X 150 Service

X150 - XK
VIN B00379 to VIN B32752

TABLE OF CONTENTS
1 : General Information
100 : Service Information
100-00 : General Information
Description and Operation

Application and Use of Specifications
General Service Information
Health and Safety Precautions
How To Use This Manual
Important Safety Instructions
Road/Roller Testing
Solvents, Sealants and Adhesives
Standard Workshop Practices
100-01 : Identification Codes

Identification Codes - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8
100-02 : Jacking and Lifting

Jacking
Lifting
100-04 : Noise, Vibration and Harshness

Noise, Vibration and Harshness (NVH)
Diagnosis and Testing
2 : Chassis
204 : Suspension
204-00 : Suspension System - General Information
Specifications
Specifications
General Procedures
Front Toe Adjustment (57.65.01)
Rear Toe Adjustment (57.65.08)
Four-Wheel Alignment
Wheel Alignment Angles
Suspension System
204-01 : Front Suspension
Specifications
Specifications
Front Suspension
Front Suspension
Removal and Installation
Front Shock Absorber - 4.2L NA V8 - AJV8/4.2L SC V8 -
AJV8 (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)
Front Stabilizer Bar - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8
(60.10.01)
Front Stabilizer Bar Link - 4.2L NA V8 - AJV8/4.2L SC V8 -
AJV8 (60.10.02)
Stabilizer Bar Link Bushing (60.10.03)
Upper Arm LH - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8
(60.35.41)
Upper Arm RH - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8
(60.35.42)
Front Wheel Bearing and Wheel Hub (60.25.03)
Wheel Knuckle (60.25.23)
204-02 : Rear Suspension
Specifications
Specifications
Rear Suspension
Rear Suspension
Lower Arm - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8
(64.35.43)
Rear Shock Absorber - 4.2L NA V8 - AJV8/4.2L SC V8 -
AJV8 (64.30.02)
Rear Stabilizer Bar (64.35.08)
Rear Stabilizer Bar Link (64.35.24)
Rear Wheel Bearing - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8
(64.15.14)
Tie Bar
Upper Arm (64.25.31)
Wheel Knuckle - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8
(64.15.22)
204-04 : Wheels and Tires
Specifications
Specifications
Wheels and Tires
Wheels and Tires - VIN Range: B10572->B32752
Wheels and Tires - VIN Range: B00379->B10571
Wheel and Tire (74.20.05)
Tire Pressure Monitoring System (TPMS) Front Antenna
Tire Pressure Monitoring System (TPMS) Rear Antenna
Tire Pressure Monitoring System (TPMS) Module -
Convertible
Tire Pressure Monitoring System (TPMS) Module - 2-Door
Tire Low Pressure Sensor
Tire Pressure Monitoring System (TPMS) Receiver
204-05 : Vehicle Dynamic Suspension - 4.2L NA V8 - AJV8/4.2L

SC V8 - AJV8
Specifications
Specifications
Vehicle Dynamic Suspension
Adaptive Damping Module - Convertible (86.56.35)
Adaptive Damping Module - 2-Door (86.56.35)
Front Suspension Vertical Accelerometer
Rear Suspension Vertical Accelerometer
205 : Driveline
205-00 : Driveline System - General Information

Driveline System
205-01 : Driveshaft
Specifications
Specifications
General Procedures
Driveshaft Runout and Balancing
Driveshaft
Driveshaft
Driveshaft - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8
(47.15.01)
205-02 : Rear Drive Axle/Differential
Specifications
Specifications
Rear Drive Axle and Differential - 4.2L NA V8 - AJV8/4.2L
SC V8 - AJV8
Axle Assembly - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8,
Vehicles Without: Differential Drain Plug (51.25.13)
Axle Assembly - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8,
Vehicles With: Differential Drain Plug (51.25.13)
Axle Housing Bushing - 4.2L NA V8 - AJV8/4.2L SC V8 -
AJV8 (64.25.30)
In Vehicle Repair
Drive Pinion Seal - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8
(51.20.01)
205-05 : Rear Drive Halfshafts
Specifications
Specifications
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 [p

Specifications
Specifications
General Procedures
Brake Disc Runout Check
Brake System Bleeding (70.25.03)
Brake System
206-03 : Front Disc Brake - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8
Specifications
Specifications
Front Disc Brake
Front Disc Brake
Brake Caliper - Vehicles With: Standard Brakes (70.55.02)
Brake Disc - Vehicles With: Standard Brakes (70.10.10)
Brake Disc - Vehicles With: High Performance Brakes
(70.10.10)
Brake Pads - Vehicles With: Standard Brakes (70.40.02)
Brake Pads - Vehicles With: High Performance Brakes
(70.40.02)
206-04 : Rear Disc Brake - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8
Specifications
Specifications
Rear Disc Brake
Rear Disc Brake
Brake Caliper (70.55.03)
Brake Disc (70.10.11)
206-05 : Parking Brake and Actuation
Specifications
Specifications
General Procedures
Parking Brake Cable Tension Release
Parking Brake
Parking Brake
Parking Brake Cable LH - 4.2L NA V8 - AJV8/4.2L SC V8 -
AJV8
Parking Brake Cable RH - 4.2L NA V8 - AJV8/4.2L SC V8 -
AJV8
Parking Brake Module - Convertible (70.35.47)
Parking Brake Module - 2-Door (70.35.47)
Parking Brake Release Actuator - 4.2L NA V8 - AJV8/4.2L
SC V8 - AJV8 (70.35.45)
Parking Brake Switch - 4.2L NA V8 - AJV8/4.2L SC V8 -
AJV8 (70.35.46)
206-06 : Hydraulic Brake Actuation
Specifications
Specifications
Hydraulic Brake Actuation
Brake Master Cylinder - LHD RWD (70.30.08)
Brake Master Cylinder - RHD RWD (70.30.08)
Brake Fluid Reservoir (70.30.16)
Brake Pedal and Bracket (70.35.03)
206-07 : Power Brake Actuation
Specifications
Specifications
Brake Booster
Power Brake System
Brake Booster - LHD RWD (70.50.17)
Brake Booster - RHD RWD (70.50.17)
206-09 : Anti-Lock Control - Stability Assist
Specifications
Specifications
www.JagDocs.com
Anti-Lock Control - Stability Assist - 4.2L NA V8 - AJV8/4.2L

SC V8 - AJV8
Anti-Lock Control - Stability Assist
Anti-Lock Brake System (ABS) Module (70.60.02)
Front Wheel Speed Sensor - 4.2L NA V8 - AJV8/4.2L SC V8
- AJV8 (70.60.03)
Hydraulic Control Unit (HCU) (70.60.18)
Rear Wheel Speed Sensor - 4.2L NA V8 - AJV8/4.2L SC V8 -
AJV8 (70.60.04)
Yaw Rate Sensor and Accelerometer (86.56.64)
211 : Steering System
211-00 : Steering System - General Information
Specifications
Specifications
General Procedures
Power Steering System Bleeding (57.15.02 )
Power Steering System Flushing (57.15.08)
Steering System
211-02 : Power Steering - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8
Specifications
Specifications
Power Steering
Power Steering
Power Steering Fluid Cooler - 4.2L NA V8 - AJV8
(57.15.11)
Power Steering Fluid Cooler - 4.2L SC V8 - AJV8 (57.15.11)
Power Steering Fluid Reservoir - 4.2L NA V8 - AJV8
(57.15.08)
Power Steering Fluid Reservoir - 4.2L SC V8 - AJV8
(57.15.08)
Power Steering Pump - 4.2L NA V8 - AJV8 (57.20.14)
Power Steering Pump - 4.2L SC V8 - AJV8 (57.20.14)
Steering Gear (57.10.01)
Steering Gear Bushing (57.10.30)
Steering Angle Sensor
211-03 : Steering Linkage
Specifications
Specifications
Steering Linkage
Steering Linkage
Steering Gear Boot (57.10.29)
Tie Rod End - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8
(57.55.02)
211-04 : Steering Column

Specifications
Specifications
Steering Column
Steering Column
Steering Column (57.40.01)
Steering Column Lower Shaft (57.40.05)
Steering Wheel (57.60.01)
Clockspring
211-05 : Steering Column Switches
Specifications
Specifications
Steering Column Switches
Steering Column Lock Actuator (57.40.41)
Steering Column Multifunction Switch LH (86.65.78)
Steering Column Multifunction Switch RH (86.65.41)
3 : Powertrain
303 : Engine
303-00 : Engine System - General Information
Specifications
Specifications
General Procedures
Bearing Inspection
Camshaft Bearing Journal Clearance
Camshaft Bearing Journal Diameter
Camshaft End Play
Camshaft Lobe Lift
Camshaft Surface Inspection
Connecting Rod Cleaning
Connecting Rod Large End Bore
Crankshaft End Play
Crankshaft Main Bearing Journal Clearance
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
Engine
303-01A : Engine - 4.2L SC V8 - AJV8
Specifications
Specifications
General Procedures
Valve Clearance Adjustment (12.29.48)
Valve Clearance Check (12.29.47)
Engine Oil Draining and Filling
Engine
Engine
Crankshaft Main Bearing Carrier
Removal
Engine (12.41.01)
Installation
Engine (12.41.01)
In Vehicle Repair
Camshafts LH (12.13.19)
Camshafts RH (12.13.18)
Crankshaft Front Seal (12.21.14)
Crankshaft Pulley (12.21.09)
Crankshaft Rear Seal (12.21.20)
Cylinder Head LH (12.29.02)
Engine Front Cover (12.65.01)
Engine Mount LH (12.45.01)
Engine Mount RH (12.45.03)
Exhaust Manifold LH - Vehicles With: Secondary Air
Injection (AIR) (30.15.55)
Exhaust Manifold RH - Vehicles Without: Secondary Air
Exhaust Manifold RH - Vehicles With: Secondary Air
Flexplate (12.53.13)
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)
Oil Filter Housing
Oil Level Indicator and Tube
Oil Cooler (12.60.68)
Twin Oil Coolers
Disassembly
Engine
Disassembly/Assembly of subassemblies
Cylinder Head (12.29.22)
Assembly
Engine
303-01B : Engine - 4.2L NA V8 - AJV8
Specifications
Specifications
General Procedures
Engine
Engine
Removal
Engine (12.41.01)
Installation
Engine (12.41.01)
In Vehicle Repair
Exhaust Manifold LH - Vehicles Without: Secondary Air
Exhaust Manifold LH - Vehicles With: Secondary Air
Exhaust Manifold RH - Vehicles Without: Secondary Air
Exhaust Manifold RH - Vehicles With: Secondary Air
Intake Manifold (30.15.01)
Oil Pan (12.60.44)
Oil Pump (12.60.26)
Oil Filter Housing
Disassembly
Engine
Disassembly/Assembly of subassemblies
Assembly
Engine
303-03A : Engine Cooling - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8
Specifications
Specifications
General Procedures
Cooling System Draining, Filling and Bleeding - 4.2L NA V8
- AJV8
Cooling System Draining, Filling and Bleeding - 4.2L SC V8
- AJV8
Cooling System Draining and Vacuum Filling
Cooling System Flushing
Engine Cooling - 4.2L NA V8 - AJV8
Engine Cooling - 4.2L SC V8 - AJV8
Engine Cooling
Coolant Expansion Tank (26.15.01)
Cooling Fan Motor and Shroud - Vehicles With:
Supercharger (26.25.25)
Radiator - Vehicles Without: Supercharger (26.40.01)
Radiator - Vehicles With: Supercharger (26.40.01)
Thermostat - Vehicles With: Supercharger (26.45.07)
Thermostat - Vehicles Without: Supercharger (26.45.07)
Thermostat Housing - Vehicles Without: Supercharger
Coolant Manifold - Vehicles With: Supercharger
Coolant Pump - Vehicles Without: Supercharger
Coolant Pump - Vehicles With: Supercharger
303-03B : Supercharger Cooling - 4.2L NA V8 - AJV8/4.2L SC V8

- AJV8

Coolant Pump
Radiator
303-04A : Fuel Charging and Controls - 4.2L SC V8 - AJV8
Specifications
Specifications
Fuel Charging and Controls
Fuel Injection Supply Manifold (19.60.13)
Fuel Injector (18.10.01)
Throttle Body (19.70.04)
303-04B : Fuel Charging and Controls - 4.2L NA V8 - AJV8
Specifications
Specifications
Fuel Charging and Controls - 4.2L NA V8 - AJV8/4.2L SC V8
- AJV8
303-05 : Accessory Drive - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8
Specifications
Specifications
Accessory Drive - 4.2L NA V8 - AJV8
Accessory Drive - 4.2L SC V8 - AJV8
Accessory Drive
Accessory Drive Belt - 4.2L NA V8 - AJV8 (12.10.40)
Accessory Drive Belt - 4.2L SC V8 - AJV8 (12.10.40)
Accessory Drive Belt Tensioner - 4.2L NA V8 - AJV8
(12.10.41)
Accessory Drive Belt Tensioner - 4.2L SC V8 - AJV8
(12.10.41)
Accessory Drive Belt Idler Pulley - 4.2L NA V8 - AJV8
(12.10.43)
Accessory Drive Belt Idler Pulley - 4.2L SC V8 - AJV8
(12.10.43)
Supercharger Belt (18.50.08)
Supercharger Belt Tensioner (18.50.24)
Supercharger Belt Idler Pulley (18.50.09)
303-06 : Starting System - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8
Specifications
Specifications
Starting System
Starting System
Starter Motor (86.60.01)
Start Control Unit
303-07 : Engine Ignition - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8
Specifications
Specifications
Engine Ignition
Engine Ignition
Spark Plugs - 4.2L NA V8 - AJV8 (18.20.02)
Spark Plugs - 4.2L SC V8 - AJV8 (18.20.02)
Ignition Coil-On-Plug - 4.2L NA V8 - AJV8 (18.20.40)
Ignition Coil-On-Plug - 4.2L SC V8 - AJV8 (18.20.40)
303-08A : Engine Emission Control - 4.2L SC V8 - AJV8
Specifications
Specifications
Engine Emission Control
Exhaust Gas Recirculation (EGR) Valve (17.45.01)
Positive Crankcase Ventilation (PCV) Valve
Secondary Air Injection (AIR) Control Valve to Exhaust
Manifold Tube
Secondary Air Injection (AIR) Control Valve
Secondary Air Injection (AIR) Pump
Secondary Air Injection Manifold Absolute Pressure
Sensor
303-08B : Engine Emission Control - 4.2L NA V8 - AJV8
Specifications
Specifications
Exhaust Gas Recirculation (EGR) Valve (17.45.01)
Secondary Air Injection (AIR) Control Valve to Exhaust
Manifold Tube
Secondary Air Injection (AIR) Control Valve
Secondary Air Injection Manifold Absolute Pressure
Sensor
303-12A : Intake Air Distribution and Filtering - 4.2L SC V8 -
AJV8
Specifications
Specifications
Intake Air Distribution and Filtering
Air Cleaner (19.10.05)
Air Cleaner Element (19.10.08)
Intake Air Resonator
Charge Air Cooler LH (18.50.19)
Supercharger Outlet Pipe (18.50.16)
Throttle Body Elbow (19.70.28)
303-12B : Intake Air Distribution and Filtering - 4.2L NA V8 -

AJV8
Specifications
Specifications
Air Cleaner Outlet Pipe (19.10.31)
303-13 : Evaporative Emissions - 4.2L NA V8 - AJV8/4.2L SC V8 -

AJV8
Specifications
Specifications
Evaporative Emissions - 4.2L NA V8 - AJV8
Evaporative Emissions - 4.2L SC V8 - AJV8
Evaporative Emissions
Evaporative Emission Canister - 4.2L NA V8 - AJV8/4.2L SC
V8 - AJV8 (17.15.13)
Evaporative Emission Canister Purge Valve - 4.2L NA V8 -
AJV8 (17.15.30)
Evaporative Emission Canister Purge Valve - 4.2L SC V8 -
AJV8 (17.15.30)
303-14A : Electronic Engine Controls - 4.2L SC V8 - AJV8
Specifications
Specifications
General Procedures
Powertrain Control Module (PCM) Long Drive Cycle Self-
Test
Powertrain Control Module (PCM) Short Drive Cycle Self-
Test
Electronic Engine Controls
Camshaft Position (CMP) Sensor LH (18.31.12)
Camshaft Position (CMP) Sensor RH (18.31.11)
Catalyst Monitor Sensor (18.30.66)
Crankshaft Position (CKP) Sensor (18.30.12)
Engine Control Module (ECM) (18.30.01)
Engine Coolant Temperature (ECT) Sensor (18.30.10)
Fuel Rail Pressure (FRP) Sensor (18.30.98)
Fuel Temperature Sensor (18.30.99)
Heated Oxygen Sensor (HO2S)
Knock Sensor (KS) (18.30.69)
Manifold Absolute Pressure (MAP) Sensor (18.30.86)
Mass Air Flow (MAF) Sensor (18.30.15)
Variable Camshaft Timing (VCT) Oil Control Solenoid
(18.30.90)
Brake Pedal Position (BPP) Switch
Oil Temperature Sensor (18.31.01)
Engine Oil Pressure (EOP) Sensor
Intake Air Temperature (IAT) Sensor (18.30.52)
303-14B : Electronic Engine Controls - 4.2L NA V8 - AJV8
Specifications
Specifications
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)
Crankshaft Position (CKP) Sensor (18.30.12)
Engine Coolant Temperature (ECT) Sensor (18.30.10)
Manifold Absolute Pressure (MAP) Sensor (18.30.86)
Variable Camshaft Timing (VCT) Oil Control Solenoid
(18.30.90)
307 : Automatic Transmission/Transaxle
307-01 : Automatic Transmission/Transaxle
Specifications
Specifications
General Procedures
Transmission Fluid Drain and Refill (44.24.02)
Transmission Fluid Level Check
Transmission Description
Diagnostic Strategy
Removal
Transmission (44.20.01)
Installation
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
Transmission Support Insulator (12.45.04)
Selector Shaft Seal
307-02 : Transmission/Transaxle Cooling
Specifications
Specifications
Transmission Cooling
307-05 : Automatic Transmission/Transaxle External Controls
Specifications
Specifications
General Procedures
Selector Lever Cable Adjustment (44.15.07)
External Controls
External Controls
Downshift Paddle Switch
Selector Lever Assembly (44.15.04)
Selector Lever Cable and Bracket (44.15.08)
Selector Lever Knob (44.15.06)
Upshift Paddle Switch
309 : Exhaust System
309-00 : Exhaust System - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8
Specifications
Specifications
Exhaust System - 4.2L NA V8 - AJV8
Exhaust System - 4.2L SC V8 - AJV8
Exhaust System
Catalytic Converter (17.50.05)
Exhaust System
Front Muffler (30.10.18)
Muffler and Tailpipe (30.10.52)
Exhaust Sound Enhancement Vacuum Pump
310 : Fuel System
310-00 : Fuel System - General Information
Specifications
Specifications
General Procedures
Fuel System Pressure Release (19.50.02)
Fuel Tank Draining
Quick Release Coupling
Quick Release Coupling - Push Connect
Spring Lock Couplings
310-01 : Fuel Tank and Lines
Specifications
Specifications
Fuel Tank and Lines
Fuel Tank and Lines
Fuel Filter (19.25.02)
Fuel Level Sender
Fuel Pump Module (19.45.08)
Fuel Tank (19.55.01)
Fuel Tank Filler Pipe (19.55.33)
310-02 : Acceleration Control
Specifications
Specifications
Acceleration Control
Accelerator Pedal (19.20.01)
310-03 : Speed Control - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8
Specifications
Specifications
General Procedures
Speed Control Sensor Adjustment
Speed Control
Speed Control
Speed Control Deactivator Switch (19.75.20)
Speed Control Module - Vehicles Without: Adaptive
Speed Control (19.75.26)
Speed Control Module - Vehicles With: Adaptive Speed
Control (19.75.26)
Speed Control Sensor
Speed Control Switch (19.75.25)
4 : Electrical
412 : Climate Control System
412-00 : Climate Control System - General Information
Specifications
Specifications
General Procedures
Air Conditioning (A/C) System Flushing
Air Conditioning (A/C) System Recovery, Evacuation and
Charging (82.30.30)
Contaminated Refrigerant Handling
Electronic Leak Detection
Refrigerant Oil Adding
Refrigerant System Tests
Climate Control System
412-01 : Air Distribution and Filtering
Specifications
Specifications
Air Distribution and Filtering
Center Registers (82.20.38)
Driver Side Register (82.20.39)
Passenger Side Register (82.20.40)
Pollen Filter (76.10.09)
412-02 : Heating and Ventilation
Specifications
Specifications
Heating and Ventilation
Auxiliary Coolant Flow Pump - 4.2L NA V8 - AJV8
(82.25.59)
Auxiliary Coolant Flow Pump - 4.2L SC V8 - AJV8
(82.25.59)
Blower Motor (82.25.66)
Heater Core (80.20.29)
Heater Core and Evaporator Core Housing (82.25.21)
412-03 : Air Conditioning
Specifications
Specifications
Air Conditioning
Air Conditioning
Air Conditioning (A/C) Compressor - 4.2L NA V8 - AJV8
(82.10.20)
Air Conditioning (A/C) Compressor - 4.2L SC V8 - AJV8
(82.10.20)
Blower Motor Resistor
Condenser Core - 4.2L NA V8 - AJV8 (82.15.07)
Condenser Core - 4.2L SC V8 - AJV8 (82.15.07)
Evaporator Core (82.25.20)
Pressure Cutoff Switch (82.10.32)
Thermostatic Expansion Valve (82.25.01)
412-04 : Control Components
Specifications
Specifications
Control Components
Control Components
Ambient Air Temperature Sensor (82.20.02)
Defrost Vent/Register Blend Door Actuator LH
Defrost Vent/Register Blend Door Actuator RH
Footwell Vent/Duct Blend Door Actuator LH
In-Vehicle Temperature Sensor (82.20.03)
Recirculation Blend Door Actuator (82.20.67)
Sunload Sensor (82.20.70)
Climate Control Module
Climate Control Assembly (82.20.07)
413 : Instrumentation and Warning Systems
413-00 : Instrument Cluster and Panel Illumination

Instrument Cluster and Panel Illumination
413-01 : Instrument Cluster
Specifications
Specifications
Instrument Cluster
Instrument Cluster
Instrument Cluster (88.20.01)
413-06 : Horn
Specifications
Specifications
Horn
Horn
Horn (86.30.02)
413-08 : Information and Message Center

Information and Message Center
413-09 : Warning Devices

Warning Devices
Low Washer Fluid Warning Indicator Switch (84.10.17)
413-13 : Parking Aid
Specifications
Specifications
Parking Aid
Parking Aid
Parking Aid Module (86.80.39)
Rear Parking Aid Sensor (86.54.14)
Front Inner Parking Aid Sensor (86.54.21)
Front Outer Parking Aid Sensor (86.54.22)
414 : Battery and Charging System

414-00 : Charging System - General Information
General Procedures
Battery Charging
Charging System
414-01 : Battery, Mounting and Cables
Specifications
Specifications
Battery and Cables
Battery
Battery (86.15.01)
414-02 : Generator and Regulator - 4.2L NA V8 - AJV8/4.2L SC

V8 - AJV8
Specifications
Specifications
Generator
Generator
Generator - 4.2L NA V8 - AJV8 (86.10.02)
Generator - 4.2L SC V8 - AJV8 (86.10.02)
415 : Information and Entertainment Systems
415-00 : Information and Entertainment System - General

Information

Audio System
Cellular Phone
415-01 : Audio Unit
Specifications
Specifications
Audio System
Audio System
Amplifier (86.50.10)
Audio Unit (86.50.03)
Steering Wheel Audio Controls (86.50.42)
415-02 : Antenna
Specifications
Specifications
Antenna
Antenna
Antenna (86.51.17.60)
415-03 : Speakers
Specifications
Specifications
Speakers
Speakers
Front Door Speaker (86.50.13)
Front Door Tweeter Speaker (86.50.63)
Subwoofer Speaker (86.51.05)
Quarter Panel Speaker - 2-Door (86.50.12)
Quarter Panel Speaker - Convertible (86.50.12)
417 : Lighting
417-01 : Exterior Lighting
Specifications
Specifications
General Procedures
Front Fog Lamp Adjustment
Headlamp Adjustment (86.40.18)
Exterior Lighting
Headlamps
Front Fog Lamp (86.40.96)
Headlamp Assembly (86.41.33)
Headlamp Bulb - Vehicles With: High Intensity Discharge
Headlamps (86.42.14)
Headlamp Leveling Module
Headlamp Leveling Front Sensor
Headlamp Leveling Rear Sensor
High Mounted Stoplamp (86.41.01)
Rear Lamp Assembly (86.40.70)
Fog Lamp Bulb
Rear Fog and Reversing Lamp - 2-Door
Rear Fog and Reversing Lamp - Convertible
417-02 : Interior Lighting

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

Daytime Running Lamps (DRL)
418 : Electrical Distribution
418-00 : Module Communications Network

Specifications
Specifications
Communications Network
Auxiliary Junction Box (AJB) (86.70.55)
Central Junction Box (CJB) (86.70.72)
418-01 : Module Configuration

Module Configuration
418-02 : Wiring Harnesses - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8

Engine Wiring Harness - 4.2L NA V8 - AJV8
Engine Wiring Harness - 4.2L SC V8 - AJV8
419 : Electronic Feature Group
419-01A : Anti-Theft - Active
Specifications
Specifications
Anti-Theft - Active
Anti-Theft - Active
Antenna
Anti-Theft Alarm Horn (86.52.03)
Rear Intrusion Sensor
419-01B : Anti-Theft - Passive
General Procedures
Anti-Theft Security Access
Key Programming Using Diagnostic Equipment
Anti-Theft - Passive
419-02 : Remote Convenience
General Procedures
Universal Transmitter Programming
Universal Transmitter
419-07 : Navigation System
Specifications
Specifications
Navigation System
Navigation System
Navigation System Antenna (86.62.06)
Navigation System Display Module (86.62.07)
Navigation System Module (86.62.05)
419-08 : Cellular Phone
Specifications
Specifications
Cellular Phone
Cellular Phone Antenna (86.51.17)
Transceiver Module
419-10 : Multifunction Electronic Modules
Specifications
Specifications
Module Controlled Functions
Multifunction Electronic Module
Driver Seat Module (DSM) (86.75.28)
Information and Entertainment Module (86.53.48)
Remote Keyless Entry (RKE) Module
5 : Body and Paint
501 : Body and Paint
501-02 : Front End Body Panels

Air Deflector (76.11.41)
Cowl Vent Screen (76.10.01)
Fender Splash Shield (76.10.90)
Radiator Splash Shield (76.22.90)
501-03 : Body Closures
Specifications
Specifications
General Procedures
Hood Alignment (76.16.02)
Luggage Compartment Lid Alignment (76.19.03)
Liftgate Alignment (76.19.54.60)
Hood (76.16.01)
Luggage Compartment Lid (76.19.01)
Door (76.28.04)
Door Check Arm
Liftgate
501-05 : Interior Trim and Ornamentation

Specifications
Specifications
A-Pillar Trim Panel (76.13.31)
B-Pillar Trim Panel (76.13.28)
Engine Cover (76.11.35)
Front Door Trim Panel (76.34.01)
Headliner (76.64.01)
Front Scuff Plate Trim Panel (76.13.81)
Scuff Plate Trim Panel (76.13.81)
Sun Visor (76.10.48)
Liftgate Upper Trim Panel (76.34.11)
Liftgate Lower Trim Panel
Rear Quarter Trim Panel - 2-Door (76.13.73)
Rear Quarter Trim Panel - Convertible (76.13.73)
Rear Quarter Trim Sliding Panel
Loadspace Trim Panel - 2-Door (76.13.73.60)
Loadspace Trim Panel - Convertible (76.13.73.60)
Luggage Compartment Lid Trim Panel (76.19.05)
501-08 : Exterior Trim and Ornamentation
Specifications
Specifications
Front Fender Moulding (76.10.48)
Rear Spoiler (76.19.86.60)
Rocker Panel Moulding (76.11.36)
501-09 : Rear View Mirrors
Specifications
Specifications
Rear View Mirrors
Rear View Mirrors
Auto-Dimming Interior Mirror (76.10.56)
Exterior Mirror (76.10.52)
Exterior Mirror Glass (76.10.53)
Exterior Mirror Motor (76.10.57)
501-10 : Seating
Specifications
Specifications
Seats
Seats
Front Seat (76.70.01)
Front Seat Backrest Cover (76.70.15)
Front Seat Control Switch (86.75.46)
Front Seat Cushion Cover (76.70.33)
Front Seat Lumbar Motor (86.75.44)
Front Seat Recliner Motor (86.75.04)
Rear Seat Armrest (76.70.39)
Rear Seat Backrest (76.70.38)
Rear Seat Cushion (76.70.37)
Front Seat Backrest Heater Mat (86.75.14)
Front Seat Cushion Heater Mat (86.75.13)
Seat Track
Assembly & Disassembly
Rear Seat Backrest - Vehicles With: 40/20/40 Split Seat
(76.70.48)
501-11 : Glass, Frames and Mechanisms
Specifications
Specifications
General Procedures
Door Window Motor Initialization
Door Window Glass Adjustment (76.31.03)
Glass, Frames and Mechanisms
Front Door Window Glass (76.31.01)
Front Door Window Regulator Motor (76.31.45)
Front Door Window Regulator
Window Control Switch (86.25.08)
Rear Quarter Window Glass - Convertible (76.31.31)
Windshield Glass (76.81.40)
Rear Quarter Window Glass - 2-Door (76.31.31)
Rear Quarter Window Regulator Motor (86.25.11)
501-12 : Instrument Panel and Console
Specifications
Specifications
Instrument Panel
Floor Console (76.25.01)
Floor Console Finish Panel (76.47.26)
Glove Compartment (76.52.03)
Instrument Panel (76.46.01)
Overhead Console (76.13.69)
Instrument Panel Lower Trim Panel (76.46.11)
501-14 : Handles, Locks, Latches and Entry Systems
Specifications
Specifications
Handles, Locks, Latches and Entry Systems
Locks, Latches and Entry Systems
Door Lock Cylinder Cover
Exterior Door Handle (76.58.07)
Front Door Lock Actuator (76.37.74)
Front Door Lock Cylinder (76.37.71)
Luggage Compartment Lid Latch Actuator (76.19.25)
Luggage Compartment Lid Lock Cylinder (76.19.19)
Liftgate Lock Cylinder
Liftgate Latch Actuator (86.25.65.60)
Radio Frequency (RF) Receiver
Keyless Vehicle Front Antenna
Keyless Vehicle Center Antenna
Hood Latch
501-16 : Wipers and Washers
Specifications
Specifications
Wipers and Washers
Wipers and Washers
Headlamp Washer Jet (84.20.08)
Headlamp Washer Pump (84.20.21)
Rain Sensor (84.12.10)
Windshield Washer Pump (84.10.21)
Windshield Washer Reservoir (84.10.01)
Windshield Wiper Motor - LHD RWD (84.15.13)
Windshield Wiper Motor - RHD RWD (84.15.13)
Wiper Pivot Arm (84.15.03)
501-18 : Convertible Top
Specifications
Specifications
General Procedures
Convertible Top Compartment Lid Alignment
Convertible Top Alignment
Convertible Top Base Plate Adjustment
Convertible Top
Convertible Top
Convertible Top Assembly (76.86.15)
Convertible Top Headliner (76.86.16)
Convertible Top Latch (76.86.19)
Header Rail Upper Trim Panel (76.86.20)
Header Rail Weatherstrip
Convertible Top Compartment Lid
Convertible Top Compartment Lid Trim Panel
Convertible Top Compartment Lid Hinge
Convertible Top Compartment Lid Moulding
Convertible Top Compartment Lid Latch
Convertible Top Compartment Lid Release Cables
Convertible Top Compartment Lid Latch and Cable
Assembly
Convertible Top Motor
Hydraulic System, Lift Cylinder and Motor
Convertible Top Module
Convertible Top Rear Panel Lower Weatherstrip
Convertible Top Tension Cylinder
Convertible Top Compartment Lid Lift Cylinder
Convertible Top Material (76.86.12)
Convertible Top Striker
501-19 : Bumpers
Specifications
Specifications
Front Bumper (76.22.08)
Front Bumper Cover (76.22.78)
Rear Bumper (76.22.27)
Rear Bumper Cover (76.22.74)
501-20A : Safety Belt System
Specifications
Specifications
Safety Belt System
Safety Belt System
Front Safety Belt Buckle (76.73.49)
Rear Safety Belt Buckle (76.73.50)
Rear Safety Belt Retractor - 2-Door (76.73.18)
Front Safety Belt Retractor (76.73.10)
Rear Safety Belt Retractor - Convertible (76.73.18)
501-20B : Supplemental Restraint System
Specifications
Specifications
General Procedures
Air Bag Disposal
Air Bag Supplemental Restraint System (SRS)
Front Impact Severity Sensor
Driver Air Bag Module (76.73.39)
Front Passenger Seat Occupant Classification Sensor
(76.73.60)
Restraints Control Module (RCM) (76.73.48)
Passenger Air Bag Module (76.73.37)
Side Air Bag Module (76.73.47)
Rollover Protection Unit
Side Impact Sensor - Convertible (76.73.53)
Side Impact Sensor - 2-Door (76.73.53)
501-20C : Pedestrian Protection System
Specifications
Specifications
Pedestrian Protection System
Pedestrian Protection Module
Pedestrian Impact Sensor
Pedestrian Protection Latch Actuator
Pedestrian Protection Accelerometer
Pedestrian Protection Hood Actuator LH
Pedestrian Protection Hood Actuator RH
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
Specifications
Specifications
Front End Sheet Metal
Front Fender
Front Crossmember
Fender Apron Panel
Fender Apron Panel Reinforcement
Fender Apron Panel Closing Panel
Front Side Member
Side Member Deformation Element
Front Side Member Extension
Front Wheelhouse
Fender Apron Panel Front Extension
Front Side Member Side Extension
Auxiliary Front Crossmember
Front Side Member Side Extension Mounting
Front Side Member To Deformation Element Bracket
Suspension Top Mount
Front Side Member and Suspension Top Mount Assembly
Windshield Frame - Convertible
501-28 : Roof Sheet Metal Repairs

Roof
Roof Panel
501-29 : Side Panel Sheet Metal Repairs

Side Panel Sheet Metal
Rocker Panel
Bulkhead Lower Reinforcement
A-Pillar Assembly
A-Pillar Outer Panel
501-30 : Rear End Sheet Metal Repairs

Rear End Sheet Metal
Rear Wheelhouse Outer
Rear Inner Wheelhouse Half
Rear Outer Wheelhouse Half
Rear Lamp Mounting Panel
Spare Wheel Well
Rear Side Member Section
Quarter Panel Lower Extension
Quarter Panel Assembly - 2-Door
Quarter Panel Assembly - Convertible
Back Panel Assembly
Rear Side Member Closing Panel
Rear Side Member Reinforcement Panel
Water Drain Panel - Convertible
Water Drain Panel Reinforcement - Convertible
502 : Frame and Mounting
502-00 : Uni-Body, Subframe and Mounting System
Specifications
Specifications
Front Subframe (76.10.05)
Rear Subframe (64.25.01)
Rear Subframe Front Bushing (64.25.34)
Rear Subframe Rear Bushing (64.25.36)
1. GENERAL INFORMATION
100 : Service information
100-00 : General information
Description and operation
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 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.
With the battery disconnected, a Radio Code Saver will allow sufficient current to pass to maintain
the radio receiver/cassette player/mini disc player and compact disc player memory, operate the
clock and supply the door operated interior lights while isolating the battery in the event of a short
circuit.
Reconnecting the Battery
WARNING: If the battery has been on bench charge the

cells may be giving off explosive hydrogen gas. Avoid creating
sparks, and if in doubt cover the vent plugs or covers with a
damp cloth.
Always make sure that all electrical systems are switched OFF before reconnecting the battery to
avoid causing sparks or damage to sensitive electrical equipment.
Always reconnect the battery positive lead first and the negative last, ensuring that there is a good
electrical contact and the battery terminals are secure.
Restart the clock (where 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.
CAUTION: 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.
CAUTION: Whilst it is not recommended that the vehicle is

jump started, it is recognized that this may occasionally be the
only practical way to mobilize a vehicle. In such an instance the
discharged battery must be recharged immediately after jump
starting to avoid permanent damage.
• Always make sure that the jump leads are adequate for the task. Heavy duty cables must be
used.
• Always make sure that the slave battery is of the same voltage as the vehicle battery. The
batteries must be connected in parallel.
• Always make sure that switchable electric circuits are switched off before connecting jump
leads. This reduces the risk of sparks occurring when the final connection is made.
WARNING: Make sure that the ends of the jump leads do

not touch each other or ground against the vehicle body at any
time while the leads are attached to the battery. A fully charged
battery, if shorted through jump leads, can discharge at a rate
well above 1000 amps causing violent arcing and very rapid
heating of the jump leads and terminals, and can even cause
the battery to explode.
Always connect the jump leads in the following sequence.
• Slave battery positive first then vehicle battery positive.

• Slave battery negative next and then vehicle ground at least, 300 mm (12 in) from the
battery terminal e.g. engine lifting bracket.
Always reduce the engine speed to idle before disconnecting the jump leads.
Before removing the jump leads, 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. Wire together mating parts where necessary to prevent
accidental interchange (e.g roller bearing components). Tie labels on to all parts to be renewed and
to parts requiring further inspection before being passed for reassembly. Place labelled parts and
other parts for rebuild in separate containers. Do not discard a part which is due for renewal until it
has been compared with the new part, to make sure that the correct part has been obtained.
Inspection
Before inspecting a component for wear or performing a dimensional check, make sure that it is
absolutely clean; a slight smear of grease can conceal an incipient failure. When a component is to be
checked dimensionally against figures quoted for it, use the correct equipment (surface plates,
micrometers, dial gauges etc.) in serviceable condition. The use of makeshift equipment can be
dangerous. Reject a component if its dimensions are outside the limits quoted, or if damage is
apparent. A 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.
Term(s) Acronym/Unit/Abbreviatio Definition

n
Air Conditioning A/C
Is a multitrack
sensor which
inputs the
Accelerator Pedal
APP drivers demand
Position
into the engine
control module
(ECM)
Event occurring
After Bottom Dead
ABDC after bottom
Center
dead center
Event occurring
After Top Dead
ATDC after top dead
Center
center
System which
prevents wheel
lock-up under
Anti-lock Brake braking by
ABS sensing lack of
System
rotation of a
wheel(s) and
diverting fluid
pressure away
from it (them)
Alternating Current ac
Amplitude Modulation AM
Automatic
ATC
Temperature Control
Automatic
ATF
Transmission Fluid
SI unit of
Ampere A
current
Ampere hour Ah
Pressure of
surrounding air
Barometric Pressure BARO at any given
temperature
and altitude
The positive
voltage from a
Battery positive battery or any
B+
voltage circuit
connected
directly to it
Event occurring
Before Bottom Dead
BBDC before bottom
Center
dead center
Event occurring
Before Top Dead
BTDC before top dead
Center
center
Lowest point of
piston travel in
Bottom Dead Center BDC
a reciprocating
engine
Battery Junction Box BJB
Brake Pedal Position BPP
Effective
horsepower
developed by
an engine or
Brake Horsepower BHP motor, as
measured by a
brake applied
to its output
shaft
Standard
specification
issued by the
British Standard BS
British
Standards
Institution
Brake Traction
BTCS
Control System
Topology of a
Bus
communication network
Coast Clutch Solenoid CCS
Camshaft Position CMP Indicates

camshaft
position
Colorless gas
with a density
of
Carbon dioxide CO²
approximately
1.5 times that
of air
Poisonous gas
produced as
Carbon monoxide CO the result of
incomplete
combustion
Chlorofluorocarbon CFC
In-line exhaust
system device
used to reduce
Catalytic converter
the level of
engine exhaust
emissions
SI term for the

Centigrade
scale, with
Celsius C freezing point
at zero and
boiling point at
100 degrees
Compact Disc CD
Cylinder Head A sensor for

CHT Sensor
Temperature Sensor measuring the
temperature of
the cylinder
head
Central Junction Box CJB
Indicates
Crankshaft Position CKP crankshaft
position
Indicates clutch
Clutch Pedal Position CPP
pedal position
A
communication
Controller Area system which
CAN
Network allows control
modules to be
linked together
Constant Velocity CV
Cubic centimeter cm³
Electronic
module to
Central Security
CSM support
Module
security system
functionality
Connector
providing
access and/or
Data Link Connector DLC control of the
vehicle
information,
operating
conditions, and
diagnostic
information
Electronic
module to
Driver Door Module DDM support driver
door
functionality
Electronic
module to
Driver Seat Module DSM support driver
seat
functionality
Daytime Running
DRL
Lamps
German
Deutsche Institut fur
DIN standards
Normung
regulation body
An
alpha/numeric
identifier for a
Diagnostic Trouble fault condition
DTC
Code identified by the
On-Board
Diagnostic
(OBD) system
Current which
Direct current dc 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
EGR
Recirculation
Sensing EGR
Exhaust Gas
function based
Recirculation EGRT
on temperature
Temperature Sensor
change
Electronic Brake
EBD
Force Distribution
Electronic
Engine Control module to
ECM
Module support engine
functionality
Sensor to
Electronic Crash measure
ECS
Sensor severity of
impact
Engine Coolant
ECT
Temperature
Engine Oil Pressure EOP

European On-Board
EOBD
Diagnostic
Electronic Pressure
EPC
Control
Electrically Erasable
Programmable Read- EEPROM
Only Memory
Erasable
Programmable Read- EPROM
Only Memory
System
designed to
prevent fuel
vapor from
escaping into
the
Evaporative Emission EVAP atmosphere.
Typically
includes a
charcoal filled
canister to
absorb fuel
vapor
Flash Electrically
Erasable
FEEPROM
Programmable Read-
Only Memory
Front Electronic
FEM
Module
Flash Erasable
Programmable Read- FEPROM
Only Memory
Frequency Modulation FM
Fuel Pump Driver

FPDM
Module
Fuel Rail Pressure FRP
Generic Electronic
GEM
Module
Electrical
conductor used
as a common
return for an
Ground GND
electrical circuit
or circuits, and
with a relative
zero potential
Global Positioning
GPS
System
Global System for

Mobile GSM
Communication
Gross Vehicle Weight GVW
Electrically
Heated Oxygen heated oxygen
HO2S
Sensor sensor which
induces fuelling
corrections
Hydrofluorocarbon HFC
High tension HT
Hydrocarbon HC
Stepper motor
driven device
which varies
the volume of
Idle Air Control IAC air by-passing
the throttle to
maintain the
programmed
idle speed
Intake Air Temperature of

IAT
Temperature intake air
An inertia
system that
shuts off the
fuel supply
when activated
Inertia Fuel Shut-off IFS by pre-
determined
force limits
brought about
by (e.g.)
collision
Indicates input
Input Shaft Speed ISS
shaft speed
Key On, Engine Off KOEO
Key On, Engine

KOER
Running
Kilogram (mass) kg
Kilogram (force) kgf
Kilogram force per

kgf/cm²
square centimeter
Kilometer km
Kilometer per hour km/h
Kilopascal kPa
Kilovolt kV
Sensor which
detects the
onset of
Knock Sensor KS detonation, and
signals the
ECM to retard
the ignition
Optical digital
display system,
to which
applied voltage
Liquid Crystal Display LCD varies the way
the crystals
reflect light,
thereby
modifying the
display
Lighting Control
LCM
Module
Light Emitting Diode LED
Primary circuit
of the ignition
system, linking
Low Tension LT the battery to
the primary
winding in the
ignition coil
Left-Hand LH
Left-Hand Drive LHD
System which
provides
information on
Mass Air Flow MAF the mass flow
rate of the
intake air to the
engine
Absolute
Manifold Absolute pressure of the
MAP
Pressure intake manifold
air
Manifold Absolute
Pressure and MAPT
Temperature
A required on-
board indicator
to alert the
Malfunction Indicator
MIL driver of an
Lamp
emission
related
malfunction
Meter (measurement) m
Metric (screw thread,

M
e.g. M8)
Unit of
Farad F electrical
capacitance
Millimeter mm
Millimeter of mercury mmHg
Millisecond ms
Model year MY
SI unit of force.
Newton N 1 N = 0.2248
pounds force
SI unit of
torque. Must
not be
Newton Meter Nm
confused with
nm
(nanometer)
Negative Temperature NTC

Coefficient
Fuelling system
using intake air
at atmospheric
Naturally aspirated N/A pressure; not
supercharged
or
turbocharged
Noise, Vibration and

NVH
Harshness
Vehicles for
North American sale in the USA
NAS
Specification and Canadian
markets
A system that
monitors some
or all computer
input and
output control
signals.
On-Board Diagnostic OBD 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
ORVR
Vapour Recovery
Output State Control OSC
Output Shaft Speed OSS
Passenger Air Bag

PAD
Deactivation
Pulsed Secondary Air

PAIR
Injection
Passive Anti-Theft
PATS
System
Positive Crankcase
PCV
Ventilation
An index
number
referring to a
parameter
Parameter
PID within a module
Identification
without
knowledge of
its storage
location
Park/Neutral Position PNP
Pulse Width
PWM
Modulation
Process
whereby a
common ECM
is programmed
Programmable on the
Electronic Control PECUS production line
Units System to suit the
market
requirements of
a particular
vehicle
ROM with
some provision
Programmable Read- for setting the
PROM
only Memory stored data
after
manufacture
Portable Support
PSE
Electronics
Power Steering
PSP
Pressure
Polytetrafluoroethylen
PTFE
e
Fast access
memory store
which is
Random Access
RAM accessible for
Memory
entry or
extraction of
data
Fast access
memory in
Read Only Memory ROM which data is
fixed and may
not be changed
Electronic
module to
support
Restraints Control functionality of
RCM
Module the
Supplemental
Restraints
System
Radio Data System RDS
Rear Electronic
REM
Module
Remote Keyless Entry RKE
Right-hand RH
Right-hand drive RHD
Research Octane
RON
Number
Electronic
module to
Rear Seat Module RSM 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
SCL
Communications Link
A high-speed,
serial
communication
s system
linking all body
system control
modules.
Standard Corporate Control
SCP
Protocol messages and
data are
passed
between
modules at up
to 786
messages per
second
Supplemental
SRS
Restraints System
Controls
shifting in an
Shift Solenoid SS
automatic
transmission
Module
controlling the
seat motor
Seat Control Module SCM systems (not
electric
raise/lower-only
seats)
System used
for a period of
time each time
the engine is
started, unless
certain
temperature
criteria are met.
Secondary Air Pumps air
AIR directly into the
Injection
exhaust system
which
generates extra
heat and
reduces the
time taken for
the catalytic
converters to
reach operating
temperature
Number
generated by
Jaguar
Methods &
Techniques
system which
relates to the
time allowed to
complete a
repair
operation.
Service Repair
SRO Further
Operation (number)
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
T/CCS
Solenoid
Torque Converter
TCC
Clutch
Transmission Control
TCIL
Indicator Lamp
Throttle Position TP
Top Dead Center TDC
Controls the
shifting pattern
TCM of the
Module
(automatic)
transmission
Modifies the
operation of
TCS electronically
Switch
controlled
transmissions
Indicates
Transmission Fluid temperature of
TFT
Temperature transmission
fluid
The range in
which the
Transmission Range TR
transmission is
operating
Indicates
rotational
speed of
Turbine Shaft Speed TSS
transmission
output shaft or
turbine shaft
Variable Assist Power
VAPS
Steering
A system by
which the
relationship of
Variable Camshaft the crankshaft
VCT
Timing and camshaft
may be altered
during engine
running
Number
assigned to the
vehicle by the
Vehicle Identification manufacturer,
VIN
Number primarily for
licensing and
identification
purposes
Sensor which
provides
Vehicle Speed Sensor VSS
vehicle speed
information
Jaguar
Worldwide Diagnostic approved
WDS
System diagnostic
system
Full throttle
Wide Open Throttle WOT
position
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).
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.
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
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.

