Signal invalid Carry out any pinpoint tests associated with this DTC
Refer to the electrical circuit diagrams and check LIN
circuit between DDM and rear door module for
short/open circuits
B1A9887 LIN Bus Circuit #1 Missing message Carry out any pinpoint tests associated with this DTC
short/open circuits
B1C0911 Driver Left/Right Driver left/right mirror motor Carry out any pinpoint tests associated with this DTC
Mirror Motor Circuit control circuit - short to ground using the manufacturer approved diagnostic system.
Refer to the electrical circuit diagrams and test driver
left/right mirror motor control circuit for short to
ground
Mirror Motor Circuit control circuit - short to power, using the manufacturer approved diagnostic system.
open circuit Refer to the electrical circuit diagrams and test driver
left/right mirror motor control circuit for short to
power, open circuit
B1C1011 Driver Up/Down Driver up/down mirror motor Carry out any pinpoint tests associated with this DTC
Mirror Motor Circuit control circuit - short to ground using the manufacturer approved diagnostic system.
Refer to the electrical circuit diagrams and test driver
up/down mirror motor control circuit for short to
ground
Mirror Motor Circuit control circuit - short to power, using the manufacturer approved diagnostic system.
open circuit Refer to the electrical circuit diagrams and test driver
up/down mirror motor control circuit for short to
power, open circuit
B1C1311 Driver Up/Down Driver up/down mirror motor Refer to the electrical circuit diagrams and test driver
Mirror Motor feedback circuit - short to up/down mirror motor feedback circuit for short to
Feedback Circuit ground ground
Mirror Motor feedback circuit - short to using the manufacturer approved diagnostic system.
Feedback Circuit power, open circuit Refer to the electrical circuit diagrams and test driver
up/down mirror motor feedback circuit for short to
power, open circuit
B1C1411 Driver Left/Right Driver left/right mirror motor Refer to the electrical circuit diagrams and test driver
Mirror Motor feedback circuit - short to left/right mirror motor feedback circuit for short to
Feedback Circuit ground ground
Mirror Motor feedback circuit - short to using the manufacturer approved diagnostic system.
Feedback Circuit power, open circuit Refer to the electrical circuit diagrams and test driver
left/right mirror motor feedback circuit for short to
power, open circuit
B1D0611 Left Turn Indicator Left side turn indicator repeater Refer to the electrical circuit diagrams and check left
lamp circuit - short to ground side turn indicator repeater lamp circuit for short to
ground
B1D0615 Left Turn Indicator Left side turn indicator repeater Carry out any pinpoint tests associated with this DTC
lamp circuit - short to power, using the manufacturer approved diagnostic system.
open circuit Refer to the electrical circuit diagrams and check left
side turn indicator repeater lamp circuit for short to
power, open circuit
B1D0711 Right Turn Indicator Right side turn indicator Refer to the electrical circuit diagrams and check right
repeater lamp circuit - short to side turn indicator repeater lamp circuit for short to
ground ground
power, open circuit power, open circuit
C1B1411 Sensor Supply #1 Window position hall sensors Refer to the electrical circuit diagrams and test
supply circuit - short to ground window position hall sensors supply circuit for short
to ground
C1B1415 Sensor Supply #1 Window position hall sensors Carry out any pinpoint tests associated with this DTC
supply circuit - short to power, using the manufacturer approved diagnostic system.
open circuit Refer to the electrical circuit diagrams and test
window position hall sensors supply circuit for short
to power, open circuit
C1B1511 Sensor Supply #2 Hall sensor supply circuit - Refer to the electrical circuit diagrams and test
short to ground window position hall sensors supply circuit for short
to ground
C1B1515 Sensor Supply #2 Hall sensor supply circuit - Carry out any pinpoint tests associated with this DTC
Refer to the electrical circuit diagrams and test
U014000 Lost Communication Missing message from CJB Carry out any pinpoint tests associated with this DTC
W ith Body Control using the manufacturer approved diagnostic system
Module
U020800 Lost Communication Missing message from driver Carry out any pinpoint tests associated with this DTC
W ith Seat Control seat module using the manufacturer approved diagnostic system
Module "A"
U030000 Internal Control Invalid configuration message Re-configure the RJB using the manufacturer
Module Software is received approved diagnostic system. Clear the DTC and
Incompatibility retest. If the DTC remains suspect the DDM. Check
and install a new module as required, refer to the
new module/component installation note at the top
of the DTC Index
U200224 Switch Signal stuck high Clear DTC and re-test. If DTC remains, suspect the
passenger side window switch. Check and install a
new passenger side window switch
U200424 Auxiliary Switch Left or right rear door local Check for stuck rear window switch. Refer to the
Pack switch - signal stuck high electrical circuit diagrams and check left or right rear
door local switch circuit for short circuit
U201011 Switch illumination Rear window switch illumination Refer to the electrical circuit diagrams and check rear
circuit - short to ground window switch illumination circuit for short to ground
U201208 Car Configuration Bus signal/message failures Cycle the ignition status and re-test. If DTC remains,
Parameter(s) re-configure the RJB using the manufacturer approved
diagnostic system
U201324 Switch Pack Signal stuck high Clear DTC and re-test. If DTC remains, install a new
driver door switch pack
U201444 Control Module Data memory failure Suspect the DDM. Check and install a new DDM as
Hardware required, refer to the new module/component
U210000 Initial Configuration No sub type information Re-configure the DDM using the manufacturer
Not Complete approved diagnostic system
U300049 Control Module Internal electronic failure Suspect the DDM. Check and install a new DDM as
U300255 Vehicle Not configured Re-configure the DDM as new using the manufacturer
Identification approved diagnostic system and re-test. If DTC
Number remains install a new module, refer to the new
DTC Index
U300281 Vehicle Vehicle/component mis-match. Check and install correct/new module as required,
Identification Corrupt VIN data being refer to the new module/component installation note
Number (VIN) transmitted, module previously at the top of the DTC Index
installed to other vehicle
U300362 Battery voltage Mis-match in battery voltage, of Carry out any pinpoint tests associated with this DTC
2 volts or more, between DDM using the manufacturer approved diagnostic system
and RJB
Multifunction Electronic Modules - Remote Keyless Entry (RKE) Module
For a detailed description of the Remote Keyless Entry system, refer to the relevant Description and Operation sections in
the workshop manual. REFER to: (419-10 Multifunction Electronic Modules)

vehicle.
Visual Inspection
Misaligned door(s), hood or luggage compartment lid Fuse(s)
Door latch(s) Wiring harness
Actuating rod(s) Electrical connector(s)
Exterior door handle(s) Door lock actuator(s)
Interior door handle(s) Remote transmitter batteries
Door lock cylinder Vehicle battery
Cable(s) Remote transmitter
Luggage compartment lid exterior release switch Door lock switch(s)
DTC Index

B102B00 Passive Key Response Error - general Using the manufacturer approved diagnostic system,
failure clear all passive keys, re-learn all passive keys
B10C100 Left Front Unlock Pull No subtype information Carry out any pinpoint tests associated with this DTC
Switch using the manufacturer approved diagnostic system
B10C124 Left Front Unlock Pull Signal stuck high - button Carry out any pinpoint tests associated with this DTC
Switch stuck in active position using the manufacturer approved diagnostic system.
Check for stuck left front unlock switch. Refer to the
electrical circuit diagrams and check left front unlock
switch circuit for short to ground
B10C200 Left Rear Unlock Pull No subtype information Carry out any pinpoint tests associated with this DTC
Switch using the manufacturer approved diagnostic system
B10C224 Left Rear Unlock Pull Signal stuck high - button Carry out any pinpoint tests associated with this DTC
Check for stuck left rear unlock switch. Refer to the
electrical circuit diagrams and check left rear unlock
B10C300 Right Front Unlock No subtype information Carry out any pinpoint tests associated with this DTC
Pull Switch using the manufacturer approved diagnostic system
B10C324 Right Front Unlock Signal stuck high - button Carry out any pinpoint tests associated with this DTC
Pull Switch stuck in active position using the manufacturer approved diagnostic system.
Check for stuck right front unlock switch. Refer to the
electrical circuit diagrams and check right front unlock
B10C400 Right Rear Unlock No subtype information Carry out any pinpoint tests associated with this DTC
Pull Switch using the manufacturer approved diagnostic system
B10C424 Right Rear Unlock Signal stuck high - button Carry out any pinpoint tests associated with this DTC
Pull Switch stuck in active position using the manufacturer approved diagnostic system.
Check for stuck right rear unlock switch. Refer to the
electrical circuit diagrams and check right front unlock
B10C524 Trunk Unlock Pull Signal stuck high - button Carry out any pinpoint tests associated with this DTC
Check for stuck luggage compartment lid unlock switch.
luggage compartment lid unlock switch circuit for short
to ground
B10C61F Exterior Trunk Circuit intermittent - Carry out any pinpoint tests associated with this DTC
Antenna general electrical error using the manufacturer approved diagnostic system.
Refer to the electrical circuit diagrams and check exterior
luggage compartment antenna circuits for short to
B10C71F Interior Trunk Circuit intermittent - Carry out any pinpoint tests associated with this DTC
Refer to the electrical circuit diagrams and check interior
luggage compartment antenna circuits for short to
B10C81F Interior Center Circuit intermittent - Carry out any pinpoint tests associated with this DTC
center antenna circuits for short to ground, power, open
circuit
B10C91F Interior Front Circuit intermittent - Carry out any pinpoint tests associated with this DTC
front antenna circuits for short to ground, power, open
circuit
B10CA1F Left Rear Door Circuit intermittent - Carry out any pinpoint tests associated with this DTC
Handle Antenna general electrical error using the manufacturer approved diagnostic system.
rear door handle antenna circuits for short to ground,
power, open circuit
B10CB1F Right Rear Door Circuit intermittent - Carry out any pinpoint tests associated with this DTC
Handle Antenna general electrical error using the manufacturer approved diagnostic system.
rear door handle antenna circuits for short to ground,
power, open circuit
B10CC24 Left Front Latch Signal stuck high - button Check for stuck left front door latch clutch switch. Refer
Clutch Switch stuck in active position to the electrical circuit diagrams and check left front
door latch clutch switch circuit for short to ground
B10CD24 Left Rear Latch Signal stuck high - button Check for stuck left rear door latch clutch switch. Refer
Clutch Switch stuck in active position to the electrical circuit diagrams and check left rear door
latch clutch switch circuit for short to ground
B10CE24 Right Front Latch Signal stuck high - button Check for stuck right front door latch clutch switch. Refer
Clutch Switch stuck in active position to the electrical circuit diagrams and check right front
B10CF24 Right Rear Latch Signal stuck high - button Check for stuck right rear door latch clutch switch. Refer
Clutch Switch stuck in active position to the electrical circuit diagrams and check right rear
B10D124 Left Front Lock Signal stuck high - button Check for stuck left front door handle lock switch. Refer
Button stuck in active position to the electrical circuit diagrams and check left front
door handle lock switch circuit for short to ground
B10D224 Left Rear Lock Button Signal stuck high - button Check for stuck left rear door handle lock switch. Refer
stuck in active position to the electrical circuit diagrams and check left rear door
handle lock switch circuit for short to ground
B10D324 Right Front Lock Signal stuck high - button Check for stuck right front door handle lock switch. Refer
Button stuck in active position to the electrical circuit diagrams and check right front
B10D424 Right Rear Lock Signal stuck high - button Check for stuck right rear door handle lock switch. Refer
Button stuck in active position to the electrical circuit diagrams and check left front
U001000 Medium Speed CAN No subtype information Carry out any pinpoint tests associated with this DTC
Communication Bus using the manufacturer approved diagnostic system.
Carry out CAN network integrity test using the
W ith Body Control using the manufacturer approved diagnostic system.
Module Carry out CAN network integrity test using the
supplies to CJB
U014200 Lost Communication Missing message from RJB Carry out any pinpoint tests associated with this DTC
W ith Body Control using the manufacturer approved diagnostic system.
Module "B" Carry out CAN network integrity test using the
supplies to RJB
W ith Instrument instrument cluster using the manufacturer approved diagnostic system.
Panel Cluster (IPC) Carry out CAN network integrity test using the
Control Module manufacturer approved diagnostic system. Refer to the
supplies to instrument cluster
U030000 Internal Control Invalid configuration Re-configure the RJB using the manufacturer approved
Module Software message is received diagnostic system. Clear the DTC and retest. If the DTC
Incompatibility is still logged suspect the remote keyless entry module,
refer to the new module installation note at the top of
the DTC Index
U201F00 External Receiver No subtype information - Suspect the RF receiver, check and install a new RF
communication error receiver as required, refer to the new module/component
U201F13 External Receiver Line open Refer to the electrical circuit diagrams and test RF
receiver communication circuit to remote keyless entry
module for short to ground or open circuit
U201F87 External Receiver Transmission error Refer to the electrical circuit diagrams and check the
data line between the RF receiver and the remote
keyless entry module for short, open circuit. Suspect the
RF receiver or remote keyless entry module, check and
install a new RF receiver or remote keyless entry module
U210000 Initial Configuration No subtype information Configure the Remote Keyless Entry module using the
Not Complete manufacturer approved diagnostic system
U210100 Control Module No subtype information Re-configure the RJB using the manufacturer approved
Configuration diagnostic system
Incompatible
U300049 Control Module Internal electronic failure Install a new remote keyless entry module, refer to the
new module installation note at the top of the DTC
Index
U300281 Vehicle Identification Vehicle/component Install correct/new module to vehicle specification, refer
Number mis-match. Module to the new module/component installation note at the
previously installed to top of the DTC Index
other vehicle
U300362 Battery Voltage Mis-match in battery Carry out any pinpoint tests associated with this DTC
voltage, of 2 volts or more, using the manufacturer approved diagnostic system
between remote keyless
entry module and RJB
Multifunction Electronic Modules - Passenger Door Module (PDM)

For a detailed description of the multifunction electronic control modules, refer to the relevant Description and Operation
sections in the workshop manual. REFER to: (419-10 Multifunction Electronic Modules)

vehicle.
Visual Inspection
Electrical
Fuse(s)
W iring Harness
DTC Index

locking motor motor control circuit - short to door double locking motor control circuit for short
ground ground
double locking motor control circuit - short to passenger door double locking motor control circuit
passenger door double locking motor control circuit
for short to power or open circuit
B10ED11 Rear door driver Rear door driver side double Refer to the electrical circuit diagrams and test rear
side double locking locking motor control circuit - door driver side double locking motor control circuit
motor short to ground for short ground
side double locking locking motor control circuit - using the manufacturer approved diagnostic system.
motor short to power, open circuit Refer to the electrical circuit diagrams and test rear
door driver side double locking motor control circuit
for short power, open circuit
B10EE11 Rear door Rear door passenger side Refer to the electrical circuit diagrams and test rear
passenger side double locking motor control door passenger side double locking motor control
double locking circuit - short to ground circuit for short ground
motor
double locking circuit - short to power, open Refer to the electrical circuit diagrams and test rear
motor circuit door passenger side double locking motor control
circuit for short power, open circuit
B110911 Passenger door Passenger door central locking Refer to the electrical circuit diagrams and test
central locking motor control circuit - short to passenger door central locking motor control circuit
B110915 Passenger door Passenger door central locking Refer to the electrical circuit diagrams and test
central locking motor control circuit - short to passenger door central locking motor control circuit
motor power, open circuit for short to power, open circuit
B110B11 Rear door Rear passenger door central Refer to the electrical circuit diagrams and test rear
passenger side locking motor control circuit - passenger door central locking motor control circuit
central locking short to ground for short ground
motor
B110B15 Rear door Rear passenger door central Refer to the electrical circuit diagrams and test rear
passenger side locking motor control circuit - passenger door central locking motor control circuit
central locking short to power, open circuit for short to power, open circuit
motor
B116311 Left Mirror Heater Left mirror heater control circuit Refer to the electrical circuit diagrams and test left
Output - short to ground mirror heater control circuit for short to ground
B116315 Left Mirror Heater Left mirror heater control circuit Carry out any pinpoint tests associated with this DTC
Output - short to power, open circuit using the manufacturer approved diagnostic system.
Refer to the electrical circuit diagrams and test left
circuit
B116411 Right Mirror Heater Right mirror heater control Refer to the electrical circuit diagrams and test right
Output circuit - short to ground mirror heater control circuit for short to ground
B116415 Right Mirror Heater Right mirror heater control Carry out any pinpoint tests associated with this DTC
Output circuit - short to power, open using the manufacturer approved diagnostic system.
circuit
B116511 Left Front Puddle Left front puddle lamp control Refer to the electrical circuit diagrams and test left
B116515 Left Front Puddle Left front puddle lamp control Carry out any pinpoint tests associated with this DTC
circuit Refer to the electrical circuit diagrams and test left
open circuit
B116611 Right Front Puddle Right front puddle lamp control Refer to the electrical circuit diagrams and test right
B116615 Right Front Puddle Right front puddle lamp control Carry out any pinpoint tests associated with this DTC
open circuit
B117C07 Rear Power Window Mechanical failure Check rear window mechanism for mechanical failure
Up
B117C72 Rear Power Window Actuator stuck open Suspect the rear door module. Check and install a
DTC Index
B117C73 Rear Power Window Actuator stuck closed Suspect the rear door module. Check and install a
DTC Index
B117C92 Rear Power Window Performance or incorrect Refer to the electrical circuit diagrams and check rear
Up operation door module power and ground supplies
B117D72 Rear Power Window Actuator stuck open Suspect the rear door module. Check and install a
DTC Index
B117D73 Rear Power Window Actuator stuck closed Suspect the rear door module. Check and install a
DTC Index
B117E07 Front Power Mechanical failure Check the front window mechanism for mechanical
W indow Up failure
B117E72 Front Power Actuator stuck open Suspect the PDM. Check and install a new PDM as
B117E73 Front Power Actuator stuck closed Suspect the PDM. Check and install a new PDM as
B117F72 Front Power Actuator stuck open Suspect the PDM. Check and install a new PDM as
B117F73 Front Power Actuator stuck closed Suspect the PDM. Check and install a new PDM as
B118929 Front W indow Front window hall position Carry out any pinpoint tests associated with this DTC
B118A29 Rear Window Rear window hall position Carry out any pinpoint tests associated with this DTC
B11D183 LIN Bus Circuit "C" Value of signal protection Suspect driver switchpack. Check and install a new
calculation incorrect driver switchpack as required, refer to the new
DTC Index
B11D186 LIN Bus Circuit "C" Signal invalid Suspect driver switchpack. Check and install a new
DTC Index
B11D187 LIN Bus Circuit "C" Missing message Suspect driver switchpack. Check and install a new
DTC Index
B11F711 Passenger Folding Passenger folding mirror motor Refer to the electrical circuit diagrams and check
Mirror Motor control circuit - short to ground passenger folding mirror motor control circuit for
short to ground
B11F715 Passenger Folding Passenger folding mirror motor Carry out any pinpoint tests associated with this DTC
Mirror Motor control circuit - short to power, using the manufacturer approved diagnostic system.
passenger folding mirror motor control circuit for
B1A9883 LIN Bus Circuit #1 Value of signal protection Refer to the electrical circuit diagrams and check LIN
calculation incorrect circuit between DDM and rear door module for
short/open circuits
B1A9886 LIN Bus Circuit #1 Signal invalid Carry out any pinpoint tests associated with this DTC
short/open circuits
B1A9887 LIN Bus Circuit #1 Missing message Carry out any pinpoint tests associated with this DTC
short/open circuits
B1C1111 Passenger Passenger left/right mirror Refer to the electrical circuit diagrams and test
Left/Right Mirror motor control circuit - short to passenger left/right mirror motor control circuit for
Motor Circuit ground short to ground
B1C1115 Passenger Passenger left/right mirror Carry out any pinpoint tests associated with this DTC
Left/Right Mirror motor control circuit - short to using the manufacturer approved diagnostic system.
Motor Circuit power, open circuit Refer to the electrical circuit diagrams and test
passenger left/right mirror motor control circuit for
B1C1211 Passenger Up/Down Passenger up/down mirror Refer to the electrical circuit diagrams and test
Mirror Motor Circuit motor control circuit - short to passenger up/down mirror motor control circuit for
B1C1215 Passenger Up/Down Passenger up/down mirror Carry out any pinpoint tests associated with this DTC
Mirror Motor Circuit motor control circuit - short to using the manufacturer approved diagnostic system.
power, open circuit Refer to the electrical circuit diagrams and test
passenger up/down mirror motor control circuit for
Mirror Motor motor feedback circuit - short passenger up/down mirror motor feedback circuit for
Feedback Circuit to ground short to ground
Mirror Motor motor feedback circuit - short passenger up/down mirror motor feedback circuit for
Feedback Circuit to power, open circuit short to power, open circuit
Left/Right Mirror motor feedback circuit - short passenger left/right mirror motor feedback circuit for
Motor Feedback to ground short to ground
Circuit
Left/Right Mirror motor feedback circuit - short passenger left/right mirror motor feedback circuit for
Motor Feedback to power, open circuit short to power, open circuit
Circuit
B1D0611 Left Turn Indicator Left side turn indicator repeater Refer to the electrical circuit diagrams and check left
lamp circuit - short to ground side turn indicator repeater lamp circuit for short to
ground
B1D0615 Left Turn Indicator Left side turn indicator repeater Carry out any pinpoint tests associated with this DTC
lamp circuit - short to power, using the manufacturer approved diagnostic system.
open circuit Refer to the electrical circuit diagrams and check left
side turn indicator repeater lamp circuit for short to
power, open circuit
ground ground
power, open circuit power, open circuit
C1B1411 Sensor Supply #1 Front window position hall Refer to the electrical circuit diagrams and test front
sensor supply circuit - short to window position hall sensor supply circuit for short to
ground ground
C1B1415 Sensor Supply #1 Front window position hall Carry out any pinpoint tests associated with this DTC
sensor supply circuit - short to using the manufacturer approved diagnostic system.
power, open circuit Refer to the electrical circuit diagrams and test front
window position hall sensor supply circuit for short to
power, open circuit
C1B1511 Sensor Supply #2 Hall sensor supply circuit - Refer to the electrical circuit diagrams and test
short to ground window position hall sensors supply circuit for short
to ground
C1B1515 Sensor Supply #2 Hall sensor supply circuit - Carry out any pinpoint tests associated with this DTC
Refer to the electrical circuit diagrams and test
W ith Body Control using the manufacturer approved diagnostic system
Module
U020800 Lost Communication Missing message from driver Carry out any pinpoint tests associated with this DTC
W ith Seat Control seat module using the manufacturer approved diagnostic system
Module "A"
U030000 Internal Control Invalid configuration message Re-configure the RJB using the manufacturer
Module Software is received approved diagnostic system. Clear the DTC and
Incompatibility retest. If the DTC remains suspect the PDM. Check
and install a new module as required, refer to the
new module/component installation note at the top
of the DTC Index
passenger side window switch. Check and install a
new passenger side window switch
U200424 Auxiliary Switch Left or right rear door local Check for stuck rear window switch. Refer to the
Pack switch - signal stuck high electrical circuit diagrams and check left or right rear
door local switch circuit for short circuit
U201011 Switch illumination Rear window switch illumination Refer to the electrical circuit diagrams and check rear
circuit - short to ground window switch illumination circuit for short to ground
U201208 Car Configuration Bus signal/message failures Cycle the ignition status and re-test. If DTC remains,
Parameter(s) re-configure the RJB using the manufacturer approved
diagnostic system
U201324 Switch Pack Signal stuck high Clear DTC and re-test. If DTC remains, install a new
driver door switch pack
U201444 Control Module Data memory failure Suspect the PDM. Check and install a new PDM as
Hardware required, refer to the new module/component
U210000 Initial Configuration No sub type information Re-configure the PDM using the manufacturer
Not Complete approved diagnostic system
U300049 Control Module Internal electronic failure Suspect the PDM. Check and install a new PDM as
U300255 Vehicle Not configured Re-configure the PDM as new using the manufacturer
Identification approved diagnostic system and re-test. If DTC
Number remains install a new module, refer to the new
DTC Index
U300281 Vehicle Vehicle/component mis-match. Check and install correct/new module as required,
Identification Corrupt VIN data being refer to the new module/component installation note
Number (VIN) transmitted, module previously at the top of the DTC Index
U300362 Battery voltage Mis-match in battery voltage, of Carry out any pinpoint tests associated with this DTC
2 volts or more, between PDM using the manufacturer approved diagnostic system
and RJB
Multifunction Electronic Modules - Driver Door Module (DDM)
Removal

2. Refer to: Front Door Trim Panel (501-05 Interior Trim and
3.
Installation

Multifunction Electronic Modules - Driver Seat Module (DSM)
Removal
1. Make the air bag supplemental restraint system (SRS) safe.

3.
Installation

Multifunction Electronic Modules - Passenger Door Module (PDM)
Removal

3.
Installation

Multifunction Electronic Modules - Rear Door Module (RDM)
Removal

2. Refer to: Rear Door Trim Panel (501-05 Interior Trim and
3. Torque: 1.5 Nm
Installation

Front End Body Panels -
Air deflector retaining nuts 7 - 62
Air deflector retaining bolts 7 - 62
Engine rear undershield retaining bolts 7 - 62
Secondary bulkhead left-hand panel retaining bolts 5 - 44
Secondary bulkhead right-hand panel retaining bolts 5 - 44
Front End Body Panels - Air Deflector
Removal

2. 2. NOTE: Note the fitted position of the washers.
Torque: 7 Nm
Installation

Front End Body Panels - Cowl Vent Screen
Removal
CAUTION: Always protect paintwork and glass when removing exterior components.
1. For additional information, refer to: Windshield Wiper Pivot

Arm (501-16, Removal and Installation).
2.
3.
4.
5.
Installation
Front End Body Panels - Engine Rear Undershield
Removal

stands.
2. Torque: 7 Nm
Installation

Front End Body Panels - Fender Splash Shield
Removal

stands.
Installation).
3.
Installation

Front End Body Panels - Radiator Splash Shield
Removal
2.
Installation

Front End Body Panels - Secondary Bulkhead Center Panel
Removal
and Installation).
2.

Installation

Front End Body Panels - Secondary Bulkhead Panel LH2.7L V6 - TdV6/3.0L
Removal
All vehicles
2.
Torque: 25 Nm
3.

4.
5.
Torque: 7 Nm
All vehicles
6.
Torque: 5 Nm
Installation

Front End Body Panels - Secondary Bulkhead Panel RH2.7L V6 - TdV6/3.0L
Removal
All vehicles
and Installation).
3. Torque: 25 Nm
4.
5.
6.
7.
8. Refer to: Air Cleaner RH (303-12 Intake Air Distribution and Filtering
- 4.2L, Vehicles W ith: Supercharger, Removal and Installation).
9.
All vehicles
10.
Installation

Body Closures - Front Door
Removal
1. NOTE: The front door is manufactured from mild steel, it
contains a side impact reinforcement manufactured from boron
steel.
The front door is serviced as a separate bolt-on panel.
2. For additional information relating to this repair procedure

please see the following:
For additional information, refer to: Health and Safety
Precautions (100-00 General Information, Description and
Operation) /
Body Repairs (501-25A Body Repairs - General Information,
Description and Operation) /
Corrosion Protection (501-25B Body Repairs - Corrosion
Protection, Description and Operation) /
Body and Frame (501-26 Body Repairs - Vehicle Specific
Information and Tolerance Checks, Description and Operation).
3. NOTE: If the procedure includes removal of the front door
components, the battery can remain connected to aid their
removal and disconnected afterwards.