Standard Workshop Practices
Protecting the Vehicle
Always install covers to protect the fenders before commencing work in the engine
compartment. Always install the interior protection kit, wear clean overalls and wash hands or
wear gloves before working inside the vehicle. Avoid spilling hydraulic fluid, antifreeze or
battery acid on the paintwork. In the event of spillage, wash off with water immediately. Use
polythene sheets in the luggage compartment to protect carpets. Always use the recommended
service tool, or a satisfactory equivalent, where specified. Protect temporarily exposed screw
threads by replacing nuts or installing caps.
Vehicle in Workshop
When working on a vehicle in the workshop always make sure that:
• The parking brake is applied or the wheels are securely chocked to prevent the vehicle
moving forwards or backwards
• If the engine is to be run, there is adequate ventilation, or an extraction hose to remove
exhaust fumes is installed
• There is adequate room to jack up the vehicle and remove the wheels, if necessary
• Fender covers are always installed if any work is to be carried out in the engine
compartment
• The battery is disconnected if working on the engine, underneath the vehicle, or if the
vehicle is jacked up
CAUTION: When electric arc welding on a vehicle, always disconnect the

generator wiring to prevent the possibility of a surge of current causing damage to the
internal components of the generator.
• If using welding equipment on the vehicle, ensure a suitable fire extinguisher is

readily available.
100-01 : Identification codes
Identification Codes - 4.2L NA V8 -

AJV8/4.2L SC V8 - AJV8
Vehicle Identification Number (VIN)
The official 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 vehicle identification number is also located on the vehicle certification label.
Item Description
1 VIN plate
2 Bar code label (America)
3 Vehicle certification label (Europe/rest of world shown)

Vehicle Identification Number (Typical)
Item 1 - World Manufacturer Identifier

Codes Manufacturer Make Type
SAJ Jaguar Cars Limited, England Jaguar Passenger Car
Item 2 - Market, Air Bag Specification

VIN code Description
A Rest of the world with four air bags
D USA with four air bags
F Canada with four air bags
K Japan with four air bags
P Mexico with four air bags

Item 3 - Transmission, Steering Code
VIN Code Description
A Automatic LHS
C Automatic RHS
Item 4 - Body Code

43 X150 2 door Coupe
44 X150 2 door Convertible
Item 5 - Engine Emission System

B 4.2L Naturally aspirated ULEV II
F 4.2L Naturally aspirated Stage 2
K 4.2L Naturally aspirated Stage 3
P 4.2L Naturally aspirated stage 4
U 4.2L Naturally aspirated Stage 2 (91 RON)
X 4.2L Naturally aspirated Stage 2 (E22 RON)
Item 6 - Check Digit

VIN Description
Code
Calculated in accordance with American standard CFR

0 - 9 or X
part 565
Item 7 - Model Year

6 2006 model year
7 2007 model year
8 2008 model year
Item 8 - Assembly Plant and Model Line

5 Castle Bromwich 4.2L
Item 9 - Production Sequence Number

Sequence Number
B00001 - B99999
Vehicle Certification Label

The vehicle certification label also contains the 17 character vehicle identification number.
Vehicle Certification Label (Europe and Rest of the world)
Item Description
Whole Vehicle Type Approval (WVTA) number printed here

1
when applicable
2 Vehicle identification number
3 Gross vehicle weight
4 Gross train weight
5 Maximum permitted front axle loading
6 Maximum permitted rear axle loading
7 Date of manufacture
8 Interior trim code
9 Paint code
Vehicle Certification Label (North America)
Item Description
6 Type
8 Paint code
Vehicle Certification Label (Saudi Arabia and Gulf States)

Item Description
4 Paint code
Vehicle Certification Label (Canada)

Item Description
6 Paint code
8 Type
Automatic Transmission Number

The serial number of the transmission unit is etched into the transmission casing.
Engine Number
The engine serial number is stamped on an engine web on the left-hand side of the cylinder block
behind the engine mounting.
100-02 : 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.
Lifting
Lifting Points—Two-Post Lift
CAUTION: 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 lift prior to lifting the vehicle.
CAUTION: Never use the rear axle as a lift point. Damage to the rear axle seals
and bushes may occur.
CAUTION: When using a two-post lift, a cushioned pad must be utilized to avoid
body damage.
Lifting Points—Floor Jack and Axle Stands
CAUTION: When using a floor jack, a cushioned pad must be utilized to avoid
body damage.
CAUTION: When using axle stands, a cushioned pad must be utilized to avoid
damage to the body.
Item Description
A Jacking point
B Axle stand positioning point
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 transporter or trailer
• Emergency towing
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 park 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
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 recovered by

transporter or trailer.
When the vehicle is being towed on its own wheels:
• Local regulations for the towing of vehicles must be adhered to. 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 to allow for
the operation of the direction indicators, horn and stop lamps
• 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
100-04 : Noise, Vibrations and Harshness

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.
o Electrical conditions usually occur at connections rather than components.
o 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.
Diagnosis and testing

Principle of Operation
For a detailed description of Noise, Vibration and Harshness issues, refer to the Description and
Operation section of the workshop manual.
Inspection and Verification

1 . Verify the customer's concerns by operating the vehicle to duplicate the condition.
2 . Visually inspect the vehicle to determine any obvious cause(s) of the concern(s).
3 . If the inspection reveals obvious causes that can be readily identified, repair as necessary.
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 . Inspect the CV joint boots for evidence of cracks, tears or splits.
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 . 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 . 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 . 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 . 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 . Road test the vehicle and define the condition by reproducing it several times during the road
test.
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 . 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 . Acceleration/deceleration: With slow acceleration and deceleration, a shake is sometimes noticed

in the steering wheel/column, seats, front floor pan, front door trim panel or front end sheet metal.
It is a low frequency vibration (around 9-15 cycles per second). It may or may not be increased by
applying brakes lightly. Refer to Idle Boom/Shake/Vibration in the Symptom Chart.
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 . 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 . 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 . 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. When the CV joint is run at a very high angle, extra
vibration as well as damage to the seals and joints can occur.
The 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.
Jacking
Lifting
1 . Raise and support the vehicle.

Jacking
Lifting
2 . Explore the speed range of interest using the Road Test Quick Checks as previously described.
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 . Raise vehicle on lift and slacken all exhaust fixings.
2 . With all fixings loose, neutralize the exhaust system.
3 . Tighten all fixings to correct torque, starting at the rear-most point working towards the front of
the vehicle.
Symptom Chart
High-speed shake
Possible Source(s):
• Wheel end vibration
• Engine/transmission
• Driveline
Action(s) to take:
• GO to Pinpoint Test G543314p1.
Tip-in moan
Possible Source(s):
• Air cleaner
• Power steering
• Powertrain
• Engine mounts
• Exhaust system
Action(s) to take:
Idle boom/shake/vibration, or shudder
Possible Source(s):
• Cable(s)/hoses(s)
• Intake air distribution and filtering system
• Engine mounts
• Exhaust system
• Belt/pulleys
Action(s) to take:

Wheel end vibration analysis
Possible Source(s):
• Suspension/rear drive halfshaft and CV joints
• Tires/wheels
• Wheel bearings
• CV joint boots
Action(s) to take:
Non-axle noise
Possible Source(s):
• Trim/mouldings
• A/C system
• Accessories
Action(s) to take:
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 G543314p1 : HIGH-

SPEED SHAKE
G543314t1 : NEUTRAL COAST
1. Carry out the neutral coast test.
• Does the vibration disappear during the neutral coast test?
-> Yes
CHECK and INSTALL new engine/transmission mounts as necessary. REPEAT Road Test as outlined.
-> No
GO to Pinpoint Test G543314t9.
PINPOINT TEST G543314p2 : TIP-IN

MOAN
G543314t2 : 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
-> No
CORRECT the condition. REPEAT the Road Test as outlined.
G543314t3 : CHECK THE EXHAUST SYSTEM

1. Carry out the exhaust system neutralizing procedure in this section.
• Is the exhaust system OK?
-> Yes
-> No
REPAIR as necessary. RESTORE vehicle. REPEAT the Road Test as outlined.
G543314t4 : 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
Power Steering
-> No
PINPOINT TEST G543314p3 : IDLE

BOOM/SHAKE/VIBRATION/SHUDDER
G543314t5 : 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.
-> Yes
-> No
G543314t16 : CHECK INTAKE AIR DISTRIBUTION

AND FILTERING SYSTEM
1. Check the intake air distribution and filtering system for loose/damaged components (primarily
upstream of the Mass Air Flow (MAF) sensor).
-> Yes
-> No
CORRECT the condition. REPEAT the road test as outlined.
G543314t6 : CHECK THE STEERING WHEEL

DAMPER
1. Remove the driver air bag module and visually inspect the steering wheel damper for correct
installation or any touch condition.
• Is the damper OK?
-> Yes
-> No
G543314t7 : 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
-> No
G543314t8 : CHECK THE EXHAUST SYSTEM

1. Carry out the exhaust system neutralizing procedure in this section.
• Is the exhaust system OK?
-> Yes
-> No
REPAIR as necessary. REPEAT Road Test.
PINPOINT TEST G543314p4 : WHEEL

END VIBRATION ANALYSIS
G543314t9 : INSPECT THE TIRES
1. Inspect the tires.
Raise and support the vehicle.

Lifting
Inspect the tires for:
Correct tire pressures
Correct tire size
Tire/wheel compatibility
Wear or damage
Tire beads correctly seated
• Are the tires OK?
-> Yes
-> No
REPAIR as necessary. REPEAT the Road Test as outlined.
G543314t10 : INSPECT WHEEL BEARINGS

1. Inspect the wheel bearings.
• Are the wheel bearings OK?
-> Yes
-> No
G543314t11 : INSPECT THE CONSTANT VELOCITY

(CV) JOINT BOOTS
1. Inspect the CV joint boots.
Inspect for evidence of cracks, tears, splits or splattered grease
• Are the CV joint boots OK?
-> Yes
-> No
G543314t12 : INSPECT WHEEL AND TIRE RUNOUT

1. Inspect the wheel and tire runout.
• 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.
REPEAT the Road Test as outlined.
PINPOINT TEST G543314p5 : NON-

AXLE NOISE
G543314t13 : 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.
-> No
G543314t14 : 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.
-> No
G543314t15 : 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
2. CHASSIS
204 : Suspension
204-00 : Suspension system – General information
Specifications
Specifications
Wheel Alignment Specification - Front
All Right-Hand Drive and Japan without dynamics pack

Item LH RH Split LH-RH
Castor Decimal degrees 7.05° ± 0.75° 6.51° ± 0.75° 0.55° ± 0.75°
Degrees/minutes 7° 3' ± 45' 6° 31' ± 45' 0° 33' ± 45'
Camber Decimal degrees -0.7° ± 0.75° -0.3° ± 0.75° -0.4° ± 0.75°
Degrees/minutes -0° 42' ± 45' -0° 18' ± 45' -0° 24' ± 45'
Total toe Decimal degrees 0.17° ± 0.20°
Degrees/minutes 0° 10' ± 12'
All Right-Hand Drive and Japan with dynamics pack

Castor Decimal degrees 7.28° ± 0.75° 6.74° ± 0.75° 0.55° ± 0.75°
Degrees/minutes 7° 17' ± 45' 6° 44' ± 45' 0° 33' ± 45'
Camber Decimal degrees -1.0° ± 0.75° -0.6° ± 0.75° -0.4° ± 0.75°
Degrees/minutes -0° 60' ± 45' -0° 36' ± 45' -0° 24' ± 45'
USA, Canada, Mexico and Dominican Republic without dynamics pack

Castor Decimal degrees 6.78° ± 0.75° 6.78° ± 0.75° 0° ± 0.75°
Degrees/minutes 6° 47' ± 45' 6° 47' ± 45' 0° 0' ± 45'
Camber Decimal degrees -0.25° ± 0.75° -0.75° ± 0.75° 0.5° ± 0.75°
Degrees/minutes -0° 15' ± 45' -0° 45' ± 45' 0° 30' ± 45'
USA, Canada, Mexico and Dominican Republic with dynamics pack

Degrees/minutes 7° 1' ± 45' 7° 1' ± 45' 0° 0' ± 45'
Degrees/minutes -0° 33' ± 45' -0° 63' ± 45' 0° 30' ± 45'
Rest of the World without dynamics pack

Degrees/minutes 6° 47' ± 45' 6° 47' ± 45' 0° 0' ± 45'
Degrees/minutes -0° 24' ± 45' -0° 36' ± 45' 0° 12' ± 45'
Rest of the World with dynamics pack

Degrees/minutes 7° 1' ± 45' 7° 1' ± 45' 0° 0' ± 45'
Degrees/minutes -0° 42' ± 45' -0° 54' ± 45' 0° 12' ± 45'
Wheel Alignment Specification - Rear

Naturally Aspirated (NA)
Item LH RH
Camber Decimal degrees -0.53° ± 0.75° -0.53° ± 0.75°
Degrees/minutes -0° 32' ± 45' -0° 32' ± 45'
Toe Decimal degrees 0.125° ± 0.14° 0.125° ± 0.14°
Degrees/minutes 0° 7.5' ± 8' 0° 7.5' ± 8'
Rear thrust angle Decimal degrees 0° ± 0.14°
Supercharged (SC) without dynamics pack

Item LH RH
Degrees/minutes -0° 38' ± 45' -0° 38' ± 45'
Degrees/minutes 0° 7.5' ± 8' 0° 7.5' ± 8'
Supercharged (SC) with dynamics pack

Item LH RH
Degrees/minutes -0° 59' ± 45' -0° 59' ± 45'
Degrees/minutes 0° 7.5' ± 8' 0° 7.5' ± 8'
Vehicle ride height
Front Rear
Naturally aspirated (NA) 396 mm ± 15 mm 396 mm ± 15 mm
Supercharged (SC) without dynamics pack 394 mm ± 15 mm 393 mm ± 15 mm
Supercharged (SC) with dynamics pack 384 mm ± 15 mm 379 mm ± 15 mm
• All the above figures are measured at "kerb" height -all fluids at full and a full fuel
tank.
• Tires must be inflated to normal pressure
• Rear thrust angle = (LH toe - RH toe) ÷ 2
• Ride height is measured from the centre of the wheel to the apex of the wheel arch,
through the wheel centre line.
General procedures

CAUTION: Make sure the vehicle is on a flat level surface.
CAUTION: Make sure the tire pressures are within

specification.
CAUTION: Make sure that only the manufacturers'

recommended four wheel alignment equipment is used.
CAUTION: Make sure the steering is in the straight ahead

position.
1. For wheel alignment information, refer to the suspension specification section.
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 tie rod end lock nuts.
8.
CAUTION: Do not allow the gaiter to twist.
NOTE:
Both tie rods must be rotated by an equal amount.
NOTE:
Adjust the front toe.

9. Tighten the tie rod end lock nuts to 55 Nm (40 lb.ft).
CAUTION: Make sure the vehicle is on a flat
level surface.
CAUTION: Make sure the tire pressures are

within specification.
CAUTION: Make sure that only the

manufacturers' recommended four wheel alignment
equipment is used.
CAUTION: Make sure the steering is in the

straight ahead position.
and free play.
• Adjust or repair any worn, damaged or incorrectly

adjusted components.

7. NOTE:
To adjust, loosen the toe link locknuts.
8.
NOTE:
NOTE:
Adjust the rear toe.

9. Tighten the toe link locknuts to 55 Nm (40 lb.ft).
CAUTION: Make sure the vehicle is on a flat
level surface.
CAUTION: Make sure the tire pressures are

CAUTION: Make sure that only the

manufacturers' recommended four wheel alignment
equipment is used.
CAUTION: Make sure the steering is in the

straight ahead position.
and free play.
• Adjust or repair any worn, damaged or incorrectly

adjusted components.

7. NOTE:
To adjust, loosen the toe link locknuts.
8.
NOTE:
NOTE:
Adjust the rear toe.

9. Tighten the toe link locknuts to 55 Nm (40 lb.ft).
10. NOTE:
To adjust the caster, loosen the front lower arm lock nuts.
11. NOTE:
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.
NOTE:
To adjust the camber, loosen the rear lower arm lock nuts.
14. NOTE:
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).
16. NOTE:
To adjust, loosen the tie rod end lock nuts.
17.

NOTE:
NOTE:
Adjust the front toe.
18. Tighten the tie rod end lock nuts to 55 Nm (40 lb.ft).

Camber, caster and toe are adjustable on the front suspension system. Only the toe is adjustable on
the rear suspension system. Camber and caster are adjusted by means of eccentric cams on the
lower arm mounting bolts. The front toe is adjusted by use of the front tie-rod. The rear toe is
adjusted by the use of toe link assemblies connecting the knuckles to the rear sub-frame.
Camber
Negative Camber
Positive Camber
Camber is the vertical tilt of the wheel when viewed from the front. Camber can be positive or
negative and has a direct effect on tire wear.
Caster
Item Description
1 Positive caster
2 True vertical
3 Steering axis
Caster is the deviation from vertical of an imaginary line drawn through the ball joints when viewed
from the side. The caster specifications in this section will give the vehicle the best directional
stability characteristics when loaded and driven. The caster setting is not related to tire wear.
Toe
Positive Toe (Toe-In)

Negative Toe (Toe-Out)
The vehicle toe setting:
• affects tire wear and directional stability.
Ride Height
NOTE:
All ride height measurements are carried out with

vehicle empty and 9 liters of fuel in the tank
(showroom condition). The vehicle must be driven
above 40 km/h (25 miles/hour) for a minimum of five
minutes to make sure that the reservoir is full.
Front Ride Height Measurement
Item Description
1 Ride height
Rear Ride Height Measurement
Item Description
1 Ride height
Wheel Track
Item Description
1 Front track
2 Rear track
Crabbing
Item Description
1 Front track
2 Rear track
3 Crabbing angle
Crabbing is the condition in which the independent rear suspension (IRS) system is not square to the
chassis. Heavily crowned roads can give the illusion of crabbing.
Wander
Wander is the tendency of the vehicle to require frequent, random left and right steering wheel
corrections to maintain a straight path down a level road.
Shimmy
Shimmy, as observed by the driver, is rotational oscillations of the steering wheel which may come
and go over time, generally resulting from wheel and tire imbalances.
Shimmy can be experienced at any speed but generally between 80 to 145 km/h (50 to 90
miles/hour) and is most often experienced on smooth roads at steady speeds.
Nibble
Sometimes confused with shimmy, nibble is a condition resulting from tire interaction with various
road surfaces or brake disc irregularity and observed by the driver as small rotational oscillations of
the steering wheel.
Poor Returnability of the Steering

Poor returnability of the steering is used to describe the poor return of the steering wheel to center
after a turn or the steering correction is completed.
Drift/Pull
Pull is a tugging sensation, felt by the hands on the steering wheel, that must be overcome to keep
the vehicle going straight.
Drift describes what a vehicle with this condition does with hands off the steering wheel.
• A vehicle-related drift/pull, on a flat road, will cause a consistent deviation from the straight-
ahead path and require constant steering input in the opposite direction to counteract the
effect.
• Drift/pull may be induced by conditions external to the vehicle (i.e., wind, road crown).
Vague On-Center Feel

Vague on-center feel is characterized by little or no buildup of turning effort felt in the steering wheel
as the wheel is rocked slowly left and right within very small turns around center or straight-ahead
(under 20 degrees of steering wheel turn). Efforts may be said to be "flat on center".
• In the diagnosis of a roadability problem, it is important to understand the difference

between wander and vague on-center feel.
Suspension System
For a detailed description of the suspension system, refer to the relevant Description and Operation
section of the workshop manual.

1 . Verify the customer's concern by carrying out a road test on a smooth road. If any vibrations are
apparent, refer to
2 . Visually inspect for obvious signs of damage and system integrity.
Visual Inspection Chart

Mechanical
• Damaged tires
• Wheel 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)
• Worn or damaged suspension bushing(s)
• Loose, worn or damaged steering system components
• Damaged axle components
1 . If an obvious cause for an observed or reported condition is found, correct the cause (if possible)
before proceeding to the next step.
2 . If the fault is not visually evident, verify the symptom and refer to the following Symptom Chart.
Symptom Chart
Crabbing
Possible Source(s):
• Incorrect rear thrust angle.
Action(s) to take:
• CHECK the rear toe adjustment.

Specifications
Possible Source(s):
• Front or rear suspension components.
Action(s) to take:
• INSPECT the front and rear suspension systems. REPAIR or INSTALL new suspension
components as necessary.
Front Suspension
Rear Suspension
Possible Source(s):
• Drive axle damaged.
Action(s) to take:
• INSTALL a new rear drive axle/differential.

Axle Assembly - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8, Vehicles Without: Differential Drain
Plug (51.25.13)
Drift/Pull
Possible Source(s):
• Unequal tire pressure.
Action(s) to take:
• CHECK and ADJUST the tire pressures. INSPECT the tire for excessive wear.
Specifications
Possible Source(s):
• Incorrect wheel alignment.
Action(s) to take:
• CHECK and ADJUST the wheel alignment.
Specifications
Possible Source(s):
• Tires.
Action(s) to take:
• CHECK and ADJUST the tire pressures. INSPECT the tire for excessive wear.
Specifications
Possible Source(s):
• Unevenly loaded or overloaded vehicle.
Action(s) to take:
• NOTIFY the customer of incorrect vehicle loading.
Possible Source(s):
• Damaged steering components.
Action(s) to take:
• CHECK the steering system.

Steering System
Possible Source(s):
• Brake drag.
Action(s) to take:
• CHECK the brakes.

Brake System
Front Bottoming or Riding Low
Possible Source(s):
• Coil springs.
Action(s) to take:
• CHECK the ride height. INSTALL new springs as necessary.

Front Shock Absorber - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8
(60.30.04)
Incorrect Tire Wear
Possible Source(s):
• Incorrect tire pressure (rapid center rib or inner and outer edge wear).
Action(s) to take:
• CHECK and ADJUST the tire pressure. INSPECT the tire for excessive wear.
Specifications
Possible Source(s):
• Excessive front or rear toe (rapid inner or outer edge wear).
Action(s) to take:

Possible Source(s):
• Excessive negative or positive camber (rapid inner or outer edge wear).
Action(s) to take:

Possible Source(s):
• Tires out of balance (tires cupped or dished).
Action(s) to take:
• BALANCE the tires.
Rough ride
Possible Source(s):
• Spring(s)
Action(s) to take:
• Check and install new spring(s) as necessary.

(60.30.04)
Rear Shock Absorber - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8
(64.30.02)
Shimmy or Wheel Tramp
Possible Source(s):
• Loose wheel nut(s).
Action(s) to take:
• CHECK and TIGHTEN the wheel nuts to specification.

Specifications
Possible Source(s):
• Loose front suspension fasteners.
Action(s) to take:
• CHECK and TIGHTEN the suspension fasteners to specification.

Specifications
Possible Source(s):
• Front wheel bearing(s).
Action(s) to take:
• CHECK the wheel bearings.

Possible Source(s):
• Worn or damaged suspension component bushing.
Action(s) to take:
• CHECK and INSTALL new components as necessary.

Possible Source(s):
• Wheel/tires.
Action(s) to take:
• CHECK the wheels/tires. BALANCE or INSTALL new wheel/tires as necessary.

Possible Source(s):
• Loose, worn or damaged ball joint(s).
Action(s) to take:
• CHECK the Ball Joint(s).

Front Suspension
Possible Source(s):
• Loose, worn or damaged steering components.
Action(s) to take:
Possible Source(s):
• Front wheel alignment.
Action(s) to take:

Possible Source(s):
• Shock absorber(s).
Action(s) to take:
• CHECK and INSTALL new shock absorber(s) as necessary.

Front Shock Absorber - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8 (60.30.04)
Rear Shock Absorber - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8 (64.30.02)
Possible Source(s):
• Spring(s).
Action(s) to take:
• CHECK and INSTALL new springs as necessary.

Poor self center action of the steering
Possible Source(s):
• Ball joints.
Action(s) to take:
• CHECK the Ball Joints.

Suspension System
Possible Source(s):
• Steering components.
Action(s) to take:
Steering wheel off-center
Possible Source(s):
• Unequal front or rear toe settings.
Action(s) to take:

Possible Source(s):
Action(s) to take:

Sway or roll
Possible Source(s):
• Overloaded, unevenly or incorrectly loaded vehicle.
Action(s) to take:
Possible Source(s):
• Loose wheel nut(s).
Action(s) to take:
• CHECK and TIGHTEN the wheel nut(s) to specification.

Specifications
Possible Source(s):
• Coil spring(s).
Action(s) to take:
• CHECK and INSTALL new coil springs as necessary.

(60.30.04)
Possible Source(s):
• Loose front stabilizer bar or rear stabilizer bar.
Action(s) to take:
• CHECK and TIGHTEN the stabilizer bar to specification.

Specifications
Specifications
Possible Source(s):
• Worn lower suspension arm stabilizer bar insulators.
Action(s) to take:
• INSTALL new lower suspension arm stabilizer bar as necessary.

Front Stabilizer Bar Link - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8
(60.10.02)
Possible Source(s):
Action(s) to take:

(60.30.04)
Rear Shock Absorber - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8
(64.30.02)
Vehicle Leans to One Side
Possible Source(s):
Action(s) to take:
Possible Source(s):
• Front or rear suspension components.
Action(s) to take:
• INSPECT the front and rear suspension systems. REPAIR or INSTALL new suspension
components as necessary.
Possible Source(s):
Action(s) to take:

Possible Source(s):
• Coil spring(s).
Action(s) to take:
• CHECK and INSTALL new spring(s) as necessary.

Possible Source(s):
• Incorrect ride height. Lateral tilt out of specification.
Action(s) to take:
• CHECK the ride height. INSTALL new spring(s) as necessary.

Vibration/Noise
Possible Source(s):
• Tires/wheels.
• Wheel bearings.
• Wheel hubs.
• Brake components.
• Suspension components.
Action(s) to take:

Wander
Possible Source(s):
Action(s) to take:

Possible Source(s):
• Ball joint(s).
Action(s) to take:
• CHECK the Ball Joint(s).

Suspension System
Possible Source(s):
• Front wheel bearing(s).
Action(s) to take:
• CHECK the wheel bearings.
Possible Source(s):
• Loose, worn or damaged suspension components.
Action(s) to take:
• CHECK and INSTALL new suspension components as necessary.
Possible Source(s):
• Loose suspension fasteners.
Action(s) to take:
• CHECK and TIGHTEN the suspension fasteners to specification.

Specifications
Specifications
Possible Source(s):
Action(s) to take:
• CHECK and INSTALL new steering components.
Possible Source(s):
• Wheel alignment (excessive total front toe-out).

Action(s) to take:

Specifications
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.

Lifting
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.
Position a safety stand beneath the front suspension lower arm or

rear suspension lower arm to be tested.
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.
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.
Upper Arm LH - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8
(60.35.41)
Upper Arm RH - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8
(60.35.42)
6 . Remove the safety stand.
7 . Lower the vehicle.

204-01 : Front suspension
Specifications
Specifications
CAUTION: Nuts and bolts must be tightened with the weight of the vehicle on the
suspension.
Description Nm lb-ft
Front lower arm to rear lower arm - nut *:
Stage 1 60 44
135 degrees in clockwise 135 degrees - clockwise
Stage 2
direction direction
Front lower arm to subframe - nut * 175 129
Rear lower arm to subframe - nut * 175 129
Rear lower arm to wheel knuckle ball
92 68
joint - nut *
Shock absorber to spring - nut:
Active shock absorber 50 37
Passive shock absorber 27 20
Shock absorber and spring assembly to
175 129
lower arm - bolt
Shock absorber and spring assembly to
27 20
top mount - nuts
Stabilizer bar clamp to subframe - bolt 55 40
Stabilizer bar link to lower arm - nut * 70 52
Stabilizer bar link to stabilizer bar - nut * 43 32
Upper arm ball-joint - nut * 90 66
Upper arm to subframe brackets - nut * 60 44
Wheel bearing and hub assembly to
90 66
wheel knuckle - bolts *
* New nut/bolt must be installed.
Front Suspension
COMPONENT LOCATION
Item Part Number Description
1 Right Hand (RH) wheel hub and bearing assembly
2 RH wheel knuckle
3 Upper control arm bush (2 off)
4 RH upper control arm

5 RH top mount plate
6 RH damper and spring assembly
7 Stabilizer link
8 RH lower lateral control arm
9 Front subframe
10 Left Hand (LH) lower lateral control arm
11 LH damper and spring assembly
12 Upper control arm bush (2 off)
13 LH top mount plate
14 LH upper control arm
15 LH wheel knuckle
16 LH wheel hub and bearing assembly
17 LH lower control arm
18 Mounting bracket (2 off)
19 Stabilizer bar
20 Stabilizer bar bush (2 off)
21 RH lower control arm
INTRODUCTION
The front suspension is a fully independent design. The front suspension components are attached to
the front subframe and the vehicle body. The subframe is attached to the vehicle body with four long
bolts which pass through bushes located in the subframe.
The front suspension on each side comprises:
• Upper control arm

• Lower lateral control arm
• Lower control arm
• Wheel knuckle and hub assembly
• Stabilizer bar
• Spring and damper module.
UPPER CONTROL ARM
1 Bush (2 off)
2 Ball joint and locknut
3 Upper control arm
The forged aluminum upper control arm is a wishbone design with three mounting points. The two
inner mounting points are fitted with bushes. The outer mounting is fitted with a ball joint which
locates in a hole in the wheel knuckle and is secured with a locknut.
The inclination of the upper control arm axis provides an anti-dive and anti-squat action during
vehicle braking and acceleration and also improves castor trail which in turn improves steering 'feel'.
LOWER LATERAL CONTROL ARM
1 Bush - subframe attachment
2 Lower lateral control arm

3 Damper module attachment
4 Insert - stabilizer link attachment
5 Lower control arm attachment
6 Wheel knuckle attachment
The forged aluminum lower lateral control arm is fitted with a bush in its inner end which locates
between brackets on the subframe. The arm is secured with an eccentric bolt, an eccentric washer
and a locknut which allow for 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. Two cast brackets on the forward face of the control arm allow for the attachment of the
lower control arm. A threaded insert is fitted behind the two cast brackets and provides for the
attachment of the stabilizer link with a bolt. A bush is fitted to a cross-holes in the control arm which
provides the locations for the forked attachment of the damper module.
LOWER CONTROL ARM
1 Hydrabush
2 Lower control arm
3 Spherical bearing
The cast lower control arm is fitted with a hydrabush in its inner end which locates between brackets
on the subframe. The arm is secured with an eccentric bolt, an eccentric washer and a locknut which
allow for adjustment of the castor and camber geometry.
The outer end of the control arm is fitted with a spherical bearing and locates between the cast
brackets on the lower lateral control arm. The lower lateral control arm and lower control arm
together form a wishbone design.
WHEEL KNUCKLE
1 Upper control arm attachment
2 Ball joint locknut
4 Bolt - Hub attachment (2 off)
5 Torx bolt - Hub attachment (2 off)
6 Steering tie rod ball joint attachment
7 Disc shield attachment
8 Ball joint - lower lateral arm attachment
9 Wheel hub and bearing assembly
10 Wheel knuckle
The cast aluminum wheel knuckle is a swan neck design which provides the attachment for 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 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 and also the brake caliper and disc shield. which is retained with 3 rivets.
The wheel hub assembly includes the wheel bearing and ABS sensor pulse ring. The hub assembly is a
non-serviceable component and requires replacement as a complete assembly. The wheel hub is
secured to the knuckle with 2 bolts and 2 Torx bolts.
STABILIZER BAR
1 Stabilizer bar
2 Bolt (4 off)
3 Bracket (2 off)
4 Locknut (2 off)
5 Ball joint (2 off)
6 Stabilizer link (2 off)
7 Locknut (2 off)
8 Bolt (2 off)
9 Bush (2 off)
The stabilizer bar is attached to the front of the subframe with bushes and mounting brackets. The
pressed steel 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 32 mm diameter, manganese steel bar. 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.
SPRING AND DAMPER MODULE

1 Damper self locking nut
2 Top mount self locking nut (4 off)
3 Spring packer
4 Gaitor
5 Spring aid
6 Damper
7 Bolt
8 Spring
9 Upper spring seat
10 Top mount
The spring and damper assemblies are located between the lower
lateral arm and the front suspension housing in the inner wing.
Two coil spring damper variants are available; a conventional oil
damped strut and a Computer Active Technology Suspension
(CATS) adaptive damper. For additional information, refer to
Vehicle Dynamic Suspension (204-05)
Different combinations of springs and dampers are available

depending on the vehicle model. The damper and spring
assemblies are similar in their construction with the CATS
adaptive damper having a solenoid operated valve installed in the
damper body.
The dampers are a monotube design with a spring seat welded

onto the damper tube. The lower end of the damper has a forked
mounting with a cross hole and captive nut. The fork locates over
the lower lateral control arm and is secured with a bolt.
The damper functions by restricting the flow of hydraulic fluid

through internal galleries in the damper piston, providing
damping of undulations in the road surface. The CATS damper
has a solenoid operated valve which further restricts the flow of
hydraulic fluid, providing a stiffer damping characteristic for the
damper and improving vehicle handling. The solenoid is computer
controlled and can switch between soft and hard damping settings
depending on driving style and vehicle speed. For additional
information, refer to Vehicle Dynamic Suspension (204-05)
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 CATS dampers have an electrical connector on the outer
end of the damper rod.
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 integral with the
damper body. The spring locates in an upper spring seat which is
located on the underside of the top mount.
The top mount has four studs which locate through mating holes
in the vehicle inner wing and are secured with self locking nuts.
Front Suspension
For additional information, refer to <<204-00>>
Removal and installation
Front Shock Absorber - 4.2L NA V8 -

AJV8/4.2L SC V8 - AJV8 (60.30.04)
Special Service Tools
Suspension spring compressor

204-476-01
Removal
1
. WARNING: Do not work on or under a vehicle supported only by a jack. Always
support the vehicle on safety stands.
2 . Remove the LH front wheel and tire.

For additional information, refer to Wheel and Tire (74.20.05)
3 . NOTE:
Use an additional wrench to prevent the ball joint rotating.
Disconnect the LH stabilizer bar link.
Remove and discard the 2 nuts.

4 . Disconnect the height sensor link.
5
. CAUTION: Use an Allen key to prevent the ball joint rotating whilst removing the
nut.
Release the upper suspension arm ball joint.
Remove and discard the nut.
6 . Release the LH lower suspension arm.

Remove the bolt and discard the nut.
7 . Remove the shock absorber and spring assembly.
Active shock absorber: Disconnect the electrical connector.
Remove the Torx bolt.
Remove the 4 nuts.
8 . Using the special tool, compress the suspension spring to remove the shock absorber.
Compress the spring.
Remove the nut.
Installation
1 . Using the special tool, compress the spring to install the shock absorber.
Passive shock absorber: Tighten the nut to 27 Nm (20 lb.ft).
Active shock absorber: Tighten the nut to 50Nm ( 37 lb.ft ).
2 . Install the shock absorber and spring assembly.
Tighten the nuts to 27 Nm (20 lb.ft).
Tighten the Torx bolt to 175 Nm ( 129 lb.ft ).
Active shock absorber: Connect the electrical connector.

3 . Install the lower suspension arm.
Install the bolt and tighten the new nut to 60 Nm (44 lb.ft) + 135 degrees.
4
. CAUTION: Use an Allen key to prevent the ball joint rotating whilst installing the
nut.
Connect the upper suspension arm ball joint.
Tighten the nut to 90 Nm (66 lb.ft).
5 . Connect the height sensor link.
6 . NOTE:
Use an additional wrench to prevent the component from rotating.
Install the stabilizer bar link.
7 . Install the wheel and tire.

Front Lower Arm (60.35.53)
Removal
suspension.
1

3 . NOTE:
Note the fitted position.
Release the forward lower control arm.
Remove the 2 bolts and discard the nuts.

Installation
1 . Install the forward lower control arm.
Install the bolt and tighten the new nut to 60 Nm (44 lb.ft) + 135 degrees.
Tighten the 14mm bolt to 175 Nm (129 lb.ft).

3 Using only four-wheel alignment equipment approved by Jaguar, check the wheel alignment,
. and adjust if required.
Rear Lower Arm (60.35.54)
Removal
suspension.
1

3 . NOTE:
Disconnect the LH stabilizer bar link.
4 . Disconnect the height sensor link.

5 . Release the forward lower control arm.
6 . Release the shock absorber from the lower arm.
7 . NOTE:
Remove the lower arm nut and bolt; discard the nut.
8
. CAUTION: Make sure the ball joint seal is not damaged. A damaged seal will lead to
the premature failure of the joint.
Remove the LH lower arm.
Using the special tool, release the ball joint from the lower suspension arm.
Installation
1 . NOTE:
Align to the position noted on removal.

Install the lower suspension arm.
Tighten the nut and bolt to 175 Nm.
2 . Install the forward lower control arm.
Install the bolt and tighten the new nut to 60 Nm + 135 degrees.
3 . NOTE:
Install the lower arm ball joint
Clean the component mating faces.
Tighten the nut to 92 Nm.
4 . NOTE:
Tighten the nuts to 43 Nm.
5 . Connect the height sensor link.

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
1
2 . Remove the LH lower arm.

For additional information, refer to Rear Lower Arm (60.35.54)
3 . NOTE:
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:
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.

Replacer support-bush
204-337
Replacer-bush
204-338
Remover-bush
204-336
Remover support-bush
204-335
Removal
1
2 . Remove the front lower suspension arm.

3 . NOTE:
Take note of the fitted position of the bush.
Using the special tools, remove the shock absorber bushing.
Installation
1 . Install the bushing into the special tool.
2 . NOTE:
Using the special tools, install the shock absorber bushing.

Front Stabilizer Bar - 4.2L NA V8 -
AJV8/4.2L SC V8 - AJV8 (60.10.01)
Engine support bracket

303-021
Engine lifting brackets

303-749
Power train assembly jack

HTJ1200-2
Subframe alignment bolts

502-010
Removal
1 . Remove the cover and disconnect the battery ground cable.
For additional information, refer to
2
3 . Remove the radiator air deflector.

For additional information, refer to Radiator Splash Shield (76.22.90)
4 . Remove the engine undershield.

For additional information, refer to Air Deflector (76.11.41)
5 . Remove the lower suspension arms.

6 . Remove the throttle body.

For additional information, refer to Throttle Body (19.70.04)
7 . With assistance, remove the A-frame.
Remove the 6 bolts.

8 . NOTE:
RH illustration shown, LH is similar
Release the engine mounts.
Raise the engine.
9 . Support and release the power steering rack.
Remove the 3 bolts.
10 . Secure the radiator assembly.
Secure with cable ties.

11 .
CAUTION: Protect the paintwork during this operation.
Using the special tools, support the engine.
12 . Using the special tool, support the subframe.
13 . NOTE:
With assistance, remove the front subframe assembly.
Remove the 4 bolts.
Release the PAS pipe to subframe clip.
Disconnect the electrical connector.

14 . Remove the stabilizer bar.
Remove the 4 bolts.
Remove the stabilizer bar bushing.
Installation
1 . Install the stabilizer bar.
Install the stabilizer bar bushings.

Tighten the bolts to 45 Nm (33 lb.ft).
2
. CAUTION: To align the sub-frame, install the special bolts in place of the front
fixings. Tighten the rear fixings to set the position, remove the special bolts.
With assistance, install the front subframe.
Position the radiator mountings.
Using the special the special tools, align the subframe.
Connect and secure the electrical connector.
3 . Tighten the subframe bolts.
Tighten the front bolts (M15) to 80 Nm plus 360deg.
Tighten the rear bolts (M12) to 80 Nm plus 270deg.
4 . With assistance, install the A-frame.
5 . Lower the engine onto its mounts.
Tighten the new nuts to 63 Nm (46 lb.ft).
Remove the special tools.
6 . Install the engine undershield.

7 . Install the radiator deflector.

8 . Remove and discard the 2 cable ties.
9 . Install the lower suspension arms.

10 . Install the throttle body.

11 . Connect the battery ground cable and install the cover.

Front Stabilizer Bar Link - 4.2L NA V8 -
AJV8/4.2L SC V8 - AJV8 (60.10.02)
Removal
1
2 . Remove the front wheel and tire.

3 . NOTE:
Remove the LH stabilizer bar link.
Installation
1 . NOTE:


Bush installer
204-340
Bush remove
204-342
Support
204-341
Support
204-339
Removal
1
2 . Remove the LH lower arm.

3 . Using the special tools, remove and discard the stabilizer bar link bushing.
Installation
1 . Using the special tools, install the stabilizer bar link bushing.

Upper Arm LH - 4.2L NA V8 - AJV8/4.2L
SC V8 - AJV8 (60.35.41)
Removal
1
2 Remove the shock absorber and spring assembly.

. For additional information, refer to Front Shock Absorber - 4.2L NA V8 - AJV8/4.2L SC V8 -
AJV8 (60.30.04)
3 . Remove the engine control module (ECM).

For additional information, refer to Engine Control Module (ECM) (18.30.01)
4 . Remove the LH upper suspension arm.
Installation
1
. CAUTION: The final tightening of the upper arm must be carried out with the
vehicle on it's wheels.
Install the upper arm.
Install the bolts and new nuts.
2 Install the shock absorber and spring assembly.

AJV8 (60.30.04)
3
Tighten the upper suspension arm nuts to 60 Nm (44 lb.ft).
4 . Install the ECM.

Upper Arm RH - 4.2L NA V8 - AJV8/4.2L
SC V8 - AJV8 (60.35.42)
Removal
1
2 Remove the shock absorber and spring assembly.

AJV8 (60.30.04)
3 . Remove the coolant expansion tank.

For additional information, refer to Coolant Expansion Tank (26.15.01)
4 . Remove the LH upper suspension arm.
Installation
1
Install the bolts and new nuts.
2 Install the shock absorber and spring assembly.

AJV8 (60.30.04)
3 . Tighten the upper suspension arm nuts to 60 Nm (44 lb.ft).
4 . Install the coolant expansion tank.

Front Wheel Bearing and Wheel Hub
(60.25.03)
Removal
1
2 Remove the front brake disc.

. For additional information, refer to Brake Disc - Vehicles With: Standard Brakes (70.10.10)
For additional information, refer to Brake Disc - Vehicles With: High Performance Brakes
(70.10.10)
3 . NOTE:
4 . Remove the wheel speed sensor.

Release the clip.
Tie aside.
5 . NOTE:
LH front: Carefully remove the hub assembly.
Remove and discard the 2 Torx bolts.
Remove and discard the 2 bolts.
Installation
1 . NOTE:
NOTE:
Make sure all component mating faces are clean.
LH front: Carefully install the hub assembly.

2 . Install the wheel speed sensor.
Secure the clip.
3 . NOTE:
4 Install the front brake disc.

. For additional information, refer to Brake Disc - Vehicles With: Standard Brakes (70.10.10)
For additional information, refer to Brake Disc - Vehicles With: High Performance Brakes
(70.10.10)
Ball joint splitter

204-327
Removal
1
2 . Remove the hub assembly.

For additional information, refer to Front Wheel Bearing and Wheel Hub (60.25.03)
3 . Remove the brake disc shield.
Remove the 3 rivets.
4 . NOTE:
Disconnect the steering gear tie rod end ball joint.
Remove and discard the tie rod end retaining nut.

5 . NOTE:
Disconnect the upper arm from the wheel knuckle.
6
. CAUTION: Make sure the ball joint seal is not damaged. A damaged seal will lead to
the premature failure of the joint.
NOTE:
Remove the wheel knuckle.

Using the special tool, release the ball joint from the lower suspension arm.
Installation
1 . NOTE:
Install the wheel knuckle.
2 . Install the brake disc shield.
Install the rivets.
Repeat the above procedure for the other side.
3 . NOTE:
Connect the upper arm and wheel knuckle.

4 . NOTE:
Connect the tie-rod end ball joint.
5 . Install the hub assembly.

For additional information, refer to Front Wheel Bearing and Wheel Hub (60.25.03)
204-02 : Rear suspension
Specifications
Specifications
suspension.
Halfshaft/hub - nut * 300 221
Lower arm to subframe - nut * 164 121
Lower arm to wheel knuckle - nut * 150 110
Shock absorber to spring - nut:
Active shock absorber 50 37
Passive shock absorber 27 20
Shock absorber and spring assembly to top mount - nuts 27 20
Shock absorber and spring assembly to lower arm - bolt 133 98
Stabilizer bar clamp to subframe - nut * 55 40
Stabilizer bar link to lower arm - nut * 48 35
Stabilizer bar link to stabilizer bar - nut * 48 35
Toe link to subframe - ball joint nut * 90 66
Toe link to wheel knuckle - nut * 55 40
Upper arm to subframe - nut * 97 71
Upper arm to wheel knuckle - ball-joint nut * 90 66
Wheel bearing to wheel knuckle - bolts 70 52

www.JagDocs.com
Rear Suspension
COMPONENT LOCATION
1 Right Hand (RH) wheel hub and bearing assembly
2 RH upper control arm
3 RH spring and damper assembly

4 RH top plate
5 Bush - upper control arm
6 Left Hand (LH) top plate
7 LH spring and damper assembly
8 Stabilizer link
9 Toe-link (2 off)
10 Ball joint
11 LH wheel knuckle
12 LH wheel hub and bearing assembly
13 LH upper control arm
14 LH lower control arm
15 Bush - lower control arm
16 Bush - upper control arm
17 Mounting bracket (2 off)
18 Bush (2 off)
19 Stabilizer bar
20 Rear crossbeam
INTRODUCTION
The rear suspension is a double wishbone design which is attached to a rear crossbeam. The
crossbeam is attached to the vehicle body with 4 long bolts which pass through bushes located in the
crossbeam.
The rear suspension on each side comprises:
• Upper control arm

• Lower control arm
• Toe-link
• Wheel knuckle and hub assembly
• Stabilizer bar
• Spring and damper module.
UPPER CONTROL ARM
1 Bolt
2 Bush
3 Locknut
4 Bolt
5 Bush
6 Locknut
7 Upper control arm
8 Ball joint
9 Washer
10 Locknut
The cast aluminum upper control arm is a wishbone design with 3 mounting points. Two bushed
mountings locate in brackets on the crossbeam. The outer end has a ball joint which mates with the
wheel knuckle.
LOWER CONTROL ARM
1 Bolt
2 Bush
3 Locknut
4 Bolt
5 Bush
6 Caged nut
7 Lower control arm
8 Rear damper attachment
9 Stabilizer link attachment
10 Locknut
11 Bolt
The cast aluminum lower control arm is a wishbone design with 3 bushed mounting points. Two
bushes locate between brackets on the crossbeam and the outer bush locates in the wheel knuckle.
The rear of the control arm has mounting points for the damper and the stabilizer link.
TOE-LINK
1 Locknut
2 Washer
3 Inner rod and ball joint
4 Locknut
5 Outer rod
6 Bolt
7 Outer ball joint
8 Locknut
The toe-link is located between the wheel knuckle and brackets on the rear crossbeam.
The toe-link comprises an inner rod with integral ball joint. The inner ball joint has a threaded spigot
which locates in a bracket on the crossbeam and is secured with a washer and locknut. The rod has
an internal thread which accepts the outer rod.
The outer rod has a ball joint at its outer end which is located between 2 brackets 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 and outer rods. This allows for
adjustment of the toe angle for the rear wheel. Once set the inner and outer rods can be locked in
position by tightening a locknut against the inner rod.
WHEEL KNUCKLE
1 Hub attachment bolt (4 off)
2 Upper control arm attachment
3 Wheel knuckle
4 Toe-link attachment
5 Wheel hub and bearing assembly
6 Half shaft nut
7 Brake dust shield attachment
8 Lower control arm attachment

9 Brake caliper attachment
The wheel knuckle is an aluminum casting which provides for the attachment of the upper and lower
control arms and the toe-link. The wheel knuckle also provides the mounting locations for the wheel
hub and bearing assembly, the wheel speed sensor and the brake caliper and brake dust shield which
is secured with 3 rivets.
The wheel hub assembly includes the wheel bearing. The hub assembly is a non-serviceable
component and requires replacement as a complete assembly. The wheel hub is secured to the
knuckle with 4 bolts.
STABILIZER BAR
1 Stabilizer bar
2 Bracket (2 off)
3 Bush (2 off)
4 Locknut (2 off)
5 Stabilizer link (2 off)
6 Locknut (2 off)
7 Caged nut (2 off)
8 Bolt (2 off)
The stabilizer bar is attached to the top of the crossbeam with 2 bushes and mounting brackets. The
brackets are secured to the crossbeam with bolts and caged nuts. 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 manganese steel bar and is available in 2 diameters,
dependant on the vehicle model. Each type of stabilizer bar has a different torsional rate and is also
color coded for identification.
Stabilizer Bar Diameters

Engine Type Model Diameter mm (in)
4.2L naturally aspirated Coupe 17 mm (0.669 in)
4.2L naturally aspirated Convertible 16 mm (0.629 in)
4.2L supercharged All models 17 mm (0.669 in)
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 which is secured with a
locknut. The links allow the stabilizer bar to move with the wheel travel providing maximum
effectiveness.
The stabilizer bar is attached to the forward face of the chassis front subframe. The stabilizer bar is
attached to the subframe with 2 rubber bushes. Pressed steel brackets locate over the bushes and
are attached to the cross member with bolts screwed into threaded locations in the subframe.
SPRING AND DAMPER MODULE
1 Damper rod self locking nut
2 Top mount self locking nut
3 Spring
4 Spring packer
5 Spring aid
6 Damper
7 Bolt
8 Gaitor
9 Upper spring seat
10 Top mount
The spring and damper modules are attached to cast brackets on the lower
control arms and to the rear floor side member assemblies via the 4 studs in
the top plate. Similar to the front suspension, two variants are available;
passive and active. The active spring and damper assemblies employ the
CATS active suspension system.
Different combinations of springs and dampers are available depending on

the vehicle model. The damper and spring assemblies are similar in their
construction with the CATS adaptive damper having a solenoid operated
valve installed in the damper body.
The dampers are a monotube design with a spring seat welded onto the
damper tube. The lower end of the damper has a bushed mounting which
locates in the lower control arm and is secured with a bolt.
The damper functions by restricting the flow of hydraulic fluid through

internal galleries in the damper piston, providing damping of undulations
in the road surface. The CATS damper has a solenoid operated valve which
further restricts the flow of hydraulic fluid, providing a stiffer damping
characteristic for the damper and improving vehicle handling. The solenoid
is computer controlled and can switch between soft and hard damping
settings depending on driving style and vehicle speed. For additional
information, refer to Vehicle Dynamic Suspension (204-05 Vehicle
Dynamic Suspension)
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 CATS dampers have an
electrical connector on the outer end of the damper rod.
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 integral with the damper body. The spring
locates in an upper spring seat which is located on the underside of the top
mount.
The top mount has 4 studs which locate through mating holes in the vehicle
rear floor side member and are secured with self locking nuts.
Rear Suspension
For additional information, refer to<<204-00>>.
Lower Arm - 4.2L NA V8 - AJV8/4.2L SC

V8 - AJV8 (64.35.43)
Removal
suspension.
1
2 . Remove the LH rear wheel and tire.

3 . Release the brake caliper.
Tie the brake caliper aside.

4 . Remove the rear brake disc.
Remove the 2 clips.
5 . NOTE:
Disconnect the stabilizer bar link.
6 . Release the rear shock absorber from the lower suspension arm.
Remove the bolt.

7 . Remove the suspension height sensor.
Release the height sensor link.
Release and disconnect the electrical connector.
Remove the 2 bolts.
8 . Release the lower suspension arm from the hub assembly.
Position a transmission jack to support the hub assembly.
9 . Remove the lower arm.

Installation
1 . Install the rear suspension arm.
Tighten the nuts and bolts to 97 Nm (72 lb.ft).
2 . Attach the hub assembly to the lower arm.
Tighten the nut and bolt to 150 Nm (110 lb.ft).
3 . Install the shock absorber.
Tighten the bolt to 133 Nm (98 lb.ft).
4 . NOTE:
5 . Install the height sensor.

Secure the height sensor link.
6 . Install the brake disc.
Secure the clips.
7 . Install the brake caliper.

9 . Carry out the final suspension tightening with the vehicle on its wheels.
Rear Shock Absorber - 4.2L NA V8 -
AJV8/4.2L SC V8 - AJV8 (64.30.02)
Suspension spring compressor

204-476-01
Removal
1 . Remove the LH loadspace trim panel.
For additional information, refer to Loadspace Trim Panel - 2-Door (76.13.73.60)
For additional information, refer to Loadspace Trim Panel - Convertible (76.13.73.60)
2

4 . Release the shock absorber and spring assembly.
Active shock absorber: Disconnect the electrical connector.
Remove the 4 nuts.

5 . Remove the shock absorber and spring assembly.
Remove the bolt.
6 . Using the special tool, compress the suspension spring to remove the shock absorber.
Compress the spring.
Remove the nut.

Installation
1 . Using the special tool, compress the spring to install the shock absorber.
Passive shock absorber: Tighten the nut to 27 Nm (20 lb.ft).
Active shock absorber: Tighten the nut to 50 Nm (37 lb.ft ).
2 . Install the shock absorber and spring assembly.
Active shock absorber: Connect the electrical connector.
3 . Install the LH rear wheel and tire.

4 . Install the loadspace trim panel.

5 Using only four-wheel alignment equipment approved by Jaguar, check and adjust the wheel
. alignment.
Rear Stabilizer Bar (64.35.08)
Removal
1
2 . Remove the rear sub-frame assembly.

For additional information, refer to Rear Subframe (64.25.01)
3 . NOTE:
Disconnect the LH rear ABS sensor.
Release the 2 clips.
Carefully tie the harness aside.
4 . Disconnect the electronic parking brake actuator electrical connector.

Release the electrical connector.
5 . Remove the headlamp levelling sensor link.
6 . NOTE:
NOTE:
Release both stabilizer bar links.
Remove the bump stops.

7 . Remove the stabilizer bar bushings.
Remove the 2 bolts and discard the cage nuts.
Release the bushings.
8 . With assistance, remove the rear stabilizer bar.
Raise the suspension arms, to release the bar.

Installation
1 . With assistance, install the rear stabilizer bar.
2 . Install the stabilizer bar bushings.
Tighten the bolts and new nuts to 55 Nm (40 lb.ft).
3 . NOTE:
Install the stabilizer bar links.
Install the bump stops.
4 . Connect the electronic parking brake actuator electrical connector.
Secure the electrical connector
5 . Install the height sensor link.
6 . Connect the LH rear ABS sensor.

Connect the electrical connector.
Carefully secure the clips.
7 . Install the rear sub-frame.

Removal
1

3 . NOTE:
Installation
1 . NOTE:


Rear Wheel Bearing - 4.2L NA V8 -
AJV8/4.2L SC V8 - AJV8 (64.15.14)
Hub puller
205-491
Flange remover forcing screw

204-269
Adaptor nuts
205-491-01
Removal
1

3 . With assistance, remove the halfshaft retaining nut, and retain it for the install procedure.
4 . Remove the wheel trim.
Remove the 2 clips.

Remove the bolt.
Tie aside.
8 . Disconnect the toe link.

9 . Release the lower arm.
10 . Using the special tools, release the halfshaft from the drive flange.
11 . NOTE:

12 . Remove the wheel bearing assembly.
Remove the 4 Allen bolts.
Installation
1 . Install the wheel bearing.
2 . Install the knuckle assembly.
3 . NOTE:
Do not fully tighten the locking nut at this stage.
Install the halfshaft.
Tighten the old nut.
4
. CAUTION: The final tightening of the suspension components must be carried out
with the vehicle on its wheels.
Install the lower arm nut and bolt.
5
Connect the toe link.
Install the bolt and tighten to 10 Nm (7 lb.ft).
Secure the clips.

9 . Install the wheel and tire assembly.
10 . Remove the old halfshaft nut and install the new one, tighten to 300 Nm (222 lb.ft)
Install the wheel trim.
11 . Install the wheel trim.

Tie Bar
Removal
1

3 . NOTE:
Remove the tie rod.
Remove and discard the 2 tie-rod end retaining nuts.
Installation
1 . NOTE:

Install the tie rod.
Tigten the new inner nut to 90 Nm (59 lb.ft).
Tighten the new outer nut to 55 Nm (41 lb.ft).

. alignment.
Brake pedal hold down tool JDS 9013
Removal
1

3
. CAUTION: Brake fluid will damage paint finished surfaces. If spilled, immediately
remove the fluid and clean the area with water.
NOTE:
Some fluid spillage is inevitable during this operation.
NOTE:
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.
4 . Release the rear wheel speed sensor lead.
5 . Remove the LH upper arm.
LH rear: Remove the upper arm 2 nuts and bolts.

Installation
1
2 . NOTE:
Connect the brake hose to the brake caliper.
Install 2 new sealing washers.
Tighten the union to 35 Nm (26 lb.ft).
3 . Install the rear wheel speed sensor lead.

5 . Bleed the brake system.

For additional information, refer to Brake System Bleeding (70.25.03)
Wheel Knuckle - 4.2L NA V8 - AJV8/4.2L
SC V8 - AJV8 (64.15.22)
Removal
1
2 Remove the wheel knuckle.

. For additional information, refer to Rear Wheel Bearing - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8
(64.15.14)
3 . Remove the brake disc shield.
Remove the 3 rivets.
Installation
1 . Install the brake disc shield.
Install the rivets.

2 Install the wheel knuckle.
. For additional information, refer to Rear Wheel Bearing - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8
(64.15.14)
204-04 : Wheels and Tires
Specifications
Specifications
Wheel and Tire Specification
NOTE:
Spare wheel assembly not fitted with runflat tires.
NOTE:
As tire fitment can vary in individual markets, consult the vehicle handbook or tire label
for further information.
Wheel Size Tire Type Tire Size

8.5" x 18" Continental Sport Contact 2 245/45R 18 96Y
9.5"v x 18" Continental Sport Contact 2 275/40R 18 99Y
8.5" x 19" Dunlop Sport 01 245/40R 19 94Y
8.5" x 19" (runflat) Dunlop Sport 01 DSST 245/40R 19 94Y
9.5" x 19" Dunlop Sport 01 275/35R 19 96Y
9.5" x 19" (runflat) Dunlop Sport 01 DSST 275/35R 19 96Y
8.5" x 20" Dunlop Sport Maxx Directional 255/35R 20 97Y
9.5" x 20" Dunlop Sport Maxx Directional 285/30R 20 99Y
4" x 18" Pirelli (spare) T135/80R 18 104M
Tire Pressures
Tire Pressure
Description
Front Rear Space Saver Spare
All Derivatives 2.1 bar (30 lb/in²) 2.3 bar (33 lb/in²) 4.2 bar (60 lb/in²)
Wheel nuts 125 92
Tire low pressure sensor 6.5 5
Wheels and Tires

INTRODUCTION
A number of alloy wheels are available ranging from 18 in. to 20 in. diameter. The rim widths are 8.5
or 9.0 in. for front wheels and 9.5 or 10.5 in. for rear wheels. An alloy space saver wheel is a standard
fitment, except for vehicles fitted with run-flat tires.
A Tire Pressure Monitoring System (TPMS) is also available as a standard or optional fitment
dependant on market. The TPMS is a driver warning system if a tire pressure is outside
predetermined thresholds.
A 'run-flat' tire option is available with the 19 in. wheel option. Vehicles fitted with these tires have
the TPMS fitted as standard and are not supplied with a spare wheel, vehicle jack or wheel brace.
WHEELS
A Venus (8.5J X 18 Front/9.5J X 18 Rear)
B Carelia (8.5J X 19 Front/9.5J X 19 Rear)
C Sabre - Run-flat tires (8.5J X 19 Front/9.5J X 19 Rear)

D Jupiter (8.5J X 19 Front/9.5J X 19 Rear)
E Senta (8.5J X 20 Front/9.5J X 20 Rear)
F Cremona (8.5J X 20 Front/9.5J X 20 Rear)
G Vortex (9.0J X 20 Front/10.5J X 20 Rear)
H Space saver wheel (4J X 18)
TIRES
Tires are available in a number of sizes and tread patterns dependent on vehicle specification. Tire
sizes are as follows:
• T135/80R18 (space saver wheel)

• 245/45ZR18 Front / 275/40ZR18 Rear
• 245/40ZR19 Front / 275/35ZR19 Rear
• 255/35ZR20 Front / 285/30ZR20 Rear
• 255/35ZR20 Front / 295/30ZR20 Rear.
WARNING: Tires should be inflated to the recommended pressures (shown on a label on the
'B' pillar) only when the tires are cold (ambient temperature). 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/adjusting the pressures.
Tire Changing
On vehicles fitted the TPMS, care must be taken when removing and refitting tires to ensure that the
tire pressure sensor is not damaged.
Vehicles fitted with TPMS can be visually identified by an external metal locknut and valve of the tire
pressure sensor on the road wheels. Vehicles without TPMS will have rubber tire valve.
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.
TIRE PRESSURE MONITORING SYSTEM (TPMS)
COMPONENT LOCATION
1 Tire pressure sensor (4 off)
2 Initiator (4 off)
3 Tire Pressure Monitoring System (TPMS) receiver
4 TPMS module
OVERVIEW
The TPMS is a driver assistance system which assists the driver to maintain the tire pressures at the
optimum level. The TPMS is a standard fitment on North American Specification (NAS) vehicles and
an optional fitment in other markets. The TPMS system has the following benefits:
• Improve fuel consumption

• Maintain ride and handling characteristics
• Reduce the risk of rapid tire deflation - which may be caused by under inflated tires
• Comply with legislation requirements in relevant markets.
CAUTION: The TPMS is not intended as a replacement for regular tire pressure and tire
condition checks and should be considered as additional to good tire maintenance practices.
The TPMS measures the pressure in each of the tires on the vehicle (the space saver spare wheel is
not monitored) and issues warnings to the driver if any of the pressures deviate from defined
tolerances.
NOTE:
During a 'blow-out' a very rapid reduction in pressure is experienced. The system is not intended
to warn the driver of a 'blow-out', since it is not possible to give the driver sufficient warning
that such an event is occurring, due to its short duration. The design of the TPMS is to assist the
driver in keeping the tires at the correct pressure, which will assist to reduce the likelihood of a
tire 'blow-out' occurring.
The controlling software for the TPMS is located within a TPMS module. The software detects the
following:
• the tire pressure is below the recommended low pressure value - under inflated tire
• the position of the tire on the vehicle.
The system comprises a TPMS module, a Radio Frequency (RF) receiver, 4 initiators and 4 tire
pressure sensors (the space saver spare wheel is not fitted with a sensor).
The TPMS module is located behind the Left Hand (LH) rear passenger seat, behind the Auxiliary
Junction Box (AJB) and the TPMS RF receiver is located on the AJB mounting bracket. The front
initiators are positioned at the front of the wheel arches, behind the fender splash shields. The rear
initiators are positioned at the rear of the rear wheel arches, behind the fender splash shields.
The 4 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 RF
transmission. The 315 or 433 MHz RF signals are detected by the RF 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 FL (front left), FR (front right),
RL (rear left) and RR (rear right). This feature is required because of the different pressure targets
and threshold between the front and rear tires.
The wheel location is performed automatically by the TPMS module using an 'auto-location' function.
This function is fully automatic and requires no input from the driver. The TPMS module
automatically re-learns the position of the wheels on the vehicle if the tire pressure sensors are
replaced or the wheel positions on the vehicle are changed.
The TPMS software can automatically detect, under all operating conditions, the following:
• one or more new tire pressure sensors have been fitted

• one or more tire pressure sensors have stopped transmitting
• 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 when the vehicle is driven for more than 15 minutes at a speed of more
than 20 km/h (12.5 mph).
The tire learn and location process is ready to commence when the vehicle has been stationary or
travelling 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.
If the tire pressure sensors fitted to the running wheels vehicle are changed, the module can learn
the new sensor identifications automatically. The learn function requires no manual intervention by
the driver.
Spare Tire Identification

Tire pressure sensors are not fitted to the space saver spare wheel and therefore the spare wheel is
not monitored.
Initiators
Four initiators are fitted to the vehicle. The front initiators are located near the front of the front
wheel arches, behind the fender splash shields. The rear initiators are located at the rear of the rear
wheel arches, behind the fender splash shields. 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 energises each initiator in turn using LF drivers. The corresponding tire pressure
sensor detects the LF signal and responds by modifying the mode status within the RF transmission.
Tire Pressure Sensor
The TPMS uses active tire pressure sensors which are located on each wheel, inside the tire cavity.
The sensor incorporates the tire valve and is secured in the wheel by a nut on the outside of the
wheel. The sensor contains a Printed Circuit Board (PCB) which houses a Positive Temperature Co-
efficient (PTC) sensor, a Piezo pressure sensor. a radio receiver and transmitter and a lithium battery.
The tire pressure sensors use the PTC sensor and the Piezo sensor to periodically measure the
pressure and temperature of the air inside the tire. The data is transmitted by RF data signals at
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 'running'
wheel, the new sensor identification will be learnt when the vehicle is driven at speed of more than
20 km/h (12.5 mph) for 15 minutes.
The tire pressure sensor can also detect when the wheel is rotating. In order to preserve battery
power, the sensor uses different transmission rates when the wheel is stationary or moving.
The care points detailed in 'Tire Changing' earlier in this section must be followed to avoid damage to
the sensor. If a new sensor is fitted, a new nut, seal and washer must also be fitted and the sensor
nut tightened to the correct torque as given in the Service Repair Manual.
Instrument Cluster Indications
1 Low tire pressure warning indicator
2 Message centre
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 then converts this data into illumination of the warning indicator
and display of an appropriate message.
When the ignition is switched on, the warning indicator is illuminated for 3 seconds for a bulb check.
NOTE:
If the vehicle is not fitted with the TPMS, the warning indicator will not illuminate.
The instrument cluster checks, within the 3 second bulb check period, for a CAN bus message from
the TPMS. During this time the TPMS performs internal tests and CAN bus initialisation. 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 illuminate on vehicles up to 2007.25MY and will flash on vehicles from 2007.25MY 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 Warning indicator illuminated. 'CHECK TYRE PRESSURE' message
in one wheel displayed and applicable tire highlighted on display.
Low pressure warning limit reached

in one or more wheels in low speed Warning indicator illuminated. 'CHECK ALL TYRE PRESSURES'
mode (only if programmed or message displayed.
learning)
On vehicles up to 2007.25MY - Warning indicator permanently

illuminated. On vehicles from 2007.25MY - Warning indicator
TPMS fault
flashes for 72 seconds and is then permanently illuminated.
'TYRE PRESSURE SYSTEM FAULT' message displayed.
No transmission from a specific tire Warning indicator illuminated. 'TYRE NOT MONITORED' message
pressure sensor or Specific tyre displayed and Amber LED flashes for 72 seconds. Amber LED
pressure sensor fault illuminated at next and subsequent ignition on cycle.
No transmission from more than Warning indicator illuminated. 'TYRE PRESSURE SYSTEM FAULT'
one tyre pressure sensor or More message displayed and Amber LED flashes for 72 seconds.
than one tyre pressure sensor fault Amber LED illuminated at next and subsequent ignition on cycle.
CAN signals missing On vehicles up to 2007.25MY - Warning indicator permanently

illuminated. On vehicles from 2007.25MY - Warning indicator
flashes for 72 seconds and is then permanently illuminated.
'TYRE PRESSURE SYSTEM FAULT' message displayed.
CONTROL DIAGRAM
NOTE:
A = Hardwired; F = RF Transmission; N = Medium speed CAN bus; W = LF Transmission

1 Battery
2 Megafuse (175A)
3 Megafuse (175A)
4 Central Junction Box (CJB)
5 Auxiliary junction box
6 TPMS module
7 TPMS receiver
8 Initiators
9 Tire pressure sensors
10 Instrument cluster
PRINCIPLES OF OPERATION
Each time the vehicle is driven the TPMS module activates each initiator in turn to transmit a LF 125
KHz signal to each tire pressure sensor. The LF signal is received by the tire pressure sensor which
responds by transmitting a 315 or 433 MHz (depending on market) signal which is received by the RF
receiver. The signal contains coded data which corresponds to sensor identification, air pressure, air
temperature and acceleration data and is passed to the TPMS module.
When the vehicle has been parked for more than 15 minutes and then driven at a speed of more
than 12.5 mph (20 km/h), the initiators fire in turn for 6 seconds on all 433 MHz vehicles or for 18
seconds on 315 MHz vehicles in the following order:
• Front left
• 6 second pause (for the TPMS module to detect a response from the tire pressure sensor)
• Front right
• 6 second pause
• Rear right
• 6 second pause
• Rear left
• 6 second pause.
Each tire pressure sensor responds in turn which allows the TPMS module to establish the sensor
positions at the start of the drive cycle. This process is repeated up to three times but less if the
sensor positions are already known. The process is known as 'Auto Location' and takes 2 to 4 minutes
www.JagDocs.com
to complete.
During this period the tire pressure sensors transmit at regular intervals, once every 5 seconds (once
every 15 seconds on 315 MHz vehicles). For the remainder of the drive cycle the tire pressure sensors
transmit once every 60 seconds or more often if a change of tire pressure is sensed until the vehicle
stops and the TPMS returns to the parking mode.
Once the wheel positions have been established, the initiators stop transmitting the LF signal and do
not transmit again until the vehicle has been parked for more than 15 minutes.
The warning appears in the instrument cluster message centre when the inflation pressure has fallen
to 25% of the nominal pressure. The displayed message will also include the position(s) of the
affected wheel(s) displayed on a vehicle graphic.
The TPMS enters 'Parking Mode' after the vehicle speed has been less than 20 km/h (12.5 mph) for
15 minutes. In parking mode the tire pressure sensors transmit a coded RF signal once every 13
hours. If the tire pressure decreases by more than 0.06 bar (1 lbf/in2), the sensor will transmit more
often if pressure in the tire is being lost.
Wheels and Tires - VIN Range: B10572-

>B32752
For a detailed description of the wheels and tires, refer to the relevant Description and Operation
section in the workshop manual.
Wheels and Tires
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 . 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 (A or B)
exist for the Tire Pressure Monitoring System when the ignition status is switched from 'OFF' to 'ON'
(A) Check Tire Pressure Warnings. A low tire

pressure warning will continuously illuminate the low
tire pressure warning lamp. This warning may be
accompanied by a text message such as CHECK
TIRE PRESSURE (refer to owner literature). The
manufacturer approved diagnostic system does NOT
need to be used. Diagnostic Trouble Codes (DTCs)
are not generated with this type of warning. To
extinguish this warning it is essential that, with the
ignition 'ON', all vehicle tires (including the spare) 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. It is not
necessary to drive the vehicle to clear 'check tire
pressure' warnings - just changing the tire
pressure causes the tire low pressure sensor to
transmit new data.
NOTE:
The tire pressures should be set by:
• Using a calibrated tire pressure gauge

• With 'cold' tires (vehicle parked in the ambient
temperature for at least one hour, not in a garage
with an artificial ambient temperature)
NOTE:
If the tire pressure warning does not clear within two

minutes, it is likely that the gauge is not correctly
calibrated or the tires are 'warm'. Carry out the
following steps until the warning has cleared:
• Increase the tire pressures by 3psi

• Wait a further two minutes
• When the tires are at ambient temperature and a
calibrated gauge is available, reset the tire
pressures to the correct pressure.
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.
(B) System Fault Warnings. When a system fault is

detected, the low tire pressure warning lamp will flash
for approximately 75 seconds prior to being
continuously illuminated. Visually inspect for obvious
signs of damage and system integrity. Check for the
presence of tire low pressure sensors on all four
wheels (note: a tire low pressure sensor has a metal
valve stem rather than a rubber one).
2 . Check for Diagnostic Trouble Codes (DTCs) and refer to the DTC Index.
NOTE:
If the tester fails to communicate with the Tire

Pressure Monitoring System module, the following
actions are recommended:
• Remove the Tire Pressure Monitoring System

power supply fuse, inspect and re-install (if
intact). Test to see if communications have been
re-established.
• Remove the Tire Pressure Monitoring System
ignition fuse (if applicable), inspect and re-install
(if intact). Test to see if communications have
been re-established.
• With ignition status set to 'ON', refer to the
electrical circuit diagrams and check Tire
Pressure Monitoring System module for power,
ignition and ground supplies .
• Carry out CAN network integrity test using the
manufacturer approved diagnostic system.
DTC Index
CAUTION: When probing connectors to take

measurements in the course of the pinpoint tests,
use the adaptor kit, part number 3548-1358-00
NOTE:
If the control module 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. When testing resistance, always take the
resistance of the DMM leads into account.
NOTE:
Check and rectify basic faults before beginning

diagnostic routines involving pinpoint tests.
NOTE:
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
Left Front Tire • Missing,

Pressure incompatibl
GO to Pinpoint
C1A5 Sensor and e or
defective Test
6-31 Transmitter
tire low G561999p6.
Assembly-no
pressure
signal
sensor or
radio
frequency
receiver
• Information
only -
vehicle
Left Front Tire exposed to
Pressure extreme
Sensor and temperature
C1A5 environment No action
Transmitter
6-68 and/or tire required.
Assembly- low
event pressure
information sensor low
battery
voltage
event
• Tire low
pressure Replace
Left Front Tire sensor has defective tire
Pressure reported out low pressure
of range
C1A5 Sensor and sensor. Refer to
information
6-91 Transmitter for the relevant
Assembly- pressure, section of the
parametric temperature workshop
or manual.
acceleration
C1A5 Left Front Tire • No tire low GO to Pinpoint

6-93 Pressure pressure Test
Sensor and sensor can G561999p7.
Transmitter be localized
Assembly-no at this
position due
operation
to an
initiator or
tire low
pressure
sensor
malfunction
• Left front GO to Pinpoint

Left Front
initiator Test
C1A5 Initiator-circuit
circuit is G561999p2.
7-11 short to short to Refer to
ground ground Pinpoint test B1
• Left front GO to Pinpoint

Left Front
initiator Test
7-12 short to short to Go to Pinpoint
battery power test B2
GO to Pinpoint
Left Front • Left front Test
C1A5
Initiator-circuit initiator G561999p2.
7-13 circuit open Go to Pinpoint
open
test B9
C1A5 Right Front • Missing, GO to Pinpoint

8-31 Tire Pressure incompatibl
Test
e or
Sensor and defective G561999p6.
Transmitter tire low
Assembly-no pressure
sensor or
signal
radio
frequency
receiver
• Information
only -
vehicle
Right Front exposed to
Tire Pressure extreme
Transmitter
Assembly- low
event pressure
battery
voltage
event
• Tire low Replace

Right Front pressure defective tire
sensor has
Tire Pressure low pressure
reported out
C1A5 Sensor and of range sensor. refer to
8-91 Transmitter information the relevant
Assembly- for section of the
parametric pressure, workshop
temperature manual.
or
acceleration
• No tire low
pressure
sensor can
Right Front be localized
Tire Pressure at this GO to Pinpoint
C1A5 Sensor and position due
Test
8-93 Transmitter to an
Assembly-no initiator or G561999p7.
operation tire low
pressure
sensor
malfunction
• Right front GO to Pinpoint

Right Front
initiator Test
ground ground test C1
• Right front GO to Pinpoint

Right Front
initiator Test
battery power test C2
Right Front GO to Pinpoint

• Right front
C1A5 Test
Initiator-circuit initiator
9-13 circuit open G561999p3.
open
Go to Pinpoint
test C9
• Missing,
incompatibl
Left Rear Tire e or
Pressure defective GO to Pinpoint
C1A6 Sensor and tire low
Test
0-31 Transmitter pressure
sensor or G561999p6.
Assembly-no
signal radio
frequency
receiver
• Information
only -
vehicle
Left Rear Tire exposed to
Pressure extreme
Transmitter
Assembly- low
event pressure
battery
voltage
event
Left Rear Tire • Tire low Replace

C1A6 Pressure pressure defective tire
0-91 Sensor and sensor has low pressure
Transmitter reported out sensor, refer to
Assembly- of range the relevant
parametric information section of the
for workshop
pressure, manual.
temperature
or
acceleration
• No tire low
pressure
sensor can
Left Rear Tire be localized
Pressure at this GO to Pinpoint
Test
operation tire low
pressure
sensor
malfunction
GO to Pinpoint
Left Rear • Left rear Test
C1A6 Initiator-circuit initiator
G561999p4.
1-11 short to circuit short
to ground Go to Pinpoint
ground
test D1
GO to Pinpoint
G561999p4.
to power Go to Pinpoint
battery
test D2
GO to Pinpoint
C1A6
open
test D9
• Missing,
incompatibl
Right Rear e or
Tire Pressure defective GO to Pinpoint
Test
Assembly-no
signal radio
frequency
receiver
• Information
only -
vehicle
Right Rear exposed to
Transmitter
Assembly- low
event pressure
battery
voltage
event
C1A6 Right Rear • Tire low Replace

2-91 Tire Pressure pressure defective tire
Sensor and sensor has low pressure
Transmitter reported out sensor, refer to
of range
Assembly- the relevant
information
parametric for section of the
pressure, workshop
temperature manual.
or
acceleration
• No tire low
pressure
sensor can
Right Rear be localized
Tire Pressure at this GO to Pinpoint
Test
operation tire low
pressure
sensor
malfunction
GO to Pinpoint
Right Rear • Right rear Test
G561999p5.
to ground Go to Pinpoint
ground
test E1
C1A6 Right Rear • Right rear GO to Pinpoint

3-12 Initiator-circuit initiator
Test
circuit short
short to to power G561999p5.
battery Go to Pinpoint
test E2
GO to Pinpoint
Right Rear • Right rear Test
C1A6
open
test E9
• Information
only -
vehicle
Spare Wheel exposed to
Transmitter
Assembly- low
event pressure
battery
voltage
event
Spare Wheel • Tire low

Replace
pressure
Tire Pressure defective tire
sensor has
C1A6 Sensor and reported out low pressure
4-91 Transmitter of range sensor, refer to
Assembly- information the relevant
parametric for section of the
pressure,
temperature workshop
or manual.
acceleration
• Missing,
incompatibl
Spare Wheel e or
Tire Pressure defective GO to Pinpoint
Test
Assembly-no
operation radio
frequency
receiver
• Tire
pressure
monitoring
External system
Receiver Data radio GO to Pinpoint
C1D1
Line-circuit frequency Test
9-11 receiver or
short to G561999p1.
ground data line
circuit is
short to
ground
External • Tire
Receiver Data pressure GO to Pinpoint
C1D1 monitoring
Line-circuit Test
9-12 system
short to G561999p9.
radio
battery
frequency
receiver or
data line
circuit is
short to
power
• Radio
Frequency
reception
blocked
• Tire
pressure
monitoring
system
radio
frequency
receiver
External faulty
GO to Pinpoint
C1D1 Receiver Data • Tire
pressure Test
9-87 Line-missing
message monitoring G561999p10.
system
radio
frequency
receiver or
data line
circuits
open circuit
• Missing,
incompatibl
e or
defective
tire low
pressure
sensors
Carry out CAN

network integrity
tests. Refer to
Medium
the electrical
U0010 Speed CAN • CAN bus
wiring diagrams
-88 Communicatio fault
and check CAN
n Bus-bus off
network for
short, open
circuit.
Refer to the
electrical wiring
Lost diagrams and
communicatio • CAN bus check Central
n with body fault Junction Box
U0140
control • Central power and
-00 Junction
module-no ground supplies
sub type Box fault for short, open
information circuit. Carry out
CAN network
integrity tests.
Lost • CAN bus Refer to the

fault
U0142 Communicatio electrical wiring
n With Body • Auxiliary diagrams and
-00 Junction
Control check Auxiliary
Box fault
Module "B" - Junction Box
no sub type power and
information ground supplies
for short, open
circuit. Carry out
CAN network
integrity tests.
Refer to the
electrical wiring
Lost
diagrams and
Communicatio
check
ns With
• CAN bus instrument
Instrument
U0155 fault cluster power
Panel Cluster
-00 • Instrument and ground
(IPC) Control cluster fault supplies for
Module-no
short, open
sub type
circuit. Carry out
information
CAN network
integrity tests.
Refer to the
Lost electrical wiring
Communicatio • CAN bus diagrams and
n With HVAC fault check climate
U0164
Control • Climate control module
-00 control
Module-no power and
sub type module fault
ground supplies
information for short, open
circuit. Carry out
CAN network
integrity tests.
Check correct
tire pressure
Internal • Incompatibl monitoring
Control e tire system module
Module pressure is installed to
U0300 monitoring
Software vehicle
-00 system
Incompatibility module for specification,
-no sub type vehicle CAN otherwise
information network suspect the
Auxiliary
Junction Box.
• Invalid data Check Anti-Lock

Invalid Data received Braking System
from the
Received Anti-Lock control module
From Anti- Braking and Instrument
Lock Brake System Cluster for
U0415
System (ABS) Control related DTCs
-00 Module
Control and refer to the
Module-no • CAN bus relevant DTC
fault
subtype Index. Carry out
• Anti-Lock
information Braking CAN network
System fault integrity tests.
U0424 Invalid Data • HVAC Check climate

-00 Received control control module
From HVAC module fault for related DTCs
Control and refer to
Module-no relevant DTC
sub type Index.
information
Install a new tire

pressure
CAN monitoring
Initialisation • Tire module. Refer to
pressure
U1A1 Failure- the new
monitoring
4-49 internal system module/compon
electronic module fault ent installation
failure note at the top
of the DTC
Index.
• Tire
pressure Check and
Control monitoring
U3000 amend the car
Module-not system
-55 configuratio configuration
configured
n data is file.
invalid
Check the
• Tire
Control Auxiliary
pressure
U3000 Module- monitoring Junction Box for
-87 missing system related DTCs
message configuratio and refer to the
n data not relevant DTC
received Index. Carry out
CAN network
integrity test.
NOTE:
This DTC
indicates that
the tire
pressure
monitoring
system
module is not
the original
• Tire
Vehicle pressure part installed
Identification monitoring to the vehicle
U3002
Number - system at the
-81 module and
invalid serial factory/dealer
data received vehicle VIN and could
mis-match have been
substituted.
Refer to the
note above
the DTC
index about
replacing
components
which may
remain under
manufacturer
warranty.
Re-install the
original or a new
tire pressure
monitoring
system control
module.
Component Tests
Wheels and Tires
For wheel and tire specification information (pressures, torques, etc).

Specifications
When replacing wheels or tires, local legislation regarding health and safety must be complied with.
If the vehicle has a Tire Pressure Monitoring System 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 Tire Pressure
Monitoring System module should be updated with the correct pressure information appropriate to
the new wheel and tire set. Update the Tire Pressure Monitoring System module using the Jaguar
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 . 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.

Specifications
• 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 G561999p1 : C1D1911

TIRE PRESSURE MONITORING
SYSTEM EXTERNAL RECEIVER DATA
LINE CIRCUIT SHORT TO GROUND
G561999t1 : C1D1911 Verify External Receiver Data Line Circuit Short To
Ground
1. Ignition off. 2. Disconnect the Tire Pressure Monitoring System Receiver electrical connector,
CA131. 3. Measure the resistance between
CA131, harness side Battery
Pin 1 Negative terminal
• Is the resistance less than 5 Ohms?
-> Yes
GO to A2. GO to Pinpoint Test G561999t2.
-> No
G561999t2 : C1D1911 Check The External Receiver Data Line Circuit For
Short Circuit To Ground
1. Disconnect the Tire Pressure Monitoring System Control Module electrical connector, CA109. 2.
Measure the resistance between
-> Yes
REPAIR the short circuit in wiring harness.
-> No
G561999t3 : C1D1911 Check The Tire Pressure Monitoring System External
Receiver For Short Circuit To Ground
1. Reconnect the Tire Pressure Monitoring System Receiver electrical connector, CA131. 2. Using
manufacturer approved diagnostic system run On Demand Self Test (0x0202).
• Is the DTC C1D1911 set?
-> Yes
Replace Tire Pressure Monitoring Receiver.
-> No
Investigate possible cause of intermittent failure.
G561999t4 : C1D1911 Check The Tire Pressure Monitoring System Control

Module For Short Circuit To Ground
1. Reconnect the Tire Pressure Monitoring System Control Module electrical connector, CA109. 2.
Reconnect the Tire Pressure Monitoring System Receiver electrical connector, CA131. 3. Using
-> Yes
Replace Tire Pressure Monitoring System Control Module.
-> No
PINPOINT TEST G561999p2 : LEFT

FRONT LOW FREQUENCY INITIATOR
CIRCUIT
G561999t5 : Check the initiator circuit for short circuit to ground
1. Ignition off. 2. Disconnect the left hand front low-frequency initiator electrical connector, FB013. 3.
4. Measure the resistance between:

FB013, harness side Battery
• Is the resistance less than 10,000 ohms?
-> Yes
-> No
G561999t6 : Check the initiator circuit for short circuit to power

Pin 2 Positive terminal
-> Yes
-> No


-> Yes
-> No

-> Yes
-> No
G561999t9 : Check whether the short circuit is in the harness or the module
1. Disconnect the Tire Pressure Monitoring System module connector, CA072. 2.

-> Yes
REPAIR the short circuit. This circuit contains intermediate connectors, FB001 and FL070. For
additional information, refer to the wiring diagram. Clear the DTC and run an On Demand Self Test
(ODST) using the manufacturer approved diagnostic system to confirm rectification.
-> No
INSTALL a new Tire Pressure Monitoring System module.
Tire Pressure Monitoring System (TPMS) Module - Convertible
G561999t10 : Check whether the short circuit is in the harness or the

module
-> Yes
-> No

module
-> Yes
-> No
module
-> Yes
-> No
G561999t13 : Check the initiator circuit for high resistance

CA072, harness side FB013, harness side
Pin 14 Pin 2
• Is the resistance greater than 5 ohms?
-> Yes
REPAIR the high resistance circuit. This circuit contains intermediate connectors, FB001 and FL070.
For additional information, refer to the wiring diagram. Clear the DTC and run an On Demand Self
Test (ODST) using the manufacturer approved diagnostic system to confirm rectification.
-> No

Pin 13 Pin 1
-> Yes
-> No
INSTALL a new left hand front low-frequency initiator.
PINPOINT TEST G561999p3 : RIGHT

FRONT LOW FREQUENCY INITIATOR
CIRCUIT
1. Ignition off. 2. Disconnect the right hand front low-frequency initiator electrical connector, FB012.
3.
Measure the resistance between:

-> Yes
-> No

-> Yes
-> No


-> Yes
-> No

-> Yes
-> No

module

-> Yes
-> No

module
-> Yes
-> No

module
1. Disconnect the Tire Pressure Monitoring System module connector, FB072. 2.
-> Yes
-> No
module
-> Yes
-> No

Pin 16 Pin 2
-> Yes
-> No

Pin 15 Pin 1
-> Yes
-> No
INSTALL a new right hand front low-frequency initiator.
PINPOINT TEST G561999p4 : LEFT

REAR LOW FREQUENCY INITIATOR
CIRCUIT
1. Ignition off. 2. Disconnect the left hand rear low-frequency initiator electrical connector, RB010. 3.

RB010, harness side Battery
-> Yes
-> No

-> Yes
-> No


-> Yes
-> No

-> Yes
-> No

module

-> Yes
REPAIR the short circuit. This circuit contains intermediate connector, RB001. For additional
information, refer to the wiring diagram. Clear the DTC and run an On Demand Self Test (ODST) using
the manufacturer approved diagnostic system to confirm rectification.
-> No

module
-> Yes
-> No

module
-> Yes
-> No
module
-> Yes
-> No
G561999t33 : Check the initiator return circuit for high resistance

CA072, harness side RB010, harness side
Pin 6 Pin 2
-> Yes
REPAIR the high resistance circuit. This circuit contains intermediate connector, RB001. For additional
-> No

Pin 5 Pin 1
-> Yes
-> No
INSTALL a new rear left hand low-frequency initiator.
PINPOINT TEST G561999p5 : RIGHT

REAR LOW FREQUENCY INITIATOR
CIRCUIT
1. Ignition off. 2. Disconnect the right hand rear low-frequency initiator electrical connector, RB009.
3.

-> Yes
-> No

-> Yes
-> No


-> Yes
-> No

-> Yes
-> No

module

-> Yes
-> No

module
-> Yes
-> No

module
-> Yes
-> No
module
-> Yes
-> No

Pin 8 Pin 2
-> Yes
-> No

Pin 7 Pin 1
-> Yes
-> No
INSTALL a new rear right hand low-frequency initiator.
PINPOINT TEST G561999p6 : MISSING,

INCOMPATIBLE OR DEFECTIVE
RUNNING TIRE LOW PRESSURE
SENSOR OR RECEIVER
G561999t45 : Check for correct wheel and tire assembly and tire low
pressure sensor
1. Establish that a full size running wheel and tire assembly has a tire low pressure sensor installed.
As a visual confirmation, a tire low pressure sensor has a metal valve stem rather than a rubber one
and cannot be installed to a mini/space saver spare wheel.
• Is a full size wheel and tire assembly with tire low pressure sensor installed?
-> Yes
-> 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.
G561999t46 : Check for additional DTCs

1. Remove the Tire Pressure Monitoring System power supply fuse and re-install it. Clear DTCs and
leave the vehicle stationary for 15 minutes, then drive it at a speed greater than 15.5 mph (25 kph)
continuously for at least 10 minutes.Note: If the vehicle speed drops below this value, the drive time
to complete the test will need to be increased. The use of the manufacturer approved diagnostic
system, and the datalogger signal ’Tire pressure monitor system status – learn mode status’ will
verify the completion of the test when the value returns to ‘Inactive’. 2. Check for additional DTCs
C1A5631, C1A5831, C1A6031, C1A6231, with identical time stamps.
• Have all four DTCs logged with identical time stamps in the tire pressure monitoring system
module?
-> Yes
Replace the tire pressure monitoring system radio frequency receiver.
Tire Pressure Monitoring System (TPMS) Receiver
-> No
G561999t47 : Verify the position of the defective tire low pressure sensor
1. 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.
-> No
No further action is required. Note: The use of the manufacturer approved diagnostic system, and
the datalogger signal ’Tire pressure monitor system status – learn completed successfully’ will verify
the successful completion of the test.
PINPOINT TEST G561999p7 :
LOCALIZATION FAILURE
1. Check for additional DTCs: C1A5711, C1A5712, C1A5713. C1A5911, C1A5912, C1A5913, C1A6111,
C1A6112, C1A6113, C1A6311, C1A6312, C1A6313.
• Are any of the DTCs listed above also logged?
-> Yes
Refer to the DTC Index and remedial actions.
-> No

1. Check for additional DTCs: C1A5631, C1A5831, C1A6031 or C1A6231
• Is a C1A5631, C1A5831, C1A6031 or C1A6231 DTC also logged?
-> Yes
Refer to the DTC Index and remedial actions.
-> No
G561999t50 : Check Initiator installation

1. Check for correct installation of Initiator.
• Is the Initiator correctly installed?
-> Yes
-> No
Rectify as required.
G561999t51 : Check for short circuit in Initiator harness
1. Locate and remove module blue connector L. 2. Measure the resistance across the relevant
initiator circuits within the blue connector.
• Is the resistance less than 1 Ohm?
-> Yes
A value of less than 1 Ohm indicates a short circuit, rectify the short circuit as required.
-> No
position identified by the logged DTC.
PINPOINT TEST G561999p8 : SPARE

TIRE LOW PRESSURE SENSOR NO
OPERATION
G561999t52 : Establish the type of spare wheel and tire assembly installed
1. Establish the type of spare wheel and tire assembly Installed.
• Is the spare wheel a mini/space saver type?
-> Yes
Tire low pressure sensors are not installed to mini/space-saver spare wheels. Tire low pressure
sensors are installed to full size spare wheels only. The DTC is to be ignored and no repair action is
required.
-> No
G561999t53 : Establish that the spare wheel has a tire low pressure sensor
installed
1. Establish that the spare wheel has a tire low pressure sensor installed, considering the following
additional information:
a) As a visual confirmation, the tire low pressure sensor has a metal valve stem rather than a rubber
one.
• Is a tire low pressure sensor installed?

-> Yes
-> No
A new spare tire low pressure sensor should be installed. Note: Refer to the note above the DTC
index about replacing components which may remain under manufacturer warranty. Refer to the
relevant section of the workshop manual.
G561999t54 : Confirm operation of the spare wheel pressure sensor

1. Deflate the spare tire, in close proximity to the vehicle, until it is completely deflated. 2. Complete
an ignition cycle to ignition on and verify that the instrument cluster reports a spare tire pressure
warning for approximately 20 seconds. 3. Re-inflate the spare tire, in close proximity to the vehicle,
to the recommended spare tire pressure. 4. Complete an ignition cycle to ignition on and verify that
the instrument cluster no longer reports a spare tire pressure warning.
• Does the instrument cluster continue to report a spare tire pressure warning?
-> Yes
-> No
No repair action is required. It is possible that the customer may have placed items in the vehicle's
luggage compartment that prevented correct RF reception.
G561999t55 : Verify that the spare Tire Low Pressure Sensor ID has been
correctly programmed to the module
1. Remove tire low pressure sensor. Record the 8 character hexadecimal ID written on the casing. 2.
Use the approved diagnostic system to read the spare tire sensor ID from the module. Refer to the
relevant procedure in the workshop manual. 3. Compare the IDs from steps 1 & 2.
• Do the IDs match?
-> Yes
Replace the spare tire low pressure sensor. Refer to the relevant installation section in the workshop
manual.
The identification for the sensor must be programmed into the tire pressure monitoring system
module using the manufacturer approved diagnostic system. The identification code is provided on a
label with the complete assembly and is also printed on the casing of each sensor.
-> No
Program the spare tire sensor ID, recorded in step 1, to the module using the approved diagnostic
system. The identification code is provided on a label with the complete assembly and is also printed
on the casing of each sensor.
www.JagDocs.com
Repeat test to ensure correct operation. GO to Pinpoint Test G561999t54.

LINE CIRCUIT SHORT TO POWER
G561999t56 : C1D1912 Verify External Receiver Data Line Circuit Short To
Power
CA131. 3. Measure the resistance between
-> Yes
-> No
G561999t57 : C1D1912 Check The External Receiver Data Line Circuit For
Short Circuit To Power
1. Disconnect the Tire Pressure Monitoring System Control Module electrical connector, CA109. 2.
Measure the resistance between

-> Yes
REPAIR the short circuit in wiring harness.
-> No
G561999t58 : C1D1912 Check The Tire Pressure Monitoring System

External Receiver For Short Circuit To Power
1. Reconnect the Tire Pressure Monitoring System Receiver electrical connector, CA131. 2. Using
-> Yes
Replace Tire Pressure Monitoring Receiver.
-> No
G561999t59 : C1D1912 Check The Tire Pressure Monitoring System Control

Module For Short Circuit To Power
1. Reconnect the Tire Pressure Monitoring System Control Module electrical connector, CA109. 2.
-> Yes
-> No

LINE MISSING MESSAGE
G561999t60 : C1D1987 Verify External Receiver Data Line Missing Message
1. Using manufacturer approved diagnostic system run On Demand Self Test (0x0202).
-> Yes
-> No
G561999t61 : C1D1987 Check External Receiver Data Line Circuit

CA131. 3. Disconnect the Tire Pressure Monitoring System Control Module electrical connector,
CA109 4. Measure the resistance between
CA131, harness side CA109, harness side
Pin 1 Pin4
• Is the resistance less than 5 ohms?
-> Yes
-> No
REPAIR the high resistance/open circuit in wiring harness.
G561999t62 : C1D1987 Check External Receiver

1. Reconnect the Tire Pressure Monitoring System Control Module electrical connector, CA109 2.
-> Yes
Replace Tire Pressure Monitoring Receiver. GO to Pinpoint Test G561999t63.
-> No
G561999t63 : C1D1987 Check Tire Pressure Monitoring System Control
Module
1. Using manufacturer approved diagnostic system run On Demand Self Test (0x0202).
-> Yes
-> No
Test is complete. No further action is required.
G561999t64 : C1D1987 Check Wheels Have Tire Sensors Installed

1. NOTE:
As a visual check, a tire low pressure sensor has a

metal valve stem rather than a rubber one and cannot
be installed to a mini/space saver spare wheel.
Check that all full size running wheel and tire assemblies have tire low pressure sensors installed.
• Is a full size wheel and tire assembly with tire low pressure sensor installed to all running
wheel positions?
-> Yes
-> No
If agreed with the customer install correct tire low pressure sensors in accordance with that defined
in the manufacturer approved diagnostic system new tire low pressure sensor application, as
required. Note: Confirm why the vehicle has non-TPMS wheel & tire assemblies fitted before
installing tire low pressure sensors, which are not to be claimed under vehicle warranty.
G561999t65 : C1D1987 Check Tire Sensor Compatibility To Tire Pressure

Monitoring System Receiver
1. Remove tire low pressure sensor from 1 wheel. 2. Verify the tire low pressure sensor part number
from the information on the casing.
• Is the tire low pressure sensor the correct part for the vehicle?
-> Yes
Replace Tire Pressure Monitoring Receiver. Carry out the following to verify repair.
Remove the Tire Pressure Monitoring System power supply fuse and re-install it. Clear DTCs and
leave the vehicle stationary for 15 minutes, then drive it at a speed greater than 15.5 mph (25 kph)
continuously for at least 10 minutes.
Note: If the vehicle speed drops below this value, the drive time to complete the test will need to be
increased. The use of the manufacturer approved diagnostic system, and the datalogger signal ’Tire
pressure monitor system status – learn mode status’ will verify the completion of the test when the
value returns to ‘Inactive’.
-> No
position(s) identified. Note: Confirm why the vehicle has incorrect TPMS wheel & tire assemblies
fitted before installing tire low pressure sensors, which are not to be claimed under vehicle warranty.
Wheels and Tires - VIN Range: B00379-
>B10571
For a detailed description of the wheels and tires, refer to the relevant Description and Operation
Wheels and Tires

1 . Verify the customer complaint.
NOTE:
Record any messages displayed by the system.
Mechanical Electrical
• Tire pressures
• Fuses
• Tire/Wheel damage. Refer to component
• Front antenna installation/damage
tests in this section
• Rear antenna installation/damage
• Tire low pressure sensor
• Tire Pressure Monitoring System (TPMS)
installation/damage
module
• Front antenna installation/damage
• Connectors/harnesses
• Rear antenna installation/damage
3 . If an obvious cause for an observed or reported concern is found, correct the cause (if possible)
4 . If the cause is not visually evident use the Jaguar approved diagnostic system or a scan tool to
retrieve the Diagnostic Trouble Codes (DTCs) before proceeding to the DTC Index.
DTC Index
CAUTION: When probing connectors to take measurements in the course of the pinpoint
tests, use the adaptor kit, part number 3548-1358-00
NOTE:
If the control module 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. When testing resistance,
always take the resistance of the DMM leads into account.
NOTE:
Check and rectify basic faults before beginning diagnostic routines involving pinpoint tests.
NOTE:
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.
• Replace the tire low

Left hand front
pressure sensor.
C1A5616 tire low pressure • Low battery detected
Tire Low Pressure
sensor Sensor
• Check for stored DTC

Left hand front C1A5616 and follow the
actions indicated. If this
C1A5631 tire low pressure • No signal detected
DTC is not stored replace
sensor the tire low pressure
sensor.
Tire Low Pressure
Sensor

Left hand front
pressure sensor.
C1A5691 tire low pressure • Data out of range
Tire Low Pressure
sensor Sensor
• Check for stored DTCs

Left hand front C1A5711, C1A5712,
• No sensor can be found at
C1A5693 tire low pressure C1A5713 or C1A5631
this location
sensor and follow the actions
indicated.
• Carry out any pinpoint

tests associated with this
Left hand front • Left hand front antenna
C1A5711 DTC using the
antenna circuit - short to ground
manufacturer approved
diagnostic system

antenna circuit - short to power
diagnostic system

antenna circuit - high resistance
diagnostic system

Right hand front
pressure sensor.
Tire Low Pressure
sensor Sensor

C1A5816 and follow the
Right hand front
the tire low pressure
sensor sensor.
Tire Low Pressure
Sensor

C1A5891 Right hand front • Data out of range
pressure sensor.
tire low pressure
Tire Low Pressure
sensor Sensor

Right hand front C1A5911, C1A5912,
this location
indicated.