Procedures).
4. NOTE: For new front door installation, this step may be carried
out later in the removal procedure.
Disconnect the front door wiring harness, accessed behind the

grommet on the A-pillar.
5. NOTE: For new front door installation, this step may be carried
Release the front door check strap from the body.

6. NOTE: This step is for removing the fully trimmed front door
for access only, for installing a new front door, continue to
removal step 7.
Remove the front door upper and lower hinge pivot bolts and
lift the front door to remove.
7. Remove the front door window regulator and motor.
For additional information, refer to: Front Door Window
Regulator and Motor (501-11 Glass, Frames and Mechanisms,
8. Remove the exterior mirror.
For additional information, refer to: Exterior Mirror (501-09
Rear View Mirrors, Removal and Installation).
9. Remove the front door latch.
For additional information, refer to: Front Door Latch (501-14
Handles, Locks, Latches and Entry Systems, Removal and
Installation).
10. Remove the front door outer window frame mouldings.
11. Remove the front door weatherstrips.
12. Remove the front door wiring harness.
13. Remove the front door impact absorbers.
14. Remove the front door check strap.
15. Remove the front door glass run felt.
16. Remove any miscellaneous front door clips, grommets and
blanking covers.
17. NOTE: If new hinges are being installed, install the
complete hinges to the A-pillar. To align the hinges at the
A-pillar it will be necessary to remove the front fender.
Remove the upper and lower front door hinge fixing bolts
and remove the front door.
Installation
1. NOTE: If the front door has been removed for access only, it
can be installed back on to its upper and lower hinge pivots and
secured with the upper and lower hinge pivot bolts.
Offer up the front door and loosely install the front door hinge
bolts.
2. Check alignment, if correct, proceed to next step, if not, rectify
and recheck before proceeding.
3. Tighten the front door hinge bolts to 30 Nm.
4. When correctly aligned and with the front door hinge bolts
tightened, the new front door can be removed at its upper and
lower hinge pivot bolts for refinishing.
5. NOTE: Install the front door upper frame weatherstrip prior to

installing the front door.
The installation of associated panels and components is the

reversal of removal procedure.
Tighten the front door upper and lower hinge pivot bolts
to 30 Nm.
Body Closures - Fuel Filler Door
Removal
CAUTION: Do not align the bowl using the hinge arm.
1.

avoid damage.
Release the clip.
Installation

Body Closures - Fuel Filler Door Assembly
Removal
CAUTION: Do not align the bowl using the hinge arm.

2. Refer to: Fuel Tank Filler Pipe (310-01, Removal and Installation).
3.
4.
5.

avoid damage.

Release the clip.
Installation

Body Closures - Luggage Compartment Lid
Removal
1. NOTE: The luggage compartment lid is manufactured from
mild steel.
The luggage compartment lid is serviced as a separate

bolt-on panel, less its hinges.

Operation) /
Procedures).
4. Remove the loadspace trim panel RH.
Installation).
5. Disconnect the luggage compartment lid wiring harness.
Remove the luggage compartment lid.

Remove the luggage compartment lid moulding.

For additional information, refer to: Luggage Compartment Lid
Moulding (501-08 Exterior Trim and Ornamentation, Removal
and Installation).
8. Remove the luggage compartment lid latch actuator.
Latch Actuator (501-14 Handles, Locks, Latches and Entry
Systems, Removal and Installation).
9. Remove both rear fog lamps.
For additional information, refer to: Rear Fog Lamp (417-01
Exterior Lighting, Removal and Installation).
10. Remove both luggage compartment lid buffers.
11. Remove the luggage compartment lid wiring harness.
W iring Harness (418-02 Wiring Harnesses, Removal and
Installation).
12. NOTE: W here it is not practical to re-use the luggage
compartment lid badges, they should be renewed, therefore
removal is not required.
Remove the luggage compartment lid badges.
Installation
Offer up the panel and loosely install the luggage compartment

lid hinge retaining nuts.
2. Check alignment, if correct, proceed to next step, if not rectify
3. Tighten the luggage compartment lid hinge retaining nuts to
25 Nm.
4. The installation of associated panels and components is the
Body Closures - Rear Door
Removal
1. NOTE: The rear door is manufactured from mild steel, it
contains a side impact reinforcement manufactured from boron
steel.
The rear door is serviced as a separate bolt-on panel.

Operation) /
3. NOTE: If the procedure includes removal of the rear door
components, the battery can remain connected to aid their
removal and disconnected afterwards.

Procedures).
4. NOTE: For new rear door installation, this step may be carried
Disconnect the rear door wiring harness, accessed behind the

grommet on the B-pillar.
5. NOTE: For new rear door installation, this step may be carried
Release the rear door check strap from the body.

6. NOTE: This step is for removing the fully trimmed rear door for
access only, for installing a new front door, continue to removal
step 7.
Remove the rear door upper and lower hinge pivot bolts and lift
the rear door to remove.
7. Remove the rear door fixed window glass.
For additional information, refer to: Rear Door Fixed W indow
Glass (501-11 Glass, Frames and Mechanisms, Removal and
Installation).
8. Remove the rear door latch.
For additional information, refer to: Rear Door Latch (501-14
Handles, Locks, Latches and Entry Systems, Removal and
Installation).
9. Remove the rear door outer window frame mouldings.
10. Remove the rear door weatherstrips.
11. Remove the rear door wiring harness.
12. Remove the rear door impact absorbers.
13. Remove the rear door check strap.
14. Remove the rear door glass run felt.
15. Remove any miscellaneous rear door clips, grommets and
blanking covers.
16. NOTE: If new hinges are being fitted, install the complete
hinges to the B-pillar.
Remove the upper and lower rear door hinge bolts and
remove the rear door.
Installation
1. NOTE: If the rear door has been removed for access only, it
can be installed back on to its upper and lower hinge pivots and
secured with the upper and lower hinge pivot bolts.
Offer up the rear door and loosely install the rear door hinge
bolts.
2. Check alignment, if correct, proceed to next step, if not, rectify
3. Tighten the rear door hinge bolts to 30 Nm.
4. When correctly aligned and with the rear door hinge bolts
tightened, the new rear door can be removed at its upper and
lower hinge pivot bolts for refinishing.
5. The installation of associated panels and components is the

Tighten the rear door upper and lower hinge pivot bolts to
30 Nm.
Interior Trim and Ornamentation -
Front Safety belt shoulder height adjuster retaining bolt 25 19 -
Rear safety belt lower retaining bolt 40 30 -
Interior Trim and Ornamentation - A-Pillar Trim Panel
Removal
1.
2.
3. Torque: 6 Nm
4.
Installation

Interior Trim and Ornamentation - B-Pillar Lower Trim Panel
Removal
1. Refer to: Front Scuff Plate Trim Panel (501-05 Interior Trim and
2. Refer to: Rear Scuff Plate Trim Panel (501-05 Interior Trim and
3.
4. 4. CAUTION: Make sure that the clips are correctly

located.
Installation

Interior Trim and Ornamentation - B-Pillar Upper Trim Panel
Removal
2.
3.
4. Torque: 40 Nm
5.
6.
7. Torque: 6 Nm
8.
9.
10. 10. WARNING: Failure to follow this instruction
may cause damage to the vehicle.
CAUTION: Make sure the locating dowels are

installed correctly.
11. 11. CAUTION: Make sure that these components

are installed to the noted removal position.
Installation

Interior Trim and Ornamentation - C-Pillar Lower Trim Panel
Removal

2.
3.
4.
5.
6. Torque: 40 Nm
7. 7. CAUTIONS:
Note the fitted position of the component prior to

removal.
Make sure that these components are installed to

Torque: 9 Nm
8. 8. CAUTION: Make sure the locating dowels are
installed correctly.
Installation

Interior Trim and Ornamentation - C-Pillar Trim Panel
Removal
1.
2.
3.
4. 4. CAUTIONS:
Make sure the locating dowels are installed

correctly.
Torque: 6 Nm
Installation

Interior Trim and Ornamentation - Cowl Side Trim Panel
Removal
1. Refer to: Front Scuff Plate Trim Panel (501-05 Interior Trim and
3.
LH side only: Remove the hood release lever.
Installation

Interior Trim and Ornamentation - Engine Cover4.2L NA V8 - AJV8
Removal
1. Remove the oil filler cap.
Installation
1. CAUTION: Correct installation of the oil filler cap can be

obtained by tightening the cap until an audible click is heard.

Interior Trim and Ornamentation - Engine CoverTDV6 2.7L Diesel
Removal
1. Remove the oil filler cap.
Installation
1. CAUTION: Correct installation of the oil filler cap can be obtained

by tightening the cap until an audible click is heard.

Interior Trim and Ornamentation - Engine Cover4.2L SC V8 - AJV8
Removal
1.
Release the clips.
Installation

Interior Trim and Ornamentation - Front Door Trim Panel
Removal
1.
2.
3.
4. 4. NOTE: Do not disassemble further if the component is
5.
6.
7.
8.
Installation

Interior Trim and Ornamentation - Front Scuff Plate Trim Panel
Removal

Installation

Interior Trim and Ornamentation - Instrument Panel Speaker Grille
Removal

2. 2. CAUTIONS:
3.


Torque: 2 Nm
Installation
Interior Trim and Ornamentation - Headliner
Removal

2. Refer to: Interior Rear View Mirror (501-09 Rear View Mirrors,
3. Refer to: Overhead Console (501-12 Instrument Panel and Console,

4.
Remove both sun visors.
Refer to: Sun Visor (501-05 Interior Trim and Ornamentation,

5.
Remove both A-pillar trim panels.
Refer to: A-Pillar Trim Panel (501-05 Interior Trim and

6.
Remove both B-pillar upper trim panels.
Refer to: B-Pillar Upper Trim Panel (501-05 Interior Trim and
7.
Remove both C-pillar trim panels.
Refer to: C-Pillar Trim Panel (501-05 Interior Trim and

8.
Remove both front seats.
Refer to: Front Seat (501-10 Seating, Removal and

Installation).
9. Refer to: Rear Seat Cushion (501-10 Seating, Removal and

Installation).
10. Torque: 2 Nm
11.
12.
13.
Vehicles with roof opening panel
14. 14. NOTE: Note the different lengths of screws.
NOTE: Make sure that the component is installed to

the position noted on removal.
Torque: 2 Nm
Vehicles without roof opening panel

15. 15. NOTE: Note the different lengths of screws.

Torque: 2 Nm
All vehicles
16.
17.
another technician.

another technician.
CAUTIONS:
Note the fitted position of the component prior to

removal.
Make sure that these components are installed to



another technician.
Installation

Interior Trim and Ornamentation - Loadspace Scuff Plate Trim Panel
Removal
1.
2.
Installation

Interior Trim and Ornamentation - Loadspace Trim Panel
Removal
1.
2.
3.
Installation

Interior Trim and Ornamentation - Loadspace Trim Panel LH
Removal
1. Refer to: Loadspace Trim Panel (501-05 Interior Trim and

3.
4.
Installation

Interior Trim and Ornamentation - Loadspace Trim Panel RH
Removal
1. Refer to: Loadspace Trim Panel (501-05 Interior Trim and

3.
Installation

Interior Trim and Ornamentation - Luggage Compartment Lid Trim Panel
Removal
1.
2.
3.
Installation

Interior Trim and Ornamentation - Parcel Shelf
Removal

2. Torque: 12 Nm
3.
4.
5.
6. 6. NOTE: The procedure must be carried out on both

sides of the seat.
7. 7. NOTE: The procedure must be carried out on both
sides of the seat.
Torque: 6 Nm
8.
9.
10. 10. NOTE: On installation, use a suitable tool to make

sure that the parcel shelf is located underneath the
rear window blind.
12.
13.
14.
15.
16.
Installation

Interior Trim and Ornamentation - Rear Door Trim Panel
Removal
1.
2.
3.
4.
5.
6.

8.
9.
10.
11.
12.
13.
Installation

Interior Trim and Ornamentation - Rear Scuff Plate Trim Panel
Removal
1. 1. CAUTION: Make sure that the clips are correctly

located.
Installation

Interior Trim and Ornamentation - Sun Visor
Removal
1. CAUTION: Take extra care not to damage the edges of

the component.
2. TORQUE: 2 Nm
3.
Installation
Exterior Trim and Ornamentation -
Luggage compartment lid moulding retaining nuts 3 - 26
Exterior Trim and Ornamentation - Radiator Grille
Removal

Installation).
2.
3. 3. NOTE: Note the fitted position of the locating pegs.
Installation

Exterior Trim and Ornamentation - Luggage Compartment Lid Moulding
Removal
1. Refer to: Luggage Compartment Lid Trim Panel (501-05 Interior Trim
2.
3. Torque: 3 Nm
4.
6.
7.
Installation

Rear View Mirrors - Rear View Mirrors - Component Location
NOTE: LHD (left-hand drive) shown RHD (right-hand drive) similar
ItemDescription
1 Passenger door mirror
2 Passenger door control module
3 Interior mirror
4 Drivers door control module
5 Mirror control switch
6 Drivers door mirror
Rear View Mirrors - Rear View Mirrors - Overview
Overview
The exterior mirrors incorporate the following:
Blind spot monitoring indicator

Auto dimming function
Approach lamps
Exterior temperature sensor
Heated mirror function
Reverse dipping function
Movement of the door mirrors is controlled from a switch pack located on the drivers door. The switch pack contains 2
non-latching mirror select buttons labeled 'L' and 'R' and a 4-way mirror movement switch. Door mirror movement
commands are transmitted to the driver's door module over the LIN (local interconnect network) bus. The drivers door
module transmits any mirror movement commands to the passenger door module over the medium speed CAN (controller
area network) bus.
Movement of the door mirrors is carried out by the respective door module. The door modules provide supply and ground
paths to the mirror motors and monitor mirror position via potentiometers located in the mirror housings.
Both exterior door mirrors and the interior mirror feature an auto dimming function. The interior rear view mirror contains
one forward and one reward facing light sensor. The light sensors control the auto dimming feature of the interior mirror to
reduce glare from the headlights of following vehicles.
When auto-dimming of the interior mirror is required, a supply is provided by the interior mirror to both door mirrors to
initiate the door mirror auto-dimming sequence.
Blind spot monitoring function alerts the driver to a vehicle located in the vehicle blind spot. A warning indicator is located
in each exterior mirror towards the outer edge.
Refer to: Blind Spot Monitoring System (413-09, Description and Operation).
Rear View Mirrors - Rear View Mirrors - System Operation and Component
Description
Control Diagram
NOTE: A = Hardwired, N = Medium speed CAN (controller area network) bus, O = LIN (local interconnect network) bus
ItemDescription
2 RH (right-hand) door module
3 RH door mirror
4 LH (left-hand)side door mirror
5 Interior mirror
6 Battery
8 LH door module
9 Exterior mirror control switches
System Operation
The rear view mirrors comprise an interior mirror mounted to the windshield, and an exterior mirror mounted on each front
door cheater. The types of mirrors and associated operating functions installed depend on the specification and trim level
of the vehicle.
Interior Mirrors
The interior rear view mirror is provided as a manual dimming or an electrically operated automatic dimming type.
The manual dimming mirror comprises a prismatic glass housed within a surrounding case that is attached with a ball joint
connector to the mirror stem. Manual dimming of the mirror is achieved using the lever mounted on the underside of the
mirror body. Operating the lever will tilt the mirror head from the 'day' position to the 'night' position.
The automatic dimming mirror comprises an electro-chromatic glass housed within a surrounding case that is attached with
a ball joint connector to the mirror stem. The mirror stem incorporates an 8-pin electrical connector that is connected to
the roof panel wiring harness. The wiring harness provides hardwired and a LIN connection to the CJB.
Light sensors are mounted on the front and rear of the mirror surround case. The sensors control the automatic dimming
feature to reduce glare from the headlights of following vehicles.
The automatic dimming function is permanently active when the ignition is in power mode 4 (Accessory) and power mode 6
(Ignition). The forward facing light sensor monitors the ambient light level at the front of the vehicle; the rearward facing
light sensor monitors the light level coming from the rear of the vehicle. W hen light from the rear of the vehicle exceeds
the ambient light level from the front of the vehicle, the automatic dimming circuit darkens the interior mirror surface.
Automatic dimming is inhibited when reverse gear is selected to provide the driver with maximum vision. On vehicles with
automatic transmission, the reverse gear signal is provided by the TCM (transmission control module) via the high speed
CAN bus to the CJB. The CJB then provides a power feed to the mirror. On vehicles with manual transmission, the reverse
gear signal is provided by a transmission switch that is hardwired to the CJB.
Exterior Mirrors
Electrically operated and heated exterior mirrors are installed as standard. Depending on the specification and trim level of
the vehicle, the following options are available:
Power fold (switch pack operated feature) and auto fold (remote handset operated feature)
Memory recall
Reverse gear mirror dip
Mirror heating
Exterior mirror lamps.
The power fold/auto fold feature is available only when power fold mirrors are installed to the vehicle.
The mirrors can be configured to automatically fold when the vehicle is locked and unfold when unlocked. This feature can
be enabled or disabled via the Vehicle settings area of the touch screen:
Select 'Vehicle' from the touch screen Home menu.

The Security menu is displayed as the default. Scroll down through the menu until the desired Mirror fold back is
displayed.
Select 'On' or 'Off' as appropriate.
The auto fold and reverse gear mirror dip functions are not customer configurable, but may be enabled or disabled by the
dealer using the Jaguar approved diagnostic system. The diagnostic system enables or disables either or both functions by
setting the EEPROM (electrically erasable programmable read only memory) contained within the instrument cluster.
The LH door mirror incorporates an ambient air temperature sensor that is hardwired to the ECM (engine control module).
The ECM is connected to the CJB and other control modules via the high speed CAN bus. The sensor provides information
to the ECM that is then transmitted on the medium speed CAN bus for use by other control modules. On vehicles installed
with a high-line instrument cluster, the CJB transmits the temperature signal to the instrument cluster that provides a
display of the ambient temperature to the driver.
The exterior mirror lamps are controlled by the interior lighting function.
The door mirrors are controlled using a switch pack located on the driver's door. The switch pack contains 2 non-latching
mirror select switches labeled 'L' and 'R' and a 4-way directional joystick. The switch pack is connected to the driver door
control module via the LIN bus. The driver and front passenger door control modules are connected via the medium speed
CAN bus. A hardwired connection between each door control module and the corresponding door mirror, provides the supply
and ground paths for the mirror motors.
Each exterior door mirror incorporates 2 motors to control horizontal (left/right) and vertical (up/down) adjustments.
On vehicles installed with a driver's power operated memory seat and memory exterior mirrors, a potentiometer is
incorporated within each mirror motor and is used to provide information regarding the actual motor positions. The current
position and memory positions of each door mirror motor are maintained and stored within the corresponding door control
module.
The memory exterior mirror positions are also monitored and stored within door control module memory when the reverse
gear mirror dip function is used.
When reverse gear is selected, the door control modules store the current mirror positions and will then dip both the driver
and passenger mirror glass to a default dip position. While reverse gear is selected it is possible to store a preferred
dipped mirror position by adjusting the driver/passenger mirror glass to the desired position via the mirror switch pack.
When the desired position is achieved using the switches, the new dip positions will be automatically stored by the door
control modules when reverse gear is de-selected. Therefore when reverse gear is re-selected, the dip position recalled by
the door control modules will be the new reverse gear mirror dip stored position. When reverse gear is deselected the
mirror glass will automatically move to the previous stored position prior to reverse gear selection.
Reverse gear mirror dip is only available when memory mirrors are installed, and reverse gear mirror dip is enabled within
the instrument cluster.
If the driver selects a memory recall function using the memory seat switch pack, the driver's memory seat and exterior
memory mirrors are moved to a stored memory position.
Exterior mirrors with the power fold/auto fold feature incorporate a motor located in the hinge of each exterior mirror arm.
Operation of the power fold feature is achieved using the exterior mirror switch pack. Operation of the auto fold feature is
achieved using the remote handset.
The power fold function is active when the ignition is in power mode 6 (Ignition).
Both exterior mirrors will power fold when the mirror switch pack 'L' and 'R' switches are pressed together. Pressing the
switches again will unfold the mirrors.
When the instrument cluster is configured for the auto fold feature, the mirrors will fold in when the remote handset lock
button is pressed. The mirrors will unfold when the vehicle is unlocked using the remote handset unlock button.
NOTE: If the mirrors are folded in using the mirror switch pack (power fold) and the vehicle is then locked, subsequent
unlocking of the vehicle will not unfold the mirrors.
When the remote handset unlock button is operated, the CJB recognizes the remote handset for that vehicle and
acknowledges the request. The door control modules are connected directly to the AJB (auxiliary junction box) for power
supply to the exterior mirror folding motors.
When the vehicle is locked the door control modules reverse the polarity of the mirror fold motor, power and ground
connections to operate the mirrors in the opposite direction.
Exterior mirror heating is provided with heater elements bonded to the back of the mirror glass. Power supply for the mirror
heating elements is provided by the corresponding driver or passenger door control module via the RJB. The door control
modules receive a power supply from the RJB, and are both connected on the medium speed CAN bus to the ATC
(automatic temperature control) module. A ground terminal from each door control module completes the circuit. The ATC
module automatically controls the mirror heating function whenever the ignition is in power mode 4 (Accessory) and power
mode 6 (Ignition).
Operation of the exterior mirror heaters is fully automatic and not controllable by the driver. Exterior mirror heater
operation is determined by ambient air temperature and windshield wiper status. W hen ambient air temperature reaches a
pre-determined level, the ATC module broadcasts an exterior mirror heating request to the door modules over the medium
speed CAN bus. On receipt of this message, the door modules provide feed and ground connections to both exterior mirror
heater elements.
The mirror heating is controlled in two phases, the initial heating phase and a second PW M (pulse width modulation)
controlled phase. In the first phase the heater elements in the mirrors are permanently powered for a pre-determined
length of time. This length of time varies with the ambient temperature. During the second PW M phase, the heater
elements are turned on and off every 30 seconds. The amount of time the exterior mirror heaters are operational increases
if the windshield wipers are switched on. This ensures the mirrors remain mist free in damp and wet conditions, where
there is an increased risk of misting.
Rear View Mirrors - Rear View Mirrors
For a detailed description of the rear view mirrors and systems, refer to the relevant Description and Operation sections in
the workshop manual. REFER to: (501-09 Rear View Mirrors)
Rear View Mirrors (Description and Operation),

Rear View Mirrors (Description and Operation),
Rear View Mirrors (Description and Operation).
vehicle.
Visual Inspection
Exterior rear view mirror glass Fuse(s)
Relay(s)
Wiring Harness
DTC Index
leads into account.

B116311 Left Mirror Heater Left mirror heater control Refer to the electrical circuit diagrams and test left mirror
Output circuit - short to ground heater control circuit for short to ground
B116315 Left Mirror Heater Left mirror heater control Carry out any pinpoint tests associated with this DTC using
Output circuit - short to power, the manufacturer approved diagnostic system. Refer to the
open circuit electrical circuit diagrams and test left mirror heater control
B116411 Right Mirror Heater Right mirror heater Refer to the electrical circuit diagrams and test right mirror
Output control circuit - short to heater control circuit for short to ground
ground
B116415 Right Mirror Heater Right mirror heater Carry out any pinpoint tests associated with this DTC using
Output control circuit - short to the manufacturer approved diagnostic system. Refer to the
power, open circuit electrical circuit diagrams and test right mirror heater control
B11F711 Passenger Folding Passenger folding mirror Refer to the electrical circuit diagrams and check passenger
Mirror Motor motor control circuit - folding mirror motor control circuit for short to ground
short to ground
B11F715 Passenger Folding Passenger folding mirror Carry out any pinpoint tests associated with this DTC using
Mirror Motor motor control circuit - the manufacturer approved diagnostic system. Refer to the
short to power, open electrical circuit diagrams and check passenger folding mirror
circuit motor control circuit for short to power, open circuit
B1C0911 Driver Left/Right Driver left/right mirror Carry out any pinpoint tests associated with this DTC using
Mirror Motor Circuit motor control circuit - the manufacturer approved diagnostic system. Refer to the
short to ground electrical circuit diagrams and test driver left/right mirror
motor control circuit for short to ground
short to power, open electrical circuit diagrams and test driver left/right mirror
B1C1011 Driver Up/Down Driver up/down mirror Carry out any pinpoint tests associated with this DTC using
short to ground electrical circuit diagrams and test driver up/down mirror
motor control circuit for short to ground
short to power, open electrical circuit diagrams and test driver up/down mirror
B1C1111 Passenger Passenger left/right Refer to the electrical circuit diagrams and test passenger
Left/Right Mirror mirror motor control left/right mirror motor control circuit for short to ground
Motor Circuit circuit - short to ground
B1C1115 Passenger Passenger left/right Carry out any pinpoint tests associated with this DTC using
Left/Right Mirror mirror motor control the manufacturer approved diagnostic system. Refer to the
Motor Circuit circuit - short to power, electrical circuit diagrams and test passenger left/right
open circuit mirror motor control circuit for short to power, open circuit
B1C1211 Passenger Up/Down Passenger up/down Refer to the electrical circuit diagrams and test passenger
Mirror Motor Circuit mirror motor control up/down mirror motor control circuit for short to ground
B1C1215 Passenger Up/Down Passenger up/down Carry out any pinpoint tests associated with this DTC using
Mirror Motor Circuit mirror motor control the manufacturer approved diagnostic system. Refer to the
circuit - short to power, electrical circuit diagrams and test passenger up/down mirror
open circuit motor control circuit for short to power, open circuit
B1C1311 Driver Up/Down Driver up/down mirror Refer to the electrical circuit diagrams and test driver
Mirror Motor motor feedback circuit - up/down mirror motor feedback circuit for short to ground
Feedback Circuit short to ground
Mirror Motor motor feedback circuit - the manufacturer approved diagnostic system. Refer to the
Feedback Circuit short to power, open electrical circuit diagrams and test driver up/down mirror
circuit motor feedback circuit for short to power, open circuit
B1C1411 Driver Left/Right Driver left/right mirror Refer to the electrical circuit diagrams and test driver
Mirror Motor motor feedback circuit - left/right mirror motor feedback circuit for short to ground
Feedback Circuit short to ground
Mirror Motor motor feedback circuit - the manufacturer approved diagnostic system. Refer to the
Feedback Circuit short to power, open electrical circuit diagrams and test driver left/right mirror
circuit motor feedback circuit for short to power, open circuit
Mirror Motor mirror motor feedback up/down mirror motor feedback circuit for short to ground
Feedback Circuit circuit - short to ground
Mirror Motor mirror motor feedback up/down mirror motor feedback circuit for short to power,
Feedback Circuit circuit - short to power, open circuit
open circuit
Left/Right Mirror mirror motor feedback left/right mirror motor feedback circuit for short to ground
Motor Feedback circuit - short to ground
Circuit
Left/Right Mirror mirror motor feedback left/right mirror motor feedback circuit for short to power,
Motor Feedback circuit - short to power, open circuit
Circuit open circuit
Rear View Mirrors - Exterior Mirror
Removal

Installation

Rear View Mirrors - Exterior Mirror Cover
Removal
and Installation).
Installation