Right hand front • Right hand front antenna
diagnostic system

diagnostic system

diagnostic system

Left hand rear tire
pressure sensor.
C1A6016 low pressure • Low battery detected
Tire Low Pressure
sensor Sensor

Left hand rear tire
C1A6031 low pressure • No signal detected
sensor sensor.
Tire Low Pressure
Sensor

Left hand rear tire
pressure sensor.
C1A6091 low pressure • Data out of range
Tire Low Pressure
sensor Sensor
• No sensor can be found at • Check for stored DTCs

C1A6093 Left hand rear tire
this location C1A6111, C1A6112,
low pressure
C1A6113 or C1A6031
indicated.

Left hand rear • Left hand rear antenna
diagnostic system

diagnostic system

diagnostic system

Right hand rear
pressure sensor.
Tire Low Pressure
sensor Sensor

Right hand rear
sensor sensor.
Tire Low Pressure
Sensor

Right hand rear
pressure sensor.
C1A6291 tire low pressure • Data out of range
Tire Low Pressure
sensor Sensor

Right hand rear C1A6311, C1A6312,
this location
indicated.
C1A6311 Right hand rear • Carry out any pinpoint

• Right hand rear antenna
antenna circuit - short to ground DTC using the
diagnostic system

Right hand rear • Right hand rear antenna
diagnostic system

Right hand rear • Right hand rear antenna
diagnostic system

Spare tire low pressure sensor.
C1A6416 • Low battery detected
pressure sensor Tire Low Pressure
Sensor

Spare tire low pressure sensor.
C1A6491 • Data out of range
pressure sensor Tire Low Pressure
Sensor
• If the vehicle has a

temporary spare wheel
and tire installed take no
action. Check for stored
DTC C1A6416 and follow
Spare tire low • No sensor can be found at
C1A6493 the actions indicated. If
pressure sensor this location
this DTC is not stored
replace the tire low
pressure sensor.
Tire Low Pressure
Sensor
• Check for DTCs

• The control module cannot
C1D1800 Location failure indicating a component
locate the sensor
fault

External receiver tests associated with this
• External receiver data line
C1D1911 data line short to DTC using the
circuit - short to ground
ground manufacturer approved
diagnostic system
External receiver tests associated with this
• External receiver data line
C1D1912 data line short to DTC using the
circuit - short to power
power manufacturer approved
diagnostic system

External receiver • External receiver data line
C1D1987 DTC using the
message missing circuit - high resistance
diagnostic system

Medium speed
U001088 • Bus OFF DTC using the
CAN manufacturer approved
diagnostic system
Lost • Carry out any pinpoint

communications • Lost communications with
U015500 DTC using the
with instrument instrument cluster
cluster diagnostic system
Lost • For Network tests.

U014000 communication • Lost communication with CJB Communications
with CJB Network

Lost tests associated with this
• Lost communication with
U014200 communication DTC using the
RJB
with RJB manufacturer approved
diagnostic system
Lost • Carry out any pinpoint

communication • Lost communication with
with climate climate control module
control module diagnostic system
• Re-configure the RJB

using the manufacturer
Internal control approved diagnostic
• Invalid configuration
U030000 module software system. Clear the DTC
message is received
incompatibility and retest. If the DTC is
still logged suspect the
TPMS module, refer to
the new module
installation note at the
top of the DTC Index
• Check ABS module for

Invalid data DTCs and refer to DTC
U041600 received from ABS • Vehicle speed signal fault Index.
control module Anti-Lock Control -
Stability Assist
Invalid data • Check climate control

received from • Invalid data received from module for DTCs and
U042400
climate control climate control module refer to DTC Index.
module Climate Control System
• Install a new TPMS

module, refer to the new
U1A1449 CAN error • Internal electronic failure module installation note
at the top of the DTC
Index
• Re-configure the RJB

approved diagnostic
system. Check TPMS
module for DTCs and
U300087 Control Module • Missing message
refer to the DTC Index.
Check CAN network
integrity using the
diagnostic system
• Vehicle/component mis-
Vehicle match. Corrupt VIN data • Install original module,
U300281 Identification being transmitted, module check for DTCs and refer
Number (VIN) previously installed to other to relevant DTC Index
vehicle
Component Tests
Wheels and Tires
For wheel and tire specification information (pressures, torques, etc).

Specifications
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 TPMS module
using the Jaguar 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 . 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.

Specifications
• 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.
Front Suspension
Rear Suspension
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.

Removal
1.
WARNING: Make sure to support the vehicle with axle stands.
2 . TORQUE: 125 Nm
Installation
1
. CAUTION: Apply a small amount of grease to the bore and spigot areas of the wheel
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
result in personal injury.
To install, reverse the removal procedure.

Tire Pressure Monitoring System (TPMS)
Front Antenna
Removal
1 . Disconnect the battery ground cable.
2 . Turn the steering on to full lock for access.
3 . Release the front of the fender splash shield.
Remove the 5 Torx bolts.
Tie the splash shield aside.
4 . Remove the tire pressure antenna.
Remove the 2 clips.

Installation
1 . Install the tire pressure antenna.
Install the clips.
2 . Install the fender splash shield.
Tighten the Torx bolts.
3 . Connect the battery ground cable.

Rear Antenna
Removal
2

4 . Release the rear lower edge of the rear fender splash shield.

Remove the 2 clips.
Installation
Install the clips.

Module - Convertible
Removal
2 . Make the SRS system safe.
3 . Remove the LH roll over protection unit.
4 . Remove the rear seat RH backrest retaining bracket.
Remove the 2 nuts and 2 bolts.
5 . Remove the RH roll over protection unit.

6 . Release the auxiliary junction box mounting bracket.
Remove the 3 nuts.
7 . Remove the tire pressure monitoring module.
Remove the 2 nuts.
Disconnect the 2 electrical connectors.

Installation
1 . Install the tire pressure monitoring module.
Connect the electrical connectors.
2 . Secure the auxiliary junction box mounting bracket.
3 . Install the rear seat RH backrest retaining bracket.
4 . Install the RH roll over protection unit.
Tighten the Torx bolts to 25 Nm (18 lb.ft).
5 . Install the LH roll over protection unit.

7 . Using WDS, configure a new module.

Module - 2-Door
Removal
2 . Remove the rear seat backrest.

For additional information, refer to Rear Seat Backrest (76.70.38)
Remove the 3 nuts.
4 . Remove the tire pressure monitoring module.
Remove the 2 nuts.

Installation
1 . Install the tire pressure monitoring module.
3 . Install the rear seat backrest.



Removal
NOTE:
It is strongly recommended that the valve seal and steel washer is replaced each time a tire is
changed to avoid a seal failure. The seal and washer must be replaced if the sensor is removed.
Removal of the sensor retaining nut must be regarded as sensor removal. The valve cap must
always be in place except when inflating, releasing pressure or checking pressure.
1
2 . Remove the wheel and tire.

4
. CAUTION: To avoid damage to the tire low pressure sensor, release the tire bead
from the rim, 180 degrees from the valve.
Remove the tire from the wheel.

5
. CAUTION: Do not push on the valve.
CAUTION: If the tire low pressure sensor is to be re-installed, a new washer, seal
and nut must be installed.
Remove the tire low pressure sensor.
Remove the nut.
Release and withdraw the sensor along the valve axis.
6 If necessary, install a new seal and washer.

.
Remove and discard the seal and washer.
Install a new washer and seal, making sure the valve remains pressed fully
onto its seat.
Installation
1
. CAUTION: Do not use compressed air to clean the sensor. Do not clean the sensor
with solvents or cleaning agents of any type, use a clean dry cloth.
2
. CAUTION: Do not apply any lubricant to the new valve.
NOTE:
If the sensor is replaced on a 'running' wheel, the new sensor identification will be learnt
in the first 15 minutes of the vehicle is being driven. If a new sensor is fitted to the spare
wheel the identification for that sensor must be programmed into the Tire Pressure
Monitoring System (TPMS) module using WDS. The identifcation code is provided on a
label with the complete assembly and is also printed on the sensor assembly.
Install the tire low pressure sensor.
Install and hand tighten the nut whilst keeping the sensor in place.
Tighten the nut to 6.5 Nm (4.8 lb.ft).

3 . Install the tire and balance the wheel.


Receiver
Removal
1 . Remove the floor console.
For additional information, refer to Floor Console (76.25.01)
2 . Remove the tire pressure monitoring receiver.
Release from the mounting pad.
Installation
1 . Install the tire pressure monitoring receiver.
Secure to the mounting pad.
2 . Install the floor console.

204-05 : Vehicle dynamic suspension
Specifications
Specifications
Item Nm lb-ft lb-in

Accelerometer - bolt 8 6 71
Adaptive damping control module - nut 4 3 35
Front shock absorber. - - -
Rear shock absorber. - - -

COMPONENT LOCATION
1 Right Hand (RH) front spring and damper assembly
2 Front vertical acceleration sensor
3 RH rear spring and damper assembly
4 Rear vertical acceleration sensor

5 Left Hand (LH) rear spring and damper assembly
6 Adaptive Damping Control Module (ADCM)
7 LH front spring and damper assembly
INTRODUCTION
An adaptive damping system, known as Computer Active Technology Suspension (CATS) is available
on certain models. The CATS system is an electronically controlled suspension system which
constantly adjusts the damping characteristics of the suspension dampers in reaction to the current
driving conditions.
The system is controlled by an Adaptive Damping Control Module (ADCM) which is located behind
the backrest of the RH rear passenger seat. The ADCM receives signals from two dedicated vertical
acceleration sensors in addition to inputs from other electronic system components to determine
vehicle body motion and driver inputs. These signals are used by the ADCM to control the damping
characteristics of each damper from soft to firm to give the optimum vehicle ride.
DAMPERS
The CATS dampers are monotube, nitrogen gas and oil filled units, manufactured by Bilstein. 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 CATS 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. When the solenoid valve is
deenergized, the damper is on its firm setting and oil flow is restricted to flowing at 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.
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 Pulse Width Modulation (PWM) signal from the ADCM. When
energized, the ADCM applies a 1.3 Ampere (A) push current for 75 milliseconds to move the valve
and then applies a 0.5 A hold current to operate the damper in the 'soft' setting. For additional
information, refer to Vehicle Dynamic Suspension (204-05)
ACCELERATION SENSORS
Two acceleration sensors are used in the CATS system. The front sensor is located in the rear of the
RH front wheel arch, behind the washer reservoir. The rear sensor is mounted in the luggage
compartment, in the rear LH corner adjacent to the rear lamp assembly.
The sensors measure acceleration in the vertical plane and output a corresponding analogue signal to
the ADCM.
Each sensor is connected to the ADCM via three wires which supply ground, 5 V supply and signal
return. The sensor terminals are gold plated due to the low signal currents.
The acceleration sensors 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 sensor is subjected to acceleration. Detection circuits within the sensor measure the peak voltage
and pass an analogue output signal to the ADCM. The sensors output a signal voltage of
approximately 1 V/g ± 0.05 V/g. For additional information, refer to Vehicle Dynamic
Suspension (204-05)
CATS SYSTEM FAULT MESSAGE

The ADCM has a CAN connection to the instrument cluster. If a fault is detected by the ADCM, 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 Diagnostic Trouble
Code (DTC) will be logged in the ADCM. The faults can be interrogated using the Integrated
Diagnostic System (IDS).
When a fault is detected, the ADCM stops outputs to the active dampers and the dampers operate
continually on their default 'hard' setting until the fault is corrected.
CONTROL DIAGRAM
NOTE:
A = Hardwired; D = High speed CAN bus

1 Battery
2 Megafuse (175 A)
4 Fuse 14 (15 A) - ACM power supply
5 High Speed CAN connection to other vehicle systems
6 RH rear active damper
7 LH rear active damper

8 Rear vertical acceleration sensor
9 LH front active damper
10 RH front active damper
11 Front vertical acceleration sensor
12 ADCM
The ADCM uses a combination of information from other system modules and data from the
acceleration sensors to measure the vehicle motion and driver inputs. Using this information, the
ADCM applies algorithms to control the dampers for the current driving conditions.
The ADCM receives signals on the high speed Controller Area Network (CAN) bus from the following
system components:
• Vehicle speed - Anti-lock Brake system (ABS) module

• Brake switch status - Engine Control Module (ECM)
• Brake pressure - ABS module
• Gear position - Transmission Control Module (TCM)
• Lateral acceleration - ABS module
• Throttle pedal position - ECM
• Power mode - CJB via 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 (CCF) 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 ADCM also outputs information for use by other systems as follows:
• CATS Fault - instrument cluster

• Front left damper status - ECM
• Front right damper status - ECM
• Rear left damper status - ECM
• Rear right damper status - ECM.
The ADCM monitors the input signals and operates the damper solenoids. The input signals are
compared against algorithms with the ADCM and preset speed thresholds.
The vehicle speed signal is the main input for the ADCM. The ADCM contains upper and lower speed
thresholds at which the dampers are set to the firm setting. 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 damper setting.
The firm setting has a higher priority than the soft setting. This is because the firm setting provides
better vehicle control in any driving condition. The dampers are set to firm when driving at high
speed or if a system fault is detected.
When the vehicle is stationary with the engine running, the dampers are set to the soft setting.
The ADCM receives its power supply via a relay in the CJB. The relay remains energised for a period
of time after the ignition is off. This allows the ADCM to record and store any fault codes relating to
CATS system faults.

For a detailed description of the adaptive damping system operation, refer to the relevant
Description and Operation section of the workshop manual.

1 . Verify the customer concern.

• Fuse(s)
• Coil spring(s)
• Wiring harness/electrical connectors
• Shock absorber(s)
• Accelerometer(s)
• Accelerometer(s) installation
• Adaptive damping module
2 . If the failure is not visually evident, check the system for any logged Diagnostic Trouble Codes
(DTCs) and refer to the DTC index.
DTC Index
tests, use the adaptor kit, part number 3548-1358-00.
NOTE:
If the control module 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.
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:
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
terminals.
Carry out any pinpoint tests

associated with this DTC using
Front vertical • Front vertical acceleration the manufacturer approved
C110A12 acceleration sensor circuit - short to diagnostic system. Refer to the
sensor power electrical circuit diagrams and
check front vertical acceleration
sensor circuit for short to power

Front vertical • Front vertical acceleration associated with this DTC using
C110A14 acceleration sensor circuit - short to the manufacturer approved
sensor ground, open circuit diagnostic system. Refer to the
electrical circuit diagrams and
check front vertical acceleration
sensor circuit for short to
ground, open circuit

Front vertical
• Signal not changing or out associated with this DTC using
C110A29 acceleration
of range the manufacturer approved
sensor
diagnostic system

Rear vertical • Rear vertical acceleration the manufacturer approved
C110B12 acceleration sensor circuit - short to diagnostic system. Refer to the
sensor power electrical circuit diagrams and
check rear vertical acceleration
sensor circuit for short to power

the manufacturer approved
Rear vertical • Rear vertical acceleration
diagnostic system. Refer to the
C110B14 acceleration sensor circuit - short to
ground, open circuit electrical circuit diagrams and
sensor
check rear vertical acceleration
sensor circuit for short to

Rear vertical
• Signal not changing or out associated with this DTC using
C110B29 acceleration
of range the manufacturer approved
sensor
diagnostic system

Left front damper • Left front damper solenoid
C110C12 diagnostic system. Refer to the
solenoid circuit - short to power
check left front damper solenoid
circuit for short to power

• Left front damper solenoid associated with this DTC using
Left front damper circuit - short to ground, the manufacturer approved
C110C14 diagnostic system. Refer to the
solenoid open circuit
• Left front damper failure electrical circuit diagrams and
check left front damper solenoid
circuit for short to ground, open
circuit. Check and install a new
damper as required

• Left front damper solenoid
Left front damper circuit - short to
C110C1D electrical circuit diagrams and
solenoid ground/power, open circuit
• Left front damper failure check left front damper solenoid
circuit for short to ground,
power, open circuit. Check and
install a new damper as required

Right front damper • Right front damper solenoid diagnostic system. Refer to the
C110D12
solenoid circuit - short to power electrical circuit diagrams and
check right front damper
solenoid circuit for short to
power

• Right front damper solenoid
Right front damper circuit - short to ground,
C110D14 electrical circuit diagrams and
• Right front damper failure check right front damper
solenoid circuit for short to
ground, open circuit. Check and

• Right front damper solenoid diagnostic system. Refer to the
Right front damper circuit - short to electrical circuit diagrams and
C110D1D
solenoid ground/power, open circuit check right front damper
• Right front damper failure solenoid circuit for short to
ground, power, open circuit.
Check and install a new damper
as required
C110E12 Left rear damper Carry out any pinpoint tests

• Left rear damper solenoid
solenoid circuit - short to power the manufacturer approved
check left rear damper solenoid

Left rear damper circuit - short to ground,
C110E14 electrical circuit diagrams and
• Left rear damper failure check left rear damper solenoid
damper as required

Left rear damper circuit - short to
C110E1D electrical circuit diagrams and
• Left rear damper failure check left rear damper solenoid

Right rear damper • Right rear damper solenoid
C110F12 diagnostic system. Refer to the
solenoid circuit - short to power
check right rear damper solenoid

• Right rear damper solenoid
Right rear damper circuit - short to ground,
C110F14 electrical circuit diagrams and
• Right rear damper failure check right rear damper solenoid
damper as required
• Right rear damper solenoid
Right rear damper circuit -short to
C110F1D electrical circuit diagrams and
• Right rear damper failure check right rear damper solenoid

Sensor supply associated with this DTC using
C1A391C • Circuit voltage out of range
voltage the manufacturer approved
diagnostic system

High speed CAN the manufacturer approved
• Vehicle CAN Bus off
U000188 communication diagnostic system. Carry out the
condition
bus CAN network integrity tests
approved diagnostic system

Lost electrical circuit diagrams and
U010087 communications • Missing message from ECM check ECM power and ground
with ECM supplies for short, open circuit.
Carry out the CAN network
integrity tests using the
diagnostic system

Lost diagnostic system. Refer to the
U010187 communication • Missing message from TCM electrical circuit diagrams and
with TCM check TCM power and ground
supplies for short, open circuit.
diagnostic system

Lost diagnostic system. Refer to the
communication electrical circuit diagrams and
• Anti-lock control - stability
U012187 with anti-lock check ABS module power and
assist system failure
control - stability ground supplies for short, open
assist module circuit. Carry out the CAN
network integrity tests using the
diagnostic system

Lost electrical circuit diagrams and
U042286 communication • Signal invalid check CJB power and ground
with CJB supplies for short, open circuit.
diagnostic system

Lost
communication • Missing message from
U015587 check instrument cluster power
with instrument Instrument cluster
and ground supplies for short,
cluster
open circuit. Carry out the CAN
network integrity tests using the
diagnostic system
Re-configure the RJB using the

Internal control diagnostic system, clear DTCs
• CAN master configuration
U030000 module software and re-test. If DTC still logged
ID incorrect
incompatibility suspect Adaptive damping
module, refer to new module
installation note at top of DTC
Index
Invalid data Check for engine management

U040186 received from • Signal invalid DTCs.
ECM/PCM Electronic Engine Controls
Invalid data Check for transmission DTCs.

U040286 • Signal invalid
received from TCM Diagnostic Strategy
Invalid data
Check for ABS DTCs.
U041586 received from ABS • Signal invalid
control module
Invalid data Check for instrument cluster

U042386 received from • Signal invalid DTCs.
Instrument Cluster Instrument Cluster
CAN initialisation • CAN network harness short, Check CAN network.

U1A1400
failure disconnected Communications Network
Check integrity of electrical

connectors and pins to module.
Check damper negative circuits
for short to ground. Install a new
U300001 Control module • General electrical failure adaptive damping module.
Adaptive Damping Module -
Convertible (86.56.35)
Adaptive Damping Module - 2-
Door (86.56.35)
Suspect adaptive damping

module, refer to new module
U300049 Control module • Internal electronic failure
Index
Configure adaptive damping

U300055 Control module • Not configured module using manufacturer
Vehicle Install original module, check for
match. Corrupt VIN data
U300281 identification being transmitted, module
adaptive damping related DTCs
number installed from donor vehicle and refer to DTC Index
U30031C Battery voltage • Circuit voltage out of range

diagnostic system
Adaptive Damping Module - Convertible

(86.56.35)
Removal
WARNING: To avoid accidental deployment, the restraints control module backup power
supply must be depleted. Wait 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 instructions may result in
personal injury.
WARNING: Always wear safety glasses when working on an air bag equipped vehicle and
when handling an air bag module. Failure to follow this instruction may result in personal injury.
WARNING: 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
WARNING: 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.
WARNING: 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.
WARNING: Never probe the electrical connectors of air bag modules or any other
supplemental restraint system component. Failure to follow this instruction may result in personal
injury.
WARNING: 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.

For additional information, refer to Specifications
2
. WARNING: Make sure that sufficient time has elapsed after disconnecting the
battery ground cable(s), before commencing work on the supplemental restraint system
(SRS). Failure to follow these instructions may result in personal injury.
Make the air bag supplemental restraint system (SRS) safe.

For additional information, refer to Rollover Protection Unit
4 . Remove the active damping module.
Remove the 4 nuts.

Installation
1 . Install the active damping module.


Adaptive Damping Module - 2-Door
(86.56.35)
Removal
2 . Remove the active damping module.
Remove the 4 nuts.
Installation
1 . Install the active damping module.

Front Suspension Vertical Accelerometer
Removal
1
2 . Remove the windshield washer reservoir.

For additional information, refer to Windshield Washer Reservoir (84.10.01)
3
. CAUTION: Make sure the accelerometer is not dropped as damage will be caused to
the internal components.
Remove the accelerometer.
Remove the 2 nuts.
Installation
1 . Install the accelerometer.

2 . Install the windshield washer reservoir.

Rear Suspension Vertical Accelerometer
Removal
1 . Remove the LH loadspace trim panel.
2
. CAUTION: Make sure the accelerometer is not dropped as damage will be caused to
the internal components.
Remove the accelerometer.
Remove the 2 nuts.
Installation
2 . Install the LH loadspace trim panel.

205 : Driveline
205-00 : Driveline system – General information
Driveline System
For a detailed description of driveline operation, refer to the relevant Description and Operation
Driveshaft
Rear Drive Axle and Differential - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8
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,
1 . Verify the customer concern by carrying out a road test of the vehicle.
2 . Visually inspect for obvious signs of mechanical damage and system integrity.
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 over a narrow vehicle speed range. Usually heard on light drive and coast
conditions.
Possible Source(s):
• Rear drive axle.

Action(s) to take:
• For additional information, GO to Pinpoint Test G544822p1.

.
Noise is the same on drive or coast
Possible Source(s):
• Road.
Action(s) to take:
• Normal conditions.
Possible Source(s):
• Worn or damaged driveshaft joint.
Action(s) to take:
• INSTALL new components as necessary.
Possible Source(s):
• Driveshaft center bearing.
Action(s) to take:
Possible Source(s):
• Wheel bearing.
Action(s) to take:
• CHECK and INSTALL a new wheel bearing as necessary.

Rear Wheel Bearing - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8
(64.15.14)
Noise is produced with the vehicle standing and

driving
Possible Source(s):
• Engine.
Action(s) to take:
• For additional information,

Engine
Possible Source(s):
• Transmission.
Action(s) to take:

Diagnostic Strategy
Loud clunk in the driveline when shifting from reverse to forward
Possible Source(s):
• Transmission calibration.
Action(s) to take:
• Using the Jaguar approved diagnostic system, re-configure the Transmission Control
Module (TCM) with the latest available calibration.
Possible Source(s):
• Transmission Mount.
Action(s) to take:
• INSPECT and INSTALL new transmission mounts as necessary.
Possible Source(s):
• Transmission.
Action(s) to take:

Diagnostic Strategy
Possible Source(s):
• Suspension components.
Action(s) to take:
• INSPECT and INSTALL new suspension components as necessary.
Possible Source(s):
• Backlash in the driveline.
Action(s) to take:
• INSPECT and INSTALL new driveline components as necessary.
Possible Source(s):
• Engine idle speed set too high.
Action(s) to take:
• Check and adjust the idle speed as necessary.
Possible Source(s):
• Engine mount.
Action(s) to take:
• INSPECT and INSTALL new engine mounts as necessary.
Clicking, popping, or grinding noises
Possible Source(s):
• Inadequate or contaminated lubrication in the rear drive halfshaft constant velocity (CV)
joint.
Action(s) to take:
• INSPECT, CLEAN and LUBRICATE with new grease as necessary.
Possible Source(s):
• Another component contacting the rear drive halfshaft.
Action(s) to take:
• INSPECT and REPAIR as necessary.
Possible Source(s):
• Wheel bearings, brakes or suspension components.
Action(s) to take:
• INSPECT and INSTALL new components as necessary.
Vibration at highway speeds
Possible Source(s):
• Out-of-balance wheel(s) or tire(s).
Action(s) to take:
• BALANCE and INSTALL new wheel(s) and tire(s) as necessary.

Possible Source(s):
• Driveline out of balance/misalignment.
Action(s) to take:
• For additional information, refer to the Jaguar approved diagnostic system.
Possible Source(s):
• Driveshaft center bearing touching body mounting point.
Action(s) to take:
• Check for correct spacer washer thickness. INSPECT and INSTALL new washers as
necessary.
Shudder, Vibration During Acceleration
Possible Source(s):
• Powertrain/driveline misalignment.
Action(s) to take:
• CHECK for misalignment. INSTALL new components as necessary. For driveshaft

alignment, GO to Pinpoint Test G544822p1.
Possible Source(s):
• High constant velocity (CV) joint operating angles caused by incorrect ride height.
Action(s) to take:
• CHECK the ride height and VERIFY the correct spring rate. INSTALL new components as
necessary.
Lubricant Leak
Possible Source(s):
• Rear drive axle breather.
Action(s) to take:
• Check oil level and correct as necessary.
Possible Source(s):
• Damaged seal.
Action(s) to take:
Possible Source(s):
• Rear drive axle filler plug.
Action(s) to take:
Possible Source(s):
• Rear drive axle rear cover joint.
Action(s) to take:

Pinpoint Tests

EXCESSIVE DRIVELINE NOISE
G544822t1 : 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.
Axle Assembly - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8, Vehicles Without: Differential Drain Plug
(51.25.13) RE-TEST the system for normal operation.
-> No
Engine
Diagnostic Strategy

DRIVESHAFT ALIGNMENT
G544822t2 : CHECK DRIVESHAFT COMPOUND ANGLE
1. Remove exhaust system and center heat shield.
Exhaust System 2.
Place inclinometer (special tool number 501-F007) on flat surface and calibrate. 3.
Using the inclinometer check the angle of the driveshaft rearwards of the center bearing and note
the reading (reading one) 4.
Check the angle of the driveshaft forward of the center bearing and note the reading (reading two).
Subtract reading two from reading one to obtain the compound angle of the driveshaft. The correct
specification for the driveshaft compound angle is 1.1° ± 0.3°
• Is driveshaft compound angle correct?
-> Yes
-> No
Adjust driveshaft center bearing height by adding or removing shims (refer to parts catalogue for
selection of shims available) and re-check compound angle. GO to Pinpoint Test G544822t3.
G544822t3 : CHECK CENTER BEARING ALIGNMENT

1.
Check the center bearing is aligned at 90° to front section of driveshaft.
• Is the center bearing aligned correctly?
-> Yes
Driveshaft alignment is correct. Install center heat shield and exhaust system.
Exhaust System
-> No
Undo but do not remove center bearing bolts, align center bearing to front section of driveshaft,
tighten bolts to correct torque.
Specifications Install center heat shield and exhaust system.
Exhaust System
205-01 : Driveshaft
Specifications
Specifications
Item Nm lb-ft lb-in

Center bearing - bolt* 40 29 -
Driveshaft balance - nut* 12 9 -
Driveshaft flange to differential flange - nut/bolt* 88 65 -
Driveshaft flange to transmission flange - nut/bolt* 108 80 -

General procedures
Driveshaft Runout and Balancing

1. For additional information, refer to the Jaguar Approved Diagnostic System.
Driveshaft
COMPONENT LOCATION
1 Driveshaft
INTRODUCTION
1 Transmission
2 Transmission flexible joint
3 Collapsible front driveshaft tube
4 Center bearing
5 Universal joint
6 Rear driveshaft tube
7 Rear drive axle flexible joint
8 Rear drive axle/differential
The driveshaft consists of the following components:
• A two-piece welded steel tube with a splined center slip joint

• One universal joint
• A center bearing
• Two flexible joints.
The two-piece driveshaft is manufactured from lightweight steel and is used to transmit drive from
the engine, via the transmission, to the differential. The driveshaft aligns with the centerline of the
vehicle’s body and is supported by a center bearing.
The driveshafts front tube is of a swaged construction, designed to collapse in a controlled manner in
the event of the vehicle being involved in a front-end collision. Low friction splines at the center of
the driveshaft provide the driveshaft's plunge capability.
A flexible coupling is used to connect the driveshaft assembly to the transmission and the
differential, allowing for angular movement of the drive shafts due to acceleration and braking. The
centre universal joint is lubricated during manufacture and sealed for life. This joint is positioned to a
specified angle using shims between the center bearing and the body.
Driveshaft
Driveshaft - 4.2L NA V8 - AJV8/4.2L SC V8

- AJV8 (47.15.01)
Removal
NOTE:
Select NEUTRAL before disconnecting the battery, to allow the driveshaft to be turned.

2
3 . Remove the exhaust system.

For additional information, refer to Exhaust System
4 . Remove the center heat shield.
Remove the 4 bolts.

5
. CAUTION: Mark the position of the driveshaft flange in relation to the drive pinion
flange.
CAUTION: Under no circumstances must the flexible coupling (or it's fixings) be
loosened or removed from the driveshaft.
Release the driveshaft from the transmission drive flange.
Remove the 3 nuts and bolts.
6
flange.
CAUTION: To avoid damage to the joint or gaiter, do not allow the driveshaft to
hang.
Release the driveshaft from the rear axle drive flange.
7 . NOTE:
Spacers are fitted between the centre bearing and the body.
NOTE:
With assistance, remove the driveshaft.
Remove the 2 driveshaft center bearing mount bolts.
Collect the spacers.

Installation
1 . NOTE:
Replace the spacers to the fitted position.
With assistance, install the driveshaft and secure the center bearing.
Install the spacers.
Align the center bearing mount.
Install the bolts, but do not tighten fully at this stage.
2 . NOTE:
Attach the driveshaft to the rear axle drive flange.

3 . NOTE:
Attach the driveshaft to the transmission flange.
4
. CAUTION: Make sure the center bearing mount is not under tension and central
within the slots.
Carefully tighten the centre bearing bolts to 40 Nm (30 lb.ft) keeping the bearing in a central
position.
5 . Install the center heat shield.

Install the bolts and tighten to 10 Nm (7 lb.ft).
6 . Install the exhaust system.


205-02 : Rear drive axle / Differential
Specifications
Specifications
General Specifications
Item Specification
Differential Ratio 3.31 : 1
Lubricants, Fluids, Sealers and Adhesives
Specifications
Differential fluid type M2C 192A Synthetic
Capacities
Liters
Differential fluid capacity 1.25 liters
Item Nm lb-ft lb-in

Differential flange to driveshaft flange - nuts/bolts* 88 65 -
Differential flange to pinion shaft - nut* A - -
Differential front mounting - bolt* 90 66 -
Differential rear mounting - bolt* 163 120 -
NOTE:
A = refer to the procedure for correct torque sequence.

Rear Drive Axle and Differential - 4.2L NA

V8 - AJV8/4.2L SC V8 - AJV8
COMPONENT LOCATION
1 Differential
INTRODUCTION
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 vehicle’s rear subframe. This mounting arrangement plus the
subframe to vehicle-body mounting arrangement provides the rear driveline with double isolation
from the vehicle’s body.
The unit is constructed of a lightweight cast-iron main casing and an aluminum rear cover. The rear
cover incorporates fins to aid cooling.
The pinion shaft aligns with the centerline of the vehicle’s body and is supported by two taper-roller
bearings. The hypoid-gear set is also supported by taper roller bearings.
The unit has a final drive ratio of 3.31:1 and the lubricant is fill for life.
CAUTION: Running-in For Final Drive Unit During the first 1500 km (940 miles) and if at any
time a new final drive unit is fitted:
• avoid full throttle applications

• do not exceed 190 km/h (120 mph)
• do not participate in motor racing events, test track days, sports driving schools or similar
• avoid towing during running-in period.
OPERATION

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 LH Output shaft 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 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 Sunwheel
27 Shaft
28 Planet gear
29 Thrust washer
The rear axle drive pinion receives power from the engine through the transmission and driveshaft.
The drive pinion gear rotates the differential drive 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 differential pinion gears are
engaged with the differential side gears to which the halfshafts are splined. As the differential gear
turns, it rotates 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.
Axle Assembly - 4.2L NA V8 - AJV8/4.2L

SC V8 - AJV8, Vehicles Without:
Differential Drain Plug (51.25.13)
Power train assembly jack HTJ

1200-2
Removal
2
3 . Remove both the rear halfshafts.

For additional information, refer to Rear Halfshaft (47.10.13)

5
flange.
Release the driveshaft from the rear axle drive flange.
6 . Remove the exhaust rear heat shield .
Remove the 4 nuts.

7 . With assistance: Remove the body K-frame.
Using a jack, support the differential.
Remove the 8 bolts.
8 . Install the 2 sub-frame mounting bolts and remove the support jack.
9 . Using a transmission jack, support the differential.
10 .
CAUTION: Note the fitted position of the special washers.
Remove the rear differential.
Remove the 3 bolts.

Installation
1 . NOTE:
Install the rear differential.
Tighten the 14mm bolts to 163Nm (120 lb.ft).
Tighten the 12mm bolt to 90Nm (66 lb.ft).
2 . With assistance, install the K-frame.
Remove the 2 bolts.
Tighten the M10 bolts to 40 Nm (30 lb.ft).
Tighten the sub frame bolts to 60 Nm (44 lb.ft), then a further 240 degrees.
3 . Remove the transmission jack.
4 . Install the heat shield.

5 . NOTE:
Install the driveshaft.
Tighten the nuts and bolts to 88Nm (65 lb.ft).

7 . Install both the halfshafts.

8 . Check and top-up the differential case.
Tighten the filler plug to 34 Nm (25 lb.ft).

Axle Assembly - 4.2L NA V8 - AJV8/4.2L
SC V8 - AJV8, Vehicles With: Differential
Drain Plug (51.25.13)
No Data Available
Axle Housing Bushing - 4.2L NA V8 -
AJV8/4.2L SC V8 - AJV8 (64.25.30)
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
1
2 Remove the rear differential.

. For additional information, refer to Axle Assembly - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8,
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 rear differential.

. For additional information, refer to Axle Assembly - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8,
Drive Pinion Seal - 4.2L NA V8 - AJV8/4.2L
SC V8 - AJV8 (51.20.01)
Flange holding tool

205-053
Pinion seal installer

204-264
Flange remover/replacer
204265
Flange remover/replacer boss

204-266
Flange remover/replacer shaft centre
204-267
Flange remover/replacer forcing screw

204-269
Removal
1
2 Remove the driveshaft.

. For additional information, refer to Driveshaft - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8
(47.15.01)
3
. CAUTION: The following step must be carried out to make sure the correct drive
pinion flange retaining nut torque is achieved.
CAUTION: Only use a paint mark to match mark the drive pinion flange, loosen the
nut 180 degrees then tighten back to mark and note the torque value.
Remove the drive pinion flange retaining nut.
Mark the drive pinion flange to nut relationship.
Loosen the nut 180 degrees, then tighten back to the mark and note the
torque value.
4 . Using the special tool, remove the drive pinion flange.
5 . Carefully remove and discard the oil seal.
Installation
1 . Using the special tool, install a new oil seal.
2 . Using the special tools, install the drive flange.
3
. CAUTION: Tighten the drive pinion flange nut to the force noted on removal.
CAUTION: Tighten the drive pinion flange nut to a further 10%.
Install the drive pinion flange retaining nut, and tighten to the torque noted on removal, then
a further 10%.
4 . Check and top-up the differential case.
5 Install the driveshaft.

(47.15.01)
205-05 : Rear drive halfshafts
Specifications
Specifications
Specifications
Constant velocity (CV) grease Optimal LN 584 LO
Driveshaft locking compound Loctite WSK-M2G349-A4
Capacities
Liters
Grease for inner CV joint/boot 140g
Grease for outer CV joint/boot 120g
Item Nm lb-ft lb-in

Halfshaft/hub - nut * 300 222 -


COMPONENT LOCATION
1 RH rear drive halfshaft
2 LH rear drive halfshaft

INTRODUCTION
1 Outer Constant Velocity (CV) joint
2 Anti-lock Braking System (ABS) ring
3 Outer CV joint gaiter
4 Rear drive halfshaft
5 Inner CV joint gaiter
6 Inner CV joint
7 Spring clip
The rear drive halfshafts are of unequal length and both inner and outer joints are of the CV type,
with plunging inboard and fixed outboard capability allowing for suspension movement.
The outer CV joints are fitted with an ABS ring, which is continuously monitored by the wheel speed
sensor.
The inner and outer CV joints are linked by a solid bar halfshaft with a spline interferance-fit into the
wheel hub. The inner CV joint is of a spline slide-fit arrangement and is retained in the rear drive axle
with the aid of a spring clip.

For additional information, refer to <<205-00>>.
Rear Halfshaft (47.10.13)

Halfshaft seal protector

205-461
Hub puller
205-491
Adapter nuts
205-491-01
Flange remover forcing screw

204-269
Halfshaft oil seal installer
205-532
Removal
CAUTION: Angularly Adjusted Roller (AAR) joints, used at the inboard end of some
halfshafts have no internal retaining mechanism and can separate.
CAUTION: Do not allow halfshafts to hang unsupported at one end or joint damage will
occur.
1

3 . With assistance, remove the halfshaft retaining nut, and retain it for the install procedure.
Remove the 2 clips.

Remove the bolt.
Tie aside.
8 . Disconnect the toe link.
9 . Release the lower arm.

10 . Using the special tools, release the halfshaft from the drive flange.
11 . NOTE:

12 . Release the halfshaft from the differential.
13 . Remove and discard the halfshaft oil seal.
14 . Remove and discard the circlip.
Installation
1 . Clean the components mating faces.
2 . Using the special tool, install a new halfshaft oil seal.

3 . Install a new circlip.
4
. CAUTION: Use Loctite WSK-M2G349-A4 or equivalent, meeting the Jaguar
specification.
Apply a 3 mm (0.125) diameter bead of sealant to the halfshaft splines.
5
. CAUTION: Application ot the sealant to assembly must take no longer than 5
minutes.
Using the special tool, to protect the seal install the halfshaft.
6 . Remove the special tool.
7 . NOTE:
Install the knuckle assembly.

8 . NOTE:
Install the halfshaft.
Lightly tighten the old nut.
9
Install the lower arm nut and bolt.
10
Connect the toe link.
Secure the clips.

14 . Remove the old halfshaft nut and install the new one, tighten to 300 Nm (222 lb.ft)
Install the wheel trim.
16 .
CAUTION: Only use lubricants meeting the Jaguar specification.
Check and top-up the differential case.

Inner Constant Velocity (CV) Joint Boot
(47.10.33)
Removal
CAUTION: The inboard joint has angularly adjusted roller (AAR) joints. AAR joints have no
internal retaining mechanism and can separate.
1
2 . Remove the halfshaft.

3 . NOTE:
Position and secure component in a bench vice fitted with soft jaws.
Remove and discard the CV joint boot outer retaining clamp.
4 . Remove the outer CV joint.
Carefully release the clip.

5 . NOTE:
Remove the outer CV joint boot.
Remove and discard the CV joint boot inner retaining clamp.
Installation
1 . Clean and inspect the components for deterioration.
2 . NOTE:
Install the CV joint boot.
Secure the clip.

3 . NOTE:
Check that the circlip is fully engaged.
Install the outer CV joint.
4.
Pack the CV joint with the grease supplied.
5
. CAUTION: Ensure enough air is present in the CV boot before the retaining clip is
secured.
Install the CV joint boot to the CV joint.
Secure the clip.
6 . Install the halfshaft.

Outer Constant Velocity (CV) Joint Boot
(47.10.32)
Removal
CAUTION: The inboard joint has angularly adjusted roller (AAR) joints. AAR joints have no
internal retaining mechanism and can separate.
1
2 . Remove the halfshaft.

3 . NOTE:
Position and secure component in a bench vice fitted with soft jaws.
Remove and discard the CV joint boot outer retaining clamp.
4
. CAUTION: Use a soft face hammer or soft drift to release the C V joint from the
retaining circlip.
Remove the outer CV joint.

5 . Remove and discard the circlip.
6 . NOTE:
Remove the outer CV joint boot.
Remove and discard the CV joint boot inner retaining clamp.
Installation
1 . Clean and inspect the components for deterioration.
2 . NOTE:
Install the CV joint boot.
Secure the clip.
3 . Install the circlip.
4 . NOTE:
Check that the circlip is fully engaged.
Install the outer CV joint.
5.
Pack the CV joint with the grease supplied.
6
. CAUTION: Ensure enough air is present in the CV boot before the retaining clip is
secured.
Install the CV joint boot to the CV joint.
Secure the clip.
7 . Install the halfshaft.

206 : Brake system
206-00 : Brake system – General information
Specifications
Specifications
Specifications
Brake fluid Shell ESL (Dot 4)
General procedures

Check
1. Remove the wheel and tire.
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.
Specifications
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.
6. If a rear hub runout check is required, remove the rear brake disc.
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. If the rear hub runout exceeds the specifications, install a new hub, brake disc and
recheck.
Rear Wheel Bearing - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8 (64.15.14)
8. If the front hub face is within specification, install a new brake disc. If the rear hub face is
within specification, install a new disc.
9. Install the wheel and tire.

CAUTION: The brake fluid reservoir must remain full with new, clean brake
fluid at all times during bleeding.
CAUTION: Brake fluid will damage paint finished surfaces. If spilled,

immediately remove the fluid and clean the area with water.
NOTE:
1.
WARNING: Do not work on or under a vehicle supported only by a jack. Always

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.

• Remove the 4 clips.
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.
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 covers.
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.
With 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.
With the brake pedal fully depressed, tighten the bleed screw.
• Vehicles with standard brakes: Tighten the front caliper bleed screw to 8 Nm (6 lb.ft).
• Vehicles with high performance brakes: Tighten the front caliper bleed screw to 15 Nm
(11 lb.ft).
• Tighten the rear bleed screw to 15 Nm (11 lb.ft).
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.
13. Apply the brakes and check for leaks.
14. Install the brake fluid reservoir cap.
15. Install the brake master cylinder cover.

• Carefully secure the clips.
Brake System
For a detailed description of the brake system, refer to the relevant Description and Operation
Front Disc Brake
Rear Disc Brake
Parking Brake
Brake Booster
Anti-Lock Control - Stability Assist - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8

NOTE:
Prior to carrying out any diagnosis, make sure that the brake system warning indicator is
functional.
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.
Specifications

• Brake master cylinder • Parking brake actuator

• Brake caliper piston(s) • Parking brake module
• Brake discs • Parking brake switch
• Wheel 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
Possible Source(s):
• Brake pads.
• Brake discs.
Action(s) to take:
• GO to Pinpoint Test A.
Vibration when brakes are applied
Possible Source(s):
• Wheels require balancing.
• Wheel hub nuts.
• Brake caliper mounting bolts.
• Brake pads.
• Foreign material/scratches/corrosion on brake disc contact surfaces.
• Excessive brake disc thickness variation.
• Excessive brake disc runout.
• Wheel bearing wear or failure.
• Suspension bushing wear or failure.
• Steering bushing wear or failure.
Action(s) to take:
• Go to Pinpoint Test B.
The brakes pull or drift
Possible Source(s):
• Tire pressures/wear.
• Brake calipers.
• Brake pads.
• Brake discs.
• Wheel alignment adjustment.
• Wheel bearing.
• Suspension bushings and ball joints.
Action(s) to take:
• GO to Pinpoint Test C.
The pedal feels spongy
Possible Source(s):
• Air in brake system.
• Leak in hydraulic system.
• Brake booster/master cylinder.
• Brake pads.
Action(s) to take:
• GO to Pinpoint Test D.
The pedal goes down fast
Possible Source(s):
• Leak in hydraulic system.
• Brake pads.
Action(s) to take:
• GO to Pinpoint Test E.
The pedal goes down slowly
Possible Source(s):
Action(s) to take:
• Go to Pinpoint Test F.
Excessive brake pedal effort
Possible Source(s):
• Brake pads.
• Brake booster.
Action(s) to take:
• GO to Pinpoint Test G.
Brake lockup during light brake pedal

force
Possible Source(s):
• Brake pads.
• Brake calipers.
Action(s) to take:
• GO to Pinpoint Test H.
Brakes drag
Possible Source(s):
• Parking brake control applied/malfunction.

• Seized parking brake cables.
• Seized caliper slide pins.
• Seized brake caliper.
• Brake booster.
• Pedal gear.
Action(s) to take:
• GO to Pinpoint Test I.
Excessive/Erratic brake pedal travel
Possible Source(s):
• Hydraulic system.
• Brake pads.
• Brake discs.
• Hub and bearing assembly.
Action(s) to take:
• GO to Pinpoint Test J.
The red brake warning indicator is always on
Possible Source(s):
• Fluid level.
Action(s) to take:
• FILL the system to specification. CHECK for leaks.
Possible Source(s):
• Brake fluid level sensor.
Action(s) to take:
• INSTALL a new brake master cylinder fluid reservoir.
Possible Source(s):
• Parking brake control.
Action(s) to take:

Parking Brake
Possible Source(s):
• Electrical circuit.
Action(s) to take:

Parking Brake
Slow or incomplete brake pedal return
Possible Source(s):
• Brake pedal binding.
Action(s) to take:
• GO to Pinpoint Test K.
Pinpoint Tests
PINPOINT TEST G545069p1 : BRAKES

NOISY
G545069t1 : 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
-> No
CLEAN the front brake pads or INSTALL new front brake pads if necessary.
Brake Pads - Vehicles With: Standard Brakes (70.40.02) CLEAN the rear brake pads or INSTALL new
rear brake pads if necessary.
Brake Pads (70.40.03) Test vehicle for presence of brake squeal.
G545069t2 : 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 brake discs and brake pads.
Brake Pads - Vehicles With: Standard Brakes (70.40.02) . INSTALL new rear brake discs and brake
pads.
Brake Pads (70.40.03) TEST the system for normal operation.
-> No
Vehicle is OK.

VIBRATION WHEN BRAKES ARE
APPLIED
G545069t3 : ROAD TEST VEHICLE
1. Road test the vehicle between 40-80 km/h (25-50 mph) without applying brakes.
• Is the vibration present?
-> Yes
TEST for noise vibration and harshness.
Noise, Vibration and Harshness (NVH) REPEAT road test if necessary.
-> No
G545069t4 : 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 as necessary. CHECK the
balance of all road wheels and tyres and REPAIR as necessary. CHECK the brake discs for excessive
wear, runout, thickness variation or cracks. INSTALL new brake discs and brake pads as necessary. GO
to Pinpoint Test G545069t5.
-> No
Vehicle is OK.
G545069t5 : 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 parts as necessary.
-> No
Vehicle is OK.
PINPOINT TEST G545069p3 : THE

BRAKES PULL OR DRIFT
1. Road test the vehicle and apply the brake pedal.
• Does the vehicle pull or drift?
-> Yes
-> No
Vehicle is OK.
G545069t7 : 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
-> No
ADJUST the tire pressures or INSTALL new tires if excessively worn. TEST the system for normal
operation.
G545069t8 : 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 necessary.
Brake Caliper (70.55.03) TEST the system for normal operation.
-> No
G545069t9 : INSPECT BRAKE DISCS

1. Check the brake discs for excessive damage, thickness variation or runout.
• Does excessive damage or runout exist?
-> Yes
INSTALL new brake discs and brake pads as necessary. TEST the system for normal operation.
-> No
G545069t10 : INSPECT THE FRONT HUB AND WHEEL BEARING ASSEMBLY

1. Check the front hub and wheel bearing assembly.
• Are the wheel bearings OK?
-> Yes
-> No
INSTALL new wheel bearings.
Front Wheel Bearing and Wheel Hub (60.25.03) TEST the system for normal operation.
G545069t11 : CHECK SUSPENSION BUSHINGS AND BALL JOINTS.