Rear View Mirrors - Exterior Mirror Glass
Removal
1.
2.
Installation

Rear View Mirrors - Exterior Mirror Motor
Removal
and Installation).
2.
3.
Installation

Rear View Mirrors - Interior Rear View Mirror
Removal
1. 1. CAUTIONS:
Take extra care not to damage the clips.
2.
3.
Installation

Seating -
Front seat backrest retaining bolts 35 26 -
Front seat safety belt anchor retaining bolts 40 30 -
Front seat retaining bolts 47 35 -
Front safety belt buckle retaining bolt 40 30 -
Rear seat backrest retaining bolts 17 13 -
Side air bag module retaining nuts 7 - 62
Seating - Seats - Component Location
COMPONENT LOCATION - MOVEMENT
ItemDescription
Note: 16-way LH (left-hand) driver's seat shown.
1 Seat height motor
2 Head restraint motor
3 Lumbar support motor
4 Lumbar support air cells
5 Seat squab recline motor
6 Seat switch pack
7 Seat slide motor
8 Seat cushion tilt motor
9 Seat cushion extension motor
COMPONENT LOCATION - TEMPERATURE - HEATED SEATS - SHEET 1 OF 2
ItemDescription
Note: Heated front seat shown
1 Squab heater element
2 Cushion heater element
COMPONENT LOCATION - TEMPERATURE - CLIMATE SEATS - SHEET 2 OF 2
ItemDescription
Note: Heated and cooled front seat shown
1 Squab liner
2 Squab climate module
3 Squab inlet duct
4 Squab blower
5 Cushion climate module
6 Cushion inlet duct
7 Cushion blower
8 Cushion liner
Seating - Seats - Overview
OVERVIEW
A number of front seating options are available. An 8-way electrically adjustable driver's seat is complemented by an
8-way electrically adjustable passenger seat. A 10-way electrically adjustable driver's seat is complemented by an 10-way
electrically adjustable front passenger seat. A 16-way electrically adjustable driver's seat is complemented by a 12-way
electrically adjustable front passenger seat.
On non-memory seats, the operation of the seats is controlled directly from the driver's seat switchpack. On memory
seats, the operation of the seat motors is controlled by a seat control module which is located on the underside of the
driver's seat frame.
The driver's seat is fitted with a seat position sensor which is located on the seat rail. The sensor is used by the RCM
(restraints control module) to determine the seat position and adjust the inflation time of the airbag deployment
accordingly.
Refer to: Air Bag and Safety Belt Pretensioner Supplemental Restraint System (SRS) (501-20B Supplemental Restraint
System, Description and Operation).
Seating - Seats - System Operation and Component Description
Control Diagram
CONTROL DIAGRAM - MOVEMENT - MEMORY SEATS
ItemDescription
Note: A = Hardwired; O = LIN (local interconnect network)
1 Battery
3 Seat switch pack
4 Lumbar support solenoids
5 Lumbar support motor
6 Seat memory switches
7 Squab recline motor
9 Head restraint motor
10 Cushion tilt motor
11 Cushion extension motor
12 Seat slide motor
13 Seat height motor
CONTROL DIAGRAM - MOVEMENT - NON-MEMORY SEATS
ItemDescription
Note: A = Hardwired
1 Battery
2 BJB
3 2-way Lumbar support
4 Seat switch pack
5 Squab recline motor
6 Cushion tilt motor
7 Seat slide motor
8 Seat height motor
9 CJB
CONTROL DIAGRAM - TEMPERATURE
ItemDescription
Note: A = Hardwired; N = Medium speed CAN (controller area network) bus; P = MOST ring
1 Battery
2 BJB
6 Information and Entertainment module
8 Passenger seat squab climate module
9 Drivers seat cushion climate module
10 Passenger seat cushion climate module
11 Drivers seat squab climate module
12 Passenger seat cushion heater element
13 Passenger seat squab heater element
14 Drivers seat cushion heater element
15 Drivers seat squab heater element
16 CJB
System Operation
HEATED SEATS - OPERATION
Heated Front Seats
The TSD receives a fused power supply from the RJB. One of the 3 seat heat temperature selections made by the driver or
passenger using the TSD soft keys are passed from the TSD on the MOST ring to the Information and Entertainment
module. The information and entertainment module processes the information and transmits the request on the medium
speed CAN bus to the ATC module.
The cushion heaters have a thermal sensor which supplies a feed back signal back to the CJB. The squab heater elements
do not have a thermal sensor and are maintained at the same temperature as the seat cushion elements.
The ATC module reacts to the driver request information received from the information and entertainment module and
requests the CJB to activate the seat heaters. The CJB measures the returned temperature signals from the thermal
sensors and relays the temperature signals back to the ATC module. The ATC module then uses the measured seat
element temperatures to provide closed-loop control of the heater elements to maintain the temperature at one the 3 heat
ranges selected.
NOTE: To prevent excessive battery discharge, the heated front seats will only operate when the engine is running.
Heated and Cooled Front Seats
The TSD receives a fused power supply from the RJB. Selections made by the driver using the TSD soft keys are passed
from the TSD on the MOST ring to the Information and Entertainment module. The information and entertainment module
processes the information and transmits the request on the medium speed CAN bus to the front seat climate control
module. The front seat climate control module is located beneath the RH (right-hand) front seat, on the floor cross
member.
The front seat climate control module receives its power supplies from the CJB. Heating and cooling requests are
generated using the soft buttons on the TSD. These requests are transmitted to the information and entertainment
module over the MOST ring. The Information and Entertainment module forwards these requests to the front seat climate
control module over the medium speed CAN bus.
The front seat climate control module supplies power to the two climate modules in each seat. The temperature sensor in
each climate module is monitored by the front seat climate control module which uses the temperature information to
control the Peltier cells accordingly and also the blower fans to distribute the heated or cooled air.
NOTE: To prevent excessive battery discharge, the heated and cooled front seats will only operate when the engine is
running.
Electric Driver's Seat Adjustment - Non-Memory Seats
The CJB supplies 3 power supplies to the driver's seat switchpack. The fused supplies provide power for the seat height
and squab recline, the seat slide and seat tilt and the lumbar adjustment respectively. The CJB only provides the power to
the driver's seat switch pack when the ignition is on (power mode 6).
For the seat movement motors, when the applicable switch is operated, the power is supplied to the applicable side of the
motor and the ground path is completed to operate the motor in the required direction. To move the motor in the opposite
direction the polarity is reversed.
For the lumbar adjustment, when the switch is operated in the inflate position, power is supplied to the pump motor to
inflate the lumbar support. When the switch is operated in the opposite direction, the power energizes a solenoid which in
turn opens a valve to deflate the lumbar support.
Electric Passenger Seat Adjustment ( 8, 10 and 12 way)
The CJB supplies 3 power supplies to the passenger seat switchpack. The fused supplies provide power for the seat height
and squab recline, the seat slide and seat tilt and the head restraint and lumbar adjustment respectively. The CJB only
provides the power to the passenger seat switch pack when the ignition is on (power mode 6).
For the seat movement and head restraint motors, when the applicable switch is operated, the power is supplied to the
applicable side of the motor and the ground path is completed to operate the motor in the required direction. To move the
motor in the opposite direction the polarity is reversed.
For the lumbar adjustment, when the switch is operated in the inflate position, power is supplied to the pump motor to
inflate the lumbar support. When the switch is operated in the opposite direction, the power energizes a solenoid which in
turn opens a valve to deflate the lumbar support.
Electric Driver's Seat Adjustment - Memory Seats (10 and 16 way)
The CJB supplies 3 power supplies to the driver's seat module and one supply to the driver's seat switch pack. The fused
supplies provide power for the movement motors in addition to the driver's seat switch pack. Power is only supplied to the
driver's seat module and the driver's seat switch pack when the ignition is on (power mode 6).
The driver's seat switch pack is connected to the driver's seat module by a LIN bus for the seat movement switches. Any
selection for seat movement generates a message which is passed via the LIN to the driver's seat module. The seat
module processes the request and operates the applicable seat function as required using the power supplies from the
CJB.
Each seat motor contains a Hall position sensor. The sensor sends a feedback signal to the driver's seat module. The
signal is used for memory store and memory recall functions.
The lumbar adjustment switch on the driver's seat switch pack is wired direct to the lumbar pump and solenoids. The
switch, when moved to the inflate position for either the upper or lower inflatable cushion cell, provides a power supply to
the lumbar pump and simultaneously activates the applicable inflate solenoid valve. When the switch is released the pump
stops and the solenoid valve closes trapping the air in the inflatable cushion. When the switch is moved to the deflate
position for either the upper or lower inflatable cushion cell, power is supplied to the applicable deflate solenoid valve
which opens to allow the air in the cushion to escape. When the switch is released, the valve is closed and the remaining
air in the cushion is retained.
FRONT SEATS - DESCRIPTION
The table below highlights the features available for each seating option.
Seat Type Non-Heated Heated Heated and Cooled Lumbar Support Memory
8-way Yes Optional No 2-way No
10-way Yes Optional Optional 2-way Optional (Driver's seat only)
12-way No No Yes 4-way No
16-way No No Yes 4-way Yes (Driver's seat only)
Seat Heating
The 3-stage heated front seats feature 2 heater elements located in the seat cushion and a single heater element located
in the seat squab. Operation of the heated front seats is controlled by the ATC module via the TSD, information and
entertainment control module and the CJB module on vehicles with heated seats. On vehicles with heated and cooled
seats the operation is controlled by the TSD, information and entertainment control module and the front seat climate
control module.
The heated and cooled front seats each contain 2 climate modules; one in the cushion, one in the squab. The climate
modules contain 'Peltier' cells which are able to deliver heating and cooling based on a voltage provided by the front seat
climate control module. Each climate module also contains a fan, which blows air over the Peltier cells to distribute heated
or cooled air via liners in the seat cushion and squab. The fan is also controlled by the front seat climate control module.
The TSD allows the driver and passenger to select 3 ranges of heated or cooled ventilation; off, minimum and
intermediate. Also, using the selections on the TSD, the driver and passenger can select between full seat ventilation or
squab backrest ventilation only.
Vehicles fitted with the 3-stage heated front seat option also feature a heated steering wheel.
Refer to: Steering Column Switches (211-05 Steering Column Switches, Description and Operation).
Electric Seat Adjustment

Lumbar Support
On 8, 10 and 12 way seats, a 2 way lumbar support is provided which allows the lumbar inflatable cushion to be inflated or
deflated as required. On 16 way seats, a 4 way lumbar support is fitted which comprises two separate cushion cells. The
upper and lower cells can be inflated or deflated individually allowing greater comfort adjustment for the driver and
passenger.
The lumbar support comprises an inflatable cushion located in the seat squab, a pump and solenoids. The pump is
activated when the applicable seat switch is moved to the inflate position, inflating the cell(s) in the inflatable cushion.
On 8 and 10 way seats, a single solenoid operated valve allows the inflatable cushion to be deflated. On 12 and 16 way
seats, 4 solenoid valves control the inflation and deflation of the upper and lower inflatable cushion cells, allowing each
cell to be adjusted individually.
Seat Motors
The head restraint motor is located in the upper section of each seat squab and is accessible by removal of the seat back.
The motor moves a cradle which is driven in a vertical motion by a rack and pinion arrangement. The cradle has the two
head restraint stems attached to it and therefore raises and lowers the head restraint as the motor moves the cradle. The
motor contains a Hall sensor which supplies positional information to the driver's seat module.
The seat slide motor is an integral component of the seat frame. The motor drives on a gear on a worm drive lead screw
which is integral with the floor rail. The lead screw has a stop at each end to limit the fore and aft seat movement.
The tilt motor is located below the seat. The tilt motor drives a gear on a lead screw to raise the front of the seat cushion.
The motor contains a Hall sensor which supplies positional information to the driver's seat module.
The cushion extend motor is located below the seat. The motor drives a gear on a lead screw which extends or retracts the
front of the seat cushion. The motor contains a Hall sensor which supplies positional information to the driver's seat
module.
The height motor is located below the seat. The height motor drives a gear on a lead screw. The lead screw moves a lever
mechanism which raises or lowers the seat cushion. The motor contains a Hall sensor which supplies positional information
to the driver's seat module.
The squab recline motor is located in the seat back rest. The recline motor rotates a shaft which is connected the seat
squab frame and raises or lowers the back rest position. The motor contains a Hall sensor which supplies positional
information to the driver's seat module.
DRIVER'S SEAT MODULE

A memory store switch is located in the lower part of the driver's door. The switch communicates with the driver's eat
module via the LIN bus in the driver's seat switch pack. The memory store switch has two buttons; 1 and 2 to allow two
separate memory positions to be stored and 'set' button with integral LED (light emitting diode). The seat, door mirror and
steering column motors have position sensors which provide feedback to driver's seat module.
Once the driver's seat, steering column and exterior mirrors have been adjusted, the vehicle is able to memorize these
settings for future use by using the following procedure:
Push the memory 'SET' button, the LED in the switch will illuminate
Press the memory button 1 or 2 to memorize the current settings. The LED will extinguish, and a chime will sound
to confirm that the settings have been memorized. If the ignition is on, power mode 6, the message center will
display a confirmation message.
The positions can be recalled by pressing the applicable button 1 or 2.
Stall Detection
Seat, steering column and mirror motors are deemed to have stalled if there is no change in the inputs that are received
from the corresponding feedback sensors for 200 ms (seat).
If a stall condition is detected then the drive to that motor is cancelled for the remainder of that memory operation
(memory recall) or until the switch is re-selected (manual movement).
If the motor movement has stopped due to loss of sensor feedback, either stall or sensor failure, then that motor may be
activated again, to move past the stall position, by re-selecting the appropriate switch and pressing for longer than 2
seconds. This allows control of the motor to be maintained if sensor feedback is lost.
Upon re-selection of movement, if sensor pulses are detected then the motor will continue to be driven until the switch is
released or another stall condition is detected. If sensor feedback is not detected then the motor is only driven for 0.5
second and then stops until the switch is released and then pressed again, when a further 0.5 second of activation is
permitted, and so on, this is known as inch mode.
For all seat motor manual movements, whenever a motor is driven and a stall occurs, the memory control module records
the position at which the stall occurred. If movement occurs beyond a stall position, then that position is erased from the
control modules memory. This will always allow movement past a previously recorded stall position once movement has
been registered beyond that position. This is the case for both manual and memory movement.
Initialization
When a replacement driver's seat module is fitted, it should be calibrated a Jaguar approved diagnostic system so that the
module can learn the seats absolute position.
Battery Monitor
If the battery voltage drops below 10.5 Volts, then the driver's seat module ignores all requests for a memory recall until
the battery voltage has reached 11.5 Volts. This will conserve as much power in the vehicle battery as possible to enable
engine cranking.
REAR SEATS - DESCRIPTION

The rear seat features a single piece cushion and a 60/40 split squab. Two latches are secured to the rear bulkhead by a
pair of M8 bolts to retain the seat squabs in the upright position. The latches can be released to fold down the individual
cushions by pulling a cable release located below the rear window parcel shelf in the luggage compartment.
ISOFIX fastening points are attached to the vehicle floor to provide secure fastening for compatible child seats.
A centrally mounted center arm rest can be folded down from the 60% squab. The arm rest contains two drinks holders.
Seating - Seats
For a detailed description of the seats and seat operation, refer to the relevant Description and Operation section in the
workshop manual. REFER to: (501-10 Seating)
Seats (Description and Operation),

Seats (Description and Operation),
Seats (Description and Operation).
vehicle.
NOTE: Prior to carrying out any diagnosis, ensure the vehicle battery is in a good serviceable condition, refer to the
battery care manual.
Visual Inspection
Security, condition and correct installation of seat components and fixings Fuses
Harnesses for damage/corrosion
Electrical connectors
Damaged/corroded pins
4. 4. If the cause is not visually evident, verify the concern and refer to the Symptom Chart, alternatively, check for
Symptom Chart

No seat movement from switch pack Seat module has Set ignition ON. Re-check seat function from switch
(including no memory recall) gone into sleep pack. Check for DTC B1A9887 and refer to DTC Index.
mode Check for DTC B1A9888 and refer to DTC Index
Seat switch pack
LIN, power or
ground circuit -
open circuit
Seat switch pack
LIN circuit - short
to power, ground
No seat movement or lumbar movement NOTE: Seat module does Refer to the electrical circuit diagrams and check seat
from switch pack (including no memory not control the seat switch pack power and ground supply circuits for open
recall) lumbar function circuit
Seat switch pack

power or ground
supply circuits -
open circuit
Seat movement and lumbar movement Seat switch pack to NOTE: Memory switch pack is separate switch
from switch pack is ok, however, no memory switch hardwired to seat adjust switch
recall from memory switch pack pack circuits -
short, open circuit Refer to the electrical circuit diagrams and check seat
switch pack to memory switch pack circuits for short,
open circuit
Seat movement and memory recall NOTE: Seat module does Refer to the electrical circuit diagrams and check seat
works correctly however seat lumbar is not control the seat movement switch to lumbar circuits for short, open
not working correctly lumbar function circuit
Seat movement
switch to lumbar
circuits - short,
open circuit
Seat movement from switch pack occurs Motor Hall sensor Check for DTCs, B1B8731, B1B9131, B1B8931,
in delayed inch mode (seat axis moves on affected axis is B1B9331, B106331, B106431. If present then check
short distance when switch pressed for not connected or Hall sensor feedback circuits between seat motor and
longer than 2 seconds and then stops). not receiving seat module and also check Hall sensor ground circuits
This behaviour could occur on any seat expected signals for affected axis. These DTCs are only logged if the
axis (slide, height, squab, tilt, headrest axis is attempted to be moved in both directions.
or cushion) when requested When hall sensor connection issue fixed press switch
on affected axis for longer than 2 seconds. By keeping
the switch pressed the axis movement should now
operate for the duration of switch-press. Re-calibrate
affected seat
Seat movement from switch pack occurs MS CAN fault Carry out CAN network integrity test using
in inch mode. When seat axis manufacturer approved diagnostic system
movement is requested from the seat
switch pack the requested seat axis
moves a short distance then stops
(does not include lumbar). This
behaviour will occur on ALL seat axis
(slide, height, squab, tilt headrest and
cushion) when requested. MS CAN
communication not possible
Seat movement from switch pack occurs Seat module is Check for Instrument Cluster DTC U020800 'Lost
in inch mode. When seat axis disconnected from Communication With Seat Module'. If this DTC is
movement is requested from the seat the CAN Bus present, refer to the electrical circuit diagrams and
switch pack the requested seat axis check seat module power and ground supplies for
moves a short distance then stops short, open circuit. Carry out CAN network integrity
(does not include lumbar). This tests using the manufacturer approved diagnostic
behaviour will occur on ALL seat axis system
Seat movement from switch pack occurs Instrument cluster Check for seat module DTC U015500 'Lost
in inch mode. When seat axis is disconnected Communication With Instrument Cluster'. If this DTC
movement is requested from the seat from the CAN Bus is present, refer to the electrical circuit diagrams and
switch pack the requested seat axis check instrument cluster power and ground supplies for
moves a short distance then stops short, open circuit. Carry out CAN network integrity
Seat movement from switch pack occurs Driver Door Module Check for seat module DTC U019900 'Lost
in inch mode. When seat axis is disconnected Communication With Driver Door Module'. If this DTC
movement is requested from the seat from the CAN Bus is present, refer to the electrical circuit diagrams and
switch pack the requested seat axis check driver door module power and ground supplies
moves a short distance then stops for short, open circuit. Carry out CAN network integrity
Seat movement from switch pack occurs Rear Junction Box Check for seat module DTC U014200 'Lost
in inch mode. When seat axis (RJB) is Communication With RJB'. If this DTC is present, refer
movement is requested from the seat disconnected from to the electrical circuit diagrams and check RJB power
switch pack the requested seat axis the CAN Bus and ground supplies for short, open circuit. Carry out
moves a short distance then stops CAN network integrity tests using the manufacturer
(does not include lumbar). This approved diagnostic system
Seat movement from switch pack occurs Central Junction Refer to the electrical circuit diagrams and check CJB
in inch mode. When seat axis Box (CJB) is power and ground supplies for short, open circuit.
movement is requested from the seat disconnected from Carry out CAN network integrity tests using the
switch pack the requested seat axis the CAN Bus manufacturer approved diagnostic system
moves a short distance then stops
(does not include lumbar). This
NOTE: Electric passenger seat can Seat module is in NOTE: A new module is NOT required to be installed,
always be activated there is no manufacturing only the module replacement routine needs to be
passenger seat module installed to this mode performed. This will set the PID required to disable
vehicle manufacturing mode
Seat module does not go to sleep. Seat Seat module needs to be configured for customer
movement is always active from driver mode. Check for DTC U1A4C68 'Build/End of Line mode
seat switch pack Active'. If this DTC is present then configure for
customer mode by running 'New Seat Module
Replacement' application for the affected seat using
Front seat fore/aft movement not Carry out the GO to Pinpoint Test A.
functioning pinpoint test
associated to this
Symptom
Front seat excessive fore/aft free play Carry out the GO to Pinpoint Test B.
pinpoint test
associated to this
Symptom
Front seat fore/aft movement noisy Carry out the GO to Pinpoint Test C.
pinpoint test
associated to this
Symptom
Front seat height, tilt and/or seat Carry out the GO to Pinpoint Test D.
extension motor movement not pinpoint test
functioning associated to this
Symptom
Front seat height, tilt and/or extension Carry out the GO to Pinpoint Test E.
movement noisy pinpoint test
associated to this
Symptom
Heating And Cooling - Inoperative Carry out the GO to Pinpoint Test F.

pinpoint test
associated to this
Symptom
Heating And Cooling - Noisy Operation Carry out the GO to Pinpoint Test G.
pinpoint test
associated to this
Symptom
Heating And Cooling - Poor Heat Or Cool Carry out the GO to Pinpoint Test H.
Efficiency pinpoint test
associated to this
Symptom
Heating And Cooling - Heat Or Cool Carry out the GO to Pinpoint Test I.
Operation Slow pinpoint test
associated to this
Symptom
Heating And Cooling - Intermittent Carry out the GO to Pinpoint Test J.

Operation pinpoint test
associated to this
Symptom
DTC Index
Driver Seat Module

B105F11 Seat Cushion Driver seat cushion extension Carry out any pinpoint tests associated with this
Extension Motor motor circuit - short to ground DTC using the manufacturer approved diagnostic
Output system. Refer to the electrical circuit diagrams and
check driver seat cushion extension motor circuit for
short to ground
B105F15 Seat Cushion Driver seat cushion extension Carry out any pinpoint tests associated with this
Extension Motor motor circuit - short to power, DTC using the manufacturer approved diagnostic
Output open circuit system. Refer to the electrical circuit diagrams and
check driver seat cushion extension motor circuit for
B106011 Seat Headrest Motor Driver seat headrest motor Carry out any pinpoint tests associated with this
Output circuit - short to ground DTC using the manufacturer approved diagnostic
system. Refer to the electrical circuit diagrams and
check driver seat headrest motor circuit for short to
ground
Output circuit - short to power, open DTC using the manufacturer approved diagnostic
circuit system. Refer to the electrical circuit diagrams and
check driver seat headrest motor circuit for short to
power, open circuit
B106331 Seat Cushion Driver seat cushion extension Carry out any pinpoint tests associated with this
Extension Motor motor speed/position sensor DTC using the manufacturer approved diagnostic
Speed/Position circuit - short to ground, power, system. Refer to the electrical circuit diagrams and
Sensor open circuit check driver seat cushion extension motor
Sensor failure speed/position sensor circuit for short to ground,
power, open circuit. Check and install a new sensor
as required
Speed/Position speed/position sensor circuit - DTC using the manufacturer approved diagnostic
Sensor short to ground, power, open system. Refer to the electrical circuit diagrams and
circuit check driver seat headrest motor speed/position
Sensor failure sensor circuit for short to ground, power, open
circuit. Check and install a new sensor as required
B106524 Cushion extend Signal stuck high Check for a stuck switch. Refer to the electrical
switch circuit diagrams and check driver seat switch pack to
seat module LIN circuit for short, open circuit and
cushion extend circuit for short to ground
B106624 Cushion retract Signal stuck high Check for a stuck switch. Refer to the electrical
cushion retract circuit for short to ground
B106D24 Headrest up switch Signal stuck high Check for a stuck switch. Refer to the electrical
circuit diagrams and check driver seat switch pack to
headrest up circuit for short to ground
B106E24 Headrest down Signal stuck high Check for a stuck switch. Refer to the electrical
headrest down circuit for short to ground
B1A9883 LIN Bus Circuit #1 Value of signal protection Check LIN network for interference/EMC related
calculation incorrect issues
B1A9886 LIN Bus Circuit #1 LIN bus Header error Carry out any pinpoint tests associated with this
system. Check LIN network for interference/EMC
related issues
B1A9887 LIN Bus Circuit #1 Slave node communication Refer to electrical circuit diagrams and test LIN Bus
missing. LIN bus circuit - short between seat switch pack and control module for
to ground, power, open circuit short to ground, power, open circuit, check power
(ECU Types 7 & 8) and ground supplies to switch pack
B1A9888 LIN Bus Circuit #1 Bus off Carry out any pinpoint tests associated with this
system. Refer to electrical circuit diagrams and test
LIN Bus between seat switch pack and control
module for short to ground or power
B1B8611 Seat Height Motor Driver seat parallel height motor Carry out any pinpoint tests associated with this
Relay circuit - short to ground DTC using the manufacturer approved diagnostic
check driver seat parallel height motor circuit for
short to ground
Relay circuit - short to power, open DTC using the manufacturer approved diagnostic
circuit system. Refer to the electrical circuit diagrams and
check driver seat parallel height motor circuit for
circuit check driver seat parallel height motor
Sensor failure speed/position sensor circuit for short to ground,
power, open circuit. Check and install a new sensor
as required
B1B8811 Seat Slide Motor Driver seat slide motor circuit - Carry out any pinpoint tests associated with this
Relay short to ground DTC using the manufacturer approved diagnostic
check driver seat slide motor circuit for short to
ground
B1B8815 Seat Slide Motor Driver seat slide motor circuit - Carry out any pinpoint tests associated with this
Relay short to power, open circuit DTC using the manufacturer approved diagnostic
check driver seat slide motor circuit for short to
power, open circuit
B1B8931 Seat Slide Motor Driver seat slide motor Carry out any pinpoint tests associated with this
circuit check driver seat slide motor speed/position sensor
Sensor failure circuit for short to ground, power, open circuit.
Check and install a new sensor as required
B1B9011 Seat Tilt Motor Driver seat tilt motor circuit - Carry out any pinpoint tests associated with this
check driver seat tilt motor circuit for short to
ground
B1B9015 Seat Tilt Motor Driver seat tilt motor circuit - Carry out any pinpoint tests associated with this
check driver seat tilt motor circuit for short to
power, open circuit
B1B9131 Seat Tilt Motor Driver seat tilt motor Carry out any pinpoint tests associated with this
circuit check driver seat tilt motor speed/position sensor
Sensor failure circuit for short to ground, power, open circuit.
Check and install a new sensor as required
B1B9211 Seat Recline Motor Driver seat recline motor circuit - Carry out any pinpoint tests associated with this
check driver seat recline motor circuit for short to
ground
B1B9215 Seat Recline Motor Driver seat recline motor circuit - Carry out any pinpoint tests associated with this
check driver seat recline motor circuit for short to
power, open circuit
B1B9331 Seat Recline Motor Driver seat recline motor Carry out any pinpoint tests associated with this
circuit check driver seat recline motor speed/position
Sensor failure sensor circuit for short to ground, power, open
circuit. Check and install a new sensor as required
B1B9424 Seat Height Up Signal stuck high Check for a stuck switch. Refer to the electrical
Switch circuit diagrams and check driver seat switch pack to
seat height up circuit for short to ground
B1B9524 Seat Height Down Signal stuck high Check for a stuck switch. Refer to the electrical
seat height down circuit for short to ground
B1B9624 Seat Slide Forward Signal stuck high Check for a stuck switch. Refer to the electrical
seat slide forward circuit for short to ground
B1B9724 Seat Slide Backward Signal stuck high Check for a stuck switch. Refer to the electrical
seat slide backward circuit for short to ground
B1B9824 Seat Tilt Up Switch Signal stuck high Check for a stuck switch. Refer to the electrical
seat tilt up circuit for short to ground
B1B9924 Seat Tilt Down Signal stuck high Check for a stuck switch. Refer to the electrical
seat tilt down circuit for short to ground
B1C0024 Seat Recline Up Signal stuck high Check for a stuck switch. Refer to the electrical
seat recline up circuit for short to ground
B1C0124 Seat Recline Down Signal stuck high Check for a stuck switch. Refer to the electrical
check seat recline down circuit for short to ground
B1C0224 Memory Store Signal stuck high Check for a stuck switch. Refer to the electrical
seat module LIN circuit for short, open circuit
B1C0324 Memory #1 Switch Signal stuck high Check for a stuck switch. Refer to the electrical
U001088 Medium speed Can Bus off Carry out any pinpoint tests associated with this
communication Bus DTC using the manufacturer approved diagnostic
check CAN network to climate controlled seat
U014000 Lost communication Lost communication with CJB Carry out any pinpoint tests associated with this
with CJB DTC using the manufacturer approved diagnostic
system. Check CJB for related DTCs and refer to the
relevant DTC Index
U014200 Lost communication Lost communication with RJB Carry out any pinpoint tests associated with this
with RJB DTC using the manufacturer approved diagnostic
system. Check RJB for related DTCs and refer to the
relevant DTC Index
U015500 Lost Lost communications with Carry out any pinpoint tests associated with this
communications instrument cluster DTC using the manufacturer approved diagnostic
with instrument system. Refer to the electrical circuit diagrams and
cluster check CAN network to climate controlled seat
module and instrument cluster for short, open circuit
U019900 Lost communication Lost communication with DDM Carry out any pinpoint tests associated with this
with Driver Door DTC using the manufacturer approved diagnostic
Module (DDM) system
U030000 Internal control Invalid configuration message is Re-configure the RJB using the manufacturer
module software received approved diagnostic system. Clear the DTC and
incompatibility retest. If the DTC is still logged suspect the
DSM/PSM, refer to the new module installation note
U1A1449 CAN Initialisation Internal electronic failure Install a new DSM, refer to the new module
U1A4C68 Build/end of line Manufacturing mode has not Place DSM in to customer mode using manufacturer
mode active been removed approved diagnostic system
U300049 Control module Internal electronic failure Install a new DSM, refer to the new module
U300055 Stored vehicle Incorrect car configuration data Re-configure the RJB using the manufacturer
configuration data received approved diagnostic system. Clear DTC and re-test.
does not match If the DTC remains suspect the DSM, refer to the
new module installation note at the top of the DTC
Index
U300087 Control Module Missing message Re-configure the RJB using the manufacturer
approved diagnostic system. Check DSM for DTCs
and refer to the DTC Index. Check CAN network
integrity using the manufacturer approved
diagnostic system
U300146 Control module Calibration/parameter memory Check for DTCs that could indicate power failure to
improper shutdown failure the module and refer to the DTC Index
U300281 Vehicle Vehicle/component mis-match. Install original module, check for DTCs and refer to
Identification Corrupt VIN data being relevant DTC Index
Number (VIN) transmitted, module previously
U300316 Battery Voltage Circuit voltage below threshold Carry out any pinpoint tests associated with this
system
U300317 Battery Voltage Circuit voltage above threshold Carry out any pinpoint tests associated with this
system
Climate Controlled Seat Module