1. Check all suspension bushings and ball joints.
• Are the suspension bushings and ball joints OK?
-> Yes
-> No
INSTALL new front suspension bushings and ball joints as necessary. INSTALL new rear suspension
bushings and ball joints as necessary. REFER to the relevant section in the workshop manual.
G545069t12 : CHECK VEHICLE ALIGNMENT

1. Check the vehicle alignment.
• Is the alignment within specification?
-> Yes
Vehicle is OK.
-> No
Adjust the alignment as necessary.

PEDAL FEELS SPONGY
G545069t13 : CHECK FOR SPONGY PEDAL (ENGINE OFF)
1. Check for a firm brake pedal.
• Is the brake pedal effort and brake pedal travel normal?

-> Yes
Vehicle is OK.
-> No
G545069t14 : 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
-> No
BLEED the brake system.
G545069t15 : CHECK BRAKE PEDAL RESERVE (ENGINE ON)

1. Engine is idle. 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
-> No
CHECK the vacuum to brake booster.
G545069t16 : CHECK BRAKE FLUID LEVEL

1. Check the brake master cylinder reservoir fluid level.
• Is the fluid level OK?
-> Yes
Brake System Bleeding (70.25.03) TEST the system for normal operation.
-> No
CHECK for leaking brake system and RECTIFY as necessary. ADD fluid and BLEED the brake system.
Brake System Bleeding (70.25.03) TEST the system for normal operation. REPEAT road test if
necessary.

PEDAL GOES DOWN FAST
1. Road test the vehicle and apply the brake pedal.
-> Yes
Vehicle is OK.
-> No
G545069t19 : 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
-> No
G545069t20 : 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 leaks found?
-> Yes
REPAIR as necessary, ADD fluid and BLEED brake system.
-> No
System is OK.
PEDAL GOES DOWN SLOWLY
G545069t21 : 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
-> No
G545069t22 : 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
REPAIR as necessary. ADD fluid and BLEED the brake system.
-> No
G545069t23 : 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.
• Are any concerns found?
-> Yes
INSTALL a new brake master cylinder, ADD fluid and BLEED the brake system.
-> No
System is OK.
EXCESSIVE BRAKE PEDAL EFFORT
G545069t24 : CHECK BRAKE PADS
1. Check the brake pads for wear, contamination, correct installation, damage and type.
-> Yes
INSTALL the front brake pads correctly or INSTALL new front brake pads if necessary.
Brake Pads - Vehicles With: Standard Brakes (70.40.02) INSTALL the rear brake pads correctly or
INSTALL new rear brake pads if necessary.
Brake Pads (70.40.03) TEST the system for normal operation. REPEAT road test.
-> No
G545069t25 : 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
-> No
LOCATE and REPAIR the source of low vacuum. TEST the system for normal operation.
G545069t26 : 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
G545069t27 : 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 if necessary.
Brake Booster - LHD RWD (70.50.17) TEST the system for normal operation.
-> No
INSTALL a new brake booster valve. TEST the system for normal operation.
PINPOINT TEST G545069p8 : BRAKE

LOCKUP DURING LIGHT BRAKE
PEDAL FORCE
G545069t28 : TEST BRAKE LOCKUP
1. Road test the vehicle and apply the brake pedal lightly.
• Do the brakes lockup?
-> Yes
-> No
Vehicle is OK.
G545069t29 : INSPECT BRAKE PADS

1. Inspect brake pads for contamination, correct installation, damage and type.
-> Yes
INSTALL the front brake pads correctly or INSTALL new front brake pads if necessary.
Brake Pads - Vehicles With: Standard Brakes (70.40.02) INSTALL the rear brake pads correctly or
INSTALL new rear brake pads if necessary.
Brake Pads (70.40.03) TEST the system for correct operation.
-> No
G545069t30 : INSPECT BRAKE CALIPERS

1. Inspect brake calipers for binding, leaking or sticking.
-> Yes
INSTALL the brake calipers correctly or INSTALL new brake calipers as necessary.
Brake Caliper (70.55.03) TEST the system for normal operation.
-> No
Vehicle is OK.
PINPOINT TEST G545069p9 : BRAKES

DRAG
1. Road test the vehicle and apply the brakes.
• Are the brakes functioning correctly?
-> Yes
Vehicle is OK.
-> No
G545069t32 : CHECK BRAKE CALIPERS

1. Check the front caliper pistons and pins for binding, leaking or sticking.
Brake Caliper - Vehicles With: Standard Brakes (70.55.02) Check the rear caliper 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 necessary. Test
the system for normal operation. Road test vehicle if necessary.
-> No
G545069t33 : 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.

EXCESSIVE/ERRATIC BRAKE PEDAL
TRAVEL
G545069t34 : TEST ON ROUGH ROAD
1. Road test the vehicle on rough road conditions. 2. Apply the brakes slowly.
-> Yes
Vehicle is OK.
-> No
G545069t35 : CHECK BRAKE FLUID LEVEL

1. Check the brake master cylinder reservoir fluid level.
• Is the fluid level OK?
-> Yes
-> 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.
Brake System Bleeding (70.25.03) TEST the system for normal operation. REPEAT road test if
necessary.
G545069t36 : CHECK BRAKE PEDAL RESERVE

1. Run engine at idle speed. 2. Apply the brake pedal lightly three or four times. 3. Wait 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
-> No
CHECK the vacuum to the brake booster.
G545069t37 : CHECK THE FRONT WHEEL BEARING ASSEMBLY

1. Check the front wheel bearing assembly.
• Are the front wheel bearings loose?
-> Yes
INSTALL a new front wheel bearing if damaged.
Front Wheel Bearing and Wheel Hub (60.25.03) TEST the system for normal operation.
-> No
CHECK the front brake discs for thickness variances.
PINPOINT TEST G545069p11 : SLOW

OR INCOMPLETE BRAKE PEDAL
RETURN
G545069t38 : 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
Vehicle is OK.
-> No
G545069t39 : 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.
-> No
REPAIR or INSTALL new brake pedal. TEST the system for normal operation.
Component Tests
Brake Booster
1 . Check all hoses and connections. All unused vacuum connectors should be capped. Hoses and
their connections should be correctly secured and in good condition with no holes and no collapsed
areas. Inspect the valve on the brake booster for damage.
2 . Check the hydraulic brake system for leaks or low fluid.
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. With the engine switched off and all
vacuum in the system exhausted, apply the brake pedal and hold it down. Start the engine. If the
vacuum system is operating, the brake pedal will tend to move downward under constant foot
pressure. If no motion is felt, the vacuum booster system is not functioning.
4 . 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 . 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.
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.
206-03 : Front disc brake
Specifications
Specifications
Brake Disc
Item Specification
Disc type Ventilated
Disc diameter 326 mm (12.83 in)
Disc diameter (Supercharged models) 355 mm (13.98 in)
Disc diameter (vehicles fitted with Alcon braking system) 400 mm (15.75 in)
Disc thickness (new) 30 mm (1.18 in)
Disc thickness (Supercharged models new) 32 (1.26 in)
Disc thickness (vehicles fitted with Alcon braking system new) 36 mm (1.42 in)
Minimum disc thickness (service limit) 28 mm (1.10 in)
Minimum disc thickness (Supercharged models service limit) 30mm (1.18 in)
Minimum disc thickness (vehicles fitted with Alcon braking system
34 mm (1.34 in)
service limit)
Disc thickness variation (new) 0.008 mm (0.0003 in)
Maximum disc run-out - installed 0.09 mm (0.0035 in)
0.0135 mm (0.00053
Maximum hub face run-out - installed
in)
Caliper and pads
Item Specification
Floating cast iron caliper with 60 mm
Caliper
single piston
Floating cast iron/aluminium composite
Caliper (Supercharged models)
caliper with 60mm single piston
Opposed aluminium caliper with 6 pistons.
Caliper (vehicles fitted with Alcon braking
Piston diameters 38.1 mm, 34.9 mm and
system)
30.2 mm
Minimum pad thickness (service limit) 2 mm (0.078 in)
Minimum pad thickness (vehicles fitted with
8.5 mm (0.335 in)
Alcon braking system service limit including
brake pad back plate)
Item Nm lb-ft
Brake caliper anchor plate - bolts* 115 85
Brake caliper - guide pins 28 21
Brake caliper - guide pins (Supercharged models) 58 43
Brake hose to caliper - union 35 26
Brake hose to caliper - union (Supercharged models) 38 28
* New nuts/bolts must be installed Torque Specifications - vehicles fitted with Alcon
braking system
NOTE:
Alcon brake system can be identified by the existence of half-moon shaped marking in
the friction surface of the brake disc.
Item Nm lb-ft
Brake caliper anchor plate to wheel knuckle - bolts* 108 80
Brake caliper to caliper anchor plate - bolts 115 85
* New nuts/bolts must be installed

Front Disc Brake

STANDARD BRAKES - COMPONENT LOCATION
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)
INTRODUCTION
The front standard type braking system used on the naturally aspirated vehicles features 326 x 20
mm (12.83 x 0.79 in) diameter ventilated brake discs and cast iron, single piston, sliding calipers.
The caliper is mounted within a fixed carrier that is secured to the front wheel knuckle with 2 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 2 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.
NOTE:
There is no wear indicator installed to the front brake pads.
The brake disc is manufactured from cast iron and is of the vented type. The disc is retained on the
wheel hub by 2 retaining washers and the wheel nuts.
PERFORMANCE BRAKES - COMPONENT LOCATION
2 Bleed screw

4 Anti-rattle spring (with 'R' type badge)
5 Piston
6 Piston dust cover
7 Inboard brake pad
9 Brake disc
11 Rivets (3 off)
12 Brake dust shield
13 Anti-lock Brake System (ABS) sensor cable
15 Caliper carrier
17 Guide pin (2 off)
19 Brake hose
INTRODUCTION
The front performance type braking system used on the supercharged vehicle features 355 x 32 mm
(13.98 x 1.26 in) diameter ventilated brake discs, and composite aluminum and cast iron, single
piston, sliding calipers.
In addition, the brake calipers on the supercharged vehicle are painted and a logo badge is formed on
the anti-rattle spring.
The caliper is mounted within a fixed carrier that is secured to the front wheel knuckle with 2 bolts.
Each inboard brake pad is installed with a pressed steel anti-rattle spring.
NOTE:
There is no wear indicator installed to the front brake pads.
Front Disc Brake

Brake Caliper - Vehicles With: Standard

Brakes (70.55.02)
Removal
CAUTION: Brake fluid will damage paint finished surfaces. If spilled, immediately remove
the fluid and clean the area with water.
1

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 and discard the two sealing washers.
4 . Remove the LH anti-rattle spring.
5 . Remove the LH brake caliper.
Remove the 2 access plugs.
Release the 2 brake caliper guide pins.

6 . Release the inboard brake pad from the caliper.
Release the clip.
7 . Remove the outboard brake pad.
8 . NOTE:
Do not disassemble further if the component is removed for access only.
Remove the brake caliper anchor plate.

Installation
1 . Install the brake caliper anchor plate.
2 . Install the LH brake pads.
Secure the inboard brake pad in the clip.
Position the outboard brake pad.
3 . Install the LH brake caliper.
Tighten the guide pins to 28 Nm ( 21 lb.ft ).
Install the access plugs.
4 . Install the LH anti-rattle spring.

5 . Connect the brake hose to the brake caliper.
Install new sealing washers.
6 . Install the front wheels and tires.


Brake Disc - Vehicles With: Standard
Brakes (70.10.10)
Removal
CAUTION: Brake discs must be renewed in pairs.
1
2 . Remove the front brake pads.

For additional information, refer to Brake Pads - Vehicles With: Standard Brakes (70.40.02)
3 . Remove the brake caliper anchor plate.
4 . Remove the brake disc.
Remove the 2 clips.

Installation
1
. WARNING: Do not use compressed air to clean brake components. Dust from
friction materials can be harmful if inhaled.
Install the brake disc.
Secure the clips.
3 . Install the brake pads.

For additional information, refer to Brake Pads - Vehicles With: Standard Brakes (70.40.02)
Brake Disc - Vehicles With: High
Performance Brakes (70.10.10)
Removal
1
2 Remove the front brake pads.

. For additional information, refer to Brake Pads - Vehicles With: High Performance Brakes
(70.40.02)
Remove the 2 clips.

Installation
1
Secure the clips.
3 Install the brake pads.

. For additional information, refer to Brake Pads - Vehicles With: High Performance Brakes
(70.40.02)
Brake Pads - Vehicles With: Standard
Brakes (70.40.02)
Removal
WARNING: Brake pads must be renewed in axle sets only. Failure to follow this instruction
may result in braking efficiency being impaired.
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.
1
2 . Remove the front wheels and tires.


4.
CAUTION: Do not allow the brake caliper to hang on the brake hose.
Remove the LH brake caliper.
Remove the 2 caliper guide pins.
Release the clip.

7 . Repeat the above procedure for the RH caliper.
Installation
1
Clean the caliper housings and anchor plates, using brake cleaning fluid.
2
. CAUTION: 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.
CAUTION: Brake fluid will damage paint finished surfaces. If spilled, immediately
Press the LH pistons into the caliper housing.

6 . Repeat the above procedure for the RH caliper.

Brake Pads - Vehicles With: High
Performance Brakes (70.40.02)
Removal
2 . Remove the front road wheels and tires.

3 . Apply protective tape to the caliper.
4
. CAUTION: Removal of the clips is a delicate procedure, damage will occur if any
force is used.
Apply heatshrink or protective tape to the end of the screw-driver.

5
force is used.
Remove the anti-rattle spring.
Lever the anti-rattle spring in the center of the spring until either side is
released.
6.
CAUTION: Do not allow the brake caliper to hang on the brake hose.
Remove the brake caliper.
Remove the 2 caliper guide pins.

Release the clip.

Installation
1
Clean the brake caliper housings and anchor plates, using brake cleaning fluid.
2
. CAUTION: 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.
CAUTION: Brake fluid will damage paint finished surfaces. If spilled, immediately
Press the piston into the caliper housing.
Tighten the guide pins to 58 Nm (43 lb.ft).
5 Install the anti-rattle spring.

.
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.
6 . Repeat the above procedure on the opposite side.
7 . Install both wheels and tires.

206-04 : Rear disc brake
Specifications
Specifications
Brake Disc
Item Specification
Disc type Ventilated
Disc diameter 326 mm (12.8 in)
Disc diameter (vehicles fitted with Alcon braking system) 350 mm (13.78 in)
Disc thickness (new) 20 mm (0.78 in)
Disc thickness (vehicles fitted with Alcon braking system new) 28 mm (1.10 in)
Minimum disc thickness (service limit) 18 mm (0.70 in)
Minimum disc thickness (vehicles fitted with Alcon braking system
26 mm (1.02 in)
service limit)
Disc thickness variation (new) 0.008 mm (0.0003 in)
Maximum disc run-out - installed 0.075 mm (0.0029 in)
0.0135 mm (0.00053
Maximum hub face run-out - installed
in)
Caliper and pads
Item Specification
Floating aluminium caliper with 45 mm
Caliper single piston and integral park brake
mechanism
Caliper (vehicles fitted with Alcon braking Opposed aluminium caliper with four 31.8
system) mm diameter pistons.
Minimum pad thickness (service limit) 2 mm (0.078 in)
Minimum pad thickness (vehicles fitted with
Alcon braking system service limit including 7.5 mm (0.30 in)
brake pad back plate)
Item Nm lb-ft
Brake caliper anchor plate - bolts* 103 76
Brake caliper - guide pins 28 21
Brake hose to caliper - union 35 26
* New nuts/bolts must be installed Torque Specifications - vehicles fitted with Alcon
braking system
NOTE:
Alcon brake system can be identified by the existence of half-moon shaped marking in
the friction surface of the brake disc.
Item Nm lb-ft
Hydraulic brake caliper anchor plate to wheel knuckle - bolts* 108 80
Hydraulic brake caliper to caliper anchor plate - bolts 115 85
Parking brake caliper to caliper anchor plate - bolts 63 46
Parking brake caliper anchor plate to rear wheel knuckle - front bolt 70 52
Parking brake caliper anchor plate to rear wheel knuckle - rear bolt 63 46
* New nuts/bolts must be installed

Rear Disc Brake

COMPONENT LOCATION
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)
16 Bleed screw
18 Anti-rattle spring
20 Caliper carrier
21 Screw (2 off) - (supercharged model)
22 'R' type logo badge (supercharged model)
INTRODUCTION
The rear braking system on both the naturally aspirated and supercharged vehicles features 326 x 20
mm (12.83 x 0.79 in) diameter ventilated brake discs with aluminum, single acting piston, sliding
calipers.
The brake calipers on the supercharged vehicle are painted and also include a logo badge. The logo
badge must be removed in order to renew the brake pads.
The caliper is mounted within a fixed carrier that is secured to the rear wheel knuckle with 2 bolts.
Each inboard brake pad is installed with a wire type anti-rattle spring.
NOTE:
There is no wear indicator installed to the rear brake pads.
Also incorporated into each rear brake caliper carrier is the parking brake mechanism. For additional
information, refer to Parking Brake (206-05 Parking Brake and Actuation)
Repairs
CAUTION: Do not use the 'Emergency Release' tool to allow work to be carried out on the
rear brakes. Work can only be carried out on the rear brakes after the 'parking brake unjam'
routine is run.
Before carrying out any work on the rear brakes, the Jaguar approved diagnostic system must be
connected and the 'parking brake unjam' routine run.
When all work is carried out on the rear brakes, the parking brake system will require resetting. For
additional information, refer to Parking Brake (206-05 Parking Brake and Actuation)
Rear Disc Brake


Brake pedal hold down tool

JDS9013
Removal
All vehicles
1

3 . Release the parking brake cable tension.

For additional information, refer to Parking Brake Cable Tension Release
4
. CAUTION: Always plug any open connections to prevent contamination.
NOTE:
Remove and discard the 2 sealing washers.
Vehicles with high performance brakes

5 . Remove the logo badge.
Remove the 2 screws.
All vehicles
7 . Disconnect and release the parking brake cable from the caliper.
Release the clip.
8 . Remove the LH brake caliper.
Release the 2 brake caliper guide pins.
9 . Remove the brake pads.

10 . NOTE:
Remove the brake caliper anchor plate.
Installation
All vehicles

Vehicles with high performance brakes

5 . Install the logo bagde.
Tighten the screws to 5 Nm ( 3 lb.ft ).
All vehicles
7 . Connect the parking brake cable.

Removal
WARNING: Brake pads must be renewed in axle sets only. Failure to follow this instruction
may result in braking efficiency being impaired.
1
2 . Remove the rear brake pads.

For additional information, refer to Brake Pads (70.40.03)
3 . Tie the brake caliper aside.

Remove the 2 clips.
Installation
1
Secure the clips.

For additional information, refer to Brake Pads (70.40.03)
206-05 : Parking brake and Actuation
Specifications
Specifications
Item Nm lb-ft lb-in

Parking brake actuator - bolts 20 15 -
Parking brake module - nuts 4 3 35
Parking brake switch- bolts 6 4 53
General procedures

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
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.
CAUTION: Ensure the vehicle transmission is in park position before the cable tension is
released.
CAUTION: The warranty of the electric parking brake release tool will be invalidated if the
casing has been removed.
NOTE:
The tools shown must only be used in the event of an emergency.

1.
WARNING: 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.
WARNING: 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.
Release the auxiliary junction box access cover.
• Release from the clip.
3. Disconnect the parking brake module.
• Disconnect the 2 electrical connectors in the sequence illustrated.

4. Connect the special tool.
5. Release the parking brake cable tension.
• An audible 'click', signals complete parking brake cable tension release.
6. Remove the special tool.
• Reverse the removal sequence, connect and secure the electrical connectors.
7. Secure the auxiliary junction box access cover.
• Align the pegs and secure the clip.
8.
WARNING: 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.

Parking Brake
For a detailed description of the Parking Brake operation, refer to the relevant Description and
Parking Brake
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 . Place gear selector lever in 'P' Park position.
2 . Release parking brake cable tension to service position.

3 . Set the ignition status to 'ON'.
4 . Apply and hold the footbrake then pull up the parking brake switch.
5 . To release the parking brake, apply and hold the footbrake then release and press down the
parking brake switch.

• 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 caps • Parking brake module
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:
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
diagnostic system).
NOTE:
three decimal places, and with an up-to-date calibration certificate. When testing resistance
NOTE:
NOTE:
NOTE:
terminals.

Parking Brake • Battery voltage is high associated with this DTC
B131700
Module voltage high (above 18 volts) using the manufacturer

• Battery voltage is low (below
Parking Brake associated with this DTC
B131800 8 volts) (not logged on
module voltage low battery disconnect) using the manufacturer
Install new Parking Brake

Parking Brake module, refer to the new
B134200 • Internal module fault
module is defective module installation note at
the top of the DTC Index
• Connector fault - bent, loose Carry out any pinpoint tests

Primary parking or corroded pin(s)
associated with this DTC
C109400 brake apply switch • Harness fault - high
resistance, open circuit using the manufacturer
circuit failure
• Switch fault approved diagnostic system
Primary parking • Connector fault - bent, loose Carry out any pinpoint tests
or corroded pin(s)
brake release switch associated with this DTC
C140800 • Harness fault - low resistance
circuit voltage out of to ground using the manufacturer
range • Switch fault approved diagnostic system
Primary parking • Connector fault - bent, loose Carry out any pinpoint tests
or corroded pin(s)
brake apply switch associated with this DTC
C140900 • Harness fault - low resistance
Primary parking • Connector fault - bent, loose Refer to the electrical circuit
or corroded pin(s)
brake apply switch diagrams and test primary
C176900 • Harness fault - short to
circuit short to ground parking brake apply switch
ground • Switch fault circuit for short to ground

Primary parking or corroded pin(s)
C178200 brake release switch • Harness fault - high
circuit failure
Primary parking • Connector fault - bent, loose Refer to the electrical circuit
or corroded pin(s)
brake release switch diagrams and test primary
C178300 • Harness fault - short to
circuit short to ground parking brake release switch
ground • Switch fault circuit for short to ground
• Connector fault - bent, loose Refer to the electrical circuit

Parking brake motor or corroded pin(s)
diagrams and test parking
C178400 output circuit short • Harness fault - short to
ground brake motor output circuit
to ground
• Actuator fault for short to ground
• Connector fault - bent, loose Refer to the electrical circuit

Parking brake motor
or corroded pin(s) diagrams and test parking
C178500 output circuit open
• Harness fault - open circuit brake motor output circuit
circuit • Actuator fault for high resistance
• Connector fault - bent, loose Refer to electrical circuit

Parking brake motor or corroded pin(s)
diagrams and test parking
C178600 output circuit short • Harness fault - short to
power brake motor output circuit
to power
• Actuator fault for short to power
• Connector fault - bent, loose

or corroded pin(s)
• Hall effect sensor power
circuit fault Carry out any pinpoint tests
Hall effect circuit • Hall effect sensor ground associated with this DTC
C179900
failure circuit fault using the manufacturer
• Hall effect sensor signal approved diagnostic system
circuit fault
• Mechanical fault with
sensor/actuator
C180100 Motor engage • Service brake not correctly Refer to parking brake
current reached adjusted following lining calibration procedure. Check
before full apply replacement for mechanical failure of
travel distance • Parking brake not calibrated parking brake system
after lining replacement
• Cables fouled, trapped or
damaged
• Cables incorrectly routed or
fixed
• Caliper malfunction
• Actuator malfunction
• Service brake not correctly

adjusted following lining
replacement
Motor engage • Parking brake not calibrated Refer to parking brake
current not reached after lining replacement calibration procedure. Check
C180200
or travelled too far • Cables broken for mechanical failure of
upon apply • Cables incorrectly routed or parking brake system
fixed
• Intermittent motor and Check for additional motor

Motor disengage full circuit - open circuit circuit DTCs and refer to DTC
C180300 travel distance not • Actuator malfunction Index. Check for mechanical
reached upon release (excessive noise may be failure of parking brake
heard during release) system
• Connector fault - bent, loose

Parking brake apply or corroded pin(s) Carry out any pinpoint tests
and release switches • Harness fault - apply and associated with this DTC
C198900
are active at the release circuits - short to using the manufacturer
same time each other approved diagnostic system
• Switch fault

Apply switch active • Connector fault - bent, loose
C1D0062 then release switch or corroded pin(s)
• Switch fault using the manufacturer
active

or corroded pin(s)
Erroneous apply associated with this DTC
C1D0064 • Harness fault - primary or
switch active secondary apply circuit using the manufacturer
Parking brake • High amount of Cycle ignition to re-enable

C1D0066 apply/release switch
apply/release applications in switch functionality
signal has too many short space of time (switch
transitions/events locked out due to abuse)
Secondary parking • Connector fault - bent, loose Carry out any pinpoint tests
or corroded pin(s)
C1D0711 • Harness fault - short to
circuit short to ground using the manufacturer
ground • Switch fault approved diagnostic system

Secondary parking or corroded pin(s)
C1D0715 brake apply switch • Harness fault - high
circuit failure
or corroded pin(s)
C1D071C • Harness fault - low resistance
or corroded pin(s)
C1D0811 • Harness fault - short to
circuit short to ground using the manufacturer
ground • Switch fault approved diagnostic system

Secondary parking or corroded pin(s)
C1D0815 brake release switch • Harness fault - high
circuit failure
or corroded pin(s)
C1D081C • Harness fault - low resistance
Field effect transistor Install a new parking brake

circuit over module, refer to the new
C1D1000 • Internal module fault
current/over module installation note at
temperature the top of the DTC Index

Release switch active • Connector fault - bent, loose
C1D1162 then apply switch or corroded pin(s)
• Switch fault using the manufacturer
active
or corroded pin(s)
Erroneous release associated with this DTC
C1D1164 • Harness fault - primary or
switch active secondary apply circuit using the manufacturer
• ECM off Bus (ECM off Bus Carry out any pinpoint tests
DTC may also be logged)
C1D1564 Brake switch status • Harness fault - brake switch
circuit open circuit to parking using the manufacturer
brake module approved diagnostic system
• Fuse Carry out any pinpoint tests

• Harness fault - high
High power battery associated with this DTC
C1D1614 resistance, open circuit
feed circuit failure • Connector fault - bent, loose using the manufacturer
or corroded pin(s) approved diagnostic system
Vehicle deceleration, Cycle the ignition. Check ABS

Implausible vehicle speed message
C1D2092 performance or for DTCs and refer to DTC
sent from ABS
incorrect operation Index

High speed CAN All CAN messages are detected associated with this DTC
U000187
communication bus missing at Ignition ON using the manufacturer

High speed CAN
U000188 communication Bus - • CAN Bus circuit fault
bus off

Lost communication associated with this DTC
U010000 • ECM off Bus
with ECM using the manufacturer

Lost communication associated with this DTC
U010100 • TCM off Bus
with the TCM using the manufacturer
Lost communication Carry out any pinpoint tests

U010400 with speed control • Speed control module off Bus
front distance range using the manufacturer
sensor approved diagnostic system

Lost communication
U012100 with anti-lock brake • ABS module off Bus
system

Lost communication
U015500 with instrument • Instrument cluster off Bus
cluster
Re-configure the RJB using

diagnostic system. Clear the
Internal control DTC and retest. If the DTC is
U030000 module software still logged suspect the
message is received
incompatibility Parking Brake module, refer
to the new module
installation note at the top of
the DTC Index
No fault with parking brake

system if this DTC is logged.
Invalid data received • Invalid message from the
U040100 Check ECM for DTCs and refer
from ECM ECM
to the DTC Index.

Invalid data received • Invalid message from the
U040200 Check TCM for DTCs and refer
from TCM TCM
to the DTC Index.
Diagnostic Strategy

Invalid data received
Check anti-lock control -
from anti-lock • Invalid message from the
U041500 stability assist module for
control - stability anti-lock brake system
DTCs and refer to the DTC
assist module
Index.

U042200 Invalid data received • Invalid message from the CJB
from Central Junction
Check CJB for DTCs and refer
Box (CJB) to the DTC Index.

• Invalid message from the Check the instrument cluster
U042300 from instrument
instrument cluster for DTCs and refer to DTC
cluster
Index.
Instrument Cluster

Invalid data received system if this DTC is logged.
• Incorrect apply request from
from speed control Check the speed control
U043364 the speed control when the
front distance range conditions were not correct module for DTCs and refer to
sensor DTC Index.
Speed Control

• Invalid or missing message Check the anti-lock control -
Reduced system
U200168 from ABS with ignition OFF stability assist module for
function and vehicle speed > 3Kph DTCs and refer to the DTC
Index.
Install original module, check

• Vehicle/component VIN mis- for parking brake related
match between RJB and DTCs and refer to DTC Index.
Vehicle Identification
U300281 parking brake module, If DTC remains suspect
Number (VIN) module installed from donor parking brake module, refer
vehicle to new module installation
note at top of DTC Index
• Mis-match of battery Carry out any pinpoint tests

voltage, of 2 volts or lower, associated with this DTC
U300362 Battery voltage
between parking brake using the manufacturer
module and RJB approved diagnostic system
Symptom Chart
Symptom Possible Cause Action
The parking brake will • Cables fouled, trapped or • Check the rear and
not engage or release damaged primary cables for
(with no parking brake • Cables incorrectly routed or correct installation and
warning message) installed damage.
• Rear lining wear Parking Brake Switch -
• Service brake incorrectly adjusted 4.2L NA V8 - AJV8/4.2L
following lining change SC V8 - AJV8 (70.35.46)
• Caliper malfunction Parking Brake Cable LH
- 4.2L NA V8 - AJV8/4.2L
SC V8 - AJV8
Parking Brake Cable RH
- 4.2L NA V8 - AJV8/4.2L
SC V8 - AJV8
• Inspect the rear brake
linings for wear
• Re-calibrate the parking
brake, refer to the
calibration procedure
• Check the rear service
brake for correct
installation and
operation
• Check the rear and

primary cables for
correct installation and
damage.
Parking Brake Release
Actuator - 4.2L NA V8 -
(70.35.45)
Parking Brake Switch -
4.2L NA V8 - AJV8/4.2L
• Cables fouled, trapped or
SC V8 - AJV8 (70.35.46)
The parking brake will damaged
Parking Brake Cable LH
• Cables incorrectly routed or
not engage or release - 4.2L NA V8 - AJV8/4.2L
installed
(with parking brake SC V8 - AJV8
• Rear lining wear
warning message) Parking Brake Cable RH
- 4.2L NA V8 - AJV8/4.2L
SC V8 - AJV8
• Inspect the rear brake
linings for wear
• Re-calibrate the parking
brake, refer to the
calibration procedure
• Check the rear service
brake for correct
installation and
operation
No communication with • Fuse • Check fuses

the parking brake • Module off Bus • Ensure battery is fully
module • CAN network error charged and in
• Parking brake module fault serviceable condition.
Check battery voltage
at parking brake
module
• Check CAN network
using manufacturer
approved diagnostic
system
'Parkbrake Fault'
• Check the parking
displayed on message
• Parking brake system fault brake module for DTCs
center with associated and refer to DTC Index
warning lamps
• Parking brake not re-calibrated

after battery has been • Re-calibrate parking
disconnected or has been in a brake, refer to the
Brakes drag state of discharge, or repairs have calibration procedure
been carried out to the rear • Check the service brake
service or parking brake system for correct operation
• Service brake system fault
Parking Brake Cable LH - 4.2L NA V8 -

Removal
become inoperative.
1


4 . Disconnect the LH parking brake cable.
Release the clip.

5 . NOTE:
Disconnect and release the parking brake cable from the caliper.
Remove the LH parking brake cable.
Installation
1 . NOTE:
Install the parking brake cable.


Parking Brake Cable RH - 4.2L NA V8 -
Removal
become inoperative.
1
2 . Remove the RH rear wheel and tire.


4 . Disconnect the RH parking brake cable.

5 . NOTE:
Disconnect and release the parking brake cable from the caliper.
Remove the LH parking brake cable.
Installation
1 . NOTE:
Install the parking brake cable.

Parking Brake Module - Convertible
(70.35.47)
Removal


4 . Remove the rear seat RH backrest retaining bracket.

Remove the 3 nuts.
7 . Remove the parking brake module.
Remove the 3 nuts.

Installation
1 . Install the parking brake module.
3 . Install the rear seat RH backrest retaining bracket.

7 . Connect WDS to the vehicle and configure a new module.

Parking Brake Module - 2-Door (70.35.47)
Removal

Remove the 3 nuts.
4 . Remove the parking brake module.
Remove the 3 nuts.

Installation
1 . Install the parking brake module.


Parking Brake Release Actuator - 4.2L NA
V8 - AJV8/4.2L SC V8 - AJV8 (70.35.45)
Removal
become inoperative.
1


Remove the 4 nuts.

Remove the 8 bolts.
6 . Install the 2 subframe mounting bolts and remove the jack.
7 . Disconnect the electrical connector.
8 . Release the LH and RH cables.

Release the clip.
9 . Release the cable securing clip.
10 . Release the parking brake actuator.
Remove the 2 bolts.
11 . NOTE:

Remove the parking brake actuator and cable assembly.
Remove the 2 bolts.
Installation
1 . NOTE:
Install the parking brake actuator and cable assembly.
Secure the clips.
3 . Connect and secure the electrical connector.
Remove the 2 bolts.


9 . Calibrate the parking brake actuator.

Parking Brake Switch - 4.2L NA V8 -
AJV8/4.2L SC V8 - AJV8 (70.35.46)
Removal
1 . Remove the floor console veneer trim panel.
For additional information, refer to Floor Console Finish Panel (76.47.26)
2 . Remove the parking brake switch.
Installation
1 . Install the parking brake switch.
Install the Torx bolts and tighten to 6 Nm (4 lb.ft).
2 . Install the floor console veneer trim panel.

206-06 : Hydraulic brake actuation
Specifications
Specifications
General
Item Specification
Brake master cylinder diameter 26.9 mm
Specifications
Item Nm lb-ft lb-in

Bleed nipple - front brake caliper 8 6 70
Bleed nipple - front brake caliper (Supercharged models) 14 10 -
Bleed nipple - rear brake caliper 14 10 -
Brake master cylinder to brake booster - nuts 25 18 -
Brake tube to components - union nut 17 13 -
Master cylinder reservoir to master cylinder 6 4 53
Master cylinder reservoir to master cylinder (Supercharged models) 4 3 35
Pedal bracket 25 18 -

COMPONENT LOCATION
1 Brake master cylinder and fluid reservoir
2 Brake pedal
3 Stoplamp switch
4 Brake pipes
5 Anti-lock Brake System (ABS) module
6 Brake booster
INTRODUCTION
The hydraulic brake system is a diagonally split dual line system, and consists of the brake pedal,
brake master cylinder and hydraulic pipes and hoses. The system also features a non-active brake
booster. For additional information, refer to Brake Booster (206-07 Power Brake Actuation)
Brake pipes distribute pressure from the master cylinder to the 4 corners of the vehicle via the ABS
module. Braided steel hoses are used to connect the brake pipes to the front and rear calipers.
BRAKE PEDAL
The brake pedal is mounted in 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 push rod of
the brake booster.
The stoplamp switch is mounted in the brake pedal bracket and is operated by the brake pedal. The
stoplamp switch is also used by the speed control system and the ABS. For additional information,
refer to Speed Control (310-03 Speed Control)
For additional information, refer to Anti-Lock Control - Stability Assist (206-09 Anti-Lock Control -
Stability Assist)
BRAKE MASTER CYLINDER AND FLUID RESERVOIR
NOTE:
Left-Hand Drive (LHD) shown, Right-Hand Drive (RHD) similar
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 Secondary circuit outlet port
8 Primary circuit outlet port
9 Secondary circuit inlet port
10 Reservoir to master cylinder seal (2 off)
The brake master cylinder is attached to the front of the brake booster, on the drivers side of the
engine compartment. The brake master cylinder consists of a cylinder housing containing 2 pistons in
tandem. The rear piston produces pressure for the primary braking circuit and the front piston
produces pressure for the secondary circuit. A reservoir is mounted on top of the master cylinder to
provide a supply of brake fluid for the primary and secondary circuits. The reservoir also provides a
location for the brake fluid level switch.
BRAKE FLUID LEVEL SWITCH

The brake fluid level switch is located in the fluid reservoir and is hardwired to the ABS module.
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 ABS module. The ABS module then broadcasts a message on
the high speed Controller Area Network (CAN) bus to the instrument cluster. On receipt of the
message, the brake fluid red warning indicator will illuminate and 'BRAKE FLUID LOW' will be
displayed in the message center.
ANTI-LOCK BRAKING SYSTEM MODULE

1 Secondary circuit inlet port
2 Left Hand (LH) front brake
3 Right Hand (RH) front brake
4 Primary circuit inlet port
5 LH rear brake
6 RH rear brake
The ABS module is located in the LH front wheel arch and incorporates the Hydraulic Control Unit
(HCU). The HCU is a 4 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 Hydraulic Control Unit (HCU) are a single unit and must
not be separated.
CONTROL DIAGRAM
Hydraulic Control Unit
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 Right front brake
28 Left rear brake
29 Right rear brake
30 Left front brake
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 pressurises 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.
Pressurised fluid enters the HCU, which is mounted on the front of the ABS module. The HCU
modulates the supply of pressurised fluid to the brakes under control of the ABS module. For
additional information, refer to Anti-Lock Control - Stability Assist (206-09 Anti-Lock Control -
Stability Assist)

Brake Master Cylinder - LHD RWD

(70.30.08)
Removal
1 . Remove the brake fluid reservoir.

For additional information, refer to Brake Fluid Reservoir (70.30.16)
2 . Release and disconnect the electrical connector.
Fully loosen the bolt.
3 . NOTE:
Disconnect the brake master cylinder lines.
4
. CAUTION: Before disconnecting or removing the components, ensure the area
around the joint faces and connections are clean. Plug open connections to prevent
contamination.
Remove the brake master cylinder.
Remove the 2 nuts.
5 . Remove and discard the O-ring seal.
Installation
1 . Install a new O-ring seal.
2 . Install the brake master cylinder.
3 . Connect the brake master cylinder lines.

Tighten the brake line unions to 17 Nm (13 lb.ft).
Tighten the bolt.
5 . Install the brake fluid reservoir.

Brake Master Cylinder - RHD RWD
(70.30.08)
Removal


3 . Release the plenum box sidewall.
Remove the 4 bolts.
4 . Remove the coolant expansion tank mounting bracket.
Remove the 3 nuts.

5 . NOTE:
Disconnect the brake master cylinder lines.
6
contamination.
Remove the brake master cylinder.
Remove the 2 nuts.
7 . Remove and discard the O-ring seal.

Installation
1 . Install a new O-ring seal.
3 . Connect the brake master cylinder lines.
4 . Install the plenum chamber panel.
5 . Install the coolant expansion tank mounting bracket.


Removal
1 . NOTE:
Remove the air intake cover.
Remove the 4 clips.
2 . Siphon the fluid from the brake master cylinder.
Position an absorbent cloth to collect fluid spillage.
3 . Disconnect the low brake fluid warning indicator switch electrical connector.
4.
CAUTION: Always plug any open connections to prevent contamination.
NOTE:
Remove the brake fluid reservoir.
Remove and discard 2 brake fluid reservoir seals.
Installation
1 . Clean the components.
2 . Install the brake fluid reservoir.
Install new brake fluid reservoir seals.
Tighten the Torx bolt to 6 Nm (4 lb.ft).
3 . Connect the low brake fluid warning indicator switch electrical connector.
5 . Install the air intake cover.

Brake Pedal and Bracket (70.35.03)
Removal
2 . Remove the instrument panel.

For additional information, refer to Instrument Panel (76.46.01)
3 . Remove the windshield wiper arms.

For additional information, refer to Wiper Pivot Arm (84.15.03)
4 . Remove the throttle pedal assembly.
Remove the 3 Torx screws.
5 . Release the brake switch.
Rotate clockwise approximately 30 degrees.

6 . Release the brake booster.
Remove the brake pedal clevis pin.
Remove the 4 nuts.
7 . Remove the nuts from the brake pedal bracket.
Remove the 5 nuts.

8 . NOTE:
Working from the engine bay.
Remove the air intake cover.
Remove the 4 clips.
9 . Remove the brake master cylinder cover.
Remove the 3 clips.

10 . Remove the plenum chamber panel.
Release the retaining clip.
Disconnect the washer jet hose.
11 . Remove the brake pedal bracket.
Remove sealant for access to the bulkhead screw heads.
Release the electrical harness clip.

Installation
1 . Install the brake pedal bracket.
Align to the studs and lightly tighten the nuts.
Install and tighten the bulkhead screws.
Apply sealant to the bulkhead screw heads.
Secure the electrical harness with the clip.
2 . Tighten the brake pedal bracket nuts to 25 Nm (18 lb.ft).
Connect the washer jet hose.
4 . Install the brake master cylinder cover.

6 . Secure the brake booster.
Install the brake pedal clevis pin.
7 . Install the brake switch.
8 . Install the throttle pedal assembly.
Install the Torx screws.
9 . Install the windshield wiper arms.

10 . Install the instrument panel.


206-07 : Power brake actuation
Specifications
Specifications
General
Item Specification
Brake booster - boost ratio 5.8:1
Brake booster - boost ratio (Supercharged models) 6.2:1
Item Nm lb-ft lb-in

Brake booster to bulk head/pedal bracket - nuts 25 18 -
Brake Booster
COMPONENT LOCATION
1 Check valve
2 Brake booster
3 Vacuum pipe
INTRODUCTION
Power assistance for the braking system is provided by a vacuum operated non-active brake booster.
The unit gives a boost ratio of 6.2:1 and is secured to the drivers side of the engine compartment
bulkhead by 4 studs/nuts.
The input push rod within the brake booster is connected to the brake pedal. The output rod locates
in the primary piston of the brake master cylinder. For additional information, refer to Hydraulic
Brake Actuation (206-06 Hydraulic Brake Actuation)
VACUUM PIPE
A 2 piece plastic vacuum pipe connects the brake booster to the inlet manifold to provide the
necessary vacuum inside the booster. The connection into the brake booster also contains a check
valve to maintain the vacuum and prevent fuel vapour from entering the brake booster.
Power Brake System

Brake Booster - LHD RWD (70.50.17)

Removal
1 . Remove the brake master cylinder.
For additional information, refer to Brake Master Cylinder - LHD RWD (70.30.08)
2
force is used.
Remove the driver's side footwell trim panel.
Carefully release the 3 clips.

4 . Release the vacuum pipe.
5 . Remove the brake booster.
Remove the 4 nuts.
6 . Remove and discard the gasket.

Installation
1 . Install new gaskets.
2 . Install the brake booster.
3 . Connect the vacuum hose.
5 . Install the driver's side footwell trim panel.
Carefully align and secure the clips.

For additional information, refer to Brake Master Cylinder - LHD RWD (70.30.08)
Removal
1 . Remove the brake master cylinder.
For additional information, refer to Brake Master Cylinder - RHD RWD (70.30.08)
2
force is used.

www.JagDocs.com
4 . Release the vacuum pipe.
5 . Remove the brake booster.
Remove the 4 nuts.
6 . Remove and discard the gasket.
Installation
1 . Install new gaskets.
2 . Install the brake booster.

3 . Connect the vacuum hose.

For additional information, refer to Brake Master Cylinder - RHD RWD (70.30.08)
206-09 : Anti-lock control – stabilty assist
Specifications
Specifications
Item Nm lb-ft lb-in

Brake tubes to hydraulic control unit - union nut 17 13 -
Hydraulic control unit bracket to vehicle - bolt 9 7 79
Hydraulic control unit to bracket - bolt 9 7 79
Rear wheel speed sensor - bolt 9 7 79
Steering angle sensor - screw 4 3 35
Yaw rate sensor and accelerometer - nut 9 7 -
Anti-Lock Control - Stability Assist - 4.2L

NA V8 - AJV8/4.2L SC V8 - AJV8
COMPONENT LOCATION
1 Left Hand (LH) front wheel speed sensor
2 Right Hand (RH) front wheel speed sensor
4 Steering angle sensor
5 RH rear wheel speed sensor
6 LH rear wheel speed sensor
7 Yaw rate and lateral acceleration sensor
8 Anti-Lock Brake System (ABS) module
INTRODUCTION
The Dynamic Stability Control system utilizes information on wheel speed, steering angle and vehicle
body attitude to enhance the stability of the vehicle. This is achieved by controlling engine torque
and application of the brakes at individual wheels. Dynamic Stability Control incorporates the
following systems:
• ABS
• Traction Control
• Panic Brake Assist
• Active Yaw Control
• Braking in Curve Stability
The Dynamic Stability Control system software also controls the braking functions of the Adaptive
Speed Control system. For additional information, refer to Speed Control (310-03 Speed Control)
The Dynamic Stability Control software is contained within the ABS module and can apply or release
braking force to each individual wheel, and increase or reduce engine torque to correct oversteer,
understeer, wheel spin and wheel lock.
WARNING: Although the vehicle is fitted with Dynamic Stability Control, it remains the
drivers responsibility to drive safely according to the prevailing conditions.
DYNAMIC STABILITY CONTROL SWITCH
The non-latching dynamic stability control switch is mounted in the floor console adjacent the L gate
and forms part of the gear selector module assembly.
Dynamic Stability Control becomes active whenever the engine is running. A momentary press of the
switch allows the driver to toggle between the standard Dynamic Stability Control settings and the
optimized 'Trac DSC' settings. For more information on 'Trac DSC' refer to 'Principles of Operation'.
On early (06.5 model year) naturally aspirated vehicles, Dynamic Stability Control can be switched off
by pressing and holding the switch for more than 3 seconds. On later (07.25 model year) naturally
aspirated and supercharged vehicles the switch needs to be pressed and held for more than 10
seconds to switch Dynamic Stability Control off.
In each case the message 'DSC OFF' will be displayed in the instrument cluster message center to
confirm Dynamic Stability Control has been switched off. The amber Dynamic Stability Control
warning indicator in the instrument cluster will remain illuminated however. The system can be
switched back on again by simply pressing and releasing the switch. The message 'DSC ON' will then
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 Dynamic Stability Control
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 Dynamic Stability Control 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 on.
WHEEL SPEED SENSORS
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 wheel speed sensor is positioned
close to a 46 tooth sensor ring. The rear sensor rings are located on the outer diameter of the
halfshaft constant velocity joints. The front sensor rings are located within the wheel hub and
bearing assemblies. A fly lead connects each sensor to the vehicle wiring.
The wheel speed sensors each have a signal and a return connection with the ABS module. When 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
Controller Area Network (CAN) bus for use by other systems.
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 lamp will illuminate. For
additional information, refer to Information and Message Center (413-08 Information and Message
Center)
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 2 offset Light Emitting Diode's (LED's)
facing 2 detectors.
An encoder ring is mounted on the inner steering column shaft and intersects the LED's and
detectors. The encoder ring contains 60 slots which break and restore the light beams between the
LED's 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
LED's 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.
For additional information, refer to Information and Message Center (413-08 Information and
Message Center)
'DSC NOT AVAILABLE' will also be displayed if the ABS module detects a steering angle sensor fault.
The amber warning indicator will also illuminate until the fault is rectified.
YAW RATE AND LATERAL ACCELERATION SENSOR
The yaw rate and lateral acceleration sensor is mounted on the transmission tunnel, forward of the
gear selector module. The sensor is secured by 2 screws and connects to the vehicle wiring via a 4 pin
multiplug.
When the ignition is ON, the sensor receives a power feed from the ABS module. The ABS module
also provides a ground path for the sensor. 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. For additional
information, refer to Information and Message Center (413-08 Information and Message Center)
STOPLAMP SWITCH
The stoplamp switch is mounted on the brake pedal bracket and is connected to the vehicle harness
via a 4 pin multiplug.
When the brake pedal is pressed, the switch contacts close. This allows a hard wired signal feed to be
sent to the Engine Control Module (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 Hydraulic Control Unit (HCU).
NOTE:
The stoplamp switch also forms part of the speed control system. For additional information,
refer to Speed Control (310-03 Speed Control)
ABS MODULE
The ABS module is secured to a mounting bracket located in the LH front wheel arch. The module is
mounted on the rear face of the Hydraulic Control Unit (HCU), which it uses to control all braking and
stability functions by modulating hydraulic pressure to the individual wheel brakes.
Two different ABS modules are available; one for vehicles with standard Speed Control, one for
vehicles fitted with Adaptive Speed Control. Both incorporate analogue valves which offer refined
pressure control and reduced noise levels over previously used systems.
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. For additional information, refer to
Information and Message Center (413-08 Information and Message Center)
CAUTION: The ABS module and the Hydraulic Control Unit (HCU) are a single unit and must
not be separated.
HYDRAULIC CONTROL UNIT (HCU)

The HCU is a 4 channel unit, secured to a mounting bracket located in the LH front wheel arch. The
HCU modulates the supply of hydraulic pressure to the brakes under the control of the ABS module.
For additional information, refer to Hydraulic Brake Actuation (206-06 Hydraulic Brake Actuation)
CONTROL DIAGRAM
NOTE:
A = Hardwired; D = High Speed CAN bus; N = Medium Speed CAN bus; V = Private CAN bus
1 Battery
2 Megafuse (175A)
3 CJB
4 Power distribution box
5 RH front wheel speed sensor
6 LH front wheel speed sensor
7 RH rear wheel speed sensor
8 LH rear wheel speed sensor
9 High mounted stop lamp
11 LH stop lamp
12 RH stop lamp
13 Diagnostic socket
14 Transmission Control Module (TCM)
16 Gear selector module
17 ECM
19 Park brake control module
20 Adaptive speed control module
21 ABS module
22 Yaw rate and lateral acceleration sensor
24 Brake fluid level switch

Trac DSC
'Trac DSC' optimizes the Dynamic Stability Control settings to maximize traction in difficult conditions
such as deep snow, gravel, sand or when snow chains are fitted. This makes greater traction possible,
without losing the benefits of Dynamic Stability Control, however the stability of the vehicle may be
less than normal.
WARNING: 'Trac DSC' must only be used when necessary for the prevailing conditions. The
vehicle should then only be driven appropriately for those conditions. When conditions improve
sufficiently, full stability of the vehicle must be regained by switching 'Trac DSC' off and returning
the vehicle to the Dynamic Stability Control mode.
Pressing and releasing the Dynamic Stability Control switch will switch the vehicle between normal
Dynamic Stability Control settings and 'Trac DSC' settings. To confirm which setting has been
selected, either 'DSC ON' or 'Trac DSC' will be temporarily displayed in the instrument cluster
message center.
When 'Trac DSC' is selected, the amber Dynamic Stability Control warning indicator located in the
instrument cluster will illuminate. The warning indicator will remain illuminated until 'Trac DSC'
becomes active. At this point the warning indicator will flash.
NOTE:
If speed control is engaged it will automatically disengage if Dynamic Stability Control or 'Trac
DSC' becomes active. For additional information, refer to Speed Control (310-03 Speed Control)
ABS
ABS controls the speed of all road wheels to ensure optimum wheel slip when braking at the
adhesion limit. This prevents the wheels from locking, which helps to retain effective steering control
of the vehicle in a braking situation.
Traction Control
Traction control attempts to optimize forward traction by reducing engine torque or braking a
spinning wheel until it regains grip.
Traction control is activated if an individual wheel speed is above that of the vehicle reference speed
and the brake pedal is not pressed. The spinning wheel is braked, allowing the excess torque to be
transmitted to the non-spinning wheel through the driveline. If necessary, the ABS module also sends
a high speed CAN bus message to the Engine Control Module (ECM) to request a reduction in engine
torque.
Panic Brake Assist
Panic Brake Assist (PBA) helps the driver bring the vehicle to a halt in an emergency braking situation
by automatically maximizing the braking effort. There are 2 situations when the ABS module will
invoke PBA:
• When the brake pedal is pressed very suddenly

• When the brake pedal is pressed hard enough to bring the front brakes into ABS operation.
When the brake pedal is pressed very suddenly, the ABS module increases hydraulic pressure to all of
the brakes until they reach the threshold for ABS operation, thus applying the maximum braking
effort for the available traction. The ABS module monitors for the sudden application of the brakes
using inputs from the stoplamp switch and from a pressure sensor within the HCU. With 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.
PBA operation continues until the driver releases the brake pedal enough for the hydraulic pressure
in the HCU to drop below a threshold value stored in the ABS module.
Active Yaw Control

Active Yaw Control monitors the vehicle for oversteer or understeer by comparing signals from the
yaw rate and lateral acceleration sensor with signals from the steering angle sensor. If the ABS
module determines the vehicle is not responding correctly to steering inputs from the driver it will
control the HCU to;
• apply brake pressure to the inner wheels to correct understeer

• apply brake pressure to the outer wheels to correct oversteer.
Braking in Curve Stability

Braking in Curve Stability influences the brake pressures below the Dynamic Stability Control and ABS
thresholds to counteract the yawing movement produced when braking in a corner. Braking in Curve
Stability produces a correction torque by limiting the brake pressure on one side of the vehicle.
System Malfunction
If an error is detected in the Dynamic Stability Control system, a message will be displayed in the
instrument cluster message center and the amber warning indicator will illuminate. In this condition
the vehicle is still safe to drive but the system may not react under slide or wheel spin conditions. For
additional information, refer to Anti-Lock Control - Stability Assist (206-09 Anti-Lock Control -
Stability Assist)

No Data Available
Anti-Lock Brake System (ABS) Module

(70.60.02)
Removal
NOTE:
The ABS Module is part of the hydraulic control unit (HCU) and cannot be serviced separately.
1 . Remove the HCU.

For additional information, refer to Hydraulic Control Unit (HCU) (70.60.18)
Installation
1 . Install the HCU.
Front Wheel Speed Sensor - 4.2L NA V8 -
AJV8/4.2L SC V8 - AJV8 (70.60.03)
Removal
1
2 . Remove the LH front wheel.

Remove the retaining clip.

Installation
Install the retaining clip.

Hydraulic Control Unit (HCU) (70.60.18)
Brake pedal hold down tool

JDS9013
Removal
1

3 . Remove the front LH fender splash shield.

For additional information, refer to Fender Splash Shield (76.10.90)
4 NOTE:
.
5 . Disconnect the hydraulic control unit (HCU) electrical connector.
6.
NOTE:
Disconnect the 6 brake pipe unions.
7 . NOTE:
Note the fitted position of the locating pegs.

Remove the HCU and pipe assembley.
8.
Remove the HCU.
Disconnect the 6 brake pipe unions.
9 . NOTE:
Remove the HCU bracket.

Installation
1 . Install the HCU bracket.
2 . Connect the brake pipe unions.
3 . NOTE:
When installing the HCU , make sure the locating peg fits securely into the grommet.
Install the HCU and pipe assembley.
Position the locating peg.




9 . Using WDS, configure a new HCU.

Rear Wheel Speed Sensor - 4.2L NA V8 -
AJV8/4.2L SC V8 - AJV8 (70.60.04)
Removal
1

Remove the bolt.
Installation


Yaw Rate Sensor and Accelerometer
(86.56.64)
Removal
2 . Remove the accelerometer.
Remove the 2 nuts.
Installation

211-00 : Steering system – General information
Specifications
Specifications
Specifications
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 System Flushing (57.15.08)
NOTE:
If heavy steering or contamination within the power steering system is found, it is
necessary to carry out the system flush procedure as detailed below. If any components
have been replaced in the power steering system the procedure below must be carried out
in full.
NOTE:
Some variation in the illustrations may occur, but the essential information is always
correct.
1. Remove the power steering fluid reservoir cap.
2. Using a suitable syringe, remove the power steering fluid from the power steering fluid
reservoir.
3.
CAUTION: Be prepared to collect escaping fluids.
NOTE:
Note the orientation of the clip.
Detach the power steering fluid reservoir.

• Detach but do not remove the power steering fluid reservoir.
• Release the power steering fluid return hose from the power steering fluid reservoir.
• If a quick release coupling is fitted to the power steering return hose, release the power
steering fluid return hose from the coupling by removing the clip.
4.

NOTE:
Make sure that all openings are sealed. Use new blanking caps.
Using a suitable blanking cap, cap the power steering reservoir return pipe.
5.
NOTE:
Make sure the extended pipe is not kinked or twisted and is correctly secured with hose
clips.
Attach a suitable pipe to the power steering return hose to allow the fluid to drain.
6. NOTE:
The suitable funnel should have the a capacity of 4 litres and O-ring seal
NOTE:
The suitable funnel must be tightly sealed to the power steering fluid reservoir to avoid
fluid leakage.
Install a suitable funnel onto the power steering fluid reservoir.

7.

Raise and support the vehicle with the wheels just clear of the ground.
8.
CAUTION: Steps 8 and 9 must be carried out within 2 - 3 seconds of each other.
Failure to follow this instruction may result in damage to the power steering system.
Using the suitable funnel, top up the power steering system with the specified fluid. Make
sure the fluid level is maintained at two thirds full in the funnel.
9.
CAUTION: Do not allow the power steering fluid level in the power steering fluid
reservoir to fall below the minimum power steering fluid level. Failure to follow this
instruction may result in damage to the power steering system.
CAUTION: Make sure the engine is switched off as soon as the full 4 litres of
power steering fluid has entered the power steering fluid reservoir.
Flush the power steering system.
• Start the engine
• With assistance turn the steering slowly lock to lock 3 times at approximately 1
revolution every 5 seconds.
• Continue to flush the power steering system until 4 litres of power steering fluid has
been added to the power steering reservoir. This should take approximately 30 seconds.
10.
Remove the suitable funnel.
11.
Remove the suitable pipe to the power steering return hose.

12.
NOTE:
Note the orientation of the clip.
If a quick release coupling is fitted to the power steering return hose, connect the power
steering fluid return hose to the coupling by installing the clip.
13. Install a new power steering fluid reservoir.

Steering System
For a detailed description of the steering system operation, refer to the relevant Description and
Power Steering
Steering Column

• Tire condition/pressure
• Fluid level • Fuses
• Leaks • Harnesses for
• Security, condition and correct installation of damage/corrosion
suspension components • Electrical connector(s)
• Security, condition and correct installation of • Damaged/corroded pins
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 . 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 torqued to the correct value.
Fluid Leakage
NOTE:
Confirm the position 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
• CORRECT the fluid level as

• Overfilled system
necessary
• Install new steering gear.

• Steering gear
• INSTALL a new fluid cap/reservoir.

• Damaged fluid
Power Steering Fluid Reservoir -
cap/reservoir
4.2L NA V8 - AJV8 (57.15.08)
• TIGHTEN the hose connection or

latch plate fixing to the
• Power steering • Loose or damaged recommended torque.
fluid leakage hoses and fittings Specifications INSTALL new
• O-ring or Dowty seals components as necessary
• INSTALL new O-ring or Dowty seals
as necessary
• INSTALL new fluid cooler.

• Fluid cooler Power Steering Fluid Cooler - 4.2L
NA V8 - AJV8 (57.15.11)
• INSTALL a new power steering

pump.
• Power steering pump
Power Steering Pump - 4.2L NA V8
- AJV8 (57.20.14)
Functional
• CHECK the steering
• Steering wheel • Steering not correctly
alignment.
misalignment centred
Specifications
• CHECK and TIGHTEN

the steering wheel
retaining bolt as
• Steering wheel loose
necessary.
Steering Wheel
(57.60.01)
• INSTALL new
• Excess play in the steering
components as
linkage
necessary
CAUTION: DO NOT
attempt to adjust the steering
gear yoke. Failure to follow
this instruction will invalidate
• Steering gear not correctly the steering gear warranty
adjusted (causing excessive
backlash)
• Excessive free play at
steering wheel (refer to
the Steering Linkage • INSTALL a new steering
Inspection and Backlash gear as necessary.
(Free play) Check in this Steering Gear
section) (57.10.01)
• CHECK and TIGHTEN

• Lower steering column the lower steering
universal joint pinch bolts column pinch bolts as
loose necessary.
Specifications
• INSTALL a new steering

column or steering
column lower shaft as
• Excessive wear in steering necessary.
column universal joints Steering Column
(57.40.01)
Steering Column Lower
Shaft (57.40.05)
• CHECK/TIGHTEN and
• Steering gear mounting
INSTALL new steering
bolts loose or damaged
gear mounting bolts as
necessary.
Specifications
• INSTALL new tie-rod

ends as necessary.
• Wear in steering gear tie-
Tie Rod End - 4.2L NA
rod end ball joints
V8 - AJV8/4.2L SC V8 -
AJV8 (57.55.02)
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 play is
optimized with the steering • INSTALL new steering
gear in the central position gear as necessary.
and should not be confused Steering Gear
with inner ball joint wear. (57.10.01)
Check for vertical motion in
the inner ball joint with the
steering gear in the central
position.
• Wear in steering gear inner

ball joints
• INSTALL new
• Wear in suspension ball
components as
joints/bushings
necessary
CAUTION: DO NOT
• Steering gear not correctly this instruction will invalidate
• Veer under braking
adjusted the steering gear warranty

gear as necessary.
Steering Gear
(57.10.01)
• RECTIFY the source of

the contamination and
INSTALL new brake
pads and discs as
necessary.
Brake Disc - Vehicles
With: Standard Brakes
(70.10.10)
• Contamination of brake
With: High
pads and discs
Performance Brakes
(70.10.10)
Brake Pads - Vehicles
(70.40.02)
Brake Pads - Vehicles
With: High
Performance Brakes
(70.40.02)
• RECTIFY sticking slide

pins and INSTALL new
calipers as necessary.
Brake Caliper - Vehicles
(70.55.02)
Brake Caliper - Vehicles
With: High
• Seized front brake caliper Performance Brakes
slide pins or piston (70.55.02)
• Damaged brake discs • INSTALL new brake
discs as necessary.
(70.10.10)
With: High
Performance Brakes
(70.10.10)
• For further information

on diagnosis of uneven
• Vehicle pulls to one
• Uneven tire wear tire wear.
side when driving on a
• Incorrect tire pressure Suspension System
level surface
• ADJUST tire pressures.
Specifications
NOTE:
Dealerships must keep a

copy of the BEFORE and
AFTER geometry figures
• Incorrect geometry with job card for future
adjustment reference
• ADJUST as necessary.
Specifications
• Notify the customer of

• Vehicle is unevenly loaded
incorrect vehicle
or overloaded
loading
CAUTION: DO NOT
this instruction will invalidate
• Steering gear is not the steering gear warranty
correctly adjusted

gear as necessary.
Steering Gear
(57.10.01)
• TIGHTEN and INSTALL

• Loose, damaged or worn new front suspension
front suspension components as
components necessary.
Specifications

• Loose, damaged or worn new rear suspension
rear suspension components as
Specifications
• For further information

• Incorrect brake operation
on diagnosis of the
brake system.
Brake System
• SET underbody
alignment referring to
the Removal and
Installation procedures
• Incorrect underbody
for instruction.
alignment
Front Subframe
(76.10.05)
Rear Subframe
(64.25.01)
• CHECK and ADJUST the

tire pressure.
Specifications
• Incorrect tire pressure or
• INSTALL a new tire as
tire size
necessary.
Wheel and Tire
(74.20.05)
• Notify the customer of

• Vehicle is unevenly or
incorrect vehicle
excessively loaded
loading
Specifications
• Incorrect toe adjustment
Front Toe Adjustment
(57.65.01)
• Vehicle wanders from
side to side when
driven straight ahead • TIGHTEN and INSTALL a
and the steering wheel new tie-rod end as
is held in a firm position necessary.
• Loose or worn steering
Specifications
gear tie-rod end(s)
V8 - AJV8/4.2L SC V8 -
AJV8 (57.55.02)
• TIGHTEN and INSTALL a

new suspension ball
joint assembly as
• Loose or worn suspension
necessary.
ball joint(s)
Specifications
Wheel Knuckle
(60.25.23)
• TIGHTEN the steering

• Steering column universal
column universal joint
joint pinch bolt loose
pinch bolt to the
correct torque.
Specifications

new rear suspension
• Loose or worn rear
components as
suspension components
necessary.
Specifications
• CHECK/ADJUST the tire

pressure and INSTALL
correct tire as
• Incorrect tire pressure, size
necessary.
or type
Specifications
Wheel and Tire
(74.20.05)
NOTE:

• Incorrect geometry with job card for future
adjustment reference
• Poor self center action
of the steering Specifications

column and steering
column lower shaft are
• Steering column/steering
free from interference
column lower shaft
from the engine
interference
harness, sound
proofing and floor
covering
• Steering column shroud • Correctly

fouling on the steering INSTALL/ALIGN as
wheel necessary
• INSTALL a new upper

or lower steering
column as necessary.
joints binding or stiff
Steering Column
(57.40.01)
Shaft (57.40.05)
• Correctly INSTALL and

• Steering column lower
INSTALL new lower
shaft floor seal incorrectly
shaft as necessary.
installed, binding or
damaged
Shaft (57.40.05)
• INSTALL a new tie-rod

end as necessary.
• Binding or damaged
steering gear tie-rod(s)
V8 - AJV8/4.2L SC V8 -
AJV8 (57.55.02)

• Loose, damaged or worn new front suspension
front suspension components as
Specifications
• CHECK and RECTIFY any

fluid leakage.
• Low power steering fluid
Steering System Fill to
correct level
• INSTALL a new FEAD

• Damaged Front End belt tensioner.
Accessory Drive (FEAD) Accessory Drive Belt
belt tensioner Tensioner - 4.2L NA V8
- AJV8 (12.10.41)
• Excessive steering
• CHECK hoses and
efforts required during
cooler for
low speed/rapid
restriction/damage and
manoeuvring and/or
INSTALL new
during parking • Power steering hose or
components as
manoeuvres fluid cooler restriction
necessary.
Power Steering Fluid
Cooler - 4.2L NA V8 -
AJV8 (57.15.11)
• BLEED the system.

• Fluid aeration Power Steering System
Bleeding (57.15.02 )
• Refer to the electrical

• Steering transducer not
circuit diagrams and
closed - no feed voltage or
test steering
cable fault transducer circuit
NOTE:
REFER to the power steering • INSTALL a new power

steering pump or
pressure check in this section.
steering gear as
necessary.
Power Steering Pump -
4.2L NA V8 - AJV8
• Power steering fluid (57.20.14)
delivery pressure or flow Steering Gear
too low (57.10.01)
• Internal steering gear
leakage

• Steering operation is • Steering transducer open circuit diagrams and
very heavy when early test steering
VEHICLE IS IN MOTION transducer circuit
AT LOW SPEED, but
when stationary • Check for vehicle speed
manoeuvring is related DTCs and refer
NORMAL • Speedometer signal error
to the relevant DTC
Index

• Steering transducer not
open, (no power steering
test steering
fluid flow)
transducer circuit
• Check for vehicle speed

related DTCs and refer
• Speedometer signal error
to the relevant DTC
• Steering operation is Index
very light when
VEHICLE IN MOTION AT
HIGHER SPEED, but • CHECK for kinking or
when stationary blockage of pipe/hose
manoeuvring is • Ensure CORRECT
• Power steering fluid low
NORMAL INSTALLATION and
pressure pipe/hose
INSTALL a new power
restricted flow
steering fluid low
pressure pipe/hose as
necessary
• INSTALL a new
• Fluid reservoir filter
reservoir, refill with
blocked
fluid and bleed the
system.
Power Steering Fluid
Reservoir - 4.2L NA V8 -
AJV8 (57.15.08)
Power Steering System

column is free from
• Lower steering column interference from the
interference engine harness, sound
proofing or the floor
covering
NOTE:

with job card for future
• Incorrect steering
geometry reference.
• CHECK the front wheel

alignment.
Specifications
• Steering operation is
heavy in one direction
NOTE:
Refer to the power

steering pressure check in
this section
• Faulty rotary valve/seal • If the power steering

system pressure is low
but the power steering
pump maximum
output pressure is
correct INSTALL a new
steering gear.
Steering Gear
(57.10.01)
• CHECK for correct

• Tire fouling on the wheel
installation or damage
arch liner or suspension
to wheel arch liner and
components suspension
components. Correctly
INSTALL and INSTALL
new components as
necessary
• CHECK tire for correct
size, type and pressure
• INSTALL new
• Damaged steering gear
components as
cylinder feed pipe
necessary
• CHECK and RECTIFY any

fluid leaks. Refer to the
fluid leakage symptom
• Low power steering fluid
charts in this section
• Fill power steering
system to correct level
NOTE:
Refer to the power

steering pressure check in
this section
• Faulty rotary valve/seal • If the power steering

• Steering operation is system pressure is low
heavy in both but the power steering
directions pump maximum
output pressure is
correct, INSTALL a new
steering gear.
Steering Gear
(57.10.01)
NOTE:
• INSTALL a new power
Refer to the power steering steering pump or
steering gear as
pressure check in this section
necessary.
Power Steering Pump -
4.2L NA V8 - AJV8
(57.20.14)
• Power steering fluid Steering Gear
delivery pressure or flow (57.10.01)
too low
• Internal steering gear
leakage
• INSTALL a new power

steering pump as
• Fluid loss at the power necessary.
steering pump shaft seal Power Steering Pump -
4.2L NA V8 - AJV8
(57.20.14)

or lower steering
Steering Column
joints binding or stiff
(57.40.01)
Shaft (57.40.05)
• INSTALL new
components as
necessary.
Wheel Knuckle
(60.25.23)
• Seized front ball joints Upper Arm LH - 4.2L
NA V8 - AJV8/4.2L SC
V8 - AJV8 (60.35.41)
Upper Arm RH - 4.2L
NA V8 - AJV8/4.2L SC
V8 - AJV8 (60.35.42)
• INSTALL new steering

• Seized or worn steering gear as necessary.
gear Steering Gear
(57.10.01)

column is free from
• Lower steering column interference from the
interference engine harness, sound
proofing and floor
• Steering operation covering
varies from heavy to
light when driving at • Check for vehicle speed
constant speed • Incorrect speedometer related DTCs and refer
signal to the relevant DTC
Index
• Steering transducer circuit • Refer to the electrical

fault circuit diagrams and
test steering
transducer circuit

or lower steering
Steering Column
joint binding or stiff
(57.40.01)
Shaft (57.40.05)

• Uncharacteristic
• Steering transducer circuit circuit diagrams and
effort/speed
fault test steering
relationship
transducer circuit
• CHECK/ADJUST the tire

pressure and INSTALL
correct tire as
• Incorrect tire pressure, size
necessary.
or type
Specifications
Wheel and Tire
(74.20.05)
NOTE:
Inner ball joint wear is rare.

The steering gear installed to
all Jaguar vehicles have a
spring loaded pinion to
ensure the correct level of
• Excessive kick-back engagement between the • INSTALL new steering
through steering wheel rack and pinion. This play is gear and tie-rod ends
optimized with the steering as necessary.
gear in the central position Steering Gear
and should not be confused (57.10.01)
with inner ball joint wear. Tie Rod End - 4.2L NA
V8 - AJV8/4.2L SC V8 -
Check for vertical motion in
AJV8 (57.55.02)
the inner ball joint with the
steering gear in the central
position.
• Badly worn steering

gear/linkage
• Loose or worn front • TIGHTEN and INSTALL

suspension new front suspension
components/bushings components as
necessary.
Specifications
• CHECK column adjust

switch datalogger
signal using the
manufacturer
approved diagnostic
system
• CHECK fuses/relays
• Check instrument
cluster for column
movement/memory
to DTC Index.
Instrument Cluster If
DTCs B1C3314,
B1C3514 are stored,
and the column inches
when the switch is
activated and there is
no memory recall
• Electrical/electronic failure function, there will be
an existing fault with
• Column will not adjust the circuit, if the
• Column will not move column function is OK
to memory position the fault is intermittent
If DTCs B1C3277,
B1C3477 are stored,
these should be
ignored in this case
• CHECK condition of
wiring and connectors
• CHECK column
calibration. The BAR
code information is
located in the right
hand luggage
compartment floor
area below the carpet
• CHECK seat control
memory module
• CHECK to see if
mechanism has
• Motor locked/jammed
reached hard end stops
• Free mechanism
• Replace motor with
appropriate service kit
• Turn column adjust

switch to AUTO
position, check that
'Column Adjust AUTO'
text is displayed in the
instrument cluster
message center
• CHECK column adjust
switch datalogger
signal using the
manufacturer
approved diagnostic
system
• CHECK fuses/relays
cluster for column
movement/memory
to DTC Index.
Instrument Cluster If
DTCs B1C3314,
B1C3514 are stored,
and the column inches
• Column easy entry/exit when the switch is
• Electrical/electronic failure
does not function activated and there is
no memory recall
function, there will be
an existing fault with
the circuit, if the
column function is OK
the fault is intermittent
If DTCs B1C3277,
B1C3477 are stored,
these should be
ignored in this case
• CHECK condition of
wiring and connectors
• CHECK column
calibration. The BAR
code information is
located in the right
hand luggage
compartment floor
area below the carpet
• CHECK seat control
memory module for
DTCs and refer to DTC
Index
• When driver memory
recall requested from
driver switch pack -
• Install the correct
Column and exterior • Driver seat has passenger
module to the driver
mirrors DO NOT move seat module installed
seat
to memory position -
Driver seat DOES move
to memory position
• When passenger
memory recall
requested from
• Install the correct
passenger switch pack - • Passenger seat has driver
module to the
Column, exterior seat module installed
passenger seat
mirrors and passenger
seat ALL move to
memory position

• Electromechanical test steering column
Steering column lock • Internal lock failure lock circuit
will not operate • Install a new steering
column lock as
necessary
Noise
• CHECK for leaks and RECTIFY as

necessary. For further
information refer to the
• Low power steering
symptom charts for leakage in
fluid level
this section. FILL power
steering fluid reservoir to
correct level
• Continuous noise
NOTE:
Look for small air • BLEED the power steering

bubbles visible in the system.
fluid, air may also get
trapped in the hydraulic
system
• Air in hydraulic
system
• CHECK and REPOSITION, or

• Power steering
INSTALL new IF
pipe/hose in contact
damaged/deformed, power
with the vehicle body
steering pipe/hose
• CHECK and CLEAR restriction to

pipe/hose
• Power steering
• REPOSITION power steering
pipe/hose restricted
pipe/hose. INSTALL new
or twisted
pipe/hose IF permanently
damaged/deformed
• TIGHTEN the power steering

• Power steering pump pump mounting bolts to the
mounting bolts loose correct torque.
Specifications
NOTE:
• CHECK and FILL power steering
Refer to the power fluid reservoir to correct level
• Bleed the power steering
steering pressure check
system.
in this section
• Noise gets worse
when system is
• CHECK power steering pump
loaded
pressure. If the pump pressure
• Low power steering is low, INSTALL a new power
fluid level steering pump.
• Aerated fluid Power Steering Pump - 4.2L NA
• Low power steering V8 - AJV8 (57.20.14)
pump pressure
• CHECK FEAD belt tension

• CHECK FEAD belt condition and
• Front End Accessory
• FEAD belt incorrectly INSTALL a new belt as
Drive (FEAD) belt
tensioned or glazed necessary.
squeal
Accessory Drive Belt - 4.2L NA
V8 - AJV8 (12.10.40)
• CHECK FEAD belt tension

• Chirp noise from the
• Loose or worn FEAD • CHECK FEAD belt condition and
steering pump when
belt INSTALL a new belt as
a load is applied
necessary.
Accessory Drive Belt - 4.2L NA
V8 - AJV8 (12.10.40)
• Correctly INSTALL the steering

column shroud to eliminate
• Steering column
the foul condition
shroud foul condition
• INSTALL a new clockspring as
or clockspring
necessary.
• Scrape/grind noise Clockspring
from behind steering
wheel while steering
• REMOVE foreign objects from
between steering column
• Foreign objects shroud and steering
wheel/steering column
rotating components
• Correctly INSTALL and INSTALL

• Clockspring or
new components as necessary.
steering column
Clockspring
multifunction switch
Steering Column Multifunction
LH
Switch LH (86.65.78)
• Click
• INSTALL a new universal joint

• Loose universal joint pinch bolt and TIGHTEN to
pinch bolt correct specification.
Specifications
• Steering column • APPLY Krytox spray to steering

shroud joints column shroud joints
• Squeak
• INSTALL new clockspring as
• Clockspring necessary.
Clockspring
• Loose fixings
• TIGHTEN fixings to correct
(universal joint pinch
• Knock specification.
bolt and steering
Specifications
column fixings)
• REMOVE foreign objects from

• Foreign objects shroud and steering
wheel/steering column
• Rattle rotating components
• TIGHTEN steering column

• Loose fixings fixings to correct specification.
Specifications
NOTE:
Before carrying out

repairs/replacement, assess
column adjustment noise levels
• Electric against other vehicles of the
motor/solenoid same model
• Noise while adjusting
column
• Install new components as

necessary
• Motor spindle/lead
• Lubricate lead screw
screw
Vibration
CAUTION: DO NOT attempt

to adjust the steering gear yoke.
Failure to follow this instruction will
• Loose or worn invalidate the steering gear
• Wheel Fight (Kick Back) steering warranty.
- condition where components/bushing
roughness is felt in the s
steering wheel by the
driver when the vehicle • TIGHTEN and INSTALL new
is driven over rough steering
surfaces components/bushings as
necessary
• Loose or worn • TIGHTEN and INSTALL new

suspension suspension
components/bushing components/bushings as
s necessary
• Nibble (Shimmy) - • CHECK for wheel and tire

condition where damage. INSTALL new
• Road wheel and tire
oscillation of the components as necessary.
condition
steering wheel occurs Wheel and Tire (74.20.05)
(not vertical which is • CHECK for tire uniformity.
Shake). This is driven INSTALL new tire(s) as
by road wheel necessary
imbalance
• Road wheel • CHECK and ADJUST road
imbalance wheel balance as necessary
NOTE:
Vibration smooths out

• Shake - condition • ENSURE tires installed are to
after several miles of
where vertical Jaguar specification. INSTALL
driving
vibration of the new tires as necessary
steering wheel/column • CHECK and ADJUST tire
occurs (not oscillation pressures to correct
which is Nibble) specification
• Road wheel
imbalance due to tire
flat-spotting
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 necessary.
NOTE:
The following steps must be carried out with assistance.
1 . With the wheels in the straight ahead position, gently turn the steering wheel to the left and the
right to check for free play.
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 . The backlash of the steering gear cannot be adjusted, install a new steering gear if excessive
backlash is diagnosed.
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 . Run the engine for 2 minutes.
2 . Check the power steering fluid system level.
3 . Observe the color and the odor. The color under normal circumstances should be dark reddish,
not brown or black.
4 . Using a suitable clean syringe extract a suitable amount of fluid from the reservoir.
5 . Allow the fluid to drip onto a facial tissue and examine the stain.
6 . If evidence of solid material is found, the power steering fluid system should be drained for
further inspection.
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).
CAUTION: To avoid excessive heating of the power steering pump when CHECKING the
pressure, do not close the valve for more than 5 seconds maximum.
CAUTION: When 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.
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. When present on a vehicle the noise, once initiated can often be maintained across a
large proportion of the available steering movement.
Whistle
Whistle is similar to hiss but is louder and of a higher frequency. It is also more of a pure tone noise
than hiss. Whistle is air-borne and is generated by a high flow rate of hydraulic fluid through a small
restriction.
Zip
Zip noise is the air-borne noise generated by power steering pump cavitation when power steering
fluid does not flow freely through the suction hose from the reservoir to the pump. Zip primarily
occurs during cold weather at start-up.
Steering System Vibrations and Harshness
Buzz
Buzz is a tactile rotary vibration felt in the steering wheel 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 (PWM) electric actuators used in
variable assist steering systems. This buzz is felt by turning the ignition key to run without starting
the engine and holding onto the steering wheel. In extreme cases, the buzz can be felt with the
engine running also.
Column/Steering Wheel Shake

Column shake is a low frequency vertical vibration excited by primary engine vibrations.
Nibble (Shimmy)
Steering nibble is a rotary oscillation or vibration of the steering wheel, which can be excited at a
specific vehicle speed. Nibble is driven by wheel and tire imbalance exciting a suspension recession
mode, which then translates into steering gear travel and finally steering wheel nibble.
Shudder (Judder)
Shudder is a low frequency oscillation of the entire steering system (tire, wheels, steering gear and
linkage, etc.) when the vehicle is steered during static-park or at low speeds. Shudder is very
dependent on road surface.
Torque/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.
211-02 : Power steering
Specifications
Specifications
Specifications
Power steering fluid Mobil ATF (meeting Dexron 3 specification)
Capacities
Liters
Power steering fluid 1
Item Nm lb-ft lb-in

Power steering pump to bracket - bolt 25 18 -
Power steering pump bracket to engine - bolt 25 18 -
Steering gear to vehicle - bolt 100 74 -
Power Steering
COMPONENT LOCATION
NOTE:
Naturally aspirated shown, Supercharged similar
1 Power steering fluid reservoir
2 Tie-rod
3 Power steering fluid cooler and hoses
4 Steering gear
5 Servotronic valve
6 Power steering pump
INTRODUCTION
The steering system comprises a ZF manufactured rack and pinion Servotronic 2 steering gear, a
power steering pump, a fluid reservoir, a fluid cooler 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, belt driven 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 (left-hand) side of the engine compartment, forward of
the front suspension housing. A fluid cooler is located in front of the engine cooling radiator. On
Supercharged models, a different design of fluid cooler to that fitted to naturally aspirated models is
mounted in a higher position in front of the radiator.
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 centre 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.
STEERING GEAR
1 Input shaft
2 Valve unit
3 Servotronic valve
4 Pressure/Return pipes
5 Tie-rod
6 Locknut
7 Tie-rod end
8 Locknut
9 Steering gear boots
10 Mounting bolts and washers
11 Pinion housing
12 Pressure/Return connection from/to pump
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 three bolts and washers which screw into threaded tubes 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 teeth angles at the centre of the rack vary from those at the end sections. 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. When 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
1 Pressure/return to/from steering gear
2 Return fluid chamber
3 Cut-off valve
4 Radial groove
5 Servotronic transducer valve
6 Fluid feed radial groove
7 Radial groove
8 Orifice
9 Balls
10 Compression spring
11 Torsion bar
12 Valve rotor
13 Reaction piston
14 Reaction chamber
15 Centering piece
16 Pressure supply from pump
17 Return to reservoir
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 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
1 Pulley
2 Pump body
3 High pressure outlet port (to steering gear)
4 Low pressure suction port (from reservoir)
The power steering pumps used on naturally aspirated and supercharged 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
pressurised fluid passes from the pump outlet port into the pressure hose to the steering gear.
The pressurised 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 pressurised 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.
RESERVOIR
1 Mounting bolt (2 off)
2 Cap
3 Maximum oil level
4 Minimum oil level
5 Bracket
6 Feed to pump
7 Return from cooler
The reservoir is located in the engine compartment, forward of the Left Hand (LH) suspension turret.
A bracket attached to the reservoir is bolted via 2 rubber mounts, to 2 brackets on the front body
crossmember.
The reservoir is a plastic moulding with an integral 100 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 into the reservoir body. The cap has a
dip stick with different diameters which denote the minimum and maximum fluid levels.
The reservoir has a fluid capacity to the maximum level of 400 cc (0.85 US pints).
HOSES AND FLUID COOLER
A Supercharged
B Naturally aspirated
1 Engine cooling radiator
2 Power steering fluid cooler
3 Reservoir suction pipe

4 Reservoir return pipe
5 Power steering pump pressure pipe
6 Steering gear pressure/return pipes
The supercharged and naturally aspirated vehicles differ in the location of the fluid cooler and
consequently the routing of the hoses. The remaining components of the power steering system are
similar in both variants.
Hoses
A mixture of metal pipes and rubber hoses are used in the power steering on both models. The high
pressure pipe from the pump and the return pipe to the cooler from the steering gear are attached
to one mounting plate. The pipe connections are sealed with O ring seals and the plate is secured
with a bolt screwed into the steering gear.
On both naturally aspirated models and supercharged models, the pump high pressure pipe is
attached to the pump with a threaded, flared, pipe fitting which is sealed with an O ring seal.
Fluid Cooler
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.
On naturally aspirated models the cooler is located near the bottom of the engine cooling radiator.
On supercharged models, the cooler is located higher up, near the top of the radiator, to allow for
the fitment of the charge air cooler required on the supercharged model.
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

NOTE:
Circuit shows steering rotary valve in neutral position with the vehicle not moving.
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
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 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 pressurised 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

NOTE:
Circuit shows steering rotary valve in right turn position, at high vehicle speed and with rapid
steering corrections. The Servotronic transducer valve is fully open and the maximum hydraulic
reaction is limited by the cut-off valve.
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
19 Torsion bar
20 Valve rotor
21 Reaction piston
22 Reaction chamber
23 Centering piece
24 Pressure relief/flow limiting valve

26 Inner track rod
27 Pinion
28 Valve sleeve
29 Steering gear
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 pressurised 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 pressurised 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 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.
Power Steering
Power Steering Fluid Cooler - 4.2L NA V8 -

AJV8 (57.15.11)
Removal
2
3 . Remove the front bumper cover.

For additional information, refer to Front Bumper Cover (76.22.78)
4 . NOTE:
Remove the horn assembly.
Release the wiring harness clip.
Remove the stud.

5 . Release the power steering fluid cooler.
Remove the 2 nuts.
6
around the joint faces and connections are clean and dry. Plug open connections to prevent
contamination.
Remove the power steering fluid cooler.
Remove and discard the hose clips.
Position a container to collect the fluid spillage.

Installation
1 . Install the power steering fluid cooler.
Clean the components.
Connect the hoses and secure with the clips.
2 . Install the horn assembly.
Tighten the stud to 25 Nm (18 lb.ft).
Attach the wiring harness.
3 . Install the front bumper cover.


5 . Refill and bleed the power steering.

For additional information, refer to Power Steering System Bleeding (57.15.02 )
Power Steering Fluid Cooler - 4.2L SC V8 -
AJV8 (57.15.11)
Removal
2
3 . Remove the intake air resonator.

For additional information, refer to Intake Air Resonator

Remove the 2 bolts.

6 . Release the 2 power steering fluid cooler clips.
7
contamination.
Remove the power steering fluid cooler.
Remove and discard the hose clips.
Installation
1 . Install the power steering fluid cooler.

Secure with the clips.

3 . Install the intake air resonator.



Power Steering Fluid Reservoir - 4.2L NA
V8 - AJV8 (57.15.08)
Removal
CAUTION: If power steering fluid comes into contact with the paintwork, the affected area
must be immediately washed down with cold water.

2 . Remove the engine cover.

For additional information, refer to Engine Cover (76.11.35)
3 . Remove the air intake duct.
Remove the bolt.
4 . Release the power steering fluid reservoir.
Remove the 2 bolts.

5
contamination.
Release the 2 power steering fluid reservoir lines.
Position a container to collect the fluid.
Release the feed line clip.
Remove and discard the return line clip.
6 . Remove the power steering fluid reservoir.

Installation
1 . Attach the power steering fluid reservoir lines.
2 . Secure the power steering fluid reservoir.
3 . Install the air intake duct.
Tighten the clips.
4 . Install the engine cover.


6 . Check and top-up power steering fluid level.

Power Steering Fluid Reservoir - 4.2L SC
V8 - AJV8 (57.15.08)
Removal
CAUTION: If power steering fluid comes into contact with the paintwork, the affected area
must be immediately washed down with cold water.

2 . Remove the LH intake air resonator.
Remove the bolt.
Disconnect the engine breather line.

Remove the 2 bolts.
4
contamination.
Release the 2 power steering fluid reservoir lines.
Release the feed line clip.
Remove and discard the return line clip.

5 . Remove the power steering fluid reservoir.
Installation
1 . Attach the power steering fluid reservoir lines.
Tighten the clips.
Connect the engine breather line.


Power Steering Pump - 4.2L NA V8 - AJV8
(57.20.14)
Removal
2

4 . Remove the accessory drive belt.

For additional information, refer to Accessory Drive Belt - 4.2L NA V8 - AJV8 (12.10.40)
5 . Release the air conditioning compressor.
Remove the 3 bolts.

6
. WARNING: Fluid loss is unavoidable, use absorbent cloth or a container to collect
the fluid.
Disconnect the low pressure line from the power steering pump.
Release the clip.
7.
Disconnect the high pressure line from the power steering pump.
Remove and discard the O-ring seal.
8 . Remove the power steering pump.
Remove the 4 bolts.

Installation
1 . Install the power steering pump.
2 . Connect the high pressure line.
Install a new O-ring seal.
3 . Connect the low pressure line.
Secure with the clip.
4 . Secure the A/C compressor.
5 . Install the accessory drive belt.



Power Steering Pump - 4.2L SC V8 - AJV8
(57.20.14)
Removal
2


For additional information, refer to Accessory Drive Belt - 4.2L SC V8 - AJV8 (12.10.40)
5 . Release the air conditioning compressor.
Remove the 3 bolts.

6
the fluid.
Release the clip.
7.
Disconnect the high pressure line from the power steering pump.
Remove the 4 bolts.

Installation
2 . Connect the high pressure line.
3 . Connect the low pressure line.
4 . Secure the A/C compressor.



Removal
CAUTION: Make sure that only the manufacturers' recommended four wheel alignment
equipment is used.
CAUTION: Do not turn the steering wheel with the lower steering column disconnected as
damage to the clock spring and steering wheel switches may occur.
NOTE:
Make sure the steering is in the straight ahead position.


4 . Remove the air deflector.

5 . Release both tie-rod end ball joints.

6 . Disconnect the power steering control valve actuator electrical connector.
7.
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.
8 . Release the power steering line support bracket.

9
contamination.
NOTE:
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.
10 . Remove the steering gear.
Remove the 3 bolts.

11 .
NOTE:
Remove both tie rod ends.
Loosen the tie-rod end ball joint retaining nut.
Installation
1 . Install both tie rod ends.
Tighten the tie rod end lock nut to 55 Nm (40 lb.ft).
2 . Install the steering gear.
Tighten the bolts to 100 Nm ( 74 lb.ft).
3 . Connect the power steering feed and return fluid lines.
Install the new O-ring seals.
Tighten the bolt to 15Nm (11 lb.ft).

4 . Connect the power steering control valve actuator electrical connector.
5 . Secure the power steering line support mount.
6 . Connect the steering column lower shaft.
7 . Connect the tie-rod end ball joints.

9 . Install the air deflector.


11 . Fill and bleed the power steering system.

. alignment.
Steering Gear Bushing (57.10.30)
Bushing remover and installer bolt

204-275
Bushing remover and installer nut

204-274
Bearing kit
JAG-061
Steering gear lower bushing remover and installer

204-273
Steering gear upper bushing remover and installer
211-271
Removal
1

Remove the 6 bolts.
4 . Disconnect the power steering control valve actuator electrical connector.
5 . Release the power steering line support bracket.

6.
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.
7 . Release the steering gear.
Remove the 3 bolts.

8 . Using the special tools, remove the steering gear lower bushing.
9 . Using the special tools, remove the steering gear upper bushing.
Installation
1 . Using the special tools, install the steering gear upper bushing.
2 . Using the special tools, install the steering gear lower bushing.
3 . Install the steering gear.
4 . Connect the power steering control valve actuator electrical connector.
5 . Secure the power steering line support bracket.
6 . Connect the steering column lower shaft.

Steering Angle Sensor
Removal

For additional information, refer to Standard Workshop Practices
3 . Remove the steering wheel.

For additional information, refer to Steering Wheel (57.60.01)
4 . Remove the instrument panel, lower trim panel.

For additional information, refer to Instrument Panel Lower Trim Panel (76.46.11)
5 Remove the steering column lower cowl.

.
If installed, disconnect the steering column and foot pedal control switch
electrical connector.
6 . Remove the steering column upper cowl.

7 . Release the multifunction switch.
Depress the 2 clips.
Repeat the above procedure on the opposite hand.
8 . Release the clockspring.

9 . Remove the steering angle sensor.
Release the 3 wiring harness clips.
Separate the harness.
Remove the 2 bolts.
Remove the reluctor ring.
Installation
1 . Install the steering angle sensor.
Install the reluctor ring.

Tighten the bolts to 3 Nm (2.2 lb.ft).
Secure the clips.
2 . Install the clockspring.
3 . Install the steering column upper cowl.
Install the screws.
4 Install the steering column lower cowl.

.
If installed, connect the steering column and foot pedal switch electrical
connector.
Secure in the clips.
Install the screws.
5 . Install the instrument panel, lower trim panel.

6 . Install the steering wheel.


211-03 : Steering linkage
Specifications
Specifications
Item Nm lb-ft lb-in

Tie rod end ball-joint to wheel knuckle - nut* 75 55 -
Tie rod end - locking nut* 55 40 -
* New nuts/bolts must be installed.

Steering Linkage
COMPONENT LOCATION
1 Taper ball joint
2 Locknut
3 Tie rod arm - outer
4 Locknut
5 Tie rod arm - inner
6 Gaitor
INTRODUCTION
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 tie rods. The external ends of the tie rods are sealed with gaitors to prevent the
ingress of dirt and moisture into the steering gear.
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 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.
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
For additional information, refer to<<211-00>>
Steering Gear Boot (57.10.29)

Removal
1
2 Remove the tie-rod end.

. For additional information, refer to Tie Rod End - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8
(57.55.02)
3 . NOTE:
Remove the locknut.
4 . NOTE:
Clean the components general area prior to dismantling.
Remove the steering gear boot.

Installation
1 . Install the steering gear boot.
2 . NOTE:
Install the locknut.
3 Install the tie-rod end.

. For additional information, refer to Tie Rod End - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8
(57.55.02)
. alignment.
For additional information, refer to Front Toe Adjustment (57.65.01)
Tie Rod End - 4.2L NA V8 - AJV8/4.2L SC
V8 - AJV8 (57.55.02)
Removal
1

3 . Loosen the tie-rod end lock nut.
4
. CAUTION: To prevent damage to the tie rods, use an additional wrench when
loosening or tightening the components.
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: To prevent damage to the tie rods, use an additional wrench when
loosening or tightening the components.
Connect the tie-rod end ball joint.
Install a new nut and tighten to 75 Nm ( 55 lb.ft).
3 . Tighten the tie-rod locking nut.
4 . Install the front wheel.

. alignment.
211-04 : Steering column
Specifications
Specifications
Item Nm lb-ft lb-in

Clock spring to steering column - bolt 7 5 62
Lower steering column, bearing-carrier to body - bolt 9 7 80
Lower steering column, bearing to bearing carrier - bolt 9 7 80
Lower steering column to steering gear - universal-joint pinch bolt* 30 22 -
Steering column to vehicle body - nuts 24 18 -
Steering column to lower steering column - universal-joint pinch bolt* 30 22 -
Steering wheel to steering column - bolt 62 46 -
* New nuts/bolts must be installed.

Steering Column
COMPONENT LOCATION
1 Steering wheel
2 Gear change paddle switch (if fitted)
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 assembly
10 Lower column - lower collapse shaft
11 Electric steering column lock mechanism
12 Column mounting plate
13 Upper shroud
INTRODUCTION
The steering column comprises the upper column assembly, the lower column assembly and the
steering wheel. The three components are positively connected together to pass driver rotary input
from the steering wheel to a linear output of the steering gear.
The upper column assembly contains electrical adjustment for steering wheel reach and rake and
also provides the location for the ignition switch, the electric steering column lock mechanism and
the steering angle sensor.
The steering column is attached to the in-vehicle crossbeam. Crash load absorption is provided by a
'peeling tube' mechanism.
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 and also
incorporates an entry/exit mode to allow the driver additional room to enter and exit the vehicle.
An electric steering column lock mechanism is positioned on the column assembly. The lock is
controlled by the CJB (central junction box) and is an integral function of the passive start system.
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.
The lower column assembly comprises two splined shafts connected by a universal joint in the
center. The splines of the upper shaft locate in a flexible coupling which in turn is located in the yoke
on the lower shaft of the upper column assembly. The splines allow the shaft to collapse in the event
of an accident. The flexible coupling controls axial and torsional movements and also assists with
noise and vibration damping.
A bulkhead mounted bearing is located on the upper shaft and supports the lower column as it
passes from the passenger compartment to the engine compartment.
The splines on the lower shaft locate in a universal joint which in turn is connected to the steering
gear input shaft. The lower column assembly incorporates a crash collapse mechanism in the form of
a 'tube-in-tube' design.
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 (if
fitted) and speed control. A clockspring is used to connect to the vehicle harness.
CONTROL DIAGRAM
NOTE:

1 Battery
2 Megafuse (175A)
3 Megafuse (175A)
5 Auxiliary fusebox
6 Electric steering column lock mechanism
7 High Speed CAN connection to other vehicle systems

8 Rake adjustment solenoid and potentiometer
9 Reach adjustment solenoid and potentiometer
10 Steering column adjustment motor
12 Steering column adjustment switch

Steering Column
Steering Column (57.40.01)

Clockspring locking tool

211-326
Driver air bag module remover

501-106
Removal
3 . Remove the instrument panel lower trim panel.


.
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.
Check the road wheels are in the straight ahead position, then remove the steering column
universal joint upper clamp bolt.
6 . Release the steering column.
Loosen but do not remove the 4 nuts.

8 . Disconnect the upper steering column wiring harness connections.

9 . Disconnect the steering angle sensor electrical connector.
10 . Remove the steering column.
Remove the 4 nuts.
11 . NOTE:

Using the special tool, remove the driver air bag module.
Rotate the steering wheel for access to slots.
12 . NOTE:
Remove the steering wheel.
Loosen, but do not fully remove the bolt.
Release the steering wheel from the spline.
Remove the bolt.

Release the electrical harness.
13
. CAUTION: Failing to install the clockspring special tool, may result in damage to
vehicle.
CAUTION: Do not dismantle the clockspring, it has no serviceable parts and must
be replaced as a complete assembly.
Install the special tool to the clockspring.
14 . Remove the clockspring.