B10B913 Blower Control Left blower control circuit Carry out any pinpoint tests associated with this DTC using
- open circuit the manufacturer approved diagnostic system. Refer to the
Left blower motor - open electrical circuit diagrams and check left blower control
circuit circuit for open circuit. Check and install new left blower
Climate controlled seat motor, climate controlled seat module as required, refer to
module failure the new module/component installation note at the top of
the DTC Index
B10B94B Blower Control Mechanical restriction Check for mechanical restriction within the left blower motor
within the left blower housing. Refer to the electrical circuit diagrams and check
motor housing left blower control circuit for short to ground. Check and
Left blower control circuit install new left blower motor, climate controlled seat module
- short to ground as required, refer to the new module/component installation
Left blower motor - short note at the top of the DTC Index
to ground
Climate controlled seat
module failure
B115713 Blower Control "B" Right blower control Carry out any pinpoint tests associated with this DTC using
circuit - open circuit the manufacturer approved diagnostic system. Refer to the
Right blower motor - electrical circuit diagrams and check right blower control
open circuit circuit for open circuit. Check and install new right blower
Climate controlled seat motor, climate controlled seat module as required, refer to
module failure the new module/component installation note at the top of
the DTC Index
B11574B Blower Control "B" Mechanical restriction Check for mechanical restriction within the right blower
within the right blower motor housing. Refer to the electrical circuit diagrams and
motor housing check right blower control circuit for short to ground. Check
Right blower control and install new right blower motor, climate controlled seat
circuit - short to ground module as required, refer to the new module/component
Right blower motor - installation note at the top of the DTC Index
short to ground
module failure
B120E13 Right Thermal Right seatback/cushion Carry out any pinpoint tests associated with this DTC using
Electric Device thermal electric device the manufacturer approved diagnostic system. Refer to the
Control control circuits - open electrical circuit diagrams and check right seatback/cushion
circuit thermal electric device control circuits for open circuit. Check
Thermal electric device and install new thermal electric device/climate controlled
failure seat module as required, refer to the new
Climate controlled seat module/component installation note at the top of the DTC
module failure Index
B120E19 Right Thermal Right seatback/cushion Carry out any pinpoint tests associated with this DTC using
Control control circuits - short to electrical circuit diagrams and check right seatback/cushion
ground thermal electric device control circuits for short to ground.
Thermal electric device Check and install new thermal electric device/climate
failure controlled seat module as required, refer to the new
B120E4B Right Thermal Right seatback/cushion Carry out any pinpoint tests associated with this DTC using
Electric Device thermal electric device the manufacturer approved diagnostic system. Check for
Control control circuits - short to restriction in thermal electric device duct. Refer to the
ground electrical circuit diagrams and check right seatback/cushion
Blocked thermal electric thermal electric device control circuits for short to ground.
device duct (restriction in Check and install new thermal electric device/climate
airflow) controlled seat module as required, refer to the new
Thermal electric device module/component installation note at the top of the DTC
failure Index
module failure
B122413 Left Thermal Left seatback/cushion Carry out any pinpoint tests associated with this DTC using
Control control circuits - open electrical circuit diagrams and check left seatback/cushion
circuit thermal electric device control circuits for open circuit. Check
Thermal electric device and install new thermal electric device/climate controlled
failure seat module as required, refer to the new
B122419 Left Thermal Left seatback/cushion Carry out any pinpoint tests associated with this DTC using
Control control circuits - short to electrical circuit diagrams and check left seatback/cushion
ground thermal electric device control circuits for short to ground.
Thermal electric device Check and install new thermal electric device/climate
failure controlled seat module as required, refer to the new
B12244B Left Thermal Left seatback/cushion Carry out any pinpoint tests associated with this DTC using
Electric Device thermal electric device the manufacturer approved diagnostic system. Check for
Control control circuits - short to restriction in thermal electric device duct. Refer to the
ground electrical circuit diagrams and check left seatback/cushion
Blocked thermal electric thermal electric device control circuits for short to ground.
device duct (restriction in Check and install new thermal electric device/climate
airflow) controlled seat module as required, refer to the new
Thermal electric device module/component installation note at the top of the DTC
failure Index
module failure
B122A11 Right Seat Cushion Right seat cushion blower Refer to the electrical circuit diagrams and check right seat
Blower Speed speed sensor circuit - cushion blower speed sensor circuit for short to ground.
Sensor short to ground Check and install a new motor/module as required, refer to
Internal motor failure the new module/component installation note at the top of
Climate controlled seat the DTC Index
module failure
B122A12 Right Seat Cushion Right seat cushion blower Refer to the electrical circuit diagrams and check right seat
Blower Speed speed sensor circuit - cushion blower speed sensor circuit for short to power. Check
Sensor short to power and install a new motor/module as required, refer to the new
Internal motor failure module/component installation note at the top of the DTC
Climate controlled seat Index
module failure
B122B11 Right Seat Back Right seatback blower Refer to the electrical circuit diagrams and check right
Blower Speed speed sensor circuit - seatback blower speed sensor circuit for short to ground.
module failure
B122B12 Right Seat Back Right seatback blower Refer to the electrical circuit diagrams and check right
Blower Speed speed sensor circuit - seatback blower speed sensor circuit for short to power.
Sensor short to power Check and install a new motor/module as required, refer to
module failure
B122C11 Left Seat Cushion Left seat cushion blower Refer to the electrical circuit diagrams and check left seat
Blower Speed speed sensor circuit - cushion blower speed sensor circuit for short to ground.
module failure
B122C12 Left Seat Cushion Left seat cushion blower Refer to the electrical circuit diagrams and check left seat
Blower Speed speed sensor circuit - cushion blower speed sensor circuit for short to power. Check
Sensor short to power and install a new motor/module as required, refer to the new
Internal motor failure module/component installation note at the top of the DTC
Climate controlled seat Index
module failure
B122D11 Left Seat Back Left seatback blower Refer to the electrical circuit diagrams and check left
Blower Speed speed sensor circuit - seatback blower speed sensor circuit for short to ground.
module failure
B122D12 Left Seat Back Left seatback blower Refer to the electrical circuit diagrams and check left
Blower Speed speed sensor circuit - seatback blower speed sensor circuit for short to power.
Sensor short to power Check and install a new motor/module as required, refer to
module failure
B122E13 Right Seat Cushion Right seat cushion Refer to the electrical circuit diagrams and check right seat
temperature sensor cushion temperature sensor circuit for open circuit. Check
circuit - open circuit and install a new sensor/module as required, refer to the
Temperature sensor new module/component installation note at the top of the
failure DTC Index
module failure
B122E98 Right Seat CushionBlockage in the right seat Check/remove any blockage/restriction from the right seat
Pinpoint Tests cushion thermal electric cushion thermal electric device fan exhaust vent
device fan exhaust vent
Right
PINPOINT TEST A : FRONT SEAT seat cushion
FORE/AFT MOVEMENT NOT FUNCTIONING
thermal electric device
fan movement restricted
CONDITIONS
A1: CHECK FOR FRONT SEAT FORWARD-REARWARD SEAT MOTOR OPERATION
WARNING: Before work is carried out, make the air bag supplemental restraint system safe. For
additional information, refer to Standard W orkshop Practices section of workshop manual.
1 Set ignition status to ' ON'.

2 From the switch pack, operate the front seat forward-rearward seat motor switch and listen for
evidence of the motor operating.
Does the motor operate?
Yes
GO to A2.
No
GO to A3.
A2: CHECK FRONT SEAT FORWARD-REARWARD SEAT MOTOR DRIVE BAR
1 Check front seat drive bar for correct installation and condition
Is the front seat drive bar correctly installed and in a serviceable condition?
Yes
Re-check for correct front seat forward-rearward movement. Remove seat to allow for further
investigation if required.
No
Correctly install front seat forward-rearward seat motor drive bar, or replace if required.
A3: CHECK FRONT SEAT FORWARD-REARWARD SEAT MOTOR
WARNING: When carrying out the following steps, stand clear of all moving parts and ensure link harness is routed
accordingly.
1 Set ignition status to 'OFF'.
2 Disconnect front seat forward-rearward seat motor connector.
NOTE: It may be that the seat has been driven to the limit of travel along the relevant axis, and when
the link harness is connected, the seat will remain in the same position. If this is the case, a jolt may be
felt from the motor. To confirm the motor operation, swap the link harness to alternate motor pin
connections and the seat should travel in the opposite direction.
3 Using a locally made fused link harness and power supply, connect power and ground to forward-
rearward seat motor.
Battery positive terminal Battery negative terminal
forward-rearward seat motor pin 1 forward-rearward seat motor pin 2
Yes
Using manufacturer approved diagnostic system, check for related Diagnostic Trouble Codes (DTCs)
and carry out the repair operations specified. Alternatively, refer to the electrical circuit diagrams and
check front seat forward-rearward seat motor circuits.
No
Replace front seat forward-rearward seat motor. Refer to relevant section of workshop manual.
PINPOINT TEST B : FRONT SEAT EXCESSIVE FORWARD-REARWARD FREE PLAY

CONDITIONS
B1: CHECK FRONT SEAT FOR EXCESSIVE FORWARD-REARWARD FREE PLAY
1 Check all accessible front seat frame fixings are installed and to the correct torque.
Are all accessible front seat frame fixings installed and to the correct torque?
Yes
GO to B2.
No
Install and tighten all accessible front seat frame fixings to correct torque and re-check for
excessive free play.
B2: COMPARE THE FRONT SEAT FORWARD-REARWARD FREE PLAY AGAINST A SIMILAR SEAT
1 Compare the front seat forward-rearward free play against a similar seat.
Is the front seat forward-rearward free play excessive when compared to a similar seat?
Yes
GO to B3.
No
The front seat frame is operating correctly. Submit Electronic Product Quality Report (EPQR) with any
further query.
B3: CHECK REMAINING FRONT SEAT FRAME FIXINGS
1 Remove front seat and/or any seat covers/trim to allow access to check remaining front seat frame
fixings are all installed and to the correct torque.
Are all remaining front seat frame fixings installed and to the correct torque?
Yes
Replace front seat frame. Refer to the relevant section of the workshop manual.
No
Install and tighten all remaining front seat frame fixings to correct torque and re-check for excessive
free play.
PINPOINT TEST C : FRONT SEAT FORWARD-REARWARD MOVEMENT NOISY

CONDITIONS
C1: COMPARE FRONT SEAT FORWARD-REARWARD MOVEMENT NOISE TO OTHER FRONT SEAT
1 Compare the front seat forward-rearward movement noise to other front seat.
Is the front seat forward-rearward movement noise excessive when compared to other front seat?
Yes
GO to C2.
No
GO to C3.
C2: COMPARE FRONT SEAT FORWARD-REARWARD MOVEMENT NOISE TO FRONT SEAT IN OTHER VEHICLE
1 Compare the front seat forward-rearward movement noise to front seat in other vehicle.
Is the front seat forward-rearward movement noise excessive when compared to front seat in other
vehicle?
Yes
GO to C3.
No
further query.
C3: CHECK FOR DEBRIS OBSTRUCTING SEAT MOVEMENT
1 Check for debris obstructing seat movement.
Is the front seat forward-rearward movement obstructed by debris?
Yes
Remove obstruction and re-check for noisy forward-rearward seat movement.
No
GO to C4.
C4: RE-ALIGN FRONT SEAT FRAME
1 Loosen front seat frame fixings.
2 Set ignition status to 'ON'.
3 Using the front seat switch pack drive the front seat fully forward then fully rearward.
4 Tighten front seat frame fixings to the correct torque.
5 Re-check for noisy seat movement.
Is the front seat forward-rearward movement still noisy?
Yes
GO to C5.
No
The front seat frame is now operating correctly.
C5: CHECK FRONT SEAT FORWARD-REARWARD SEAT MOTOR DRIVE BAR
1 Check front seat drive bar for correct installation and condition.
Is the front seat drive bar correctly installed and in a serviceable condition?
Yes
Replace front seat forward-rearward seat motor. Refer to relevant section of workshop manual.
No
Correctly install front seat forward-rearward seat motor drive bar, or replace if required.
PINPOINT TEST D : FRONT SEAT HEIGHT, TILT AND/OR SEAT EXTENSION MOTOR MOVEMENT NOT
FUNCTIONING
CONDITIONS
D1: CHECK FRONT SEAT HEIGHT, TILT OR EXTENSION MOTOR
W ARNINGS:
Before work is carried out, make the air bag supplemental restraint system safe. For additional information, refer to
Standard Workshop Practices section of workshop manual.
W hen carrying out the following steps, stand clear of all moving parts and ensure link harness is routed accordingly.
1 Set ignition status to ' OFF'.
2 Disconnect front seat height, tilt or extension motor connector.
NOTE: It may be that the seat has been driven to the limit of travel along the relevant axis, and when
the link harness is connected, the seat will remain in the same position. If this is the case, a jolt may be
felt from the motor. To confirm the motor operation, swap the link harness to alternate motor pin
connections and the seat should travel in the opposite direction.
3 Using a locally made fused link harness and power supply, connect power and ground to relevant
motor.
Battery positive terminal Battery negative terminal
motor pin 1 motor pin 2
Yes
Using manufacturer approved diagnostic system, check for related Diagnostic Trouble Codes (DTCs)
and carry out the repair operations specified. Alternatively, refer to the electrical circuit diagrams and
check relevant motor circuits.
No
Replace the relevant motor. Refer to relevant section of workshop manual.
PINPOINT TEST E : FRONT SEAT HEIGHT, TILT AND/OR EXTENSION MOVEMENT NOISY
CONDITIONS
E1: COMPARE THE HEIGHT, TILT OR EXTENSION MOVEMENT NOISE WITH THE OTHER FRONT SEAT
1 Compare the front seat movement noise to other front seat.

Is the front seat height, tilt or extension movement noise excessive when compared to other front seat?
Yes
GO to E2.
No
GO to E3.
E2: COMPARE FRONT SEAT HEIGHT, TILT OR EXTENSION MOVEMENT NOISE TO FRONT SEAT IN OTHER VEHICLE
1 Compare the front seat height, tilt or extension movement noise to front seat in other vehicle.
Is the front seat height, tilt or extension movement noise excessive when compared to front seat in
other vehicle?
Yes
GO to E3.
No
further query.
E3: CHECK FOR DEBRIS OBSTRUCTING SEAT MOVEMENT
1 Check for debris obstructing seat movement.
Is the front seat height, tilt or extension movement obstructed by debris?
Yes
Remove obstruction and re-check for noisy height, tilt or extension seat movement. If still noisy GO
to Pinpoint Test ??.
No
GO to E4.
E4: CHECK FOR HEIGHT, TILT OR EXTENSION MOVEMENT MECHANISM LUBRICATION
1 Check and apply manufacturer approved lubrication to seat height, tilt or extension movement
mechanism and re-test for noise.
Is the front seat height, tilt or extension noise still apparent?
Yes
Replace the relevant motor. Refer to relevant section of workshop manual.
No
The front seat height, tilt or extension motor is operating correctly.
PINPOINT TEST F : HEATER AND COOLING - INOPERATIVE

CONDITIONS
F1: CHECK FOR STORED DTC
1 Check the Climate Controlled Seat Module for stored DTC's.
Are there any stored DTC's?
Yes
For information on stored DTC's refer to the information in the Climate Controlled Seat Module DTC
index.
No
GO to F2.
F2: DRIVER OR FRONT PASSENGER SEAT BACKREST CLIMATE ASSEMBLY - FUNCTIONALITY CHECK
WARNING: Before work is carried out, make the air bag supplemental restraint system safe. For additional
information, refer to Standard W orkshop Practices section of workshop manual.
NOTE: The Climate Controlled Seat's (heat and cool) function will only operate when the vehicle's engine is running.
NOTE: If a fault is identified and repaired, check for correct operation of the driver and front-passenger climate
controlled seat (heat and cool) functions.
1 Check the heat and cool function of the backrest.
Does the backrest heat and cool function operate correctly?
Yes
GO to F3.
No
GO to F5.
F3: DRIVER OR FRONT PASSENGER SEAT CUSHION CLIMATE ASSEMBLY - FUNCTIONALITY CHECK
1 Check the heat and cool function at the cushion.
Does the cushion heat and cool function operate correctly?
Yes
If there are no faults evident, verify the customer concern.
No
GO to F4.
F4: CUSHION BELLOWS
1 Check the condition of the bellows.
Are the bellows obstructed, have they collapsed?
Yes
Remove the obstruction or replace collapsed bellows.
No
Suspect an internal fault with the Seat Climate Assembly. Replace as required, refer to the Warranty
Policy and Procedures manual (section B1.2). Prior to installing a new component.
F5: BACKREST BELLOWS DUCT
1 Check the security of the bellows duct.
Is the bellows duct correctly installed?
Yes
GO to F6.
No
Securely reconnect the bellows duct.
F6: BACKREST BELLOWS
1 Check the security of the bellows.
Yes
No
Policy and Procedures manual (section B1.2). Prior to installing a new component. Follow the link
below to check operation of the Driver or Front Passenger Seat Cushion Climate Assembly.GO to F2.
PINPOINT TEST G : HEATING AND COOLING - NOISY OPERATION

CONDITIONS
G1: CHECK FOR STORED DTC
Yes
index.
No
GO to G2.
G2: DRIVER OR FRONT PASSENGER SEAT BACKREST CLIMATE ASSEMBLY - NOISE
1 There is a known issue which effects a limited number of vehicles where under acceleration of the
vehicle the occupant of seat can deform the suspension mat (snake wire) which then presses on the
casing of the seat backrest climate assembly, this causes the casing to distort and the noise issue to
occur. If contact has occurred there will be a witness mark on the casing. Carry out visual inspection
of the seat backrest climate assembly that has been identified as noisy by the customer.
Is there a witness mark on the casing?
Yes
Contact the local in market support for further information.
No
GO to G3.
G3: DRIVER OR FRONT PASSENGER SEAT CLIMATE ASSEMBLY - NOISE 2
1 Operate the heat and cool function of the seat. Listen for a 'W AH W AH' noise (the fan speeds up and
slows down repeatedly).
Does the fan speeds up and slow down repeatedly?
Yes
Confirm the latest Strategy and Calibration software is installed, using the manufacturer approved
diagnostic system carry out the new Climate Controlled Seat Module application and update the
Climate Controlled Seat Module software if required.If the noise is still evident after software update
follow link below.GO to G4.
No
GO to G4.
G4: DRIVER OR FRONT PASSENGER SEAT BACKREST CLIMATE ASSEMBLY - NOISE LEVEL COMPARISON
1 Compare the noise level of the suspect climate seat assembly to another climate seat assembly.
Is the noise level equal between the two seats?
Yes
The noise level is standard and comparable to the design intent.
No
PINPOINT TEST H : HEATING AND COOLING - POOR HEAT OR COOL EFFICIENCY

CONDITIONS
H1: CHECK FOR STORED DTC
Yes
index.
No
GO to H2.
H2: DRIVER OR FRONT PASSENGER SEAT BACKREST CLIMATE ASSEMBLY - FUNCTIONALITY CHECK
1 Check the heat and cool function of the backrest.
Yes
GO to H3.
No
GO to H5.
H3: DRIVER OR FRONT PASSENGER SEAT CUSHION CLIMATE ASSEMBLY - FUNCTIONALITY CHECK
Yes
No
GO to H4.
H4: CUSHION BELLOWS
Yes
No
GO to H7.
H5: BACKREST BELLOWS DUCT
Yes
GO to H6.
No
H6: BACKREST BELLOWS
Yes
No
below to check operation of the Driver or Front Passenger Seat Cushion Climate Assembly.GO to H2.
H7: DRIVER OR FRONT PASSENGER SEAT BACKREST CLIMATE ASSEMBLY -EFFICIENCY COMPARISON
1 Compare the efficiency of the suspect climate seat assembly to another climate seat assembly.
Is the efficiency equal between the two seats?
Yes
The efficiency is standard and comparable to the design intent.
No
PINPOINT TEST I : HEATING AND COOLING - HEAT OR COOL OPERATION SLOW

CONDITIONS
I1: CHECK FOR STORED DTC
Yes
index.
No
GO to I2.
I2: DRIVER OR FRONT PASSENGER SEAT BACKREST CLIMATE ASSEMBLY - FUNCTIONALITY CHECK
1 Check the heat and cool function of the backrest?
Yes
GO to I3.
No
GO to I5.
I3: DRIVER OR FRONT PASSENGER SEAT CUSHION CLIMATE ASSEMBLY - FUNCTIONALITY CHECK
Yes
No
GO to I4.
I4: CUSHION BELLOWS
Yes
No
GO to I7.
I5: BACKREST BELLOWS DUCT
Yes
GO to I6.
No
I6: BACKREST BELLOWS
Yes
No
below to check operation of the Driver or Front Passenger Seat Cushion Climate Assembly.GO to I2.
I7: DRIVER OR FRONT PASSENGER SEAT BACKREST CLIMATE ASSEMBLY - OPERATION COMPARISON
1 Compare the operation of the suspect climate seat assembly to another climate seat assembly.
Is the operation equal between the two seats?
Yes
The operation is standard and comparable to the design intent.
No
PINPOINT TEST J : HEATING AND COOLING - INTERMITTENT OPERATION

CONDITIONS
J1: CHECK FOR STORED DTC
Yes
index.
No
GO to J2.
J2: CABLE CONNECTION CHECK
1 Identify from customer concern or stored DTC's which Seat Climate Assembly is operating
intermittently and confirm the harness connector is fully connected.
Is the harness connector is fully connected?
Yes
Suspect an internal fault with the Seat Climate Assembly. Replace as required, refer to the W arranty
No
Disconnect the harness connector, inspect connector and terminals for damage. Repair or replace if
required. Reconnect connector and check operation.
Seating - Front Seat
Removal
Operation).
Position the front seat fully forwards.
Lower the front seat head restraint to the fully lowered

position.
Remove the safety belt lower anchor trim panel.

Release the safety belt lower anchor from the front seat.

Remove the 2 rear bolts from the front seat.
6. Position the front seat fully rearwards.

Remove the 2 front bolts from the front seat.
8. Reposition the front seat to the central position.

Procedures).
10. Disconnect the front seat harness electrical connectors.
Tilt the front seat rearwards to aid disconnecting the

front seat electrical connectors.
11. NOTE: Make sure no damage is caused to the vehicle trim

when removing the front seat.
Remove the front seat.
Installation
TORQUE: 47 Nm

TORQUE: 47 Nm
TORQUE: 40 Nm
Seating - Front Seat Backrest
Removal
Operation).
Procedures).
For additional information, refer to: Front Seat (501-10
4. WARNING: This step requires the aid of another

technician.
CAUTION: Take extra care when handling the component.
Remove the front seat backrest assembly.
5. Remove the front seat backrest cover.

For additional information, refer to: Front Seat Backrest Cover
(501-10 Seating, Removal and Installation).
6. Remove the backrest halo panel.

Remove the front seat recliner motor.