15 . NOTE:
Remove the steering angle sensor.
Remove the 2 bolts.
Remove the reluctor ring.
Installation
1 . Install the steering angle sensor.
Install the reluctor ring.
Install the bolts and tighten to 3 Nm (2.2 lb.ft).
2 . Install the clockspring.

4 . NOTE:
Install the steering wheel.
Check the clockspring is aligned.
Position the electrical harness.
5 . Install the driver air bag module.
6 . Install the steering column.
Install the 4 nuts, do not tighten at this time.
7 . Connect the steering angle sensor electrical connector.
Secure the 3 clips.
8 . Connect the steering harness electrical connectors

Secure the 3 clips.
Install the screws.
10 . Secure the steering column.
11 . Connect the steering column lower shaft to the steering column.
Align the shafts.

.
connector.
Install the screws.
13 . Install the instrument panel lower trim panel.


15
16 . Loosen the upper bolt from the steering column lower universal joint.
Allow the steering column lower universal joint to settle.
17 . Connect WDS and configure the steering angle sensor.

Steering Column Lower Shaft (57.40.05)
Removal
1 . Turn the steering wheel to the straight ahead position.
2
3 . Remove the steering column lower universal joint assembly for access.
4 . Remove the instrument panel lower trim panel.

5 . Disconnect the steering column lower shaft from the steering column.
Remove the bolt.
6 . Remove the steering column lower shaft.

Remove the 2 nuts.
Release the bearing carrier.
Discard the gasket.
7 . NOTE:
Remove the bearing carrier.
Remove the 2 bolts.
Installation
1 . Install the bearing carrier.
Install a new gasket.

2 . Install the steering column lower shaft.
3 . Connect the steering column lower shaft to the steering column.
Align the shafts.
4 . Raise the vehicle.
5 . Install the steering column lower universal joint assembly.
Align the shafts.
Tighten the new bolts to 30 Nm (22 lb.ft).
6 . Install the instrument panel lower trim panel.

Steering Wheel (57.60.01)

211-326
Removal
3 . Remove the driver air bag module.

For additional information, refer to Driver Air Bag Module (76.73.39)
4 . NOTE:
Remove the bolt.

5
. CAUTION: Failing to install the clockspring special tool, may result in damage to
vehicle.
CAUTION: Do not dismantle the clockspring, it has no serviceable parts and must be
replaced as a complete assembly.
CAUTION: Do not allow the clockspring to unwind.
Install the special tool to the clockspring.
6 . NOTE:
Remove the upshift and downshift paddle switches.

Release the assembly.
Repeat the procedure and remove the opposite hand.
7 . Remove the steering wheel switch assembly.
Disconnect the electrical connectors.
8 . Remove the air bag housing.

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.
3 . Install the steering wheel switch assembly.
Connect and secure the electrical connectors.
4 . Install the upshift and downshift paddle switches.
Tighten to 3 Nm.

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.
Remove the special tool.
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.


Clockspring

211-326
Removal
WARNING: Always wear safety glasses when repairing an air bag supplemental restraint
system (SRS) vehicle and when handling an air bag module.
WARNING: Carry a live air bag module with the air bag and trim cover pointed away from
your body. This will reduce the risk of injury in the event of an accidental deployment. Failure to
follow this instruction may result in personal injury.
WARNING: Do not set a live air bag module down with the trim cover face down. Failure to
follow this instruction may result in personal injury.
WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide,
a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap
and water afterwards. Failure to follow this instruction may result in personal injury.
WARNING: Never probe the connectors on the air bag module. Doing so may result in air
bag deployment, which may result in personal injury. Failure to follow this instruction may result in
personal injury.
WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not
repainted.
WARNING: Vehicle sensor orientation is critical for correct system operation. If a vehicle
equipped with an air bag supplemental restraint system (SRS) is involved in a collision, inspect the
sensor mounting bracket and wiring pigtail for deformation. If damaged, replace the sensor
whether or not the air bag is deployed.
WARNING: To avoid accidental deployment and possible personal injury, the backup power
supply must be depleted before repairing or replacing any air bag supplemental restraint system
(SRS) components. To deplete the backup power supply energy, disconnect the battery ground
cable and wait one minute. Failure to follow this instruction may result in personal injury.
CAUTION: Make sure the wheels are in the straight-ahead position. Failure to follow this
instruction may result in damage to the component.


3.
4
. CAUTION: Make sure that special tool 211-326 is installed to the clockspring.
CAUTION: Make sure that the road wheels are in the straight ahead position, failure
to follow this instruction may result in damage to the vehicle.
NOTE:
Remove the bolt.
5
. CAUTION: Failing to install the special tool to the clockspring may result in damage
to the vehicle.
6.
7.
8
. CAUTION: Failing to install the special tool to the clockspring may result in damage
to the vehicle.
TORQUE: 6 Nm
9
. CAUTION: Make sure no damage is occured to the electrical connectors. Failure to
follow this instruction may result in damage to the vehicle.
10 . NOTE:
12 .
Installation
1 . To install, reverse the removal procedure.
2
. CAUTION: Make sure that special tool 211-326 is installed to the clockspring.
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. Failure to
follow this instruction may result in damage to the component.
NOTE:
Make sure that the road wheels are in the straight ahead position, failure to follow this
instruction may result in damage to the vehicle.

3 . Tighten to 65 Nm.

211-05 : Steering column switch
Specifications
Specifications
Item Nm lb-ft lb-in

Gearshift paddle switch 2.5 - 22
Speed and audio control switch 3.5 - 31
Steering column lock actuator 9 7 80

COMPONENT LOCATION
Part
Item Description
Number
1 Audio and telephone switches
2 Left Hand (LH) (-) gear change paddle switch
3 Steering column multifunction switches and clockspring

4 Right Hand (RH) (+) gear change paddle switch
Speed control switches (Adaptive Speed Control switch pack shown, non adaptive
5
speed control switch pack has a single thumbwheel)
INTRODUCTION
The steering column switches comprise the following:
• Steering column multifunction switch

• Steering column adjustment switch
• Steering wheel mounted audio, telephone and speed control switches
• Heated steering wheel contact module.
The steering column multifunction switch is situated on the steering column and consists of the
wiper switch and the direction indicator/lighting, trip computer switch.
The RH multifunction switch controls the following windshield wiper functions:
• Flick wipe
• Intermittent wipe
• Slow speed wipe
• High speed wipe
• Wash/Wipe
• Headlamp powerwash
• Rain sensing / variable wipe selection.
For additional information, refer to Wipers and Washers (501-16 )
The LH multifunction switch controls the following lighting functions:
• Turn signal indicators

• Side lamps
• Headlamps
• Auto lamps
• High/low beam
• Headlamp flash
• Headlamp timer
• Trip computer.
For additional information, refer to Exterior Lighting (417-01 )

For additional information, refer to Information and Message Center (413-08 )
The steering column adjustment switch is located in the steering column lower shroud on the LH
side. The switch is a four 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 center.
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.
CONTROL DIAGRAM
NOTE:
A = Hardwired; N = Medium speed CAN Bus; P = Fiber Optic MOST

Part
Item Description
Number
1 Battery
2 Megafuse (175A)

5 Steering column RH multifunction switch
6 Steering column LH multifunction switch
Speed control switches (Adaptive Speed Control switch pack shown, non adaptive
8
speed control switch pack has a single thumbwheel)
9 Audio/telephone switches
10 Clockspring
11 Information and entertainment module
12 MOST connection to other vehicle systems
13 Medium speed CAN bus to other vehicle systems


For a detailed description of the steering column switches, refer to the relevant Description and
Operation section in the workshop manual.

• Fuse(s)
• Switches
• Electrical connector(s)
• Steering column lock
• Wiring Harness
4 . If the cause is not visually evident, check for DTCs and refer to the DTC Index.
DTC Index
NOTE:
module/component.
NOTE:
fault (the last two digits give extra information read by the manufacturer-approved diagnostic
system).
NOTE:
three decimal places and with a current calibration certificate. When testing resistance, always
take the resistance of the DMM leads into account.
NOTE:
NOTE:
terminals.
Check ignition, power and ground

supplies to steering column lock
Column lock and instrument cluster. Re-
B100D51 • Not programmed
authorisation synchronise ID by re-configuring
the steering column lock as a new
module
Check CAN network between

• CAN fault steering column lock and
• Steering column lock fault instrument cluster. Check power
• Instrument cluster fault and ground supplies to steering
Column lock • Incorrect module installed
column lock and instrument
authorisation - (Steering column
B100D62 cluster. Confirm the correct
signal compare lock/Instrument cluster)
• Target ID synchronisation modules are installed. Re-
failure
error following re- synchronize ID by re-configuring
programming the steering column lock as new.
• Noise/EMC related error Check CAN network for
interference/EMC related issues
B100D64 Column lock • CAN fault

Check CAN network to steering
• Steering column lock fault
authorisation - • Instrument cluster fault column lock. Check power and
signal plausibility ground supplies to steering
failure column lock and instrument
cluster

Column lock • Steering column lock fault
instrument cluster. Check power
B100D87 authorisation - • Instrument cluster fault
• Low voltage at steering and ground supplies to steering
missing message
column lock < 8V column lock and instrument
cluster

High speed CAN
• Vehicle CAN bus off associated with this DTC using the
U000188 communication
condition manufacturer approved diagnostic
bus
system

manufacturer approved diagnostic
Internal control system. Clear the DTC and retest.
U030000 module software If the DTC is still logged suspect
message is received
incompatibility the steering column lock, refer to
the new module installation note
at the top of the DTC Index
Install a new steering column lock,

refer to the new module
U300049 Control Module • Internal electronic failure
installation note at the top of the
DTC Index

system. Check steering column
U300087 Control Module • Missing message lock for DTCs and refer to the DTC
Index. Check CAN network
integrity using the manufacturer
Vehicle match. Corrupt VIN data Install original module, check for
U300281 Identification being transmitted, module DTCs and refer to relevant DTC
Number (VIN) previously installed to other Index
vehicle
Steering Column Lock Actuator (57.40.41)

5 point security torx bit

418-535
Removal
1 . Remove the steering column. <<211-04>>
2 Remove the steering column lock actuator.

.
Using the special tool, remove the steering column lock actuator retaining
bolts.
Installation
Tighten to 9 Nm.
Steering Column Multifunction Switch LH
(86.65.78)
Removal
.

3 . Remove the steering column multifunction switch.
Installation
1.
CAUTION: Make sure the electrical harness is not trapped during the installation.
Steering Column Multifunction Switch RH
(86.65.41)
Removal

For additional information, refer to General Service Information


.

6 . Remove the steering column multifunction switch.
Installation
1 . Install the multifunction switch.
Align the lugs and secure the clips.

Install the screws.

.
connector.
Install the screws.


3. POWERTRAIN
303 : Engine
303-00 : Engine System - General
Specifications
Specifications
Specifications
Bearing Inspection
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.
Camshaft Bearing Journal Clearance
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.
Camshaft Bearing Journal Diameter
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.
Camshaft End Play
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.
End play = maximum value minus minimum value.
• If the measurement is out of specification, install new components.
Camshaft Lobe Lift
1. Measure the diameter (1) and diameter (2) with a vernier caliper. The difference in
measurements is the lobe lift.
Camshaft Surface Inspection
1. Inspect camshaft lobes for pitting or damage in the active area. Minor pitting is acceptable
outside the active area.
Connecting Rod Cleaning
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.
Connecting Rod Large End Bore
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.
Crankshaft End Play
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.
Crankshaft Main Bearing Journal
Clearance
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.
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:
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
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
• Blue / Green and Blue
• Blue and Blue
• Blue and Green
• Green and Green
• Green and Yellow
• 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.
Cylinder Bore Out-of-Round
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.
Cylinder Head Distortion
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.
Exhaust Manifold Cleaning and Inspection
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.
Piston Inspection
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.
Piston Pin Diameter
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.
Piston Pin to Bore Diameter
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.
Piston Ring End Gap
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.
www.JagDocs.com
Piston Ring-to-Groove Clearance

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.

Valve Spring Free Length
1. Using a vernier gauge, measure the free length of each valve spring. Verify the length is
Valve Stem Diameter
1. Using a micrometer measure the diameter of the valve stems.
• If the measurements are not to specification, install a new valve.
Engine
1 . Verify the customer concern by operating the system.
• 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, when 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
• Check ECM for Diagnostic Trouble Codes (DTCs) and refer to DTC
All engine related
Index.
issues Electronic Engine Controls
• Carry out general engine checks: Compression test. Refer to

Difficult to start hot
component tests in this section. Valve clearances.
and cold Valve Clearance Check (12.29.47) Spark plug condition and color
• Ensure the air intake system is free from leaks

Valve Clearance Check (12.29.47) Spark plug condition and color
• 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
Poor idle
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.
• Carry out a vacuum gauge check. Refer to component tests in this
section.
• Ensure the air intake system is free from leaks

• Check for collapsed catalytic converter/blocked exhaust system
• Check long and short term fuel trim datalogger signals Readings up to
Insufficient
10%: may be considered as acceptable if the readings are equal bank
power/Insufficient
to bank Positive readings of between 10-20%: check for air leaks in
compression 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.
• Carry out a vacuum gauge check. Refer to component tests in this
section.
• Carry out oil leak check followed by an oil consumption test. Refer to
the component tests in this section
• If oil consumption is excessive:
Oil consumption • Check the integrity of the engine breather system
• Refer to the Special Service Messages on the Electronic Product

Noise
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 . Clean the engine with a suitable cleaning fluid (brake cleaner).
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 . 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 . 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 . 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 operating temperature.
Check the Compression Pressure
WARNING: Move gear selector lever to 'P' position. Failure to follow this instruction may
1 . Remove the fuel pump relay.
2 . Start the engine - the engine will start, run for a few seconds then stall.
3 . Remove the spark plugs.
4 . Install the compression tester.
5 . Install an auxiliary starter switch in the starting circuit. With the ignition switch OFF, using the
auxiliary starter switch, crank the engine a minimum of five compression strokes and record the
highest reading. Note the approximate number of compression strokes required to obtain the
highest reading.
6 . Repeat the test on each cylinder, cranking the engine approximately the same number of
compression strokes.
7 . Install the removed components in reverse order, observing the specified tightening torques.
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 . 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 . Verify that the engine has no external oil leaks as described under Engine Oil Leaks in this section.
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 . Check the Positive Crankcase Ventilation (PCV) system. Make sure the system is not plugged.
5 . Check for plugged oil drain-back holes in the cylinder head and cylinder block.
6 . If the condition still exists after carrying out the above tests go to step 9.
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 . Check valve guides for excessive guide clearance. Install new valve stem seals after verifying valve
guide clearance.
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 . NORMAL READING: Needle between 51-74 kPa (15-22 in-Hg) and holding steady.
2 . NORMAL READING DURING RAPID ACCELERATION: When 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 . 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 . 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 . STICKING VALVES: When 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 . 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 . POOR VALVE SEATING: A small but regular downscale flicking can mean one or more valves are
not seating correctly.
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 . WEAK VALVE SPRINGS: When 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 . LATE VALVE TIMING: A steady but low reading could be caused by late valve timing.
11 . IGNITION TIMING RETARDED: Retarded ignition timing will produce a steady but somewhat low
reading.
12 . INSUFFICIENT SPARK PLUG GAP: When spark plugs are gapped too close, a regular, small
pulsation of the needle can occur.
13 . INTAKE LEAK: A low, steady reading can be caused by an intake manifold or throttle body gasket
leak.
14 . BLOWN HEAD GASKET: A regular drop of fair magnitude can be caused by a blown head gasket
or warped cylinder head to cylinder block surface.
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.
303-01A : Engine – 4.2L SC V8 – AJV8
Specifications
Specifications
Engine Data
Maximu Maximu Maximu Maximu

Engine m m m m
Engine Compressio Bor Strok
Capacit Engine Engine Engine Engine
Description n Ratio e e
y Torque Power Torque Power
(EEC) (EEC) (SAE) (SAE)
• 90°
'Vee'
• 8 560 410 560 420
Cylin Nm/413 BHP/306 Nm/413 BHP/313
4196 86.0 90.3
der lb/ft at kW at lb/ft at kW at 9.1:1 ± 0.5:1
cm³ mm mm
• 32 4000 6250 4000 6250
Valve RPM RPM RPM RPM
s
Engine Firing Order
Firing Order
1:2:7:3:4:5:6:8
Engine Valve Clearance (cold)
Intake Valve Exhaust Valve

0.18 - 0.22 mm 0.23 - 0.27 mm
Spark Plugs
Specification Spark Plug Gap

AJ8 4575 0.9 - 1.0 mm

Description Specification
Core plug and stub pipe retainer WSK-M2G349-A4
Engine oil, SAE 5W-30 WSS-M2C-913B
Sealant WSE-M4G323-A4
Capacities
Description Liters
Engine oil, initial fill 8.5
Engine oil, service fill with oil filter change 7.0
Cylinder head and Valvetrain
Item Specification
Cylinder head maximum permitted warp (mm) 0.125
Valve guide inner diameter (mm) 5.00 - 5.02
Intake valve effective length (mm) 88.87 - 89.17
Exhaust valve effective length (mm) 88.40 - 88.70
Valve stem to guide clearance intake decimetrical
0.022 - 0.057
(mm)
Valve stem to guide clearance exhaust decimetrical
0.030 - 0.065
(mm)
Valve head diameter intake (mm) 34.8 - 35.0
Valve head diameter exhaust (mm) 30.8 - 31.0
Intake valve face angle (degrees) 45° 15' 30" ± 7° 30'
Exhaust valve face angle (degrees) 45° - 44° 45'
Valve stem diameter intake (mm) 4.963 - 4.978
Valve stem diameter exhaust (mm) 4.955 - 4.970
Valve spring free length (mm) 43.5 MAX
Valve spring installed height (mm) 33.20
Camshaft lobe lift intake (mm) 8.50
Camshaft lobe lift exhaust (mm) 8.50
• Front bearing 0.045 - 0.085
Camshaft journal to cylinder head bearing surface
• Other bearings 0.055 - 0.075
clearance diametrical (mm)
• Center bearing to outer

Camshaft journal diameter standard runout limit (mm) bearings 0.07
• Other bearings to outer
bearings 0.05
Camshaft journal diameter standard out of round (mm) 0.005
Description Nm lb-ft lb-in

Accessory drive belt tensioner retaining bolt 40 30 -
Air conditioning compressor retaining bolts 25 18 -
Air conditioning compressor mounting bracket bolt 25 18 -
Camshaft bearing caps retaining bolts 10 7 88
Camshaft exhaust sprocket A - -
Camshaft position sensor bolt 7 5 62
Connecting rod to bearing cap bolts A - -
Coolant drain in engine block - plug M10 x 16 25 18 -
8+ 6+ 71 +
Coolant pump bolt
90° 90° 90°
Crankshaft damper pulley - bolt 320 236 -
Cylinder head - bolt A - -
Engine cover (top) 4 3 35
Engine cover (top) mounting bracket - nut 6 4 53
Engine front cover retaining bolts 12 19 -
Engine mounting to engine mounting bracket - nut 48 35 -
Engine mounting to subframe - nut 63 46 -
Engine mounting bracket to engine - bolt 40 30 -
Engine wiring harness bracket - nut/bolt 10 7 88
Exhaust manifold - bolt A - -
Exhaust manifold heat shield - bolt 3 2 27
Flexplate - bolt A - -
Generator upper reatining bolts 2 15 -
Ignition coil retaining bolts 5 4 44
Intake manifold assembly retaining bolts 21 15 -
Intercoolers 12 9 -
Intercooler duct clamp plates 21 15 -
Knock sensor retaining nuts 20 14 -
Lifting eye (front) - bolt 30 22 -
Lifting eye (rear) - bolt 40 30 -
MAP sensor 6 4 53
Oil filter 17 13 -
Oil filter housing to engine - bolt 21 15 -
Oil level indicator tube - nut 6 4 53
Oil pan to oil pan body - bolt A - -
Oil pan body to engine A - -
Oil pan drain plug 25 18 -
Oil pump pick-up pipe to oil pan body - bolt 12 9 -
Oil pump to engine block - bolt 12 9 -
Oil pump to pick-up pipe - bolt 12 9 -
Piston cooling jet - bolt 9 7 80
Plug - M30 x 12 to engine block 50 37 -
Plug (flanged) - M30 - 1.5 x 20 to engine block 50 37 -
Power steering pump retaining bolts 25 18 -
Power steering pump bracket to engine - bolt 28 18 -
Primary timing chain tensioner - bolt 12 9 -
Primary timing chain tensioner, guide blade - bolt 12 9 -
Radio frequency interference suppressor to engine cover bracket -
10 7 88
bolt
Secondary timing chain tensioner - bolt 12 9 -
Spark plugs 27 20 -
Starter motor retaining bolts 43 32 -
Supercharger 21 15 -
Supercharger outlet duct - bolt 10 7 88
Supercharger outlet duct - screw 21 15 -
Timing belt cover - bolt A - -
Valve cover - bolt A - -
Variable camshaft timing, oil control solenoid housing - bolt 22 16 -
Variable camshaft timing, oil control solenoid housing - nut 11 8 -
Variable camshaft timing sprocket - center bolt A - -
A = refer to procedure for correct torque sequence

General procedures

Tappet hold-down tool

303-540
Tappet hold-down tool adaptor

303-540/02
Fan nozzle - air gun

303-590
CAUTION: 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.
CAUTION: Camshaft lobes must be 180 degrees away from each valve tappet or valve
clearance will be incorrect.
1. Remove the cover and disconnect the battery ground cable.
Specifications
2. Check the valve clearances.

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 (7 lb.ft).
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.
CAUTION: Shims must be fitted with the size markings facing the tappet, not the camshaft.
CAUTION: Do not use a magnet to install shims. Failure to follow these instructions may
Install the new shim.
• Clean the components.
• 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.
CAUTION: 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.
CAUTION: Camshaft lobes must be 180 degrees away from each valve tappet or
valve clearance will be incorrect.

Specifications
2. Remove the LH valve cover.

3. Remove the RH valve cover.

5. Using the feeler gauge set, measure the clearance between the camshaft and the valve
shim.
6. Repeat the above procedure for the remaining 31 shims.
7. Adjust the clearance as necessary.

8. For cylinder head data, refer to specifications.
Specifications
9. Install the RH valve cover.

10. Install the LH valve cover.

11. Connect the battery ground cable and install the cover.
Specifications
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:

Specifications
2.
WARNING: Do not work on or under a vehicle supported only by a jack. Always support the
vehicle on safety stands.
3. Remove the engine undershield.

4. Remove the oil pan drain plug.
• Position a container to collect the fluid.
• Discard the oil pan drain plug seal.
5. Remove the oil filter.
• Discard the oil filter.
6. Using the special tool, install the oil filter.
• Lubricate the oil filter seal with clean engine oil and tighten to 18 Nm (13 lb.ft).
7. Tighten the drain plug to 25 Nm (18 lb.ft).
• Install a new seal.
8. Fill the engine with oil.

Specifications
10. Start engine and run at idle speed until the oil pressure warning light extinguishes.
• Stop the engine.
• Check for leaks.
11. Install the engine undershield.

12. Check and top-up the engine oil.

Engine
EXTERNAL VIEW
OVERVIEW
The V8 supercharged petrol engine is a 4.2 liter, 8-cylinder, 90 degrees 'Enclosed' V unit, with 4
valves per cylinder, operated by 2 overhead camshafts per cylinder head. The engine emissions
comply with ECD4 (European Commission Directive) legislative requirements and employs catalytic
converters, electronic engine management control and positive crankcase ventilation to limit the
emission of pollutants. The cooling system is a low volume, high velocity system. The Engine Control
Module (ECM) controls the fuel injection system, the ignition system and the electric throttle.
The cylinder block is of aluminum alloy construction with cast iron liners. A cast aluminum bedplate is
bolted to the bottom of the block to improve lower structure rigidity. The cylinder heads are cast
aluminum with thermo-plastic camshaft covers. The single-piece oil sump is also cast aluminum. The
fabricated stainless steel twin skin exhaust manifolds are unique for each cylinder bank. A moulded
plastic acoustic cover is fitted over the upper engine to reduce engine-generated noise.
Engine Structure
1 Cylinder heads
2 Cylinder block
3 Bedplate
4 Structural sump
5 Sump pan
TECHNICAL FEATURES
The technical features include:
• An 8-cylinder 90-degree 'Enclosed V' configuration liquid cooled aluminum cylinder block
with cast iron liners
• Pistons are of open-ended skirt design, with 2 compression rings and a 3-piece oil control
ring
• Two aluminum cylinder heads, each incorporating 2 camshafts manufactured in chilled cast
iron
• Four valves per cylinder
• Graded valve lifters (shimless)
• Belt driven supercharger
• Top fed, 12-hole fuel injectors
• Engine front cover manufactured from aluminum, accommodating the crankshaft front oil
seal
• Primary and secondary chain drive for the camshafts
• An aluminum bedplate
• A cast iron crankshaft
• Fracture-split connecting rods in sintered-forged steel
• A twin multi-V belt, driving the front-end accessories
• Fabricated stainless steel twin skin exhaust manifolds
• An advanced engine management system incorporating electronic throttle control
• Meets with the fault handling requirements, as detailed in the European On-Board
Diagnostic (EOBD) III, US Federal OBD and California OBDII legislation.
ENGINE DATA
DESCRIPTION TYPE
Configuration 90 degree V8
Maximum power 283 kW at 5750 rpm
Maximum torque 550 Nm at 3500 rpm
Displacement 4196 liters
Stroke/bore 90.3/86 mm
Compression ratio 9.1 : 1
Firing order 15426378
Oil volume 7 liters (wet)

CYLINDER BLOCK COMPONENTS
1 Piston rings
2 Piston
3 Circlip
4 Connecting rod
5 Bolts
6 Connecting rod bearing shells
7 Bearing
8 Piston pin
9 Circlip
10 Cylinder block
11 Piston assemblies
12 Bolts (8 off)
13 Flywheel
14 Seal
15 Dowel
16 Crankshaft
17 Thrust washer
18 Thrust washer
19 Bearing shells - upper
20 Bearing shells - lower
21 Oil level gage tube
22 Oil level gage
23 Bedplate
24 Bolts (10 off)
25 Bolts (10 off)
26 Bolts (12 off)
27 Bolt
28 Bolts (8 off)
29 Windage tray
30 Sump
31 Crankshaft Position (CKP) sensor
32 Flange
33 Bolts (11 off)
34 Clip
35 Bolts (2 off)
36 Stud
37 Oil pick-up pipe
38 Bolts (17 off)
39 Sump pan
40 Gasket
41 Bolts (3 off)
42 Engine oil temperature sensor
43 Oil filter head assembly
44 Oil filter
45 Seal
46 Oil pressure switch
47 Bolts (4 off)
48 Oil pump
49 Crankshaft sprocket
50 Crankshaft pulley
51 Taper collet
52 Crankshaft bolt
Cylinder Block
The cylinder block is an 'Enclosed V' design, which provides an inherently 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 right hand cylinder bank is designated as 'A' bank, and
the left hand as 'B' bank. The cylinder bores are numbered from 1 to 4, for bank 'A' and 5 to 8 for
bank 'B', starting from the front of the engine (for more information refer to the Vehicle Specification
Book (VSB)).
Engine Data Locations
Part
Item Description
Number
1 Engine part number
Engine data (main bearing diameters, cylinder bore diameters, etc), emissions
2
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
alphabetical and numerical codes; keys to the codes are in the Service Repair Procedures (SRP)
section of this manual.
Piston Cooling Jets
1 Piston cooling jet (4 off)
2 Bolt (4 off)
Jets located in the cylinder block provide piston and piston pin lubrication and cooling. These jets
spray oil on the underside of the piston.
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 big-end bearings via
holes machined into the crankshaft.
Connecting Rods and Pistons
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. They are also manufactured
from a higher strength aluminum alloy and incorporate a thicker top land to resist the increased
thermal and mechanical loads produced by supercharging. Three piston rings, 2 compression and 1
solid oil control ring, are installed on each piston. Each piston is installed on a piston pin located in an
bronze bushing in the connecting rod.
Connecting Rod and Piston Installation

1 Bank A (RHS)
2 Bank B (LHS)
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 'A' - piston grade number and the thick flange of the connecting rod must face the front
of the engine
• Bank 'B' - piston grade number and the thin flange of the connecting rod must face the front
of the engine
Crankshaft Position Sensor

1 Crankshaft position sensor (CKP)
The CKP sensor is installed at the rear of the sump. It is a variable reluctance sensor that provides an
input of engine crankshaft speed and position. For additional information, refer to Electronic Engine
Controls (303-14 Electronic Engine Controls - Vehicles Without: Supercharger)
Knock Sensors
1 Knock sensor
2 Bolt
The knock sensors are installed in the cylinder block on the inboard side of each cylinder bank. They
are piezo-electric sensors that provide inputs to detect and locate detonation during combustion. For
additional information, refer to Electronic Engine Controls (303-14 Electronic Engine Controls -
Vehicles Without: Supercharger)
Starter
1 Bolt
2 Starter motor
3 Bolt
The engine starter motor is installed at the rear right side of the engine, at the cylinder block to
bedplate split line. For additional information, refer to Starting System (303-06 Starting System)
Coolant Drain Plug/Heater
A coolant drain plug is installed on the rear left side of the cylinder block. On vehicles with the cold
climate package, the cylinder block heater replaces the drain plug.
On vehicles destined for Canada, the coolant heater is installed during engine manufacture, but for
Scandinavian vehicles the heater is supplied in kit form to be installed at the dealership.
Coolant Pump
1 Coolant pump
2 Bolt
3 Pulley
4 Bolt
The coolant pump is installed between the 2 cylinder banks, on the front face of the cylinder block.
Coolant Inlet and Outlet Assembly
1 Coolant outlet elbow

2 Coolant hose
3 Thermostat housing
To accommodate the installation of the supercharger, the thermostat housing and coolant outlet
duct are combined into an aluminum alloy coolant outlet assembly, which is installed between the 2
cylinder banks, immediately above the coolant pump. A hose connects the coolant outlet assembly
to a coolant inlet housing attached to the coolant pump intake on the cylinder block. The thermostat
controls the flow of coolant through the radiator.
CRANKSHAFT AND SUMP COMPONENTS
1 Bedplate
2 Main bearings - lower

Crankshaft and Main Bearings
1 Crankshaft
2 Thrust washer
3 Thrust washer
4 Main bearings - upper
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 centre 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, minimise 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.
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 section for more information).
Starter Drive Plate
1 Starter drive plate
2 Bolt
The starter drive plate is attached to the rear of the crankshaft. A timing disc, for the CKP sensor, is
spot welded to the front face of the drive plate.
CAMSHAFT TIMING COMPONENTS
1 Secondary chain tensioner
2 Secondary chain
3 Variable valve timing unit
4 Primary chain
5 Primary chain tensioner
Timing Gear
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.
Timing Cover
The aluminum alloy timing cover accommodates the crankshaft front oil seal (a PTFE lip seal). Silicon
rubber in-groove gaskets seal the joint between the timing cover and the front face of the engine.
CYLINDER HEAD COMPONENTS
1 Camshaft bearing cap
2 Tappet (shimless)
3 Collet
4 Valve spring cap

5 Valve spring
6 Valve stem oil seal
7 Valve
8 Inlet camshaft
9 Exhaust camshaft
Cylinder Heads
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 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.
Camshaft Covers
The camshaft covers are manufactured from thermo-plastic. The A bank camshaft cover incorporates
an outlet for the part load engine breather and the Pressure Control Valve (PCV). The B bank
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.
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.
Cylinder Head Gasket

The multi-layered steel cylinder head gasket has cylinder specific water flow cross-sections for
uniform coolant flow.
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 Ring

1 Inlet camshaft
2 Sensor ring
Timing rings for each camshaft position sensor are 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 Position Sensor
The camshaft position sensors are installed in each cylinder head at the rear of the intake camshaft.
It is a variable reluctance sensor that provides an input to the ECM regarding the position of the
camshaft. For additional information, refer to Electronic Engine Controls (303-14 Electronic Engine
Controls - Vehicles Without: Supercharger)
Inlet and Exhaust Valves

Each cylinder head incorporates dual overhead camshafts operating 4 valves per cylinder via solid
shimless 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.
CAUTION: Due to slight variations in length, the valves are not interchangeable between
marques (Land Rover, Jaguar and Aston Martin).
Fuel Injectors
1 RH fuel rail (2 off, 1 per bank)
2 Injector (8 off, 4 per bank)
Eight, top fed, 12-hole, fuel injectors are installed in the fuel rails and are held in position by spring
clips. Two O-rings are installed between the injector mounts of the fuel rails and the related recesses
in the intercooler adapters. The injectors are electromagnetic solenoid valves controlled by the ECM.
The fuel jets from the injectors are directed onto the back of the intake valves. For additional
information, refer to Electronic Engine Controls (303-14 Electronic Engine Controls - Vehicles
Without: Supercharger)
Fuel Rails
The fuel rails are installed on the intercooler adapters. A fuel crossover pipe connects the fuel rails
together at the front of the engine.
VARIABLE VALVE TIMING (VVT)

The continuously VVT unit turns the intake camshaft in relation to the primary chain to advance and
retard the timing.
The system improves low and high-speed engine performance, engine idle quality and exhaust
emission.
The VVT system changes the phasing of the intake valves, relative to the fixed timing of the exhaust
valves, to alter:
• the mass of air flow into the engine's cylinders,

• and the engine's torque response and emissions
The VVT unit uses a vane device to control the camshaft angle (refer to VVT operation). The system
operates over a range of 48 degrees and is advanced or retarded to the optimum angle within this
range.
The ECM controls the VVT, using engine speed and load, and engine oil temperature signals to
calculate the appropriate camshaft position. For additional information, refer to Electronic Engine
Controls (303-14 Electronic Engine Controls - Vehicles Without: Supercharger)
The continuous VVT system provides the following advantages:
• Reduces engine emissions and fuel consumption by further optimising the camshaft timing,
this improves the engine's internal exhaust gas re-circulation (EGR) effect over a wider
operating range
• Improves full-load torque characteristics as the camshaft timing is optimised at all engine
speeds for superior volumetric efficiency
• Improves fuel economy by optimising torque over the engine's speed range
This system also has the added benefits of operating at a lower oil-pressure and faster response time
when compared to a non-VVT system.
Variable Valve Timing (VVT) Operation
A Retarded
B Advanced
1 Engine oil pressure
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.
When 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. When 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.
When directed by the ECM, the VVT 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
energising 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 assess any decrease in shuttle-
valve oil-pressure, via signals from the camshaft position sensor. The ECM will increase the
energizing signal, when required, to maintain the shuttle-valve hold 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. 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 bar (14.5 psi), as there is insufficient
pressure to control the phasing. 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.
SUPERCHARGER
1 Supercharger outlet assembly

2 Supercharger outlet duct clamp
3 RH intercooler air inlet duct
4 LH intercooler air inlet duct
5 RH Intercooler coolant return connection
6 Throttle body and by-pass valve adapter assembly
7 LH Intercooler coolant return connection
8 LH intercooler
9 LH intercooler adapter
10 LH Intercooler coolant inlet and outlet connection
11 Supercharger assembly
12 RH intercooler adapter
13 RH Intercooler coolant inlet and outlet connection
14 RH intercooler
The supercharger is a compressor used to pump air into the cylinders. This increases the
concentration of oxygen and fuel in the charge to create a more powerful combustion inside the
cylinder. This increases cylinder pressure upon ignition and creates more power.
As the supercharger compresses the air its temperature increases. This raise in air temperature
reduces the potential for power gains. By installing intercoolers the air is cooled to overcome this.
The supercharger is an Eaton M112 unit attached to the 3 mounting bosses between the 'V' of the
cylinder block. Positive alignment with the drive belt is provided by a dowled mounting bracket. An 8-
ribbed belt drives the supercharger, via the crankshaft, at 2.1 engine speed. The maximum pressure
increase is approximately 0.8 bar.
On the 4.2L V8 supercharged engine the intake manifold is replaced by:
• A supercharger
• Two intercoolers
• Outlet assembly
• A bypass valve
• A bypass valve actuator
• Two intercooler adapters
The supercharger has a sealed-for-life internal lubrication system.
Intercooler
Each of the 2 intercoolers is a fin and tube air-to-liquid heat exchanger. Two rubber ducts, secured by
clamp plates, provide the interfaces between the outlet duct and the intercoolers. After passing
through the heat exchanger core, the air flows into individual outlets to the cylinders. At the rear of
the B bank intercooler there is a mounting boss for an air intake temperature sensor.
Outlet Assembly
The outlet assembly directs air from the supercharger into the 2 intercoolers. A filler point for the
intercooler coolant system is integrated into the front and right side of the outlet duct. A vacuum
take-off for the fuel pressure regulator/cruise control system is located on the right side of the outlet
assembly. Isolating bolts, to reduce noise, secure the outlet assembly to the supercharger and a
rubber gasket seals the supercharger to the outlet assembly throttle body and by-pass valve adapter.
Bypass Valve
The bypass valve attaches to an opening in the induction elbow and controls a bypass flow from the
intercoolers back to the inlet side of the supercharger. At closed or partially open throttle settings
(i.e. idle and most cruise conditions), the bypass valve is fully open to provide maximum bypass and
optimum fuel economy. As the throttle opens, the bypass valve progressively closes to reduce the
bypass flow and increase the pressure of air supplied to the engine for optimum power output.
Bypass Valve Actuator

The bypass valve actuator is a diaphragm-operated actuator attached to the valve spindle of the
bypass valve. A vacuum pipe connects the actuator to the induction elbow.
Intercooler Adapter
The intercooler adapters provide an interface between the intercoolers and the cylinder heads, and
also locate the fuel rails and injectors. One-piece gaskets seal the joints between the intercoolers and
the intercooler adapters, and between the intercooler adapters and the cylinder heads.
LUBRICATION SYSTEM
Oil is drawn from the reservoir in the oil pan and pressurised 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. Pressurised 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 the 'B' bank camshaft cover.
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
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 psi).
Oil Filter Assembly
3 Seal
4 Sump
5 Oil filter
6 Oil temperature sensor
7 Bolt (3 off)
The oil filter is a replaceable cartridge installed on an adapter. An internal bypass facility permits full
flow bypass if the filter is blocked.
The oil pressure switch 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).
Oil temperature is monitored through a Negative Temperature Coefficient (NTC) sensor. The sensor
is mounted near to the oil pressure sensor at the front of the engine and locates into the oil filter
head assembly.
Oil Level Gage
1 Oil level gage
The oil level gage locates along the left side of the oil pan, supported in a tube installed in the sump.
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 quart) between the 2 levels.
EXHAUST MANIFOLD
1 Cylinder head
2 Gasket
3 Heat shield
4 Bolt
5 Gasket
6 LH exhaust manifold
7 Spacer (8 off)
8 Connector for Secondary Air Injection (SAI)
9 Bolt (8 off)
10 Heat shield
11 Bolt (4 off)
The fabricated stainless steel twin skin exhaust manifolds are unique for each cylinder bank.
Each exhaust manifold assembly includes 2 metal gaskets, located either side of the inner heat shield,
2 heat shields and a connection for the Secondary Air Injection (SAI) system. For additional
information, refer to Engine Emission Control (303-08 Engine Emission Control - Vehicles Without:
Supercharger)
Spacers on the securing bolts allow the manifolds to expand and retract with changes of temperature
while maintaining the clamping loads.
Engine
No Data Available

No Data Available
Removal
Engine (12.41.01)

303-536

303-749
Engine lifting bracket

303-1297
Fuel spring lock decoupling tool

310-D005
Removal
2 Evacuate the A/C system.
. For additional information, refer to Air Conditioning (A/C) System Recovery, Evacuation and
Charging (82.30.30)
3 . Remove the hood.

For additional information, refer to Hood (76.16.01)
4 . Remove the cowl vent screen.

For additional information, refer to Cowl Vent Screen (76.10.01)
5 . Remove the engine compartment braces.
Release the grommet.

7 . Disconnect the brake booster vacuum hose quick release connector.

8 . Release and disconnect the engine wiring harness electrical connector.
9 . Release the ground cable from the power distribution box bracket.
Remove the nut.

10 . Release the engine wiring harness from the engine compartment side wall.
11 . Disconnect the fuel line.
12
. CAUTION: Before disconnecting or removing the components, make sure the area
contamination.
Release the clip and disconnect the purge inlet line.

13

15 Drain the cooling system.

. For additional information, refer to Cooling System Draining, Filling and Bleeding - 4.2L SC V8
- AJV8
16 . Disconnect the LH catalytic converter from the exhaust manifold.
17 . Disconnect the RH catalytic converter from the exhaust manifold.

18
. CAUTION: Before disconnecting or removing components, ensure the area around
the joint faces and connections are clean. Plug open connections to prevent
contamination.
Disconnect the 2 engine oil cooler lines.
Remove the 2 bolts.
Remove and discard the 2 O-ring seals.
Position hoses in front of the anti roll bar.
19 .
Disconnect the high pressure line from the power steering gear.
Remove and discard the Torx bolt.

Release from the clip.
20
. CAUTION: Immediately cap all refrigerant lines to prevent ingress of dirt and
moisture.
Disconnect the A/C high-pressure line from the intermediate joint.
Remove the nut.
Discard the O-ring seal.
21 . Disconnect the refrigerant lines from the A/C compressor.
Remove the 2 bolts.

Remove the lower A/C pipe.
Disconnect and tie aside the upper A/C pipe.
22
. CAUTION: The transmission ground cable must be replaced if disconnected from
the vehicle body.
Disconnect the transmission ground cable.
Remove the bolt.
23 . Release the transmission fluid lines from the engine.
Remove the nut.
Release the clip.

24 . Release the wiring harness from the RH side of the transmission.
25 . Disconnect the battery positive and generator cables.
Release the cover.
Remove the nut.

Remove the 6 bolts.
27 . Release the flexplate.
Remove the access plugs.
Rotate the crankshaft to access the retaining bolts.

28 . NOTE:
RH illustration shown, LH is similar.
30
contamination.
NOTE:
correct.
Disconnect the charge air cooler coolant hoses.
Tie aside.
Repeat the above procedure on the opposite side.

31 . Disconnect the radiator upper hose.
Release the hose clip.
32 . Remove the radiator top hose.
Release the clips.
Disconnect the quick release connector.
Tie the hose assembly aside for access.

33 . Disconnect the radiator lower hose.
34 . Remove the radiator lower hose.
Release the clip.

35 . Disconnect the secondary air injection (AIR) control valve supply hose.
36 . Disconnect the secondary air injection (AIR) reservoir vacuum line.
Release the clip.
Remove the 2 bolts.
38 . Disconnect the power steering supply hose.

39 .
CAUTION: Make sure the torque converter remains connected to the
transmission.
Release the transmission from the engine.
Remove the 15 bolts.
Support the transmission.
40 . Install the special tools to the engine.

Support the engine.
41
. CAUTION: Protect the suspension turrets to prevent damage upon engine
removal.
With assistance, carefully remove the engine.

42 . Install the torque converter retainer.
Installation
Engine (12.41.01)

303-536

303-749
Engine lifting bracket

303-1297

310-D005
Installation
1 . Remove the torque converter retainer.
2.
CAUTION: Apply grease of the correct specification to the torque converter spigot.
With assistance, carefully install the engine.
3 . Carefully lower the engine onto the engine mounts.
4 . Remove the special tools.
5
6 . Attach the flexplate to the torque converter.

8 . Connect the battery positive and generator cables.
Secure the cover.
9 . Attach the wiring harness.
Secure the clips.
10 . Attach the transmission fluid lines to the engine.
11 . Connect the transmission ground cable.
12 .
CAUTION: Lubricate the new seals with clean refrigerant oil.
Connect the A/C high-pressure line intermediate joint.

13 . Attach the power steering gear high-pressure line.
Secure in the clip.
14 . Connect the low pressure line to the power steering pump.
15 . Connect the engine oil cooler lines.
Install new O-ring seals.
16 . Secure the LH catalytic converter to the exhaust manifold.
Tighten the nuts to 40 Nm (29.5 lb.ft).
17 . Secure the RH catalytic converter to the exhaust manifold.

20 . Connect the AIR reservoir vacuum line.
21 . Install the radiator bottom hose.
Install the hoses and secure with the clips.
22 . Install the radiator top hose.
Connect the quick release connector.
23 . Attach the engine wiring harness to the engine compartment side wall.
Position and secure the grommet.
24 . Attach the ground cable to the power distribution box bracket.
25 . Connect the engine wiring harness electrical connector and secure with the captive bolt.
26 . Connect the fuel line.

For additional information, refer to Spring Lock Couplings
27 . Connect the brake booster vacuum hose quick release connector.

28 . Install the engine compartment braces.
Tighten the 4 Torx bolts to 25 Nm (18 lb.ft).
Install the grommet.
29 . Install the cowl vent screen.

30 . Install the hood.

31 . Recharge the A/C system.

In vehicle repair
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
2
3 . Remove the timing drive components.

For additional information, refer to Timing Drive Components (12.65.13)
4 . Remove the special tool from the LH cylinder head.
5
. 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).
6 . Remove the camshafts.
Installation
1 . Install the camshafts.
Replace the valve shims, with the smallest shim available.
Lubricate the journals and camshaft lobes.
2 Install the camshaft bearing caps.

.
Evenly and progressively tighten the bolts in the sequence shown to 10 Nm

(7 lb.ft).
3 . NOTE:
Install the special tool to the LH cylinder head.
Install the 3 bolts.
4 . NOTE:
Do not install the LH valve cover until valve clearance adjustment has been completed.
Install the timing drive components.

5 . For cylinder head data, refer to specifications.

6 . Rotate the engine clockwise to position the camshaft lobe away from the valve tappet.
7
. CAUTION: Camshaft lobes must be 180 degrees away from each valve tappet or
Using the feeler gauge set, measure the clearance between the camshaft and the valve shim.
8 . Repeat the above procedure for the remaining 15 shims.
9 . Install the special tool 303-540, to the cylinder head.
Tighten the 2 bolts to 10 Nm (7 lb.ft).
10
. CAUTION: Do not rotate the crankshaft while the special tool 303-540/02 is
attached to 303-540.
Secure with the 2 wing nuts.
11 . Position the special tool to the tappet as shown.
12 . Using the special tool, compress the valve spring.
13
. 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.
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.
14
. CAUTION: Shims must be fitted with the size markings facing the tappet, not the
camshaft.
CAUTION: Do not use a magnet to install shims. Failure to follow these instructions
may result in damage to the vehicle.
Lubricate the shim with clean engine oil.
Release and remove the special tools as required.
15 Using the feeler gauge set, measure the clearance between the camshaft and the valve
shim.
.
16 . Repeat the above procedure for the remaining valves.


303-530
Timing Setting tool

303-645

303-532

303-540
303-540/02

303-590
Removal
2
3 . Remove the engine front cover.

For additional information, refer to Engine Front Cover (12.65.01)
4 . Remove the crankshaft position (CKP) sensor.

For additional information, refer to Crankshaft Position (CKP) Sensor (18.30.12)
5
. CAUTION: 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.
CAUTION: Rotate the crankshaft clockwise to position the engine to top dead center
(TDC) number 1 cylinder.
Lock the crankshaft.
Install the special tool.
Install the screw.
6 . Remove the RH variable camshaft timing (VCT) control solenoid housing.
Remove the 3 bolts.
Remove and discard the O-ring seals.
7 Install the special tool to the RH cylinder head.

.
Rotate the crankshaft until the flats on the camshafts are parallel with the
cylinder head joint faces.
8 . Install the special tool to the LH cylinder head.
9 . Remove the RH primary timing chain tensioner.
Remove the 2 bolts.

10 . Remove the RH upper and lower primary timing chain tensioner guides.
Remove the 2 bolts.
11 . Remove the RH primary timing chain.
12 . Release the RH camshaft sprocket assembly.
13 . Remove the RH secondary timing chain, tensioner and sprocket assembly.

Remove the 2 retaining bolts.
14 . Remove the special tool from the RH cylinder head.
Remove the 3 bolts.
15
NOTE:
Remove the camshaft bearing caps. Note: their position, orientation and markings.
Each is marked with its position (number) and an orientation (arrow).

Installation

.
Evenly and progressively tighten the bolts in the sequence shown to 10

Nm.
3 . Install the special tool to the RH cylinder head.

4
. CAUTION: Make sure that new bolts are installed.
CAUTION: Make sure the secondary timing chain and camshaft sprockets are free to
rotate.
NOTE:
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 the bolts to 12 Nm.
6 Install the RH primary timing chain.

.
Make sure the timing chain slack is on the tensioner side of the timing
chain.
7 . Install the RH primary timing chain tensioner guides.
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.
Using 3 mm diameter metal rod, retain the chain tensioner piston.
Remove the retaining rod.

9
. CAUTION: Using the special tool, apply force to the tool in a counter-clockwise
direction, to tension the primary timing chain on its drive side.
CAUTION: 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.
Install the special tool to the RH 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.
10 . Install the RH VCT control solenoid housing.
Tighten the new bolts to 22 Nm.

13 . Remove the crankshaft locking tool.
Remove the screw.
14 . Install the CKP sensor.