For additional information, refer to: Front Seat Recliner Motor
(501-10 Seating, Removal and Installation).
8. Remove the lumbar assembly.
For additional information, refer to: Lumbar Assembly (501-10,
9. Remove the front seat head restraint motor.
For additional information, refer to: Front Seat Head Restraint
Motor (501-10, Removal and Installation).
Installation
TORQUE: 35 Nm

Seating - Front Seat Backrest Cover
Removal
Operation).
For additional information, refer to: Front Seat (501-10
3. Remove the side air bag module.
For additional information, refer to: Side Air Bag Module
Installation).
4. NOTE: If equipped.
Reposition the front seat backrest thermo-electric device.
Release the front seat backrest thermo-electric device duct
Remove the front seat backrest thermo-electric device retaining

screws.
Remove the front seat backrest thermo-electric device.
8. Remove the front seat head restraint.

9. Remove the front seat head restraint motor.
For additional information, refer to: Front Seat Head Restraint
Motor (501-10, Removal and Installation).
Using a suitable tool, remove the front seat head restraint

guide sleeves.
11. Remove the front seat backrest cushion and cover from the
front seat frame.
12. Remove and discard the hog rings.
Remove the 22 hog rings.
13. Remove the front seat backrest cover.
Installation
1. NOTE: Make sure that new hog rings are installed.
NOTE: 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.

Seating - Front Seat Cushion Cover
Removal
1. Refer to: Front Safety Belt Buckle (501-20A Safety Belt System,
2.
3.
4.
5.
6.
another technician.
CAUTION: Take extra care when handling the

component.
Torque: 35 Nm
8.
9.
10.
11.
12.
13. 13. NOTE: Make sure that new hog rings are installed.
Installation

Seating - Front Seat Track Motor
Removal

3.
4.
5.
6.
Installation

Seating - Memory Seat Position Switch
Removal
2.
Installation

Seating - Seat Base
Removal
W ARNINGS:
To avoid accidental deployment, the restraints control module backup power supply must be depleted. W ait at least
one minute after disconnecting the battery ground cable(s) before commencing any repair or adjustment to the
supplemental restraint system (SRS), or any component(s) adjacent to the SRS sensors. Failure to follow these
Always wear safety glasses when working on an air bag equipped vehicle and when handling an air bag module.
To minimize the possibility of premature deployment, do not use radio key code savers when working on the
supplemental restraint system. Failure to follow this instruction may result in personal injury.
To minimize the possibility of injury in the event of premature deployment, always carry a live air bag module with
the bag and trim cover pointed away from the body. Failure to follow this instruction may result in personal injury.
To minimize the possibility of premature deployment, live air bag modules must only be placed on work benches
which have been ground bonded and with the trim cover facing up. Failure to follow these instructions may result in
personal injury.
Never probe the electrical connectors of air bag modules or any other supplemental restraint system component.
Painting over the driver air bag module trim cover or instrument panel could lead to deterioration of the trim cover
and air bags. Do not for any reason attempt to paint discolored or damaged air bag module trim covers or instrument
panel. Install a new component. Failure to follow this instruction may result in personal injury.

3. Refer to: Front Safety Belt Buckle (501-20A Safety Belt System,
4. Refer to: Front Seat Cushion Cover (501-10 Seating, Removal and
Installation).
5.
6.
7.
8. 8. CAUTION: Make sure that new bolts are
installed.
Torque: 35 Nm
Installation

Seating - Rear Seat Backrest Cover
Removal
2. Release both the rear seat back rest catches.
3. Fold down the rear seat backrest.

4. Remove the rear seat head restraint(s).
Lower both rear seats.
5. NOTE: The procedure must be carried out on both sides of

the seat.
Remove both rear seat bolsters.
7. Release the backrest cover.

6. CAUTION: Make sure no damage is caused to the vehicle
trim when removing
Release all 4 the rear seat.
sides.
W ith assistance, remove the rear seat backrest.
Both rear seat backrests need to be in an upright position

but not latched for access to retaining bolts.
8. Remove the rear seat backrest hinge(s).
9. Remove the rear armrest retaining screw covers.
10. Remove the rear armrest retaining screws.
Remove the 2 Torx screws.
11. CAUTION: Make sure no damage is caused to the seat

trim when removing the seat armrest.
Remove the rear seat armrest.
12. Release the rear seat backrest cover from the armrest
aperture.
Release the 3 plastic retaining strips from the securing

clips.
13. Remove the cappings from the rear head restraint retaining
posts.
Release the rear backrest cover over the head restraint
posts.
14. Remove the rear seat backrest cushion and cover from the
rear seat backrest.
15. Remove and discard the hog rings.
Remove the 36 hog rings securing the rear 60% seat

backrest cover to the backrest seat cushion.
Remove the 26 hog rings securing the rear 40% seat

backrest cover to the backrest seat cushion.
16. Remove the rear seat backrest cover.
Installation
1. NOTE: Make sure that new hog rings are installed.
NOTE: 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.

Seating - Rear Seat Cushion
Removal
1. Detach the rear seat cushion.
Release the rear seat cushion retaining clips.
Detach the rear seat cushion.
Guide the safety belt buckles through the rear seat

cushion aperture.
Remove the rear seat cushion.
Installation
Seating - Front Seat Height Adjustment Motor
Removal

Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting

4.
5.
6.
7.
8.
another technician.
CAUTION: Take extra care when handling the

component.
Torque: 35 Nm
10. 10. NOTE: Some variation in the illustrations may

occur, but the essential information is always correct.
Torque: 35 Nm


Installation

Seating - Front Seat Control Switch
Removal
2.
3.
4.
Remove and discard the retaining clips.
5.
Installation
1.
2. Install new clips.
3.
4.
5.
6.

Seating - Rear Seat Bolster
Removal
1.
2.
3.
Installation

Glass, Frames and Mechanisms -
Front door window glass regulator retaining screws to BIW 7 - 62
Front door window glass regulator motor retaining screw to panel 2 - 18
Rear door window glass regulator retaining screws to BIW 7 - 62
Rear door window glass regulator motor retaining screw to panel 2 - 18
Rear door glass run retaining nuts 4 - 35
Glass, Frames and Mechanisms - Glass, Frames and Mechanisms -
Component Location
Component Location
ItemDescription
1 W indow regulator motor front passenger
2 W indow control switch - front passenger
3 Door module front passenger
4 W indow control switch RH (right-hand) rear passenger
5 W indow regulator motor RH rear passenger
6 Door module RH rear passenger
7 W indow regulator motor LH (left-hand) rear passenger
8 Door module LH rear passenger
9 W indow control switch LH rear passenger
10 Door module driver's door
11 W indow control switches - driver's door
12 W indow regulator motor driver's door
Glass, Frames and Mechanisms - Glass, Frames and Mechanisms - Overview
Overview
The windshield is manufactured from laminated green-tinted glass with two variants of windshield being available:
standard and heated.
The rear window is manufactured from toughened green-tinted glass. The heated rear window grid-wire and antennas are
incorporated in the rear window. There are two variants of rear window dependant on the TV antenna specification.
The door windows are manufactured from green-tinted toughened glass. The driver and passenger windows are electrically
operated; the rear glass sections in the rear doors are fixed units. Door windows can be operated individually, or by the
driver's window control switch. An anti-trap function is included that stops the window's travel when an obstacle is
detected in the in the window's path.
Glass, Frames and Mechanisms - Glass, Frames and Mechanisms - System
Control Diagram
NOTE: A = Hardwired; N = Medium speed CAN; O = LIN bus
ItemDescription
1 Battery
5 W indow control switches - driver's door
6 Door module driver's door
7 W indow regulator motor driver's door
8 Door module LH (left-hand) rear passenger
9 W indow control switch - LH rear passenger
10 W indow regulator motor LH rear passenger
11 Door module front passenger
12 W indow control switches - front passenger
13 W indow regulator motor front passenger
14 Door module RH (right-hand) rear passenger
15 W indow control switch - RH rear passenger
16 W indow regulator motor RH rear passenger
System Operation
Door Windows
All windows can be operated individually, or by the driver's window control switch. The operation of the windows is
proportional to the switch activation. The driver window can be controlled by 'one touch' in an upward or downward
direction. When the 'one touch' operation is activated in the upwards direction an anti-trap sensor is automatically checked
prior to the window closing. If the anti-trap sensor is inoperative the window will not close. When the anti-trap sensor
detects an obstacle in the window's path, the upward travel of the window will automatically cease. Downward travel of
the window will begin and then stop when a preset time has elapsed.
Electric window operation is enabled while the ignition is in power mode 4 and 6. W hen the switches in the driver's door
are used to operate the passenger windows, the driver's door module outputs a related message on the LIN (local
interconnect network) bus and medium speed CAN (controller area network) bus. The passenger door module responds to
the message by operating the appropriate window. When the child lock is engaged, the rear door modules ignore inputs
from the rear window switches.
End of travel shut off
End of travel shut-off for the window motors is determined by monitoring the current draw of the motors. Each time it
switches on a window motor, the door module measures the window motor current for a preset time. The maximum value
measured within that time is stored as the switch-on current. When the window motor current next exceeds the switch-on
current, the door module assumes the window has reached the end of its travel and switches off the power supply to the
window motor even if a window switch is still being activated.
Anti-trap
The anti-trap function is enabled for window closing in both the inching and one-shot modes. If the anti-trap feature is
activated while a window is closing, the window motor is reversed for a preset period.
A Hall sensor, located in the window regulator motor, monitors the speed of the motor and if the speed decreases below a
set threshold, indicating an obstruction, the power feed to the motor is reversed so the window goes back down for preset
time.
In an emergency the anti-trap function can be overridden by holding the window switch in the one-shot closed position.
After the battery has been disconnected it is necessary to initialize the door window motors to be able to operate the
one-shot up function.
Windshield
The windshield, manufactured from 5mm laminated green-tinted glass is positioned to the vehicle's body by two locator
pins, one in each top corner of the windshield. This allows for centralizing movement of the windshield across the car upon
fitment. The base of the windshield carries a leaf-screen retainer. The windshield is bonded and sealed to the vehicle body
aperture using Polyurethane (PU) adhesive. The windshield finisher is a three-sided extruded flip, taped onto the inner
surface of the glass; this helps to centralize the glass in the aperture.
Two variants of windshield are available:
standard, and
heated.
Interior Mirror and Rain Sensor

The interior mirror and rain sensor mounting positions are located at the top of the windshield.
Refer to: Wipers and Washers (501-16 Wipers and W ashers, Description and Operation).
Rear Window
The rear window, manufactured from toughened 4mm green-tinted glass, is positioned to the vehicle's body by two locator
pins, one in each top corner of the windshield. This allows for the centralizing movement of the windshield across the car
upon fitment. The window is bonded and sealed to the vehicle body aperture using PU adhesive. The window finisher is a
three-sided extruded flip, taped onto the inner surface of the glass; this helps to centralize the glass in the aperture.
The heated rear window grid wire and antennas are incorporated in the rear window. There are two derivatives of rear
window dependant on the TV antenna specification.
Refer to: Video System (415-01 Information and Entertainment System, Description and Operation).
Door Windows
The door windows are manufactured from 4.85mm green-tinted toughened glass. The driver and passenger windows are
electrically operated, and are raised and lowered by a cable mechanism; the rear glass sections in the rear doors are fixed
units.
All windows can be operated individually, or by the driver's window control switch. The operation of the windows is
proportional to the switch activation. The driver window can be controlled by 'one touch' in an upward or downward
direction. When the 'one touch' operation is activated in the upwards direction an anti-trap sensor is automatically checked
prior to the window closing. If the anti-trap sensor is inoperative the window will not close. When the anti-trap sensor
detects an obstacle in the window's path, the upward travel of the window will automatically cease. Downward travel of
the window will begin and then stop when a preset time has elapsed.
Glass, Frames and Mechanisms - Glass, Frames and Mechanisms
For a detailed description of the Glass, Frames and Mechanisms, refer to the relevant Description and Operation section in
the workshop manual. REFER to: (501-11 Glass, Frames and Mechanisms)
Glass, Frames and Mechanisms (Description and Operation),

Glass, Frames and Mechanisms (Description and Operation),
Glass, Frames and Mechanisms (Description and Operation).
vehicle.
Visual Inspection
W indow glass Fuse(s)
W indow regulator Window motor
Loose or corroded electrical connector(s)
Switch
Circuit(s)
4. 4. If the concern is not visually evident, check for Diagnostic Trouble Codes (DTCs) and refer to the DTC Index.
DTC Index
NOTE: If the control module is suspect and the vehicle remains under manufacturer warranty, refer to the W arranty 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.

B109712 Heated Heated windshield relay Carry out any pinpoint tests associated with this DTC using the
W indshield control circuit - short to manufacturer approved diagnostic system. Refer to the electrical
Relay power circuit diagrams and check heated windshield relay control
B109714 Heated Heated windshield relay Refer to the electrical circuit diagrams and check heated
W indshield control circuit - short to windshield relay control circuit for short to ground, open circuit
Relay ground, open circuit
B117C07 Rear Power Mechanical failure Check rear window mechanism for mechanical failure
W indow Up
B117C72 Rear Power Actuator stuck open Suspect the rear door module. Check and install a new module
W indow Up as required, refer to the new module/component installation
B117C73 Rear Power Actuator stuck closed Suspect the rear door module. Check and install a new module
W indow Up as required, refer to the new module/component installation
B117C92 Rear Power Performance or incorrect Refer to the electrical circuit diagrams and check rear door
W indow Up operation module power and ground supplies
B117D72 Rear Power Actuator stuck open Suspect the rear door module. Check and install a new module
W indow Down as required, refer to the new module/component installation
B117D73 Rear Power Actuator stuck closed Suspect the rear door module. Check and install a new module
W indow Down as required, refer to the new module/component installation
B117E07 Front Power Mechanical failure Check front window mechanism for mechanical failure
W indow Up
B117E72 Front Power Actuator stuck open Suspect the DDM. Check and install a new DDM as required,
W indow Up refer to the new module/component installation note at the top
of the DTC Index
B117E73 Front Power Actuator stuck closed Suspect the DDM. Check and install a new DDM as required,
W indow Up refer to the new module/component installation note at the top
of the DTC Index
B117F72 Front Power Actuator stuck open Suspect the DDM. Check and install a new DDM as required,
W indow Down refer to the new module/component installation note at the top
of the DTC Index
B117F73 Front Power Actuator stuck closed Suspect the DDM. Check and install a new DDM as required,
W indow Down refer to the new module/component installation note at the top
of the DTC Index
B118929 Front W indow Front window hall Carry out any pinpoint tests associated with this DTC using the
Position Sensor position sensor - signal manufacturer approved diagnostic system
invalid
B118A29 Rear Window Rear window hall Carry out any pinpoint tests associated with this DTC using the
Position Sensor position sensor - signal manufacturer approved diagnostic system
invalid
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.
Glass, Frames and Mechanisms - Door Window Regulator Motor
Removal
2. 2. NOTE: Right-hand shown, left-hand similar.
3. 3. NOTE: Components removed for clarity.

4. 4. NOTE: Make sure the door window glass is in the
fully closed position.
NOTE: Components removed for clarity.
Apply suitable adhesive tape to the door window

glass and over the door frame, to prevent the
door window glass from damage.
5. 5. CAUTION: Make sure the drum remains in

position. Use a suitable flat blade screwdriver to secure
the drum while seperating the motor.
Installation
1.
Torque: 5 Nm
2. 2. CAUTIONS:
Install all the bolts finger tight before final

tightening.
Care must be taken not to damage the outer door

panel.
Install the retaining bolt 1 to the witness mark

on the body.
Torque:
1 1.9 Nm
2 5 Nm
3. 3. NOTE: Components removed for clarity.
Torque: 1.5 Nm
Glass, Frames and Mechanisms - Driver Door Window Control Switch
Removal
1. For additional information, refer to: Front Door Trim Panel
Installation).
2.
3.
Installation
Glass, Frames and Mechanisms - Front Door Window Glass
Removal
1.
2.
3.
Installation

2.
Glass, Frames and Mechanisms - Front Door Window Regulator and Motor
Special Tool(s)
Door glass release lever
501-114
Removal

3. WARNING: Do not allow the glass to drop.
4. For additional information, refer to: Front Door Trim Panel

Installation).
6.
TORQUE: 7 Nm
Installation
Glass, Frames and Mechanisms - Rear Door Fixed Window Glass
Removal
1. Lower the rear door window glass.
2. Remove the rear door trim panel.
Refer to: Rear Door Trim Panel (501-05 Interior Trim and
3.
4.
5.
6.
7.
8.
9.
11.
12.
13.
Installation
2. Tighten the Torx screws securing the fixed window glass after
alignment of the bright external trim.
Glass, Frames and Mechanisms - Rear Door Window Glass
Removal
1. Refer to: Rear Door Fixed Window Glass (501-11 Glass, Frames and
Mechanisms, Removal and Installation).
2. Refer to: Rear Door Window Regulator and Motor (501-11 Glass,
Frames and Mechanisms, Removal and Installation).
3.
Installation

Glass, Frames and Mechanisms - Rear Door Window Regulator and Motor
Removal
1. Remove the rear door speaker.
Refer to: Rear Door Speaker (415-01 Information and Entertainment

System, Removal and Installation).
2.
3. 3. WARNING: Do not allow the glass to drop.
NOTE: The door glass should be lowered by

approximately one third.
Torque: 7 Nm
Installation

Glass, Frames and Mechanisms - Rear Window Glass
Removal
CAUTIONS:
Always protect paintwork and glass when removing exterior components.
Always protect the interior components when removing body glass.
Lay the glass on felt covered supports. Do not stand on edge as this can cause chips which subsequently develop
into cracks.
NOTE: The following equipment is required: l Cutting wire and handles l Kent knife l Glazing knife l Windshield
replacement kit l Sealant applicator gun l Suction cups l A felt covered table or stand to support glass

2.
Remove the polyurethane (PU) adhesive cap and
heat the PU adhesive for a minimum of 30
minutes.
3.
4. 4. CAUTIONS:
Protect the surrounding components.

damage.

another technician.
Installation
1. 1. CAUTION: Make sure that the mating faces are

clean and free of foreign material.
Prepare the window glass, window glass flange

and trimmed PU adhesive in accordance with the
instructions included with the PU adhesive kit.
2. 2. CAUTION: Touching the adhesive surface will
impair rebonding.
NOTE: Install new spacers.
3.
4. 4. CAUTION: Make sure that no excess sealant

residue is evident.
If water is used as a means for the leak check,

then allow sealant to dry before testing.
Spray water around the windshield glass, mark
any area that leaks. Dry the windshield glass
and sealant before applying additional sealant.
5.

Glass, Frames and Mechanisms - Windshield Glass
Removal
and Installation).
2. Refer to: A-Pillar Trim Panel (501-05 Interior Trim and

3. Refer to: Rain Sensor (501-16 W ipers and W ashers, Removal and
Installation).
4.
Remove the polyurethane (PU) adhesive cap and
heat the PU adhesive for a minimum of 30
minutes.
5.
6. 6. CAUTIONS:
Protect the surrounding components.

damage.
another technician.
Installation
1. 1. CAUTION: Make sure that the mating faces are

clean and free of foreign material.
Prepare the window glass, window glass flange

and trimmed PU adhesive in accordance with the
instructions included with the PU adhesive kit.
2. 2. CAUTION: Touching the adhesive surface will

impair rebonding.

another technician.
CAUTIONS:

Make sure that equal pressure is applied to the

full length of the component.
If the ambient temperature falls below 10

degrees C, apply warm air (25 degrees C)
continuously for 15 minutes.
4. 4. CAUTION: Make sure that no excess sealant
residue is evident.
If water is used as a means for the leak check,

then allow sealant to dry before testing.
Spray water around the windshield glass, mark
any area that leaks. Dry the windshield glass
and sealant before applying additional sealant.
5.
6. Refer to: Rain Sensor (501-16 W ipers and W ashers, Removal and
Installation).

and Installation).
Instrument Panel and Console -
Instrument panel retaining bolts 20 15 -
Floor console retaining nuts 5 - 44
Instrument panel support brackets retaining bolts 9 - 80
Instrument panel support brackets retaining nuts 9 - 80
Instrument Panel and Console - Instrument Panel - Component Location
COMPONENT LOCATION
ItemDescription
1 Cross car beam
2 JaguarSense glovebox module
3 Energy absorbing brackets (2 off)
Instrument Panel and Console - Instrument Panel - Overview
OVERVIEW
The instrument panel incorporates a magnesium cross car beam. North American Specification (NAS) vehicles also feature a
pair of energy absorbing brackets. The energy absorbing brackets are mounted behind the driver's side of the instrument
panel. Each is secured to the cross car beam by 2 screws.
The cross car beam acts as a support and provides mounting points for the instrument panel top pad. The instrument
panel top pad supports various other system components. These include ducting, vents and registers for the climate
control system and the passenger airbag. For additional information, refer to:
Safety Belt System (501-20A Safety Belt System, Description and Operation),
Air Bag and Safety Belt Pretensioner Supplemental Restraint System (SRS) (501-20B Supplemental Restraint System,
Pedestrian Protection System (501-20C Pedestrian Protection System, Description and Operation).
Instrument Panel and Console - Instrument Panel - System Operation and
System Operation
JAGUARSENSE OPERATION
JaguarSense uses a capacitive proximity sensor which operates along similar lines to a capacitor. The sensor comprises a
single capacitor conductor plate. The second capacitor conductor plate is the operators hand, known as the target. The
capacitor dielectric is the air gap between the sensor conductor plate and the target.
As the target approaches the proximity sensor, current flow through the conductor plate increases. Circuitry within the
sensor module detects the rise in current flow and provides a signal output to the relevant control module. Both the glove
box and interior lamp JaguarSense systems are controlled by the CJB (central junction box).
The glove box proximity sensor is also inhibited if the anti-theft alarm system is armed and if valet mode is selected using
the Touch Screen Display (TSD).
JAGUARSENSE DESCRIPTION
The conventional glove box release and overhead console lamp switches have been replaced with capacitive proximity
sensors. This feature is known as 'JaguarSense'. The glove box proximity sensor takes the form of a roundel located above
the inboard end of the glove box. The interior lamp assembly contains 3 capacitive proximity sensors located behind the
lamp lense.
The glove box proximity sensor module also incorporates 2 anti-wipe sensors. The anti-wipe sensors are located on either
side of the proximity sensor and can detect a wiping movement along the instrument panel veneer. When this movement
is detected the proximity sensor is temporarily inhibited.
Instrument Panel and Console - Floor Console
Removal

2. Refer to: Floor Console Cup Holder (501-12 Instrument Panel and
3. 3. CAUTIONS:
Cover fiber optic cable connectors to minimize

dust ingress and avoid bending the cables in a radius of
less than 30 mm.
4. Torque: 9 Nm
5.
6. Torque: 6 Nm
7.
8. Torque: 6 Nm
9.
10.
Installation

Instrument Panel and Console - Floor Console Cup Holder
Removal

2. Refer to: Floor Console Double Cup Holder (501-12 Instrument Panel
3.

component.

Installation
1. 1. NOTE: Make sure that the veneer trim panel is correctly installed
and secured.
Instrument Panel and Console - Floor Console Double Cup Holder
Removal

2. Refer to: Transmission Control Switch (TCS) (307-05 Automatic

Installation).
3.
4.
5.
6. Open the floor console single cup holder.

7. Carefully release the front edge of the floor console
double cup holder from under the rear edge of the floor
console single cup holder.
8.
9. 9. CAUTION: Take extra care not to damage

the component.
NOTE: Do not disassemble further if the

component is removed for access only.
Installation
and secured.
Instrument Panel and Console - Floor Console Side Trim Panel
Removal
NOTE: LHD right-hand floor console side trim panel shown, LHD left-hand and both RHD floor console side trim panels
are similar.
1. Recline the front seats and move to the rear most position.

instrument panel.
3.
4.
5.
6.

center console.
8.
9.

11.
Installation
and secured.

Instrument Panel and Console - Glove Compartment
Removal
1. Refer to: Passenger Side Register (412-01 Climate Control, Removal

and Installation).
2.
3. 3. CAUTION: Fixings must be started by hand to

avoid damaging threads.
Upper 3 bolts.
Torque: 2.5 Nm
Lower 3 bolts.
Torque: 9 Nm
4.
5. 5. NOTE: Do not disassemble further if the component is

6. Using a screwdriver, carefully release the latch and
open the glove compartment.
7.
8.
Installation

Instrument Panel and Console - Instrument Panel Console
Removal

2. Refer to: Cooling System Draining, Filling and Bleeding (303-03A,


5. Refer to: Floor Console (501-12 Instrument Panel and Console,




10. Refer to: Steering Wheel (211-04 Steering Column, Removal and
Installation).

coolant.
12. 12. CAUTION: Take care not to damage the O-ring
seals during installation.
Torque: 9 Nm
13.
14. Torque: 30 Nm
15.
16. Torque: 4 Nm
17.
18. Torque: 12 Nm
19. Torque: 9 Nm
20.
21. Torque: 20 Nm
22. Torque: 20 Nm
23. 23. CAUTIONS:

damage.
Installation

Instrument Panel and Console - Instrument Panel Lower Trim Panel
Removal
1.
2.
3.
5.
6.
7. 7. CAUTION: Fixings must be started by hand to
avoid damaging threads.
Upper 3 bolts.
Torque: 2.5 Nm
Lower 3 bolts.
Torque: 9 Nm
8.
10.
11.
Installation

Instrument Panel and Console - Overhead Console
Removal

edges of the component.
2.

wiring harnesses.
Take precautions to avoid any electrostatic

charging, which could damage this comopnent.
5.

wiring harnesses.
7.
8.
Installation
wiring harnesses.

Handles, Locks, Latches and Entry Systems -
Front and rear door latch retaining screw 7 - 62
Front and Rear exterior door handle / Door lock captive retaining screw 4 - 36
Front and Rear Exterior Door handle seperate retaining screw 3 - 28
Front and Rear Door striker retaining screw 25 18 -
Interior Door handle retaining Screw 1.3 - 11.5
Hood latch Reataining screw 10 8 -
Hood Striker Retaining screw 22 17 -
Trunk Latch Retaining screw 20 15 -
Trunk Striker Retaining screw 22 17 -
Trunk Lock Retaining screw 3 - 28
Handles, Locks, Latches and Entry Systems - Handles, Locks, Latches and
Entry Systems - Component Location
Locks and Latches
ItemDescription
1 RH (right-hand) front door handles, latch and motor
2 RH rear door handles, latch and motor
3 Fuel filler door and motor
4 Luggage compartment emergency key barrel
5 Luggage compartment latch and motor
6 LH (left-hand) rear door handles, latch and motor
7 Door emergency key barrel - LH front door only
8 LH front door handles, latch and motor
9 Engine-compartment-lid release-lever and cable
10 Engine-compartment-lid striker
11 Engine-compartment-lid safety hook and guide
Central Locking and Keyless Vehicle Locking
ItemDescription
2 Keyless vehicle, RH front door antenna * integral to the handle
3 Keyless vehicle, RH rear door antenna * integral to the handle
4 Central locking radio frequency receiver
6 Keyless vehicle, luggage compartment antenna *
8 Keyless vehicle, LH rear door antenna * integral to the handle
9 Keyless vehicle, LH front door antenna * integral to the handle
Comments:
(* Only w ith passive entry option fitted)
Entry Systems - Overview
The hinged panels are secured with latches and strikers. A remotely operated central locking system controls the locking
and unlocking of the door and luggage compartment latches. A radio frequency Smart Key allows the vehicle to be locked
and unlocked by pressing the appropriate handset buttons. Two levels of central locking system are available:
remote central locking, and an

optional passive entry system.
The remote central locking system, provides locking and unlocking of the vehicle from inside and outside of the vehicle.
The system is operated using buttons on the Smart Key, which transmits radio frequency signals to the central locking
radio frequency receiver.
On vehicles fitted with the optional passive entry system, the vehicle can be unlocked without the use of a key or pressing
buttons on the Smart Key. The Smart Key operates the passive entry system.
Entry Systems - System Operation and Component Description
Control Diagram
Central Locking
ItemDescription
Note: A = Hardwired; N = Medium speed CAN (controller area network); O = LIN (local interconnect network) bus
1 Battery
2 Megafuse (250 A)
4 Door module - front passenger
5 Door ajar switch - front passenger
6 Door latch - front passenger
7 Door module - RH (right-hand) rear passenger
8 Door latch - RH rear passenger
9 Door ajar switch - RH rear passenger
10 Door latch - LH (left-hand) rear passenger
11 Door ajar switch - LH rear passenger
12 Door module - LH rear passenger
13 Door ajar switch - driver door
14 Door latch - driver door
15 Door module - driver door
17 Central-locking radio-frequency receiver
Luggage Compartment Lid and Fuel Filler Door Locking
ItemDescription
Note: A = Hardwired; N = Medium speed CAN
1 Battery
2 Megafuse (250 A)
3 RJB
4 Locking motor - fuel door
5 Keylesss vehicle module
6 Emergency key barrel - luggage compartment
7 Release latch - luggage compartment lid
8 Ajar switch - luggage compartment lid
9 Fascia switch - luggage compartment lid
11 CJB
Passive Entry System
ItemDescription
Note: A = Hardwired; N = Medium speed CAN
1 Battery
2 Megafuse (250 A)
3 CJB
5 Keylesss vehicle module
6 Door handle, lock/unlock switch and antenna - front passenger
7 Door latch, fast latch - front passenger
8 Door latch, fast latch - RH rear passenger
9 Door handle, lock/unlock switch and antenna - RH rear passenger
10 Door latch, fast latch - LH rear passenger
11 Door handle, lock/unlock switch and antenna - LH rear passenger
12 Door latch, fast latch - driver door
13 Door handle, lock/unlock switch and antenna - driver door
System Operation
The hinged panels are secured with latches and strikers. A remotely operated central locking system controls the locking
and unlocking of the door and luggage compartment latches. A radio frequency Smart Key allows the vehicle to be locked
and unlocked by pressing the appropriate handset buttons. Two levels of central locking system are available: remote
central locking and an optional passive entry system.
The passive entry and associated passive start system allows the driver to unlock and start the vehicle without using a
vehicle key in a door-lock or ignition switch. The passive entry system is an optional fitment while the passive start
system is a standard fitment on all vehicles. The passive start system is combined with the passive anti-theft
immobilization system.
Emergency access to the vehicle is provided by two concealed key barrels: one located in the front left-hand door handle
and one located on the underside of the luggage compartment lid finisher. An emergency, removable key blade is fitted
into the Smart Key.
Operation of either key barrel unlocks the vehicle but does not disarm the alarm system. The key barrels in the door and
luggage compartment lid are concealed by a plastic cover which can be removed by inserting the blade of the emergency
key into a slot in the cover.
Locking and unlocking conditions using the emergency key in the door key barrel:
If the alarm is not armed the vehicle can be centrally unlocked.

If the alarm is armed the door only can be opened and the alarm will be triggered.
The vehicle cannot be double locked or the alarm system armed using the emergency key.
The vehicle can be centrally locked and unlocked from inside using the interior handle release levers on the front doors
only. Central locking and unlocking can also be performed using lock and unlock buttons on the vehicle's fascia. The driver
can select locking options, single point entry or drive away locking for example, from a menu available on the touch
screen.
Central Locking Radio Frequency Remote System

The radio frequency central locking system, provides locking and unlocking of the vehicle from inside and outside of the
vehicle. The system is operated using buttons on the Smart Key, which transmits radio frequency signals to the central
locking radio frequency receiver.
The system provides additional security by double-locking the doors from outside the vehicle if the lock button, on the
Smart Key, is pressed twice within 3 seconds; this function is not applicable in North American Specification (NAS) and
Japanese markets.
Additional buttons on the Smart Key provide for the convenience operation of the luggage compartment lid release,
headlamp delay and panic alarm functions. A global open or close feature is also available in certain markets using the
lock/unlock buttons.
Passive Entry
On vehicles fitted with the optional passive entry system, the vehicle can be unlocked without the use of a key blade or
pressing buttons on the Smart Key. The Smart Key operates the passive entry system in addition to the passive start
system.
The passive entry system is controlled by the keyless vehicle module and five low frequency antennas. One antenna
located in each door handle and one antenna located behind the rear bumper cover.
When a vehicle door handle is pulled to the first five-percent of its travel and the Smart Key is within one meter of the
handle; the Smart Key receives the low-frequency signal transmitted from the keyless vehicle module. The Smart Key
responds with a radio frequency transmission of its authorization code. The radio frequency signal is received by the
central locking radio-frequency receiver and passed to the keyless vehicle module which checks and approves the code as
valid. Once the handle is pulled to eighty percent of its travel the keyless vehicle module then drives the fast latch directly
to allow the door to be opened. The keyless vehicle module also transmits an unlock request to the CJB. The CJB then
passes an unlock request to the door modules.
Locking of the vehicle is performed by pressing one of the buttons located on each exterior door handle, with the Smart
Key within a one meter range of the vehicle. W hen the door handle button is pressed, the keyless vehicle module
transmits a low-frequency signal via the low-frequency handle antenna to the Smart Key. The Smart Key transmits a radio
frequency signal which is verified by the keyless vehicle module and allows the doors to be locked or double locked and the
alarm system to be armed.
To double lock the vehicle, the button on the exterior door handle must be pressed twice within three seconds, with the
Smart Key within one meter range of the vehicle.
If a door, engine-compartment lid or the luggage compartment lid is ajar when an attempt to lock the vehicle is made, an
error tone is emitted and no locking action will occur.
Engine Compartment Lid Latches
Two engine-compartment lid latches are located on the front crossmember. An engine-compartment lid release lever is
located below the instrument panel on the left-hand 'A' pillar and is connected with a cable to the latches. An engine-
compartment lid ajar switch is integrated in the engine-compartment lid latch.
Door Latches
The door latches are located at the rear of each door and engage with a striker on the adjacent pillar. Each door latch
motor assembly contains micro-switches for lock, unlock and door ajar. Motors provide for the central door locking and the
double locking feature. The electrical control for the door latch components is provided by the CJB and RJB via the driver's
and passenger door modules.
The interior door handles are connected by a cable to the latch release mechanisms. The interior door handles also
incorporate a locking facility to allow the doors to be locked from inside the vehicle when all the doors are closed. If a door
is ajar the locking feature is inhibited.
Luggage Compartment Lid Latch

The luggage compartment latch is attached to the bottom of the lid. The latch can be released electrically by pressing the
interior release button located on the outboard side of driver's lower knee bolster; a release button is also provided on the
Smart Key. There is also a release switch on the underside of the luggage compartment lid finisher.
On NAS vehicles an emergency release cable is attached to the latch. This allows the latch to be manually opened by
pulling a handle located in the luggage compartment lid interior trim.
Fuel Filler Door

The fuel filler door is electrically locked by a motor located on the fuel door housing. The fuel door is locked when the
vehicle is locked and alarmed. The fuel door can be opened when the vehicle is unlocked or locked:
via an interior handle,

via drive-a-way locking,
via the lock switch on the fascia,
via the external door key barrel.
Handles, Locks, Latches and Entry Systems - Locks, Latches and Entry
Systems

For a detailed description of the handles, locks, latches and entry systems, refer to the relevant Description and Operation
sections in the workshop manual. REFER to: (501-14 Handles, Locks, Latches and Entry Systems)
Handles, Locks, Latches and Entry Systems (Description and Operation),

Handles, Locks, Latches and Entry Systems (Description and Operation),
Handles, Locks, Latches and Entry Systems (Description and Operation).
vehicle.
NOTE: For remote keyless entry issues,

REFER to: Remote Keyless Entry (RKE) Module (419-10 Multifunction Electronic Modules, Diagnosis and Testing).
Visual Inspection
Misaligned door(s), hood or luggage compartment lid Fuse(s)
Door latch(s) Wiring harness
Actuating rod(s) Electrical connector(s)
Exterior door handle(s) Door lock actuator(s)
Interior door handle(s) Remote transmitter batteries
Door lock cylinder Vehicle battery
Cable(s) Remote transmitter
Luggage compartment lid exterior release switch Door lock switch(s)
DTC Index

B108413 Boot/Trunk Motor Trunk latch open signal Refer to the electrical circuit diagrams and check trunk
Close Switch circuit - open circuit latch open signal circuit for open circuit
B10EB11 Driver door double Driver door double locking Refer to the electrical circuit diagrams and test driver door
locking motor motor control circuit - short double locking motor control circuit for short ground
to ground
locking motor motor control circuit - short using the manufacturer approved diagnostic system. Refer
to power, open circuit to the electrical circuit diagrams and test driver door
double locking motor control circuit for short to power or
open circuit
B10EC11 Passenger door Passenger door double Refer to the electrical circuit diagrams and test passenger
double locking locking motor control circuit door double locking motor control circuit for short ground
motor - short to ground
B10EC15 Passenger door Passenger door double Carry out any pinpoint tests associated with this DTC
double locking locking motor control circuit using the manufacturer approved diagnostic system. Refer
motor - short to power, open to the electrical circuit diagrams and test passenger door
circuit double locking motor control circuit for short to power or
open circuit
B10ED11 Rear door driver Rear door driver side double Refer to the electrical circuit diagrams and test rear door
side double locking motor control circuit driver side double locking motor control circuit for short
locking motor - short to ground ground
side double locking motor control circuitusing the manufacturer approved diagnostic system. Refer
locking motor - short to power, open to the electrical circuit diagrams and test rear door driver
circuit side double locking motor control circuit for short power,
open circuit
B10EE11 Rear door Rear door passenger side Refer to the electrical circuit diagrams and test rear door
passenger side double locking motor control passenger side double locking motor control circuit for
double locking circuit - short to ground short ground
motor
passenger side double locking motor control using the manufacturer approved diagnostic system. Refer
double locking circuit - short to power, to the electrical circuit diagrams and test rear door
motor open circuit passenger side double locking motor control circuit for
short power, open circuit
B110811 Driver door central Driver door central locking Refer to the electrical circuit diagrams and test driver door
locking motor motor control circuit - short central locking motor control circuit for short ground
to ground
locking motor motor control circuit - short using the manufacturer approved diagnostic system. Refer
to power, open circuit to the electrical circuit diagrams and test driver door
central locking motor control circuit for short to power,
open circuit
B110A11 Rear door driver Rear driver door central Refer to the electrical circuit diagrams and test rear driver
side central locking motor control circuit door central locking motor control circuit for short ground
locking motor - short to ground
B110A15 Rear door driver Rear driver door central Refer to the electrical circuit diagrams and test rear driver
side central locking motor control circuit door central locking motor control circuit for short to
locking motor - short to power, open power, open circuit
circuit
B114511 Glovebox Locking Glovebox latch locking Carry out any pinpoint tests associated with this DTC
Motor motor circuit - short to using the manufacturer approved diagnostic system. Refer
ground to the electrical circuit diagrams and check glovebox latch
locking motor circuit for short to ground
B114512 Glovebox Locking Glovebox latch locking Refer to the electrical circuit diagrams and check glovebox
Motor motor control circuit - short latch locking motor control circuit for short to power
to power
B114513 Glovebox Locking Glovebox latch locking Refer to the electrical circuit diagrams and check glovebox
Motor motor control circuit - open latch locking motor control circuit for open circuit
circuit
B117513 Driver Door Ajar Driver door ajar switch Refer to the electrical circuit diagrams and check driver
Switch signal circuit - open circuit door ajar switch signal circuit for open circuit
B11C013 Driver Side Rear Left rear door ajar switch Refer to the electrical circuit diagrams and check left rear
Door Ajar Switch signal circuit - open circuit door ajar switch signal circuit for open circuit
B11C113 Passenger Side Right rear door ajar switch Refer to the electrical circuit diagrams and check right rear
Rear Door Ajar signal circuit - open circuit door ajar switch signal circuit for open circuit
Switch
B122223 Master Master lock or unlock switch Refer to the electrical circuit diagrams and check master
Lock/Unlock digital input circuit - signal lock and unlock switch digital input circuits for short to
Switch stuck low ground, open circuit
B111D12 Boot/Trunk Motor Luggage compartment lid Carry out any pinpoint test associated with this DTC using
Open latch actuator control circuit the manufacturer approved diagnostic system. Refer to the
- short to power electrical circuit diagrams and check luggage compartment
lid latch actuator control circuit for short to power
B111D14 Boot/Trunk Motor Luggage compartment lid Carry out any pinpoint test associated with this DTC using
Open latch actuator control circuit the manufacturer approved diagnostic system. Refer to the
- short to ground, open electrical circuit diagrams and check luggage compartment
circuit lid latch actuator control circuit for short to ground, open
circuit
B111E11 Boot/Trunk Lamps Luggage compartment lamp Carry out any pinpoint test associated with this DTC using
control circuit - short to the manufacturer approved diagnostic system. Refer to the
ground electrical circuit diagrams and check luggage compartment
B111E12 Boot/Trunk Lamps Luggage compartment lamp Refer to the electrical circuit diagrams and check luggage
control circuit - short to compartment lamp control circuit for short to power
power
B111E13 Boot/Trunk Lamps Luggage compartment lamp Refer to the electrical circuit diagrams and check luggage
control circuit - open circuit compartment lamp control circuit for open circuit
B113E12 External External luggage Refer to the electrical circuit diagrams and check external
Boot/Trunk compartment lid release luggage compartment lid release switch digital input
Release Switch switch digital input circuit - circuit for short to power
short to power
B113E23 External External luggage Carry out any pinpoint test associated with this DTC using
Boot/Trunk compartment lid release the manufacturer approved diagnostic system. Refer to the
Release Switch switch digital input circuit - electrical circuit diagrams and check external luggage
signal stuck low compartment lid release switch digital input circuit for
short to ground
B126113 Fuel Flap/Door Fuel filler flap digital input Refer to the electrical circuit diagrams and check fuel filler
Release Switch signal circuit - open circuit flap digital input signal circuit for open circuit
B1C9112 Fuel Flap/Door Fuel filler flap locking motor Refer to the electrical circuit diagrams and check fuel filler
Lock Relay Coil control circuit - short to flap locking motor control circuit for short to power
Circuit power
B1C9114 Fuel Flap/Door Fuel filler flap locking motor Refer to the electrical circuit diagrams and check fuel filler
Lock Relay Coil control circuit - short to flap locking motor control circuit for short to ground, open
Circuit ground, open circuit circuit
passenger side window switch. Check and install a new
passenger side window switch
U200424 Auxiliary Switch Left or right rear door local Check for stuck rear window switch. Refer to the electrical
Pack switch - signal stuck high circuit diagrams and check left or right rear door local
switch circuit for short circuit
U201011 Switch Rear window switch Refer to the electrical circuit diagrams and check rear
illumination illumination circuit - short window switch illumination circuit for short to ground
to ground
U201324 Switch Pack Signal stuck high Clear DTC and re-test. If DTC remains, install a new driver
door switch pack
Handles, Locks, Latches and Entry Systems - Exterior Front Door Handle
Removal
1. 1. NOTE: Remove the screw sufficiently, only to release

the component.
Torque: 4 Nm

wiring harnesses.
NOTE: Secure the connection in the service position.
4.
Installation
1. 1. CAUTION: Make sure that the wiring harnesses

are correctly located.

Handles, Locks, Latches and Entry Systems - Exterior Luggage
Compartment Lid Release Switch
Removal
All vehicles
2.
3. Torque: 3 Nm
4.
Vehicles with parking aid

5.
All vehicles
6.
Installation

Handles, Locks, Latches and Entry Systems - Exterior Rear Door Handle
Removal

the component.
Torque: 4 Nm

wiring harnesses.
NOTE: Secure the connection in the service position.
4.
Installation
1. 1. CAUTION: Make sure that the wiring harnesses

are correctly located.

Handles, Locks, Latches and Entry Systems - Front Door Latch
Special Tool(s)
501-114
Release Lever, Door Glass
Removal
1. 1. WARNING: Do not allow the glass to drop.
NOTE: The door glass should be lowered by

approximately one third.
Special Tool(s): 501-114
Refer to: Exterior Front Door Handle (501-14 Handles, Locks, Latches
and Entry Systems, Removal and Installation).

Torque: 7 Nm
Torque: 3 Nm
Torque: 7 Nm

11. 11. NOTE: Note the position of the wiring harness.

13.
14.
15.
Installation
2.
Handles, Locks, Latches and Entry Systems - Front Door Lock Cylinder
Removal
1.

the component.
Torque: 4 Nm
Installation

Handles, Locks, Latches and Entry Systems - Interior Front Door Handle
Removal
2.
Installation

Handles, Locks, Latches and Entry Systems - Luggage Compartment Lid
Latch Actuator
Removal
1. Refer to: Luggage Compartment Lid Lock Cylinder (501-14 Handles,

Locks, Latches and Entry Systems, Removal and Installation).
2. Torque: 20 Nm
Installation

Handles, Locks, Latches and Entry Systems - Luggage Compartment Lid
Lock Cylinder
Removal
2.
3. Torque: 3.2 Nm
4.
Installation

Handles, Locks, Latches and Entry Systems - Rear Door Latch
Removal
1. Remove the rear door window regulator and motor.
Refer to: Rear Door Window Regulator and Motor (501-11 Glass,
Frames and Mechanisms, Removal and Installation).
2. Remove the rear door exterior handle.
Refer to: Exterior Rear Door Handle (501-14 Handles, Locks, Latches
and Entry Systems, Removal and Installation).
3. Torque: 3 Nm
4.
5. Torque: 7 Nm
6.
7. 7. CAUTION: Note of the routing of the wiring

harnesses.
9.
10.
11.
Drill out the rivet.
Release the clip.
12. 12. CAUTION: Note of the routing of the wiring

harnesses.
13.
Installation
1. 1. CAUTION: Make sure that the wiring harnesses are correctly

located.

Wipers and Washers -
W iper arm retaining nuts 22 16.2 194.7
W iper linkage bolts / screws 11 8.1 97.4
Wipers and Washers - Wipers and Washers - Component Location
COMPONENT LOCATION
ItemDescription
1 W asher reservoir
2 W iper motor and linkage assembly
3 W iper/washer switch - RH (right-hand) steering column multifunction switch
4 Rain/light sensor
6 Headlamp washer jets (2 off)
Wipers and Washers - Wipers and Washers - Overview
OVERVIEW
The wipers and washers comprise a windshield wiper system with a conventional wiper linkage and 2 wiper blades and a
windshield washer with jets located on the wiper arms. A headlamp powerwash is available on certain models.
The front wipers have 4 operational states:
Flick wipe
Auto
Slow wipe
Fast wipe.
Operation of the windshield wipers and washers and the headlamp powerwash is controlled by the CJB (central junction
box) in response to driver inputs and signals from the rain/light sensor. The instrument cluster monitors the condition of
the wiper/washer control switch and transmits driver requests to the CJB over the medium speed CAN (controller area
network) bus.
The 'Auto' function requires an input from the rain sensor. The rain sensor is mounted on the inner surface of the
windshield and transmits an infra-red signal to determine the amount of water on the outer surface of the windshield. A
value is then transmitted to the CJB over the LIN (local interconnect network) bus.
Wipers and Washers - Wipers and Washers - System Operation and
Control Diagram
NOTE: A = Hardwired; N = Medium speed CAN (controller area network) bus; O = LIN (local interconnect network) bus
ItemDescription
1 Battery
3 W iper motor
4 Headlamp washer pump
5 Rain/Light sensor
6 W asher reservoir fluid level switch
7 W indshield washer pump
8 W iper/Washer switch - RH (right-hand) steering column multifunction switch
System Operation
WINDSHIELD WIPERS
Operation of the wipers and washers is controlled by the CJB in response to driver inputs from the wiper control switch and
signals from the rain/light sensor. The instrument cluster monitors the condition of the wiper/washer control switch and
transmits driver requests to the CJB over the medium speed CAN bus.
The wiper control switch is connected via hardwired connections to the instrument cluster. The instrument cluster outputs
on 4 wires a reference voltage to the wash/wipe switch, the auto wiper switch, the wiper switch and the flick wipe switch.
All the switches are connected to the instrument cluster on a common ground. Each switch function is connected to ground
via a resistor or series of resistors and the instrument cluster monitors the ground signal and determines which function
has been selected. The instrument cluster then outputs the appropriate message on the medium speed CAN bus to the
CJB which responds to the requested wiper function. The CJB then activates the appropriate function either directly or via
relays in the EJB for the wipers and headlamp powerwashers.
Speed Dependent Mode
When the wipers are operating, a vehicle speed signal received by the CJB on the high speed CAN bus is used to operate a
speed dependent mode. If the wipers are in fast wipe and the vehicle speed decreases to below 2 km/h (1.2 mph), the
wipers will reduce to the normal wipe speed. W hen the vehicle speed increases to above 8 km/h (5 mph) the fast wiper
speed selection is restored. If slow speed is selected and the vehicle speed drops below 2km/h (1.2 mph), the wipers will
operate in the intermittent mode. When the vehicle speed increases to above 8 km/h (5 mph) the slow wiper speed
selection is restored this feature is configurable by the dealer using the approved Jaguar diagnostic system.
Wiper Motor
The wiper motor is controlled by the CJB. The CJB is connected to a wiper motor normal/fast relay in the EJB on 2 wires.
The CJB is also connected to a wiper run/park relay, also located in the EJB.
Driver requests are received by the CJB which energizes the wiper motor normal/fast relay in the appropriate mode (normal
or fast wipe) and also energizes the run/park relay in the run mode by providing a ground for the relay coils. W hen wiper
operation is deselected by the driver, the CJB monitors a park switch which is integral with the wiper motor. On receipt of
a signal from the park switch, the CJB de-energises the run/park relay, removing the power supply through the normal/fast
relay, stopping the wipers in the park position on the windshield.
The wiper motor is a DC (direct current) motor which drives a gear wheel via a worm drive attached to the motor spindle.
The motor has 3 sets of brushes with one brush connected to ground. W hen the normal/fast relay is energized in the
normal position, a power feed is supplied to the brush directly opposite the ground brush and operates the motor at slow
speed. When the relay is energized in the fast position, a power feed is connected to the second motor brush, which is
offset from the ground brush and operates the motor at the fast speed. With power supplied through the offset brush, the
current flows through fewer motor coil windings. This results in a lower resistance to current flow to the ground brush and
produces a higher motor rotational speed.
WINDSHIELD WASHERS
The windshield washers are controlled by the CJB. A driver request for washer operation, via the wiper control switch, is
passed to the instrument cluster on the LIN bus. The instrument cluster passes the message to the CJB on the medium
speed CAN bus.
The CJB energizes the windshield washer pump during the up stroke of the first 2 wash/wipe cycles. This ensures that
wiper fluid is pushed to the sides of the windshield and eliminates the trail of fluid which can occur if the fluid is pushed to
the bottom of the windshield. The wipers will continue for 3 more cycles, followed after a delay of 4 seconds, by a single
dry wipe.
NOTE: The dry wipe feature is configurable using an approved Jaguar diagnostic system.
The operation of the washer pump on the wiper up stroke only is configurable using an approved Jaguar diagnostic system.
The washer button can be pressed and held and the wipers will operate continuously for up to 10 seconds. After this period
when the button is released, the wipers will continue for 3 more cycles, followed after a delay, by a single dry wipe. After
this period washing will be inhibited, the wipers will continue for 3 more cycles, followed after a delay, by a single dry
wipe. Reactivating the switch will recommence the wash/wipe cycle.
RESERVOIR LEVEL SWITCH

The level switch is connected directly to the CJB. The switch is operated by a float which closes contacts within the switch
when the fluid level falls to below the switch level. When the contacts are closed a ground path is completed from the CJB
through the switch. This is sensed by the CJB which issues a message to the instrument cluster which displays a low fluid
level warning.
HEADLAMP POWERWASHERS
The headlamp powerwash is activated when the driver requests windshield washer operation. The CJB receives the driver
request via a CAN bus message from the instrument cluster. The CJB then checks for an exterior lights active signal and
that a low washer fluid level signal is not present.
The CJB outputs a control voltage to a headlamp powerwash pump relay located in the EJB. The relay is energized by the
CJB for a pre-determined period to allow the headlamp telescopic washers to operate.
The CJB monitors the driver washer requests and only operates the headlamp powerwash on every fourth request for
windshield washer operation, provided that 10 minutes have elapsed since the last headlamp powerwash operation. The
powerwash sequence is reset when the headlamps or the ignition is switched off.
NOTE: If a low fluid reservoir level is present the CJB prohibits headlamp powerwash.
RAIN/LIGHT SENSOR
On receiving a request for automatic windshield wiper operation, the CJB interprets LIN bus messages received from the
rain sensor. The rain sensor provides LIN bus messages with values ranging from 0 to 7.
A signal value of 0 is interpreted by the CJB as the windshield is dry. A signal value from 1 to 5 is interpreted by the CJB
as a small amount of water hitting the windshield. In this instance, the CJB initiates a slow wipe. A signal value of 7 is
interpreted by the CJB as a large amount of water hitting the windshield. In this instance, the CJB initiates a fast wipe.
NOTE: The CJB will only change a fast wipe routine to a slow wipe routine if the rain sensor value is lower than 7.
NOTE: A = Clean and dry windshield; B = W et and dirty windshield
ItemDescription
1 W indshield outer surface
2 Optical element
3 Transmitter diodes (100% light transmitted)
4 Rain sensor
5 Receiver diodes (100% light received)
6 W ater droplets/film
7 Receiver diodes (less than 100% light received)
8 Lost light
WINDSHIELD WIPER MOTOR AND LINKAGE
NOTE: LHD (left-hand drive) wiper linkage shown
ItemDescription
1 Quick release wiper blade attachment
2 RH wiper arm
3 W iper blade (2 off)
4 LH (left-hand) wiper arm
5 W iper arm cap (2 off)
6 Nut (2 off)
7 W iper linkage location hole (hidden)
8 Pivot housing (2 off)
9 Screw and washer (2 off)
10 W iper motor
The wiper linkage and motor assembly differs between LHD and RHD (right-hand drive) models. The wiper linkage and
motor assembly is not available as separate service components. If the wiper linkage and motor assembly is replaced, it is
important that alignment is made to marks on the windshield and the fixings are tightened in the correct order.
The wiper linkage and motor assembly is attached to the vehicle body with screws and washers at each end. The screws
are located in rubber bushes in the linkage assembly which isolate the linkage from the vehicle body. A rubber grommet is
located behind the motor and engages on a spigot on the vehicle body to locate the linkage.
The linkage assembly comprises a main tube with a pivot housing located at each end. The motor assembly is attached to
the tube by a clamp plate and 4 screws. The motor output shaft is fitted with a crank. A link rod is connected to the motor
crank and is connected at the opposite end to the LH pivot housing via a crank. The LH pivot housing crank is fitted with a
second link rod which is connected directly to the crank on the RH pivot housing.
The motor crank converts rotary motion from the motor output shaft into linear movement of the link rods. The cranks
connected to each pivot housing, convert the linear motion of the link rods back to rotary motion of the pivot housings.
This rotary motion is passed to the wiper arms and blades causing the blades to wipe an arc across the windshield.
Each wiper arm is located on a taper spline on the respective pivot housing. A nut is screwed on the end of the pivot
housing shaft and positively secures the wiper arm on the taper spline.
The wiper blades are attached to the wiper arms with a quick release fittings. The blades are of the flat blade type. These
blades have an integral spring along their full length which curves the blade to match the windshield and provides even
blade to windshield contact pressure along the entire length of the blade.
WASHER RESERVOIR
NOTE: Type 'B' washer reservoir shown
ItemDescription
1 Scrivet
2 W indshield washer feed pipe to washer jets
3 Reservoir cap
4 Reservoir filler neck
5 Captive nut (2 off)
6 Headlamp powerwash feed pipe to telescopic washer jets
7 Screw and washer (2 off)
8 Grommet
9 W asher fluid level sensor
10 W indshield washer pump
11 Headlamp washer pump
12 Location spigot
The washer reservoir is located in the RH wheel arch. The reservoir is a plastic moulding and is secured in the wheel arch
with 2 screws and washers and a scrivet. A level sensor is located in the reservoir and is connected to the CJB. The
reservoir is fitted with a washer pump which supplies pressurized washer fluid to the windshield washer jets mounted on
the wiper arms.
A vehicle fitted with optional headlamp washers is fitted with a larger reservoir and an additional pump for the headlamp
washers. The larger reservoir is identifiable by a letter 'B' moulded on the casing and has a capacity of 5.5 liters.
Reservoirs moulded with the letter 'A' are for use on vehicles with windshield washers only and have a capacity of 4.4
liters.
A filler cap is located at the top of the reservoir and is accessible from the engine compartment.
The pumps are located in rubber sealing grommets in holes in the reservoir and secured with clips. The pump fluid hoses
have quick release connectors which mate with the pumps. The fluid level sensor is a push fit into a sealing grommet in
one side of the reservoir body.
HEADLAMP POWERWASHERS (if fitted)
ItemDescription
1 Powerwash trim cap
2 W asher jets
3 Self-tapping screws (2 off)
4 Pressure feed from powerwash pump
5 Telescopic arm
On vehicles with headlamp powerwash, each headlamp assembly is fitted with a headlamp powerwasher. The powerwasher
is located on the underside of the headlamp assembly. The powerwasher is located in a clip at the front of the headlamp
and secured with 2 self tapping screws to the headlamp body.
The powerwasher is a telescopic unit which extends forwards from the headlamp assembly under washer fluid pressure
supplied by the headlamp powerwash pump. When the pump pressure decreases the powerwasher is automatically
retracted back into the housing. The outer end of the powerwasher is fitted with a trim which blends the powerwasher into
the headlamp when it is not operating. The powerwasher has two washer jets which direct washer fluid under high
pressure onto the headlamp lens when the powerwasher is extended.
RAIN/LIGHT SENSOR
The rain/light sensor is located at the upper edge of the windshield, behind the interior rear view mirror. Contact between
the rain sensor and windscreen is provided via a silicon pad which is compressed during the assembly process by two
locking retaining clips either side of the sensor.
The rain/light sensor unit attaches to the windshield via two clips, which latch onto formed tags on the windshield bracket.
The sensor provides information to the CJB for the optimum wiper operation for the prevailing conditions to maintain the
shield in a clear condition at all times. The rain/light sensor is an optical unit, which operates on an infrared waveband.
The sensor uses the principle of the laws of reflection on interfacing surfaces between materials with differing refraction
properties.
The rain/light sensor is connected to the CJB via a LIN bus. The sensor also receives a hardwired power and ground from
the CJB. The 'auto' wipers are activated when the column stalk is moved to position 1 (first position from off in the upward
direction). The sensitivity of the sensor can be adjusted by rotating the sensitivity collar on the wiper column stalk in the
clockwise or counterclockwise direction. Clockwise rotation will decrease sensitivity, while counterclockwise adjustment will
increase sensitivity. An increase in sensitivity adjustment results in a single wipe of the front wiper motor.
NOTE: The rain sensor also contains a light sensor. The light sensor is used to control operation of the automatic
headlamps function.
Refer to: Exterior Lighting (417-01 Exterior Lighting, Description and Operation).
WIPER CONTROL SWITCH

The wiper control switch is located on the RH steering column multifunction switch. The switch allows selection of the
following functions:
Slow wipe
Fast wipe
Auto
Flick wipe
Windshield wash and headlamp powerwash (if fitted).
All wiper functions are connected to the instrument cluster by a resistor or series of resistors within the switch. The
instrument cluster uses the returned current to determine the selected function.
WIPER SERVICE POSITION

The wiper service position allows the wipers to be parked in a position to allow easy access to the wiper blades for
replacement. The service position is initiated by pulling the RH steering column multifunction switch towards the steering
wheel and pressing the start/stop button to switch on the ignition. The wipers will move and stop in a vertical position on
the windshield. The RH steering column multifunction switch can be released and the ignition switched off. The service
position is terminated at the next ignition on cycle and the wipers return to their normal park position.
Wipers and Washers - Wipers and Washers
For a detailed description of the wipers and washers, refer to the relevant Description and Operation sections in the
workshop manual. REFER to: (501-16 Wipers and W ashers)
Wipers and Washers (Description and Operation),

Wipers and Washers (Description and Operation),
Wipers and Washers (Description and Operation).
vehicle.
Visual Inspection
W iper blade(s) Fuse(s)
W iper pivot arm shaft Wiring harness
W asher reservoir Electrical connector(s)
Hose(s) Washer pump(s)
W asher jet(s) Wiper motor
DTC Index

B109512 W iper On/Off W iper On/Off relay Carry out any pinpoint tests associated with this DTC using the
Relay control circuit - short to manufacturer approved diagnostic system. Refer to the
power electrical circuit diagrams and check wiper On/Off relay control
B109514 W iper On/Off W iper On/Off relay Refer to the electrical circuit diagrams and check wiper On/Off
Relay control circuit - short to relay control circuit for short to ground, open circuit
B109612 W iper High/Low W iper Fast/Slow relay Carry out any pinpoint tests associated with this DTC using the
Relay control circuit - short to manufacturer approved diagnostic system. Refer to the
power electrical circuit diagrams and check wiper Fast/Slow relay
control circuit for short to power
B109614 W iper High/Low W iper Fast/Slow relay Refer to the electrical circuit diagrams and check wiper
Relay control circuit - short to Fast/Slow relay control circuit for short to ground, open circuit
B10AD09 Rain Sensor Component failures Carry out any pinpoint tests associated with this DTC using the
manufacturer approved diagnostic system. Suspect the
rain/light sensor, check and install a new sensor as required
B10AD11 Rain Sensor Rain/light sensor power Carry out any pinpoint tests associated with this DTC using the
electrical circuit diagrams and check rain/light sensor power
B10AD96 Rain Sensor Component internal Suspect the rain/light sensor, check and install a new sensor
failure as required
B117712 Screenwash Screenwash level switch Refer to the electrical circuit diagrams and check screenwash
Level Switch signal circuit - short to level switch signal circuit for short to power
power
B1C4513 Front W iper Park W indshield wiper motor Refer to the electrical circuit diagrams and check windshield
Position Switch park switch signal circuit wiper motor park switch signal circuit for open circuit
- open circuit
B1C4523 Front W iper Park Signal stuck low Refer to the electrical circuit diagrams and check front wiper
Position Switch park position switch input circuit for short, open circuit
B1C7812 Powerwash Powerwash relay control Refer to the electrical circuit diagrams and check powerwash
Relay circuit - short to power relay control circuit for short to power
B1C7814 Powerwash Powerwash relay control Refer to the electrical circuit diagrams and check powerwash
Relay circuit - short to ground, relay control circuit for short to ground, open circuit
open circuit
B1C7911 Front W asher Screenwash pump control Refer to the electrical circuit diagrams and check screenwash
Pump circuit - short to ground pump control circuit for short to ground
B1C7913 Front W asher Screenwash pump control Carry out any pinpoint tests associated with this DTC using the
Pump circuit - open circuit manufacturer approved diagnostic system. Refer to the
electrical circuit diagrams and check screenwash pump control
circuit for open circuit
Wipers and Washers - Headlamp Washer Jet
Removal
1. Refer to: Headlamp Assembly (417-01 Exterior Lighting, Removal

and Installation).
Installation

Wipers and Washers - Headlamp Washer Pump
Removal
1.

fluids.
4.

fluids.
6.
seal.
Installation
1. 1. CAUTION: The seals are to be reused unless damaged.

Wipers and Washers - Rain Sensor
Removal
1. Refer to: Interior Rear View Mirror (501-09 Rear View Mirrors,
2.
3.
Installation
1. 1. CAUTIONS:
Make sure that the component is secured in the

retainer.

Wipers and Washers - Windshield Washer Reservoir
Removal
1.

fluids.
4.

fluids.
6.
7.
Installation
1. 1. CAUTION: The seals are to be reused unless damaged.

Wipers and Washers - Windshield Wiper Motor
Removal

and Installation).
3. 3. CAUTION: Tighten the bolts in the sequence

shown.
NOTE: LHD illustration shown, RHD is similar.
Torque: 12 Nm
4. 4. NOTE: LHD illustration shown, RHD is similar.
5. 5. NOTE: LHD illustration shown, RHD is similar.

NOTE: LHD illustration shown, RHD is similar.
Installation

Wipers and Washers - Windshield Washer Pump
Removal
2.

fluids.

seal.
Installation
1. 1. CAUTION: The seal is to be reused unless damaged.

Roof Opening Panel -
Roof opening panel frame retaining bolts 9 80
Roof opening panel motor retaining bolts 4 35
Roof opening panel glass retaining screws 4 35
Roof Opening Panel - Roof Opening Panel - Component Location
Component Location
ItemDescription
2 Roof opening panel, rocker switch
3 Rear window sunblind, switch
4 Roof opening panel, motor
5 Roof opening panel, control module
6 Roof opening panel
7 Rear window sunblind
8 Rear window sunblind, motor assembly
9 Drain tubes (4 off)
Roof Opening Panel - Roof Opening Panel - Overview
Overview
The roof opening panel is operated through a two-way rocker switch located in the roof console. A motor, attached to the
front of the roof-opening-panel frame, drives the glass panel to the tilt, open or closed positions using a pair of steel
cables.
Tilt
With the roof opening panel closed, a press and release on the front of the rocker switch, tilts the rear of the panel
upwards. If the switch is pressed again before the full tilt position is reached, the panel stops at the chosen position.
Fully open
With the roof opening panel closed, a press and release on the rear of the rocker switch, moves the panel to the fully open
position automatically. It can be stopped at any point by pressing the button again.
Close
From the fully open position, press and release the front of the switch. The panel will return to the closed position
automatically.
From the tilted position, press and release the rear of the switch. The panel will return to the closed position
automatically.
Anti-trap
The roof opening panel has an 'anti-trap' function which prevents the panel from closing if an obstruction is sensed. W hen
an obstruction is sensed, the motor will automatically retract the panel as far as possible. When the obstruction is
removed, the panel can be closed by the normal method.
Roof opening sunblind

A sunblind integrated into the roof-opening-panel frame, is operated manually and can be opened or closed when the roof
opening panel is in either the tilted or closed position. W hen the roof opening panel opens (slides rearwards) the sunblind
automatically slides rearwards and cannot be pulled forward until the roof opening panel is in a forward position.
Rear window sunblind

The rear window sunblind is operated through a switch in the roof console.
Roof Opening Panel - Roof Opening Panel - System Operation and
Control Diagram
NOTE: A = Hardwired
ItemDescription
1 Battery
2 Megafuse (250 A)
3 Rear window sunblind, switch
4 Rear window sunblind, motor
6 Roof opening panel, control module
7 Roof opening panel, rocker switch
System Operation
Roof opening panel
Operation of the roof opening panel is controlled by the roof opening panel control module, which is integral with the
motor. The control module receives inputs from the CJB, which provides an 'open' or 'close' signal for remote handset
operation, and an 'enable' signal when the vehicle enters power mode 6.
The control module also receives a vehicle speed signal from the ABS module. The vehicle speed signal is used by the
control module to calibrate the anti-trap feature.
If the battery is disconnected, or the power supply is interrupted while the roof opening panel is in a partially open
position, the motor and control module will need to be calibrated to restore full functionality. To recalibrate:
Switch ignition on.

Press the front of the switch, so the roof opening panel is the tilt position, and then release the switch.
Press the front of the switch and hold for thirty seconds.
After thirty seconds the roof opening panel will begin to move. Keep the front of the switch pressed until the roof
opening panel has fully opened and then closed.
Once the open/close cycle has completed and the roof opening panel has stopped moving, release the switch.
The roof opening panel can now be operated as normal.
Drain hoses are connected to the front and rear corners of the roof opening panel frame. The drain hoses are located inside
of the cabin on the 'A' and 'D' post pillars to allow water, which has collected in the frame, to escape. One-way valves
fitted to the end of each drain hose, prevent the ingress of dirt and moisture.
Rear window sunblind

The powered rear window sunblind is operated through a switch in the roof console. Power to the sunblind motor is
provided by a pair of relays located in the CJB when the vehicle enters power mode 4. The sunblind motor is located
beneath the rear parcel shelf and is supplied as a sealed unit with the sunblind mechanism.
If the battery is disconnected or a replacement sunblind is fitted, the motor will require re-calibrating. To re-calibrate the
motor the sunblind should be powered through two-full cycles of movement.
Roof opening panel, motor
The roof opening panel motor has a worm drive which drives a gear in the cast housing attached to the end of the motor.
The gear has a small pinion gear attached to the outer part of its spindle. The pinion engages with two cables to form a
rack and pinion drive. Rotation of the motor turns the pinion which in turn drives the cables in the required direction.
The two cables are attached either side of the pinion. One end of each cable is attached to the guide; the opposite end of
each cable is held in position on the pinion by a metal insert in the frame. The cables run in channels, in the panel frame
to the guides. As the panel is closed the cables are pushed through channels in the front of the frame. The displaced cable
is guided into a further two channels in the frame, which protect the cable and prevent it from snagging. The cables
manufactured from rigid spring steel can pull as well as push the panel along the guides.
The motor contains a micro-switch and Hall effect sensor. Signals received from these components enable the control
module to calculate the exact position of the roof opening panel. The Hall effect sensor is also responsible for the
operation of the anti-trap function.
If the anti-trap feature is activated while the roof opening panel is closing, the panel is reversed for 200mm or as far as
possible. The Hall effect sensor, located in the motor, monitors the speed of the motor and if the speed decreases below a
set threshold, indicating an obstruction, the power feed to the motor is reversed so the panel goes back. In an emergency
the anti-trap function can be overridden by holding the switch in the closed position.
Roof opening panel, control module

The roof opening panel control module is integrated within the motor. The control module receives inputs from the CJB,
which provides an 'open' or 'close' signal for remote handset operation, and an 'enable' signal when the vehicle enters
power mode 6.
The control module also contains the algorithm for the anti-trap system and receives a vehicle speed signal from the ABS
module. The vehicle speed signal is used by the control module to calibrate the anti-trap feature.
Roof Opening Panel - Roof Opening Panel
For a detailed description of the roof opening panel, refer to the relevant Description and Operation sections in the
workshop manual. REFER to: (501-17 Roof Opening Panel)
Roof Opening Panel (Description and Operation),

Roof Opening Panel (Description and Operation),
Roof Opening Panel (Description and Operation).
vehicle.
Visual Inspection
Roof opening panel Fuses/relays (refer to electrical guide)
Helixed drive cables W iring harness
Switch Correct engagement of electrical connectors
Control unit/motor Loose or corroded connections
DTC Index
account.

B10F211 Sunroof Control Sunroof enable signal Carry out any pinpoint tests associated with this DTC using
circuit - short to ground the manufacturer approved diagnostic system. Refer to the
electrical circuit diagrams and check sunroof enable signal
B10F212 Sunroof Control Sunroof enable signal Refer to the electrical circuit diagrams and check sunroof
circuit - short to power enable signal circuit for short to power
B10F213 Sunroof Control Sunroof enable signal Refer to the electrical circuit diagrams and check sunroof
circuit - open circuit enable signal circuit for open circuit
B113D12 Sunroof Global Roof opening panel global Carry out any pinpoint tests associated with this DTC using
Open/Close open/close control circuit - the manufacturer approved diagnostic system. Refer to the
Control short to power electrical circuit diagrams and check roof opening panel global
open/close control circuit for short to power
B113D14 Sunroof Global Roof opening panel global Refer to the electrical circuit diagrams and check roof opening
Open/Close open/close control circuit - panel global open/close control circuit for short to ground,
Control short to ground, open open circuit
circuit
Roof Opening Panel - Roof Opening Panel Alignment
General Procedures
1. With the roof opening panel closed, check the alignment of

the glass to the roof panel. The glass should be central in
its aperture. Profile of sunroof to body should be flush or up
to 1.0 mm (0.40") low all round.
2. Open the roof opening panel blind.

3. Release the cover.
5. 4. Loosen
Align the 4
the roof roof opening
opening panel. panel Torx screws.
TORQUE: 4 Nm
6. Install the cover.
7. Close the roof opening panel blind.

Roof Opening Panel - Motor Synchronization
General Procedures
1. NOTE: If a new component is installed.
Press and hold the front of the switch, hold down untill the roof
opening panel has completed a full open/close cycle.
The roof opening panel is now synchronized.
2. NOTE: If the removed component is re-installed.
Press and hold the the front of the switch, the roof opening
panel will move to the tilt postion. Release the switch then
press and hold the front of the switch, then the roof opening
panel will move slightly more after 20 seconds.
The roof opening panel is now un-synchronized.
3. NOTE: If the removed component is re-installed.
Press and hold the front of the switch, hold down untill the roof
opening panel has completed a full open/close cycle.
This action must be done within 2-3 seconds of the last

action.
The roof opening panel is now synchronized.

Roof Opening Panel - Roof Opening Panel Front Drain Hose
Removal
2.
4. Refer to: Headliner (501-05 Interior Trim and Ornamentation,

5.
6.
Installation

Roof Opening Panel - Roof Opening Panel Frame
Removal
1. Refer to: Motor Synchronization (501-17 Roof Opening Panel,


3. Refer to: Roof Opening Panel Glass (501-17 Roof Opening Panel,
4.
5.
another technician.
NOTE: Note the fitted position of the spacers.
Torque: 8 Nm

Torque: 4 Nm
8.
9.
Installation
1. 1. CAUTION: Make sure that the component is correctly located

NOTE: Replace the spacers to the fitted position.

Roof Opening Panel - Roof Opening Panel Glass
Removal
1.
2.
Repeat procedure for the other side.
Torque: 4 Nm
Installation

Roof Opening Panel - Roof Opening Panel Motor
Removal
1. Refer to: Overhead Console (501-12 Instrument Panel and Console,

2. Torque: 4 Nm
Installation

Roof Opening Panel - Roof Opening Panel Rear Drain Hose
Removal
1. Refer to: Loadspace Trim Panel RH (501-05 Interior Trim and


3. 3. NOTE: RH side only.
4. 4. NOTE: RH illustration shown, LH is similar.

Installation

Roof Opening Panel - Roof Opening Panel Weatherstrip
Removal
1. Refer to: Roof Opening Panel Glass (501-17 Roof Opening Panel,
2. 2. NOTE: Make sure that this component is installed to

Installation

Bumpers -
Radiator splash shield outer retaining bolts 3 - 26
Radiator splash shield inner retaining bolts 7 - 62
Radiator splash shield inner retaining screws 2 - 18
Front bumper cover retaining bolts 2 - 18
Rear bumper cover retaining bolts 7 - 62
Rear bumper retaining bolts 25 18 -
Bumpers - Front Bumper Cover
Removal

stands.
2. Torque: 3 Nm
3. Torque:
Retaining screws 2 Nm
Retaining bolts 7 Nm
4. Torque: 2 Nm
5. 5. NOTE: This step requires the aid of another
technician.
6. 6. NOTE: On both sides.

7. 7. NOTE: This step requires the aid of another
technician.
Installation
1. To install, reverse the removal procedure

Bumpers - Front Bumper Cover Insert
Removal

Installation).
2.

Installation

Bumpers - Rear Bumper Cover
Removal
NOTE: Removal steps may contain installation details.
1. Remove the rear lamp assemblies.
Refer to: Rear Lamp Assembly (417-01 Exterior Lighting, Removal

and Installation).
2. Torque: 7 Nm
3.
4.
5.
Installation

Bumpers - Rear Bumper
Removal
1. Refer to: Rear Bumper Cover (501-19 Bumpers, Removal and

Installation).
2.
3.
4. Torque: 25 Nm
Installation
Safety Belt System -
Front safety belt retractor to seat track retaining bolt 40 30 -
Front safety belt retractor retaining bolt 40 30 -
Front safety belt D loop retaining bolt 40 30 -
Front safety belt buckle retaining bolt 40 30 -
Front safety belt shoulder height adjuster retaining bolts 25 18 -
Rear centre safety belt retractor retaining bolts 40 30 -
Rear safety belt long end retaining bolts 40 30 -
Rear safety belt D loop retaining bolt 40 30 -
Rear safety belt long end retaining bolt 40 30 -
Rear safety belt buckle retaining bolts 40 30 -
Safety Belt System - Safety Belt System - Component Location
NOTE: Authoring Template
ItemDescription
1 Belt tension sensor - if fitted
2 RH (right-hand) front safety belt retractor
3 RH front safety belt
4 RH rear safety belt
5 RH rear safety belt retractor
6 Child seat tethers (3 off)
7 Center rear safety belt retractor
8 LH (left-hand) rear safety belt retractor
9 LH rear safety belt buckle
10 RH rear and center safety belt buckles
11 LH front safety belt
12 LH front safety belt retractor
13 LH front safety belt buckle and pre-tensioner
14 RH front safety belt buckle and pre-tensioner
Safety Belt System - Safety Belt System - Overview
Authoring Template
OVERVIEW
A three point safety belt is fitted to all seating positions. Each safety belt retractor incorporates an emergency locking
feature. The emergency locking retractor incorporates 2 mechanical inertia devices. One inertia device activates if the
safety belt is subjected to a sharp pull. The second inertia device activates if the vehicle is subject to a sudden
deceleration or is on a severe incline.
North American Specification (NAS) safety belt retractors also include an automatic locking feature. The Automatic Locking
Retractor (ALR) is fitted to all passenger seating positions and allows the safety belt to be tensioned to aid the safe
fitment of child or booster seats. For additional information, refer to the Owners Handbook.
NAS vehicles are also fitted with a belt tension sensor on the front passenger seat. The belt tension sensor is incorporated
into the seat belt lower anchorage and is attached to the seat frame by an M10 Torx head bolt. The belt tension sensor
forms part of the SRS (supplemental restraint system) occupancy detection and classification feature.
The center rear safety belt features a mini-buckle lower anchorage. The mini-buckle is disengaged by inserting a suitable
tool into the small aperture on the front face of the housing.
To aid the fitment of child seats, 3 tethers are located on the rear parcel shelf. Each tether is attached to the parcel shelf
with an M10 Torx head bolt.
A safety belt warning indicator is located in the instrument cluster to remind front seat passengers to fasten their safety
belts. The warning indicator will illuminate if the safety belt of an occupied front seat is not fastened.
Refer to: Instrument Cluster (413-01, Description and Operation).
Safety Belt System - Safety Belt System - System Operation and Component
Description
System Operation
Refer to: Safety Belt System (501-20A Safety Belt System, Description and Operation).
Safety Belt System - Safety Belt System
For a detailed description of the safety belt system, refer to the relevant Description and Operation section in the
workshop manual. REFER to: (501-20A Safety Belt System)
Safety Belt System (Description and Operation),

Safety Belt System (Description and Operation),
Safety Belt System (Description and Operation).

1. 1. Verify the customer concern by operating the safety belt.
Visual Inspection
Loose webbing W arning indicator bulb
Damaged/frayed webbing
Safety belt retractor
3. 3. If the fault is not visually evident determine the symptom(s) and proceed to the Symptom Chart.
Symptom Chart

Normal Mode - Occupant Restraint Broken tooth on retractor sensor gear REFER to the Component Tests in
System inoperative Loose webbing this section
Automatic Locking Retraction System Broken tooth on retractor sensor gear REFER to the Component Tests in
(ALR) Inoperative Loose webbing this section
Seatbelt - Jammed (ALR) automatic locking retractor in use GO to Pinpoint Test A.

(normal operation)
Twist in webbing
Webbing guide incorrect location
Foreign object in webbing route
Safety belt reel is incorrectly installed
Seatbelt - Not retracting (ALR) automatic locking retractor in use GO to Pinpoint Test A.
(normal operation)
Twist in webbing
Seatbelt - Not working (ALR) automatic locking retractor in use GO to Pinpoint Test A.
(normal operation)
Twist in webbing
Seatbelt - Slow retraction (ALR) automatic locking retractor in use GO to Pinpoint Test A.
(normal operation)
Twist in webbing
Seatbelt - Binding (ALR) automatic locking retractor in use GO to Pinpoint Test A.

(normal operation)
Twist in webbing
Seatbelt - Inoperative (ALR) automatic locking retractor in use GO to Pinpoint Test A.

(normal operation)
Twist in webbing
Seatbelt - Intermittent (ALR) automatic locking retractor in use GO to Pinpoint Test A.
(normal operation)
Twist in webbing
Seatbelt - Jamming (ALR) automatic locking retractor in use GO to Pinpoint Test A.

(normal operation)
Twist in webbing
Component Tests
Poor Retraction
WARNING: In the event of an accident in which the air bags have been deployed, the front safety belts that were in
use, and the rear safety belts whether in use or not, at the time of the accident must be removed and NEW safety belts
MUST be installed. Failure to follow this instruction may result in personal injury and component failure.
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. W here necessary, check the safety belt webbing is not rubbing at one end of the
retractor cover slot and if so, correct by loosening the retaining bolt, aligning the retractor to centralize the safety belt
webbing and re-tighten 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 average build 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 and the driver should not brace themselves against the steering
wheel. However, both the driver and the passenger must prepare themselves for the possibility that the safety belt will
not lock. The passenger should hold their hands in front of him, just clear of the instrument panel or front seat backrest.
Depending on which belt is being tested. Failure to follow these procedures may result in personal injury.
Select for this test, a quiet or private stretch of road. Make sure that the road is clear and that full visibility is
maintained at all times
Both driver and passenger should adopt a normal, comfortable seating position. Both occupants should wear the
safety belts and the safety belt webbing must be correctly adjusted, with no slack
Proceed at a speed of approximately 10 km/h (6 miles/hour), do not exceed 10 km/h (6 miles/hour) for this test
When safe to do so, 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 used. A NEW safety belt
must be installed
Test Method 2 (turning circle)
This method requires a flat open area of private road, sufficient for the vehicle to be driven safely in a continuous circle on
full lock.
The driver should wear the safety belt provided and the belt webbing must be correctly adjusted, with no slack
The passenger should occupy a rear seat with the safety belt correctly adjusted
Start the engine and, with the steering on full right-hand lock, drive the vehicle in a continuous circle at 16 km/h
(10 miles/hour), do not exceed 16 km/h (10 miles/hour)
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 (on the tongue side of the upper
safety belt anchor) and pull out quickly. The retractor should lock within 0.25 metre (10 inches), preventing further
webbing pullout. Any safety belt retractor from which it is possible to extract further webbing must not be used. A NEW
safety belt must be installed.
Service Installation of Safety Belts
It is possible that the safety belt assemblies installed in service may have been damaged during handling or installation
to the vehicle. The damage is contained within the inner workings of the retractor and is therefore, not visible. However,
the damage usually causes the retractor to stick or jam. The damage can only occur before installation is completed and is
usually in one of the following ways:
The safety belt webbing is allowed to retract onto the spindle until it jams the locking mechanism in a way that
cannot occur when the safety belt is installed in the car. The safety belt webbing prevents the correct locking action
and if the safety belt webbing is snatched or jerked out of the retractor, the loads are not taken on this high
strength locking mechanism
The webbing is snatch loaded by attempted fast extraction or manual testing with the safety belt held in the hand.
This can result in deceleration which are much higher than those occurring in accident situations and there is a risk
of damage to the mechanism
When handling safety belt assemblies, adopt the following procedures:
WARNING: If the following procedures are not successful, reject the safety belt assembly. Do not try to jerk or
snatch the webbing out of the retractor as this may cause damage. Failure to follow these procedures may cause damage
or personal injury.
If the safety belt webbing retracts and will not extract under low webbing tension, install the retractor onto its
mounting in the car , which will set it at its correct angle, and the safety belt webbing should extract easily
If it does not, feed 5-10 mm (3/16 - 3/8 inch) more safety belt webbing onto the spindle (rotate the spindle using
finger pressure if necessary) and the safety belt webbing should then extract
Pinpoint Test
PINPOINT TEST A : DIAGNOSTIC GUIDE FOR THE SECOND AND THIRD ROW SAFETY BELTS
CONDITIONS
A1: SAFETY BELT
NOTE: During normal conditions the (ALR) automatic locking retractor can operate giving the impression of a jammed
safety belt this can be overcome by drawing 20mm of webbing from the belt reel with moderate force, the belt reel should
then operate correctly. Check the operation, if the webbing moves freely then retracts correctly no further action required,
do not replace safety belt.
1 Visually inspect the condition of the safety belt.
Is the safety belt fully retracted?
Yes
The safety belt is fully retracted, no slack in the webbing.GO to A2.
No
Not fully retracted, the webbing is slack.GO to A3.
A2: REQUIRED FORCE
1 Draw the webbing from the safety belt reel with moderate force then release the webbing. Carry out
this operation twice.
Does the webbing move freely then retract correctly?
Yes
No further action required, do not replace safety belt.
No
GO to A3.
A3: WEBBING SLACK - NOT FULLY RETRACTED
1 Remove any trim panels to expose the D loop (anchor point) and safety belt reel. Check the webbing
is not trapped or twisted.
Yes
W hile refitting the trim panels, ensure there are no obstruction and the webbing does not catch or
rub. Check the operation, if the webbing moves freely then retracts correctly no further action
required, do not replace safety belt.
No
GO to A4.
A4: TRAPPED OR TWISTED SAFETY BELT WEBBING
1 If the webbing is twisted due to a fold passing through the anchor point (do not remove the safety
belt reel) feed the twist back through the anchor point to remove. If the webbing is trapped, release
and inspect for damage, if the webbing is damaged replace the safety belt.
Yes
If the webbing moves freely then retracts correctly no further action required, do not replace safety
belt. While refitting the trim panels, ensure there are no obstruction and the webbing does not catch
or rub.
No
GO to A5.
A5: SAFETY BELT WEBBING GUIDE LOCATION
NOTE: The safety belt reel has a guide installed that can cause the safety belt reel to operate poorly if incorrectly
located.
1 Visually and manually inspect the safety belt reel webbing guide for location and installation.
Is the safety belt reel webbing guide for location and installation correct and secure?
Yes
GO to A6.
No
Refit the safety belt reel webbing guide ensure the fixing lug is properly located in the retractor
frame. W hen correct draw the full length of the webbing from the reel then allow the belt to retract,
the webbing will now be central on the spindle. Check the operation, if the webbing moves freely then
retracts correctly, no further action required, do not replace safety belt. W hile replacing the trim
panels, ensure there are no obstruction and the webbing does not catch or rub.
A6: SAFETY BELT REEL LOCATION
NOTE: Incorrect installation / location of the safety belt reel can affect operation.
1 Confirm that the safety belt reel is correctly installed, check for correct location of both anti rotational
pins if present.
Is the safety belt reel is correctly installed?
Yes
Check the operation, if the webbing moves freely then retracts correctly, no further action required, do
not replace safety belt. While replacing the trim panels, ensure there are no obstruction and the
webbing does not catch or rub.
No
Correctly install the safety belt reel ensuring correct location of both anti rotational pins if present.
Check the operation, if the webbing moves freely then retracts correctly, no further action required, do
not replace safety belt. While replacing the trim panels, ensure there are no obstruction and the
webbing does not catch or rub.
Safety Belt System - Front Safety Belt Buckle
Removal
1. Refer to: Standard W orkshop Practices (100-00 General Information,

3. 3. CAUTION: Discard the bolt.
Torque: 35 Nm
Installation
1. 1. CAUTION: Make sure that a new bolt is installed.

Safety Belt System - Front Safety Belt Retractor
Removal
Torque: 40 Nm
3. Refer to: B-Pillar Upper Trim Panel (501-05 Interior Trim and
4.
5. Torque: 40 Nm
6. Torque: 40 Nm
Installation
1. 1. CAUTION: Fixings must be started by hand to avoid

damaging threads.

Safety Belt System - Rear Center Safety Belt Retractor
Removal

2. Torque: 40 Nm
Installation

Safety Belt System - Rear Safety Belt Buckle
Removal
1.
2. Torque: 40 Nm
Installation

Safety Belt System - Rear Safety Belt Retractor
Removal
1. Refer to: C-Pillar Lower Trim Panel (501-05 Interior Trim and
2. Torque: 40 Nm
3.
Installation

Safety Belt System - Safety Belt Shoulder Height Adjuster
Removal
1. Refer to: B-Pillar Upper Trim Panel (501-05 Interior Trim and
2. Torque: 40 Nm
3. Torque: 25 Nm
Installation

Supplemental Restraint System -
Description Nm Lb/Ft Lb/In
Passenger air bag module retaining nuts 6 - 55
Passenger air bag earth lead retaining bolt 9 - 80
Restraints control module (RCM) retaining nuts 10 - 89
Side air curtain module inflator retaining bolts 9 - 80
Side air curtain module tether straps retaining bolts 9 - 80
Side air bag module retaining nuts 7 - 62
Side impact sensor retaining bolt 10 - 89
Front crash sensor retaining bolt 10 - 89
Clock spring retaining screws 5 - 44
Supplemental Restraint System - Air Bag and Safety Belt Pretensioner
Supplemental Restraint System (SRS) - Component Location
ItemDescription
1 LH (left-hand) curtain airbag
2 Front passenger airbag
3 RH (right-hand) curtain airbag
4 Passenger thorax airbag
5 Driver's seat safety belt pretensioner
7 Front passenger seat safety belt pretensioner
8 Drivers thorax airbag
9 Driver's airbag
ItemDescription
1 Occupant classification system pressure pad
2 Safety belt tension sensor
3 Occupant detection system pad
4 Drivers seat position sensor
6 RH side impact sensor
7 RH rear impact sensor
8 LH rear impact sensor
9 LH side impact sensor
10 Occupant detection system LED (light emitting diode)
12 LH front impact sensor
13 RH front impact sensor
Supplemental Restraint System (SRS) - Overview
OVERVIEW
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.
Refer to: Standard W orkshop Practices (100-00 General Information, Description and Operation).
The SRS (supplemental restraint system) provides additional protection for the vehicle occupants in certain impact
conditions. The system is controlled by the RCM (restraints control module), which is mounted beneath the floor console.
The system includes twin stage drivers and front passenger airbags.
The RCM receives inputs from various sensors around the vehicle and determines which, if any, airbags should be
deployed.
The SRS features an occupant detection system. The occupant detection system comprises a mat fitted inside the front
passenger seat. By monitoring the condition of the mat, the RCM can determine if the front passenger seat is occupied. It
uses this information to determine which airbags to deploy in the event of an impact. This information is also used to
illuminate the safety belt instrument cluster warning lamp if the front passenger seat is occupied and the safety belt is
not engaged.
North American Specification (NAS) vehicles also feature an occupant classification system. The occupant classification
system comprises a control module, pressure pad and safety belt tension sensor. The system can determine the size and
weight of the front seat passenger. This information is transmitted to the RCM over the high speed CAN (controller area
network) bus. The RCM uses this information to help determine which airbags to deploy in the event of an impact.
Supplemental Restraint System (SRS) - System Operation and Component
Description
Control Diagram
NOTE: A = Hardwired; D = High speed CAN (controller area network) bus
ItemDescription
1 descriptionBJB (battery junction box)
2 BJB
5 Safety belt tension sensor
6 Occupant classification system pressure pad
7 Occupant detection system LED (light emitting diode)
9 Occupant detection system pad
10 Driver's seat position sensor
11 Front passenger seat safety belt pretensioner
12 Driver's seat safety belt pretensioner
13 LH (left-hand) front impact sensor
14 RH (right-hand) front impact sensor
15 RH rear impact sensor
16 RH side impact sensor
17 LH rear impact sensor
18 LH side impact sensor
ItemDescription
1 Battery
2 BJB
3 RJB
4 Front passenger airbag
5 Clockspring
6 Driver's airbag
7 Front passenger seat safety belt switch
8 Driver's seat safety belt switch
9 LH curtain airbag
10 Driver's seat thorax airbag
11 Front passenger seat thorax airbag
12 RH curtain airbag
13 RCM
System Operation
System Operation
In a collision, the sudden deceleration or acceleration is measured by the impact sensors and the accelerometers in the
restraints control module. The restraints control module evaluates the readings to determine the impact point on the
vehicle and whether the deceleration/acceleration readings exceed the limits for firing any of the air bags, pretensioners,
and battery disconnect unit. During a collision, the restraints control module only fires the air bags and pretensioners if
the safing function confirms that the data from the impact sensor(s) indicates an impact limit has been exceeded.
The restraints control module incorporates the following impact thresholds to cater for different accident scenarios:
Front impact, pretensioners

Front impact, driver and passenger air bags stage 1, belt unfastened
Front impact, driver and passenger air bags stage 1, belt fastened
Front impact, driver and passenger air bags stage 2, belt unfastened
Front impact, driver and passenger air bags stage 2, belt fastened
Rear impact
Driver side impact
Passenger side impact.
The front impact thresholds increase in severity from pretensioners, through to driver and passenger air bag stage 2, belt
fastened.
Firing Stratergies
The safety belt pretensioners are fired when the pretensioner impact limit is exceeded. The RCM only fires the
pretensioners if the related safety belt is fastened.
The driver and passenger air bags are only fired in a frontal impact. If an impact exceeds a stage 1 limit, but is less than
the corresponding stage 2 limit, only one inflator in each air bag is fired (stage 2 is still fired for disposal after a delay of
100ms). If an impact exceeds the stage 2 limit, the two inflators in each air bag are fired simultaneously.
The passenger air bag is disabled unless the front passenger seat is occupied by a large person (NAS only), or the
passenger air bag deactivation switch is on (all except NAS & AUS).
The stage 2 inflator of the driver air bag is disabled if the driver seat is forward of the switching point of the seat position
sensor.
If there is a fault with a safety belt buckle sensor, the RCM assumes the related safety belt is fastened for the
pretensioner firing strategy and unfastened for the driver and passenger air bag firing strategies. If there is a fault with
the occupant classification sensor, the RCM disables the passenger air bag. If there is a fault with the passenger air bag
deactivation switch, the RCM disables the passenger air bag.
If a side impact limit is exceeded, the RCM fires the side air bag and the side head air bag on that side of the vehicle. If
the side impact limit on the front passenger side of the vehicle is exceeded, the RCM also evaluates the input from the
occupant classification sensor, and fires the side air bag only if the front passenger seat is occupied by a large person
(NAS only).
If multiple impacts occur during a crash event, after responding to the primary impact the RCM will output the appropriate
fire signals in response to any further impacts if unfired units are available.
Front and Rear Impact Firing Strategy (All Except NAS)

Safety Belt Status Strategy
Driver Passenger Applicable Pretensioner Driver Air Bag Passenger Air Bag
Fastened - Fired at pretensioner threshold Fired at belt fastened threshold -
Unfastened - Not fired Fired at belt unfastened threshold -
- Fastened Fired at pretensioner threshold - Fired at belt fastened threshold
- Unfastened Not fired - Fired at belt unfastened threshold
Front and Rear Impact Firing Strategy (NAS Only)
Safety Belt Status Passenger Seat Strategy
Driver Passenger Status Applicable Pretensioner Driver Air Bag Passenger Air Bag
Fastened - - Fired at pretensioner Fired at belt fastened -
threshold threshold
Unfastened - - Not fired Fired at belt unfastened -
threshold
- Fastened Occupied allow Fired at pretensioner - Fired at belt fastened
threshold threshold
- Fastened Unoccupied Fired at pretensioner - Not fired
inhibit/empty threshold
- Unfastened Occupied allow Not fired - Fired at belt unfastened
threshold
Unfastened Unoccupied Not fired - Not fired
inhibit/empty
The battery disconnect unit is fired:
At driver and passenger air bag belt fastened threshold in a frontal impact
At the driver and passenger side impact threshold in a side impact
At the rear impact threshold in a rear impact.
Crash Signal
When the RCM outputs any of the fire signals it also outputs a crash signal to the RJB and the ECM (engine control
module) on the High speed CAN. The crash signal is also hardwired to the ECM and the RJB. The instrument cluster picks
up the crash signal from the High speed CAN and gateways it to the LCM (lighting control module). On receipt of the crash
signal, the RJB goes into a crash mode and the ECM cuts the power supply to the fuel pump relay. In the crash mode, the
RJB:
Activates all of the unlock signals of the vehicle locking system, even if the vehicle is already unlocked.
Ignores all locking/superlocking inputs until it receives an unlock input, when it returns the locking system to
normal operation.
Activates the interior lamps. The interior lamps remain on permanently until they are manually switched off at the
lamp unit, or the RJB crash mode is switched off and they return to normal operation.
Disables the rear window child lock input until the crash mode is switched off.
Sends a crash message to the LCM, to activate the hazard flashers. The hazard flashers remain on until cancelled
by the hazard warning switch or the crash mode is switched off.
The RJB crash mode is switched off by a valid locking and unlocking cycle of the locking system.
Restraints Control Module
The RCMis installed on the top of the transmission tunnel, in line with the B pillars, and controls operation of the SRS
(supplemental restraint system). The main functions of the RCM include:
Crash detection and recording

Air bag and pre-tensioner firing
Self test and system monitoring, with status indication via the air bag warning lamp and non volatile storage of
fault information.
The RCM determines which elements of the SRS are to be deployed by using two internal areas:
Crash severity evaluation

Deployment handler.
Crash severity evaluation evaluates crash severity by using data from the RCM internal accelerometer, the front crash
sensor and the safety belt buckle sensor. Based on this data, the RCM decides which level of air bag module deployment is
required and forwards the information to the second area, the deployment handler.
The deployment handler evaluates the status of the seat track position sensor and safety belt buckle sensors before a
decision is made about which restraints should finally be deployed.
Data from the side crash sensors is used by the RCM in conjunction with acceleration data from the RCM internal
accelerometer to make a deployment decision. The RCM processes the acceleration data and subject to an impact being of
high enough severity, decides whether the side air bag module should be deployed.
On board testing of the air bag modules, front safety belt pretensioner firing circuits, warning indicator circuits and module
status (the crash and side impact sensors perform basic self-tests) is performed by the RCM together with the storing of
fault codes.
The RCM drives the SRS indicator on the instrument pack via a CAN signal. If the warning lamp fails, a fault code is
recorded and a warning tone is sounded in place of the lamp if a further fault occurs. It also provides a temporary back-up
power supply to operate the air bag modules in the event that in crash conditions, the battery supply is lost. In the event
of a crash, it records certain data which can be accessed via the diagnostic connector.
A safing sensor in the RCM provides confirmation of an impact to verify if air bag and pretensioner activation is necessary.
A roll-over sensor monitors the lateral attitude of the vehicle. Various firing strategies are employed by the RCM to ensure
that during an accident only the appropriate air bags and pretensioners are fired. The firing strategy used also depends on
the inputs from the safety belt switches and the occupant monitoring system.
An energy reserve in the RCM ensures there is always a minimum of 150 milliseconds of stored energy available if the
power supply from the ignition switch is disrupted during a crash. The stored energy is sufficient to produce firing signals
for the driver air bag, the passenger air bag and the safety belt pretensioners.
When the ignition is switched on the RCM performs a self test and then performs cyclical monitoring of the system. If a
fault is detected the RCM stores a related fault code and illuminates the air bag warning indicator. The faults can be
retrieved by the reccomended Jaguar diagnostic tool over the CAN bus. If a fault that could cause a false fire signal is
detected, the RCM disables the respective firing circuit, and keeps it disabled during a crash event.
Clock Spring
The clockspring is installed on the steering column to provide the electrical interface between the fixed wiring harness of
the steering column and the components that rotate with the steering wheel, i.e. the driver air bag, the horn and the
steering wheel switch packs.
The clockspring consists of a plastic cassette which incorporates an outer cover fixed to the steering column and an inner
rotor which turns with the steering wheel. Four securing lugs attach the cover to the multifunction switch on the steering
column. The rotor is keyed to the steering wheel by a drive peg. A lug on the underside of the rotor operates the
self-cancelling feature of the turn signal indicator switch. A ribbon lead, threaded on rollers in the rotor, links two
connectors on the cover to two connectors on the rotor. Link leads for the driver air bag are installed in one of the
connectors on the rotor.
To prevent damage to the ribbon lead, both the steering and the clockspring must be centralized when removing and
installing the clockspring or the steering wheel. The clockspring is centralized when the drive peg is at six o'clock and 50 -
100% of a yellow wheel is visible in the viewing window.
Replacement clocksprings are fitted with a stopper, which locks the cover to the rotor, in the central position. The stopper
must be broken off when the replacement clockspring is installed.
Drivers Airbag Module

The driver air bag module is controlled by the RCM which chooses between single or dual stage deployment, depending on
the occupant position and the crash severity. To reduce the risk of an air bag module induced injury to a driver that is
positioned close to the steering wheel, the air bag module deploys radially. It has a non-azide propellant that reduces
particulates and effluents. It consists of a two stage inflator with separate chambers for the two inflation stages, each
being independently activated by the RCM. It has two electrical connectors that are color coded and mechanically keyed to
the respective connector on the inflator.
Passenger Airbag Module
The passenger airbag module is controlled by the RCM which chooses between single or dual stage deployment, depending
on the occupant status and the crash severity. It consists of a two stage inflator with two air bag electrical connectors to
accommodate the two stage inflation.
The heated gas inflator consists of a high-pressure mix of clean air and hydrogen gas, triggered by two separate ignition
squibs. It produces a controlled generation of clean gas to rapidly fill the air bag. It is classified as a stored flammable
gas (not as an explosive) and as such, has less restrictive storage and transportation requirements. It produces a very
clean burn and almost no particulates and is almost free of any toxins, making disposal or recycling much easier.
Head Airbag
Side air curtains protect against head injuries in a side impact, while also helping to ensure unrestrained occupants are not
ejected through open or broken windows during a rollover event.
A single inflator mounted behind the rear seat unfurls the curtain and fills five separate chambers to provide head
protection cushions for occupants in side-impact and roll-over events. Steel ramps guarantee the curtain does not snag on
the interior trim as it unfurls, while tethers at the front and rear of the curtain ensure the curtain is held taut.
The side air curtain deflation characteristics are deliberately slow to ensure it remains inflated throughout the duration of
a vehicle rollover event.
Side Airbag Module

A side air bag is attached to the outside of each front seat backrest frame, under the backrest cover.
The side air bags are handed, and each consist of a molded plastic case which contains the folded air bag and the inflator.
A cable connects the igniter of the inflator to a connector in the main seat harness connector block located under the front
edge of the seat cushion.
When the air bag deploys it forces the front edge of the molded plastic case apart and splits open the backrest cover.
The side air bags use compressed argon as the inflation medium. The inflated volume of each side air bag is 12 liters
(0.42 ft3).
Impact Sensors
Impact sensors are installed in the front and both sides of the vehicle. The use of multiple impact sensors provides shorter
air bag trigger times, through faster detection of lateral and longitudinal acceleration, and improves detection accuracy.
There are two front impact sensors, attached to the headlamp surround panel below the headlamps.
There are four side impact sensors located in the passenger compartment, as follows:
One attached to the base of each B/C pillar

One attached to the base of each D pillar.
Each impact sensor incorporates an accelerometer and a microchip powered by a feed from the RCM. The power feed also
provides the interface connection through which the side impact sensor communicates with the RCM using serial data
messages. Acceleration is evaluated by the microchip and transmitted to the restraints control module, which then makes
the decision on whether or not to activate the air bags and pretensioners.
When the ignition is switched on the RCM supplies power to the impact sensors, which perform a self test. After
satisfactory self tests the impact sensors continually output 'digital acceleration' messages to the restraints control
module. If a fault is detected the relevant impact sensor sends a fault message, instead of the digital acceleration
message, to the restraints control module. The RCM then stores a related fault code and illuminates the air bag warning
indicator. Faults can be retrieved by the Jaguar approved diagnostic system from the RCM via the high speed CAN bus
connection.
Seat Position Sensor

The seat position sensor allows the RCM to detect when the driver seat is forward of a given point on the seat track. The
seat position sensor consists of a Hall effect sensor attached to the driver seat frame. W hile the ignition is on, the RCM
supplies the sensor with power, and monitors the return current. When the seat frame moves forwards, the sensor moves
over the edge of the seat track, which changes the reluctance of the sensor. The change of current is detected by the RCM
and used as a switching point. The switching point is when the center of the sensor is 3 4 mm from the leading edge of
the seat track.
When the driver seat is forward of the switching point, the RCM increases the time delay between firing the two stages of
the inflator in the driver air bag. When the driver seat is rearward of the switching point, the RCM uses the normal time
delay between firing the two stages.
Safety Belt Sensor

A safety belt switch is installed in the buckle of each front safety belt to provide the RCM with a status signal of the
related safety belt(s). When the safety belt is unfastened the switch outputs a low current to the RCM. When the safety
belt is fastened the switch outputs a high current to the RCM.
Pretensioners
The pretensioners are used to tighten the front safety belts during a collision to ensure the occupants are securely held in
their seats. A pretensioner is integrated into each front safety belt buckle and attached to a bracket on the inboard side of
the seat.
Each pretensioner has a tube containing propellant and a piston. The piston is attached to a steel cable, the opposite end
of which is attached to the safety belt buckle. A squib in the base of the tube provides an ignition source when triggered
by a fire signal from the RCM.
On receipt of a fire signal from the RCM, the squib ignites the propellant. The propellant produces nitrogen gas that rapidly
expands to drive the piston along the tube, pulling the cable and drawing the buckle downwards.
Airbag Warning Indicator

The air bag warning indicator consists of a red LED behind a SRS graphic in the instrument cluster.
Operation of the air bag warning indicator is controlled by a high speed CAN bus message from the RCM to the instrument
cluster. The RCM sends the signal to illuminate the air bag warning indicator if a fault is detected, and for approximately 6
seconds during the bulb check at the beginning of each ignition cycle.
Occupant Monitoring
There are two types of occupant monitoring:
In all markets except NAS & Australia, vehicles have an occupant detection sensor
In NAS markets, vehicles have an occupant classification system
For markets which have an occupant detection sensor, this has no interface with the restraints system and only provides
the belt reminder function.
For markets that have an occupant classification system, this provides the RCM with the occupancy status of the front
passenger seat. The restraints control module uses this

2008 XF Workshop Manual PDF

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

2008 XF Workshop Manual PDF

Uploaded by

Copyright:

Available Formats

Workshop Manual

VIN R00019 to VIN R47514

100: Service Information

100-00: General Information

100-01: Identification Codes

100-02: Jacking and Lifting

100-04: Noise, Vibration and Harshness

204-00: Suspension System - General Information

204-01: Front Suspension

204-02: Rear Suspension

204-04: Wheels and Tires

204-05: Vehicle Dynamic Suspension

204-06: Ride and Handling Optimization

205-00: Driveline System - General Information

205-02: Rear Drive Axle/Differential

205-05: Rear Drive Halfshafts

206: Brake System

206-00: Brake System - General Information

206-03: Front Disc Brake - 2.7L V6 - TdV6/3.0L NA V6 - AJ27/4.2L NA V8 - AJV8/4.2L SC V8

206-04: Rear Disc Brake - 2.7L V6 - TdV6/3.0L NA V6 - AJ27/4.2L NA V8 - AJV8/4.2L SC

206-06: Hydraulic Brake Actuation

206-07: Power Brake Actuation

206-09: Anti-Lock Control - Stability Assist

211: Steering System

211-00: Steering System - General Information

211-02: Power Steering

211-03: Steering Linkage

211-04: Steering Column

211-05: Steering Column Switches

303-00: Engine System - General Information

303-01A: Engine - TDV6 2.7L Diesel

303-01B: Engine - V6 3.0L Petrol

303-01C: Engine - 4.2L NA V8 - AJV8

303-01D: Engine - 4.2L SC V8 - AJV8

303-03A: Engine Cooling - TDV6 2.7L Diesel

303-03B: Engine Cooling - V6 3.0L Petrol

303-03C: Engine Cooling - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8

303-03D: Supercharger Cooling - 4.2L SC V8 - AJV8

303-04A: Fuel Charging and Controls - TDV6 2.7L Diesel

303-04B: Fuel Charging and Controls - Turbocharger - TDV6 2.7L Diesel

303-04C: Fuel Charging and Controls - V6 3.0L Petrol

303-04D: Fuel Charging and Controls - 4.2L NA V8 - AJV8

303-04E: Fuel Charging and Controls - 4.2L SC V8 - AJV8

303-05B: Accessory Drive - V6 3.0L Petrol

303-05C: Accessory Drive - 4.2L NA V8 - AJV8

303-06A: Starting System - TDV6 2.7L Diesel

303-06B: Starting System - V6 3.0L Petrol

303-07A: Engine Ignition - V6 3.0L Petrol

303-07B: Engine Ignition - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8

303-07C: Glow Plug System

303-08A: Engine Emission Control - TDV6 2.7L Diesel

303-08B: Engine Emission Control - V6 3.0L Petrol

303-12A: Intake Air Distribution and Filtering - TDV6 2.7L Diesel

303-12B: Intake Air Distribution and Filtering - V6 3.0L Petrol

303-12C: Intake Air Distribution and Filtering - 4.2L NA V8 - AJV8

303-12D: Intake Air Distribution and Filtering - 4.2L SC V8 - AJV8

303-13A: Evaporative Emissions - V6 3.0L Petrol

303-13B: Evaporative Emissions - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8

303-14A: Electronic Engine Controls - TDV6 2.7L Diesel

303-14B: Electronic Engine Controls - V6 3.0L Petrol

303-14C: Electronic Engine Controls - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8

307: Automatic Transmission/Transaxle

307-01: Automatic Transmission/Transaxle - 2.7L V6 - TdV6/3.0L NA V6 - AJ27/4.2L NA