17

Tighten the 2 bolts to 10 Nm.
20

23
NOTE:
24
camshaft.
. shim.
27 . Install the engine front cover.


Removal
1 . Remove the crankshaft pulley.
For additional information, refer to Crankshaft Pulley (12.21.09)
Installation
1 . Install the crankshaft pulley.
Crankshaft pulley locking tool

303-191
Crankshaft pulley locking tool adapter

303-191/02
Crankshaft pulley/damper remover

303-588
Seal extractor
303-751
Seal installer
303-750
Removal
2
3 Remove the cooling fan motor and shroud.

. For additional information, refer to Cooling Fan Motor and Shroud - Vehicles With:
4 . Remove the oil filter housing.

For additional information, refer to Oil Filter Housing
5 Release the accessory drive belt.

.
Rotate the accessory drive belt tensioner counter-clockwise, using a 3/8 "
drive wrench.
6
. CAUTION: Under no circumstances should the crankshaft setting peg, 303-645, be
used in the following operations, to restrain the crankshaft.
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.
7 . Using the special tools, remove the crankshaft pulley.
Collect the locking ring.
8 . Check the crankshaft pulley and locking ring for damage.
9 . Using the special tool, remove the crankshaft front seal.

Installation
1.
CAUTION: Make sure the crankshaft seal mating faces are clean and dry.
CAUTION: Do not remove the seal protector at this stage.
Using the special tool, install the crankshaft front seal.
2 . Remove the seal protector.
Lubricate the seal with clean engine oil.
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
Using the special tools, retain the crankshaft pulley.
Tighten the crankshaft pulley bolt to 380 Nm (280 lb.ft).
6 . Attach the accessory drive belt.
7 . Install the oil filter housing.

8 Install the cooling fan motor and shroud.

. For additional information, refer to Cooling Fan Motor and Shroud - Vehicles With:

Crankshaft rear oil seal remover/installer

303-538
Removal
2
3 . Remove the torque converter flexplate.

For additional information, refer to Flexplate (12.53.13)
4 . Install the special tools.
Tighten the 2 nuts to retain the special tool.

5 . Using the special tool, pierce the seal to create holes for the 6 self-tapping screws.
6 . 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.
2
. CAUTION: Make sure the seal is installed parallel
Using the special tool, install the crankshaft rear oil seal.
Tighten the special tool nuts evenly and progressively to fully install the
seal.
3 . Install the torque converter flexplate.

4 . Check and top-up the engine oil.

Removal
2
3 . Remove the fuel injection supply manifold.

For additional information, refer to Fuel Injection Supply Manifold (19.60.13)
4
contamination.
Remove the LH charge air cooler adaptor assembly.
Remove the 5 bolts.
Discard the gasket.

7
NOTE:

9 . NOTE:
NOTE:
Make sure the shim remains with the tappet.
Remove the 16 tappets.
10 . Remove the CMP sensor.

11 . Release the LH catalytic converter.
12
. CAUTION: The bolts can only be used twice, mark the bolts with a center punch. If
two punch marks are visible, discard the bolts.
CAUTION: 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
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. Failure to
With assistance remove the cylinder head.
14 . Remove and discard the cylinder head gasket.
Clean the cylinder head locating dowels.
Clean and inspect the cylinder head and cylinder block.
15 . NOTE:

Remove the LH heat shield.
16 . NOTE:
Remove the exhaust manifold.
Remove the 8 spacers.
17 . Remove and discard the exhaust manifold gasket.
Remove the bolt.

Installation
1 . Clean the component mating faces.
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.

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).
Tighten the screws.
8.
CAUTION: The head gasket must be installed over the cylinder block dowels.
Install a new cylinder head gasket.
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, a further 90 degrees.
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.
13 . Install the tappets.
Lubricate the components with clean engine oil.
Lubricate the journals and camshaft lobes with clean engine oil.

.
Nm (7 lb.ft).
16 . NOTE:
17 . NOTE:

18 . Install the charge air cooler adaptor assembly.
19 . Install the fuel injection supply manifold.

21

24

27
NOTE:
28
camshaft.
. shim.

Removal
2 . Recover the A/C refrigerant.
3

5 Vehicles with secondary air injection: Remove the air control valve to exhaust manifold tube.
. For additional information, refer to Secondary Air Injection (AIR) Control Valve to Exhaust
Manifold Tube
6 . Remove the coolant manifold.

For additional information, refer to Coolant Manifold - Vehicles With: Supercharger
7 . Remove the LH valve cover.

For additional information, refer to Valve Cover LH (12.29.43)
8 . Remove the RH valve cover.

For additional information, refer to Valve Cover RH (12.29.44)
10 . Remove the radiator bottom hose.
Release the clip.

For additional information, refer to Power Steering Pump - 4.2L SC V8 - AJV8 (57.20.14)
12 . NOTE:
Restrain the pulley to aid the removal of the bolts.
Remove the coolant pump pulley.
Remove the 3 bolts.

13 . Remove the accessory drive belt idler pulley.
Remove the bolt.
14 . Remove the accessory drive belt tensioner.
Remove the bolt.
15
moisture.
Disconnect the refrigerant lines from the A/C compressor.
Remove the 2 bolts.

16 . Position the A/C compressor aside to access the A/C compressor mounting bracket.
17 . Remove the A/C compressor mounting bracket.
Remove the 4 bolts.
18 . Remove the power steering pump mounting bracket.
Remove the 4 bolts.

19 . LH side: Release the wiring harness.
20 . RH side: Release the wiring harness.
Remove the bolt.
Release the clip.
Remove and discard the 2 gaskets.

Installation
1 Install the engine front cover.
.
Install the gaskets.
Install the O-ring seals.
Apply a bead of sealant 3 mm diameter, by 12 mm long, to the 8 places

indicated.
2 Install the engine front cover bolts.
.
(9 lb.ft).
3 . RH side: Attach the wiring harness.
Secure the clip.
4 . LH side: Attach the wiring harness.
Secure the clips.
5 . Install the power steering pump mounting bracket.
6 . Install the A/C compressor mounting bracket.
7.
Connect the refrigerant lines.
8 . Install the accessory drive belt tensioner.
9 . Install the accessory drive belt idler pulley.
10 . Install the coolant pump pulley.

Secure the clip.

14 . Install the RH valve cover.

15 . Install the LH valve cover.
16 . Install the coolant manifold.

17 Vehicles with secondary air injection: Install the air control valve to exhaust manifold tube.
Manifold Tube


Removal
All vehicles
2


Left-hand drive vehicles

5 . NOTE:
Remove the steering gear flexible coupling.

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.
9 . NOTE:
Remove the engine mount.
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.

3 . Secure the steering gear.
4 . Install the steering gear flexible coupling.
Tighten the new bolts to 35 Nm (26lb.ft).
All vehicles


Removal
All vehicles
2

Right-hand drive vehicles

4 . NOTE:

Remove the 3 bolts.
All vehicles
6 . Remove the generator cooling duct.
Support the engine.

Raise the engine.
Remove the 4 bolts.
9 . NOTE:

Installation
All vehicles
Lower the engine.
3 . Install the generator cooling duct.
Tighten the screws.


All vehicles

Exhaust Manifold LH - Vehicles With:
Secondary Air Injection (AIR) (30.15.55)
Removal
2
3 . Remove the oil level indicator and tube.

For additional information, refer to Oil Level Indicator and Tube

5 . Remove the LH engine mount.

For additional information, refer to Engine Mount LH (12.45.01)
6 . Release the LH exhaust manifold heat shield.
7 . Release the AIR tube from the LH exhaust manifold.

8 . Remove the LH exhaust manifold heat shield.
9 . Remove the exhaust manifold.
Remove the bolt.

Installation

.
24 Nm (18 lb.ft).
3 . Install the exhaust manifold heat shield.

4 . Attach the air tube.
5 . Secure the exhaust manifold heat shield.
Tighten the screws.
6 . Install the LH engine mount.


8 . Install the oil level indicator and tube.


Exhaust Manifold RH - Vehicles Without:
Removal
2

4 . Release the EGR valve to exhaust manifold pipe.
Remove the 2 nuts.
Remove and discard the gasket.

6 . Remove the RH engine mount.
For additional information, refer to Engine Mount RH (12.45.03)
7 . Remove the RH heat shield.
Remove the bolt.

Installation

.
24 Nm (18 lb.ft).
Tighten the screws.
4 . Install the RH engine mount.


6 . Attach the EGR valve to exhaust manifold pipe.


Exhaust Manifold RH - Vehicles With:
Removal
2

Remove the 2 nuts.

7 . Release the RH exhaust manifold heat shield.
8 . Release the AIR tube from the RH exhaust manifold.
9 . Remove the RH exhaust manifold heat shield.

Remove the bolt.
Installation

.
24 Nm (18 lb.ft).
Tighten the screws.




Removal
2
3 . Remove the transmission.

For additional information, refer to Transmission (44.20.01)
4
. CAUTION: The bolts can only be used 3 times, mark the bolts with a center punch. If
2 punch marks are visible, discard the bolts.
NOTE:
Prevent the flexplate from rotating.
Remove the torque converter flexplate.
Remove the 8 bolts.

Installation
1 . NOTE:
Install the torque converter flexplate.
Tighten the bolts evenly in 2 stages to the sequence shown.
Tighten the bolts to 15 Nm (11 lb ft).
2 . Install the transmission.


Oil Pan (12.60.44)
Removal
1

3 . Remove the oil pan drain plug.
Discard the oil pan drain plug seal.
4 . Remove the oil pan.
Position a container to collect the oil spillage.

Installation
1 . Install the oil pan.
Install the new gasket.
2 . Evenly and progressively tighten the bolts in the sequence shown to 12 Nm (9 lb.ft).
3 . Tighten the drain plug to 25 Nm (18 lb.ft).
Install a new seal.

5 . Fill the engine with the recommended oil to the correct level.
Oil Pump (12.60.26)
Removal
2


For additional information, refer to Oil Pan (12.60.44)
5 . NOTE:
The bolts will remain captive.
Remove the oil strainer pick-up assembly.
Remove the 2 bolts.

6 . Remove the oil pump assembly.
Remove the 4 bolts.
Installation
1 . Install the oil pump assembly.
Clean the components mating faces.
2 . Install the oil strainer pick-up assembly.

4 . Install the timing drive components.



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.

2


5
Install the screw.

Remove the 3 bolts.

.
Remove the 2 bolts.

Remove the 2 bolts.
11 . Remove the LH variable camshaft timing (VCT) control solenoid housing.
Remove the 2 bolts.
Remove the nut.

13 . Remove the LH primary timing chain tensioner.
Remove the 2 bolts.

14 . Remove the LH upper and lower primary timing chain tensioner guides.
Remove the 2 bolts.
15 . Remove the LH primary timing chain.
16 .
CAUTION: Discard the bolts.
Release the LH camshaft sprocket assembly.

17 . Remove the LH secondary timing chain, tensioner and sprocket assembly.
Remove the 2 bolts.
18 .
Release the RH camshaft 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.
2
. CAUTION: Make sure the secondary timing chain and camshaft sprockets are free to
rotate.
NOTE:
Install the LH secondary timing chain, tensioner and sprocket assembly.
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.
4 . Install the LH secondary timing chain tensioner retaining bolts.

5 Install the LH primary timing chain.
.
chain.
6 . Install the LH primary timing chain tensioner guides.
7
NOTE:
Install the LH primary timing chain tensioner.

8
not followed.
CAUTION: Make sure that new bolts are installed.
Install the special tool to the LH exhaust camshaft sprocket.
9 . Install the LH VCT control solenoid housing.

10
. CAUTION: Make sure the secondary timing chain and camshaft sprockets are free
to rotate.

.
chain.
14

15
not followed.

Remove the 3 bolts.
Remove the 3 bolts.

Remove the screw.


Removal
2 Remove the purge valve.

. For additional information, refer to Evaporative Emission Canister Purge Valve - 4.2L SC V8 -
AJV8 (17.15.30)
3 . Remove the ignition coil-on-plug.

For additional information, refer to Ignition Coil-On-Plug - 4.2L SC V8 - AJV8 (18.20.40)
4 . Remove the remaining ignition coil-on-plugs.
Remove the nut.
6 . Remove the engine breather line.

7 . Disconnect the variable camshaft timing (VCT) oil control solenoid electrical connector.
8 . Remove the engine cover bracket.
Remove the 3 nuts.
Release the wiring harness.
9 . Disconnect fuel line from the fuel rail.

10 . Release the engine wiring harness.

11 . Release the coil-on-plug wiring harness.
12 . NOTE:
Note the fitted position of the retaining bolts prior to removal.
Remove the valve cover.
Remove the 14 valve cover retaining bolts.

13 . Remove and discard the valve cover retaining bolt O-ring seals.
14 . Remove and discard the valve cover gasket.
Carefully remove the sealant.
15 . Remove and discard the valve cover plug aperture seals.
16 . Remove and discard the VCToil control solenoid seal.

17 . NOTE:
Remove the oil filler pipe.
Installation
1 . Install the oil filler pipe.
2 . Install the new VCT oil control solenoid seal.
3 . Install the new valve cover plug aperture seals.
4 . Install a new valve cover gasket.
5 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.
6 . Install valve cover retaining bolts to their position previously noted.
Install new valve cover bolt O-ring seals.
Complete the tightening sequence as illustrated.
7 . Attach the coil-on-plug wiring harness.

8 . Attach the engine wiring harness.
9 . Install the engine cover bracket.
10 . Connect the VCT oil control solenoid electrical connector.
11 . Install the engine breather line.

14 . Install the ignition coil-on-plug.

15 . Install the remaining ignition coil-on-plugs.
16 Install the purge valve.

. For additional information, refer to Evaporative Emission Canister Purge Valve - 4.2L SC V8 -
AJV8 (17.15.30)
Removal

4 . Disconnect the positive crankcase ventilation (PCV) line.
Remove the 3 nuts.
Release the hose.

7 . Release the coil-on-plug wiring harness.
9 . NOTE:
Remove the valve cover.
10 . Remove and discard the valve cover retaining bolt O-ring seals.

12 . Remove and discard the valve cover plug aperture seals.
13 . Remove and discard the VCToil control solenoid seal.
14 . NOTE:
Remove the PCV valve.

Installation
1 . Install the PCV valve.
Tighten the Torx screws.
2 . Install the new VCT oil control solenoid seal.
3 . Install new valve cover plug aperture gaskets.
5 NOTE:
.

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.
10 . Install the engine cover bracket.
Secure the wiring harness.
Secure the hose.

11 . Connect the PCV line.


Oil Filter Housing
Wrench, Oil filter

303-752
Removal
2

4 . Disconnect the engine oil temperature sensor electrical connector.
5 . Disconnect the engine oil pressure (EOP) sensor electrical connector.

6 . NOTE:
Some oil spillage is inevitable during this operation.
NOTE:
Remove the oil filter.
7
the joint faces and connections are clean. Plug open connections to prevent contamination.
Disconnect the 2 engine oil cooler lines.
Remove the 2 bolts.
Remove the 3 bolts.
9 . NOTE:
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 the sensor to 15 Nm (11 lb.ft).
2 . Install the engine oil temperature sensor.
4 . Connect the engine oil cooler lines.

5 Using the special tool, install the oil filter.

.
Lubricate the oil filter seal with clean engine oil and tighten to 18 Nm (13
lb.ft).
6 . Connect the EOP sensor electrical connector.
7 . Connect the engine oil temperature sensor electrical connector.



Oil Level Indicator and Tube
Removal

3 . Remove the LH intake air resonator.
Remove the bolt.
4 . Remove the LH ignition coil-on-plug cover.

5
Remove the nut.
Installation
1 . With assistance, install the oil level indicator and tube.
Lubricate the O-ring seal with clean engine oil.
2 . Install the LH ignition coil-on-plug cover.


Oil Cooler (12.60.68)
Removal
1
2 . Remove the radiator splash shield.

3 . Remove the front bumper air ducting.
Remove the 7 clips.
Remove the 4 retainers.

5
. 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.
6 . Remove the oil cooler.
Remove the 2 bolts.

Remove the retainer.
Remove the 2 support brackets.
Installation
1 . Install the oil cooler.
Install the support brackets.
Install the retainer.
2 . Connect the oil cooler lines.

Install the retainers.
4 . Install the front bumper air ducting.
5 . Install the radiator splash shield.


Twin Oil Coolers
Removal
1

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.
NOTE:
Right-hand shown, left-hand similar.
Disconnect the 2 oil cooler lines.
Position a container to collect the engine oil.
Remove the 2 nuts.
Remove the 2 brackets.

4 . NOTE:
Remove the oil cooler.
Remove the 4 securing nuts.
Installation
Install the support brackets.
Install the retainer.
Tighten to 5 Nm.
2 . Connect the oil cooler lines.
Tighten to 7 Nm.


Disassembly
Engine
Crankshaft locking, main tool

303-191
Adapter
303-191-02

303-588
Crankshaft setting, main tool

303-645
Camshaft setting
303-530
Crankshaft damper holding tool

303-D055
Cylinder Bore Protectors

303-535
Disassembly
1 . Disconnect the oil cooler hoses.

2 . Detach the supercharger belt.
• Use a 1/2 inch square drive bar to rotate the supercharger belt tensioner.
• Detach the supercharger belt.
3 . Release the accessory drive belt tension.
• Use a 3/8 inch square drive bar to rotate the drive belt tensioner.
• Detach the accessory drive belt.
• Remove the accessory drive belt.

6 . Detach the wiring harness.
7 . Detach the generator battery positive cable protective cover.

8 . Disconnect the generator battery positive cable.
9 . Disconnect the generator electrical connector.
10 . Remove the generator.
11 . Detach the engine wiring harness.

12 . Remove the generator mounting bracket.
13 . Detach the right-hand oxygen sensor retaining bracket.
15 . Remove the starter motor.

• Remove and discard the O-ring seal.
17 . Remove the heat shield.
18 . Remove the heat shield retaining bolt.
19 . Remove the left-hand exhaust manifold.
• Remove and discard the gasket.

20 . Remove the left-hand engine mount.
21 . Remove the left-hand engine mounting bracket.
22 . Disconnect the A/C compressor electrical connector.

23 . Remove the A/C compressor.
24 . Remove the air conditioning compressor mounting bracket.

27 . Disconnect the crankshaft position sensor electrical connector.
28 . Remove the crankshaft position sensor.

1. Disconnect the variable valve timing (VVT) solenoid electrical connector.
2. Detach the engine wiring harness.
33 . Disconnect the coolant temperature sensor electrical connector.

35 . Detach the hoses.
• Reposition the hose retaining clip.
36 . Detach the supercharger outlet pipe coolant hose.
• Cap the coolant ports.
37 .
CAUTION: Make sure no foreign matter enters the supercharger.
Remove the supercharger outlet pipe
38 . Remove and discard the supercharger outlet pipe gasket.
39 . Remove and discard the supercharger outlet pipe retaining bolt seals.
40 . Remove and discard the supercharger outlet pipe to charge air coolers ducts.
41 . Disconnect the thermostat housing hoses

43 . Reposition the thermostat housing hose retaining clip.
44 . Disconnect the hose.

48 . Remove the thermostat housing retaining bolts.
49 . Remove the thermostat housing.
• Remove and discard the thermostat housing O-ring seals.

50 . Disconnect the charge air cooler coolant pipes.
51 . Disconnect the intake air temperature (IAT) sensor electrical connector.
52 . Disconnect the electrical connectors.

53 . NOTE:
Cap the exposed ports.
Detach the coolant hose from the throttle body.
55 . Disconnect the exhaust gas recirculation (EGR) valve electrical connector.
56 . NOTE:
Disconnect the coolant hoses.
57 . Remove the EGR valve and the exhaust manifold to EGR valve tube.
• Remove the retaining bolts.
• Remove and discard the exhaust manifold to EGR valve tube gasket.
• Remove and discard the EGR valve to air intake elbow gasket.
58 . Disconnect the air intake elbow pipes.

59 . NOTE:
Make sure correct location of the ground strap is noted.
Remove the air intake elbow retaining bracket lower retaining bolts.
60 . Detach the air intake elbow.
• Remove and discard the retaining bolt seals.
61 . Remove the air intake elbow.
• Disconnect the manifold absolute pressure (MAP) sensor.

62 . Remove the supercharger.
63 .
CAUTION: Make sure no foreign matter enters the cylinder head ports.
NOTE:
Remove the charge air coolers.
• Remove and discard the charge air cooler gasket.

64 . Disconnect the knock sensor electrical connectors.
65 . NOTE:
Left-hand shown, right-hand similar.
Remove the ignition coil cover.
66 . Remove the engine cover retaining bracket.

68 . NOTE:
Detach the engine wiring harness.
69 . NOTE:
Disconnect the fuel injector electrical connectors.
70 . Disconnect the ignition on-plug coil electrical connectors.

73 . Disconnect the camshaft position sensor electrical connector.

• Detach the ground cable.
• Disconnect the variable valve timing (VVT) solenoid electrical connector.
• Remove the retaining bolt.

77 . Disconnect the positive crankcase ventilation pipe.
78 . Disconnect the fuel pressure regulator electrical connector.
79 . Disconnect the exhaust gas recirculation valve electrical connector.
80 . Disconnect the exhaust gas recirculation valve coolant hose.

82 . Disconnect the fuel injector electrical connectors.

85 . Disconnect the fuel temperature sensor electrical connector.
87 . Detach the engine wiring harness

89 . Remove the intake manifold.
90 . Remove the lower intake manifold.
91 . NOTE:
Place a suitable container underneath the filter to prevent oil spillage.
Remove the oil filter element.

93 . Disconnect the oil pressure switch and oil temperature sensor electrical connectors.
95 . Detach the right-hand oxygen sensor.

96 . Detach the engine wiring harness retaining clips.
97 . Remove the engine wiring harness
98 . Remove the noise and vibration insulating pad.
99 . Remove the intake manifold heater coolant hose.
4. Remove the knock sensors.
5. Remove the intake manifold heater coolant hose.

100 . Remove the engine block insulation grommet.
101 . Remove the water pump pulley.
• Using the special tool, retain the water pump pulley.
102 . Remove the water pump.

• Remove and discard the O-ring seals.
104 . NOTE:
Left-hand shown, right-hand similar
Remove the ignition coils.

106 . Remove the right-hand camshaft position (CMP) sensor.
107 . Remove the left-hand camshaft position (CMP) sensor.
108
. CAUTION: Under no circumstances should the crankshaft setting peg 303-645 be
used in the following operations to lock the crankshaft.
NOTE:
The crankshaft retaining bolt will be very tight.
Using special tools, retain the crankshaft pulley.
• Remove and discard the crankshaft pulley bolt.

110 . NOTE:
The crankshaft pulley will be very tight.
Using special tools, remove the crankshaft pulley.
• Collect the locking ring.

112
. CAUTION: Make sure the spark plugs are removed to enable the engine to rotate
freely.
CAUTION: Do not rotate the crankshaft counterclockwise. The timing chains may
bind causing engine damage.
CAUTION: Rotate the crankshaft clockwise to position the engine to top dead
center (TDC) No. 1 cylinder.
Install the special tool 303-645.
113 . Remove the right-hand valve cover.
• Discard the valve cover gaskets.

114 . Remove the left-hand valve cover.

116 . Remove the right-hand variable camshaft timing oil control unit housing.
117 . Remove the left-hand variable camshaft timing oil control unit housing.

118 . Install the special tool to the left-hand cylinder head.
119 . Install the special tool to the right-hand cylinder head.
120 . Remove the primary timing chain tensioner assembly.

121 . Remove the primary timing chain tensioner guide.
122 . Remove the primary timing chain.
123 . Remove the primary timing chain guide.
124 . Remove the secondary timing chain tensioner retaining bolts.

125 Remove the camshaft sprockets.
.
• Remove the secondary timing chain tensioner and secondary timing chain from the
camshaft sprockets.

129 . Remove the crankshaft sprocket.

.
camshaft sprockets.
133 . Remove the camshaft setting tool.
135 Remove the camshaft bearing caps.

.
• Remove the camshaft bearing cap retaining bolts evenly and in stages.
• Remove the camshaft bearing caps. Note their orientation and markings, each is
marked with its position (a number) and orientation (an arrow).
136 . Remove the right-hand exhaust camshaft.

.
138 . Remove the right-hand intake camshaft.

.
140 . Remove the left-hand exhaust camshaft.

.
142 . Remove the left-hand inlet camshaft.
143
Remove the right-hand cylinder head.
• Remove the bolts in the indicated sequence.

144
Remove the left-hand cylinder head.
145 . Remove the crankshaft setting peg 303-645 from the crankshaft position sensor location.
146 . Remove the flexplate.
6. Remove the flexplate retaining bolts.
7. Remove the flexplate.
147 . Remove the lower oil pan.

148 . Remove the oil strainer.
149 . Remove the upper oil pan.

150 . Remove the oil pump.
151 Inspect the tops of the cylinder bores. As necessary remove ridge and carbon build up from
. each cylinder.
152 . Remove the piston cooling jets.
153
. CAUTION: Pistons, connecting rods and connecting rod bearings should be
numbered to make sure they are reassembled in the same position.
NOTE:
Mark the position of the connecting rod caps to the connecting rods to make sure of
correct installation.
NOTE:
Discard the connecting rod bolts after removal.
Remove the connecting rod bolts, the connecting rod caps and the lower connecting rod
bearings.
154
. CAUTION: Use appropriate protection to prevent damage to the crankshaft
bearing journals and cylinder bore surfaces.
Install special tools to the connecting rods.
155
. CAUTION: Care should be taken not to damage the connecting rod and cap joint
face surfaces or possible engine damage may occur. Avoid contaminating the fractured
joint surfaces with dirt or grease.
NOTE:
Attach the connecting rods and caps after removal to avoid mismatch.
Remove the pistons.
• Rotate the crankshaft to locate pistons at the bottom of travel.
• Push the piston, connecting rod and upper bearing through the top of the cylinder.
156 . NOTE:
Remove the lower cylinder block bolts in the indicated sequence.
NOTE:
Mark the position of the upper and lower crankshaft main bearings for reassembly.
Remove the lower cylinder block.
• Remove the lower cylinder block retaining bolts in the indicated sequence.
157 . Discard the crankshaft rear main oil seal.
158
. CAUTION: Avoid damage to any crankshaft bearing surfaces.
NOTE:
Never remove any pipe, plugs or dowels unless they are to be newly installed or the
cylinder block is to be washed.
Remove the crankshaft.
159 . Remove the upper crankshaft main bearings.
8. Remove the upper crankshaft thrust washers.
9. Remove the upper crankshaft main bearings.
160 Clean the cylinder block with a soap and water solution. Dry the cylinder block completely
. with compressed air.
Disassembly/assembly of subassemblies

Valve Spring Compressor

303-252
Disassembly
1
. CAUTION: Do not use a magnet to remove shims. Failure to follow these instructions
CAUTION: If the cylinder head valve components are to be reused, mark the
position of the valve components to make sure they are reassembled in the same position.
Remove the bucket tappet and shim assemblies.

2 . Remove the camshaft position (CMP) sensor.
• Remove and discard the 'O' ring seal.
3 . Using the special tool, compress the valve springs.
• Remove the valve collets.
4 . Remove the valve spring retainers and valve springs.
1. Remove the valve spring retainers.
2. Remove the valve springs.
3. Remove the valve stem oil seals.

5 . Remove the valves from the cylinder head.
4. Remove the intake valves.
5. Remove the exhaust valves.
6 Inspect the cylinder heads and related components. For additional information, refer to
. <<303-00>>
7 . Remove the pipe plugs and alignment dowels as necessary to clean the cylinder heads.
Assembly
1
. WARNING: Eye protection is required during use of compressed air. Failure to follow
these instructions may result in personal injury.
CAUTION: The cylinder head surface finish is measured in microns. For correct head
gasket sealing, avoid any contact of finish with metallic objects.
Clean gasket material, dirt and foreign material from cylinder heads. Wash with a suitable
soap and water solution and dry the cylinder head completely using compressed air if pipe
plugs have been removed.
2 . Install the pipe plugs and alignment dowels to cylinder heads.
• Apply pipe sealant to plugs prior to installation.
3 . NOTE:
Lubricate the valve stems before assembly.
Install the valves into the cylinder heads.
6. Install the intake valves.
7. Install the exhaust valves.
4 . Install the valve spring retainers and valve springs.
8. Install the valve stem oil seals.

9. Install the valve springs.
10. Install the valve spring retainers.
• Install the valve collets.
6 . Install the camshaft position (CMP) sensor.
• Install a new 'O' ring seal.
• Tighten to 7 Nm.
7
. CAUTION: Do not use a magnet to install shims. Failure to follow these instructions
Install the bucket tappet and shim assemblies.

Assembly
Engine

303-191
Adapter
303-191-02

303-645
Camshaft setting
303-530
303-532

303-535
Piston Ring Compressor

303-372
Crankshaft rear oil seal remover/replacer

303-538
Crankshaft front seal installer

303-538
303-D055
Assembly
1
. CAUTION: Use only a plastic scraper when removing old gasket material.
Clean all the mating faces and reusable parts thoroughly and check for damage.
• If gasket material remains on the cylinder head after cleaning, use a plastic tipped
scraper to remove remaining material.
2 . NOTE:
Never remove pipe plugs or alignment dowels unless they are to be serviced.
Reseal oil passage blanking plugs, as necessary.
3 . NOTE:
The main bearings are precision selective fit.
NOTE:
Lubricate the upper crankshaft main bearings and thrust washers.
Install the upper crankshaft main bearings.

For additional information, refer to Camshaft Bearing Journal Clearance
1. Install the upper crankshaft thrust washers.
2. Install the upper crankshaft main bearings.
4.
CAUTION: Avoid damage to any crankshaft bearing surfaces.
Install the crankshaft.
5 NOTE:
.
NOTE:
Install lower cylinder block and tighten bolts to specification within twenty minutes of
applying sealer.
Apply a bead of sealant to the cylinder block housing.

• Use WSS-M4G320-A3-RTV sealant.
6
. CAUTION: Make sure all dowels are fully seated into lower cylinder block prior to
tightening the bolts.
CAUTION: Do not lubricate the lower cylinder block bolts.
CAUTION: Do not rotate crankshaft until all bolts are tightened to specification.
CAUTION: Bolts must be tightened within twenty minutes of applying sealer.
CAUTION: Tighten the bolts in the sequence shown.
Install the lower cylinder block to the upper cylinder block.
3. Tighten bolts 21 to 32 to 15 Nm
7. Tighten bolts 1 to 10 to 35 Nm +135°
7 . Rotate the crankshaft to check correct operation.
8 . Remove excess sealant which may squeeze out at the front cover sealing surfaces.
9.
CAUTION: Do not use any lubricant on the seal, the transit sleeve or the crankshaft.
CAUTION: Make sure all components are clean and dry.
Make sure the transit sleeve is correctly in place and install the new seal over the crankshaft.
10 . Carefully remove the transit sleeve, leaving the seal in place.
11 . Install the special tool to the crankshaft.
12 Reposition the nuts to hold the special tool against the crankshaft rear seal. Check that the
. crankshaft rear seal and the special tool are parallel to the rear of the engine.
13 .
CAUTION: Alternate nut tightening to correctly seat the crankshaft rear seal.
Using the special tool, install the crankshaft rear seal.

14 . Remove the special tool from the crankshaft.
• Check that the seal is located correctly.
15
• Position the crankshaft journal at the bottom of the stroke.
16
. CAUTION: Make sure the piston rings are positioned at different positions opposite
the thrust side of the piston before installation.
CAUTION: Install pistons with arrow to front of engine.
Using the special tool compress the rings and install the piston and connecting rod.
• Lubricate all piston components.

17
. CAUTION: When assembling the connecting rods and connecting rod caps it is
imperative that bearing slots and tangs be located on the same side of the connecting
rods.
CAUTION: Connecting rod bolts are torqued to yield and must be replaced.
CAUTION: Bolts must be tightened equally.
NOTE:
Remove the special tools from the connecting rods.
Position the connecting rod cap on the appropriate connecting rod.
11. Tighten to 10 Nm
13. Tighten to 90°

19 . Install the piston cooling jets.
• Tighten to 9 Nm
20 . Install the oil pump.
• Install a new gasket.
21 . Install the upper oil pan.
22 . Install the oil strainer.
• Install a new O-ring seal.
• Install, but do not fully tighten the retaining bolts.

24 Tighten to 12 Nm.
.
• Tighten in the sequence shown.
• A new oil pan is supplied with the drain plug installed. Check that the drain plug is
tightened to 25 Nm.
25 . Install the flexplate.

14. Install the flexplate.
15. Install the flexplate retaining bolts.
26 . Reposition the crankshaft.
• Install the crankshaft setting peg 303-645 to the crankshaft position sensor location.
27 . Install a new left-hand cylinder head gasket.
• Make sure the cylinder head dowels are correctly located.

28
. CAUTION: Vehicles fitted with Polydrive cylinder head bolts, the cylinder head
bolts must be installed using a 10 mm Polydrive socket or a 10 mm Allen key. Failure to
CAUTION: Tighten the bolts 1 to 10 in the sequence shown.
Install the left-hand cylinder head.
16. Tighten bolts 1 to 10 to 20 Nm.
18. Tighten bolts 1 to 10 to 90°.

29 . Install a new right-hand cylinder head gasket.
30
Install the right-hand cylinder head.

31 . NOTE:
Make sure all components are clean.
Apply oil (EP-90) to the camshaft and bearing surfaces, as follows:
• To the upper face of each bearing surface in the cylinder head.
• To the upper face of each bearing surface in each bearing cap.
• On the cam lobes ONLY, not on the base circle area.
32 . Install the left-hand inlet camshaft.

33 .
CAUTION: Alternate bolt tightening to correctly seat the camshaft bearing caps.
Install the camshaft bearing cap bolts evenly.
34 . NOTE:
35 . Install the left-hand exhaust camshaft.

36 .
37 . NOTE:

38 . Install the right-hand inlet camshaft.
39 .
40 . NOTE:

41 . Install the right-hand exhaust camshaft.
42 .
43 . Install the camshaft setting tool.
45
. CAUTION: Do not tighten the camshaft sprocket retaining bolts.
CAUTION: Make sure the secondary timing chain and camshaft sprockets are free
to rotate.
Install the camshaft sprockets.

• Install the secondary timing chain tensioner and secondary timing chain to the
camshaft sprockets.
46 . Using a suitable tool, retain the left-hand timing chain tensioner piston.
47 . Release the tension in the left-hand timing chain tensioner.
• Remove the retaining tool.
48 . Install the secondary timing chain tensioner.
49 Install the timing chain tensioning tool 303-532 to the exhaust camshaft sprocket.
.
• Reposition the camshaft sprockets for the most advantageous position for use of the
tool.
50 . Install the primary timing chain tensioner guide.

52
. CAUTION: Make sure the timing chain slack is on the tensioned side of the timing
chain.
Install the primary timing chain.
• Install the primary chain over the crankshaft sprocket and the intake sprocket.
54
Using a suitable tool, hold the left-hand timing chain tensioner ratchet lock mechanism away
from the ratchet stem.
55 NOTE:
.
The timing chain tensioner piston should retract with minimal force. If binding occurs,
reposition the timing chain tensioner to eliminate side loading.
Slowly compress the left-hand timing chain tensioner.
56 NOTE:
.
The retaining tool must remain in the timing chain tensioner until the timing chain
tensioner is installed to the engine with the piston bottomed in the bore.
Using a suitable tool, retain the left-hand timing chain tensioner piston.
57 . Install the primary timing chain tensioner assembly.
59
. CAUTION: While applying the opposing force to sprocket and chain, tighten the
sprocket bolt.
Using the special tool apply force to the tool in an anti-clockwise direction to tension the
primary timing chain on its drive side.
• Tighten to 20 Nm + 90 deg.
60
sprocket bolt.
Using the special tool apply force to the tool in an anti-clockwise direction.
61
to rotate.
camshaft sprockets.
62 . Using a suitable tool, retain the right-hand timing chain tensioner piston.
63 . Install the secondary timing chain tensioner retaining bolts.
64 . Release the tension in the right-hand timing chain tensioner.
.
tool.
66 . Install the primary timing chain guide.
67
chain.
69
Using a suitable tool, hold the right-hand timing chain tensioner ratchet lock mechanism
away from the ratchet stem.
70 NOTE:
.
Slowly compress the right-hand timing chain tensioner.
71 NOTE:
.
Using a suitable tool, retain the right-hand timing chain tensioner piston.
74
sprocket bolt.
75
sprocket bolt.
76 . Remove the special tool from the right-hand cylinder head.

77 . Remove the special tool from the left-hand cylinder head.
78 . Install the left-hand variable camshaft timing oil control unit housing.
• Install new O-ring seals.
79 . Install the right-hand variable camshaft timing oil control unit housing.
81 . Install the crankshaft position sensor.
82 . Install new seals to the timing cover.
26. Install the new seal to the inner groove on the face of the timing cover.
27. Install the new seal to the outer groove on the face of the timing cover.
83 Apply sealant to the eight joints on the engine face.

. • Sealant beads to be 3mm diameter and 12mm long. Cut the nozzle of the sealant tube
to produce a 3 mm bead. (Install and tighten the securing bolts within twenty minutes of
sealant application).
84 . Install the timing cover.
85 .
CAUTION: Make sure the crankshaft front seal mating faces are clean and dry.
CAUTION: Do not remove the crankshaft front seal protector.
Using the special tool, install a new crankshaft front seal.
86 . Remove the crankshaft seal protector.
87 . Install a new O-ring seal to the crankshaft pulley.
• Lubricate the new O-ring.
88
. CAUTION: The screw thread in the crankshaft must be cleaned out before a new
crankshaft pulley bolt is installed.
CAUTION: A new crankshaft pulley bolt must be used.
Install, but do not tighten, a new crankshaft pulley retaining bolt.

• Install the crankshaft pulley and locking ring to the crankshaft.
89
• Tighten the crankshaft pulley retaining bolt to 375 Nm.
91 . Carry out a valve clearance check.

For additional information, refer to Valve Clearance Check (12.29.47)
92 NOTE:
.
Apply an 8mm diameter bead of silicone gasket sealant on the two places where the
cylinder head and front cover join.
Install the left-hand valve cover.
• Install new valve cover gaskets.
93 NOTE:
.
Install the right-hand valve cover.
94 . Install the spark plugs.
95 . Install the left-hand camshaft position (CMP) sensor.
96 . Install the right-hand camshaft position (CMP) sensor.
97 . NOTE:

Install the ignition coils.
98 . Install the thermostat housing.
99 . Install the water pump.
• Install new O-ring seals and gaskets.
100 . Install the water pump pulley.
• Using special tool, retain the water pump pulley.
• Tighten to 10 Nm + 45°.
101 . Install the engine block insulation grommet.
102 . Install the intake manifold heater coolant hose.
28. Install the knock sensors.
29. Install the intake manifold heater coolant hose.
103 . Install the noise and vibration insulating pad.
104 . Install the engine wiring harness.
105 . Attach the engine wiring harness retaining clips.
106 . Attach the right-hand oxygen sensor.
108 . Connect the oil pressure switch and oil temperature sensor electrical connectors.
110 . NOTE:
Apply a suitable amount of clean engine oil to lubricate the oil filter O-ring seal.
Install a new oil filter.
111 .
112 . Install the intake manifold.
114 . NOTE:
Left-hand shown, right-hand simular.
Install the lower intake manifold.
116 . Connect the camshaft position sensor electrical connector.
117 . Connect the fuel temperature sensor electrical connector.
118 . Connect the ignition on-plug coil electrical connectors.

120 . Connect the fuel injector electrical connectors.
122 . Connect the exhaust gas recirculation valve coolant hose.

123 . Connect the exhaust gas recirculation valve electrical connector.
124 . Connect the fuel pressure regulator electrical connector.
125 . Connect the positive crankcase ventilation pipe.

128 . Attach the engine harness.
30. Connect the earth wire.
31. Connect the variable valve timing (VVT) solenoid electrical connector.
• Attach the engine harness.

133 . NOTE:
Left-hand shown, right hand similar.
Connect the fuel injector electrical connectors.

135 . Install the engine cover retaining bracket.

137 . NOTE:
Install the ignition coil cover.
138 . Connect the knock sensor electrical connectors.
139 . NOTE:
Install the charge air coolers.
• Install a new charge air cooler gasket.
140 . Install the supercharger.
141 . Connect the manifold absolute pressure (MAP) sensor.
142 . Install the air intake elbow.
• Install new retaining bolt seals.
143 . NOTE:
Make sure ground strap is correctly installed to the location noted.
Install the air intake elbow retaining bracket lower retaining bolts.
144 . Connect the air intake elbow pipes.
145
. 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.
Install the throttle body.
• Install a new throttle body gasket.
146 . NOTE:
Un-cap the coolant hose.
Attach the coolant hose to the throttle body.
147 . Connect the electrical connectors.

148 . Install the EGR valve and the exhaust manifold to EGR valve tube.
• Install a new exhaust manifold to EGR valve tube gasket.
• Install a new EGR valve to air intake elbow gasket.
150 . NOTE:
Un-cap the exposed ports.

Connect the coolant hoses.
151 . Connect the exhaust gas recirculation (EGR) valve electrical connector.
152 . Connect the IAT sensor electrical connector.
153 . Connect the charge air cooler coolant pipes.

154 . Install new O-ring seals to the thermostat housing.
155 . Install thermostat housing.
158 . Connect the hose.


163 . Connect the coolant temperature sensor electrical connector.
164 . Connect the thermostat housing hoses
165 . Install new supercharger outlet pipe to charge air coolers ducts.
166 . Install a new supercharger outlet pipe gasket.
167 . Install new seals to the supercharger outlet pipe retaining bolts
168 .
Install the supercharger outlet pipe
169 . NOTE:
Un-cap the coolant ports.
Attach the supercharger outlet pipe coolant hose.
170 . Attach the hoses.

33. Attach the engine wiring harness.

177 . Connect the crankshaft position sensor electrical connector.

180 . Install the air conditioning compressor mounting bracket.
181 . Install the A/C compressor.
182 . Connect the air conditioning compressor electrical connector.
183 . Install the left-hand engine mounting bracket.
184 . Install the left-hand engine mount.
185
. CAUTION: Make sure the exhaust manifold and gasket are correctly aligned to
the cylinder head.
CAUTION: Make sure the exhaust manifold torque is checked after initial tighten.
Install the left-hand exhaust manifold.
186 . Install the heat shield retaining bolt.
189 . Install the starter motor.

191 . Attach the right hand oxygen sensor retaining bracket.
192 . Install the generator mounting bracket.
194 . Install the generator.
• Tighten the generator upper retaining bolt to 21 Nm.
• Tighten the generator lower retaining bolt to 40 Nm.

196 . Connect the generator electrical connector.
197 . Attach the generator battery positive cable.
• Tighten to 12 Nm
198 . Attach the generator battery positive cable protective cover.

• Install the accessory drive belt.

• Attach the accessory drive belt.
202 . Install the supercharger belt.
203 . Connect the oil cooler hoses.

303-01B : Engine – 4.2L NA V8 – AJV8
Specifications
Specifications
Engine Data
Maximu Maximu
Maximu Maximu
m m
Engine m m
Engine Engine Engine Compressio Bor Strok
Capacit Engine Engine
Description Torque Torque n Ratio e e
y Torque Power
(EC and (EC and
(DIN) (DIN)
SAE) SAE)
• 90°
'Vee'
293.5
• 8 300 BHP
BHP /
Cylin 420 Nm / 224 kW 410.8 Nm
4196 218.9 kW 11.0:1 ± 86.0 90.3
der at 4100 / 304 PS at 4100
cm³ / 298 PS 0.5:1 mm mm
• 32 RPM at 6000 RPM
at 6000
Valve RPM
RPM
s
Engine Firing Order
Firing Order
1:2:7:3:4:5:6:8
Engine Valve Clearance (cold)
Intake Valve Exhaust Valve

0.18 - 0.22 mm 0.23 - 0.27 mm
Spark Plugs
Specification Spark Plug Gap

AJ8 4575 0.9 - 1.0 mm
Description Specification
Core plug and stub pipe retainer WSK-M2G349-A4
Engine oil, SAE 5W-30 WSS-M2C-913B
Sealant WSE-M4G323-A4
Capacities
Description Liters
Engine oil, initial fill 7.8
Engine oil, service fill with oil filter change 7.0
Cylinder head and Valvetrain
Item Specification
Cylinder head maximum permitted warp
0.125
(mm)
Valve guide inner diameter (mm) 5.00 - 5.02
Intake valve effective length (mm) 88.87 - 89.17
Exhaust valve effective length (mm) 88.40 - 88.70
Valve stem to guide clearance intake
0.022 - 0.057
decimetrical (mm)
Valve stem to guide clearance exhaust
0.030 - 0.065
decimetrical (mm)
Valve head diameter intake (mm) 34.8 - 35.0
Valve head diameter exhaust (mm) 30.8 - 31.0
Intake valve face angle (degrees) 45° 15' 30" ± 7° 30'
Exhaust valve face angle (degrees) 45° - 44° 45'
Valve stem diameter intake (mm) 4.963 - 4.978
Valve stem diameter exhaust (mm) 4.955 - 4.970
Valve spring free length (mm) 43.5 MAX
Valve spring installed height (mm) 33.20
Camshaft lobe lift intake (mm) 8.50
Camshaft lobe lift exhaust (mm) 8.50
Camshaft journal to cylinder head bearing * Front bearing 0.045 - 0.085 * Other bearings
surface clearance diametrical (mm) 0.055 - 0.075
Camshaft journal diameter standard runout * Center bearing to outer bearings 0.07 * Other
limit (mm) bearings to outer bearings 0.05
Camshaft journal diameter standard out of
0.005
round (mm)

Camshaft bearing caps - bolt 10 7 88
Camshaft exhaust sprocket A - -
Connecting rod to bearing cap - bolt A - -
Crankshaft damper pulley - bolt 320 236 -
Cylinder head - bolt A - -
Engine cover (top) 4 3 35
Engine cover (top) mounting bracket - nut 6 4 53
Engine mounting to engine mounting bracket - nut 48 35 -
Engine mounting to subframe - nut 63 46 -
Engine mounting bracket to engine - bolt 40 30 -
Engine wiring harness bracket - nut/bolt 10 7 88
Exhaust manifold - bolt A - -
Exhaust manifold heat shield - bolt 3 2 27
Flexplate - bolt A - -
Intake manifold - bolt 21 19 -
Lifting eye (front) - bolt 30 22 -
Lifting eye (rear) - bolt 40 30 -
Oil cooler to oil filter housing 58 43 -
Oil filter 17 12 -
Oil filter housing to engine - bolt 21 15 -
Oil level indicator tube - nut 6 4 53
Oil pan to oil pan body - bolt A - -
Oil pan body to engine A - -
Oil pan drain plug 23 17 -
Oil pump pick-up pipe to oil pan body - bolt 12 9 -
Oil pump to engine block - bolt 12 9 -
Oil pump to pick-up pipe - bolt 12 9 -
Piston cooling jet - bolt 9 7 80
Plug - M30 x 12 to engine block 50 37 -
Plug (flanged) - M30 - 1.5 x 20 to engine block 50 37 -
Primary timing chain tensioner - bolt 11 8 -
Primary timing chain tensioner, guide blade - bolt 11 8 -
Radio frequency interference suppressor to engine cover bracket - bolt 10 7 88
Secondary timing chain tensioner - bolt 11 8 -
Timing belt cover - bolt A - -
Valve cover - bolt A - -
Variable camshaft timing, oil control solenoid housing - bolt 21 15 -
Variable camshaft timing, oil control solenoid housing - nut 11 8 -
Variable camshaft timing sprocket - center bolt A - -
A = refer to procedure for correct torque sequence
General procedure


303-540

303-540/02

303-590
CAUTION: 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.
CAUTION: Camshaft lobes must be 180 degrees away from each valve tappet or valve
clearance will be incorrect.
2. Check the valve clearances.

4. Install the special tool 303-540, to the cylinder head.
5.
CAUTION: Do not rotate the crankshaft while the special tool 303-540/02 is attached 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
NOTE:
Use the following formula to calculate the required shim thickness. Original shim thickness +
measured shim clearance - desired clearance = required shim thickness.

• 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.
CAUTION: Shims must be fitted with the size markings facing the tappet, not the camshaft.
CAUTION: Do not use a magnet to install shims. Failure to follow these instructions may
• 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 tappet.
11. Repeat the above procedure for the remaining valves.
CAUTION: 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.
CAUTION: Camshaft lobes must be 180 degrees away from each valve tappet or
2. Remove the LH valve cover.

3. Remove the RH valve cover.

4. Rotate the engine clockwise to position the camshaft lobe away from the valve tappet
5. Using the feeler gauge set, measure the clearance between the camshaft and the valve
tappet.
6. Repeat the above procedure for the remaining 31 tappets.
7. Adjust the clearance as necessary.

8. For cylinder head data, refer to specifications.
9. Install the RH valve cover.

10. Install the LH valve cover.

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:

Specifications
2.
3. Remove the engine undershield.

4. Remove the oil pan drain plug.
• Discard the oil pan drain plug seal.
5. Remove the oil filter.
• Discard the oil filter.
6. Using the special tool, install the oil filter.
• Lubricate the oil filter seal with clean engine oil and tighten to 18 Nm (13 lb.ft).
7. Tighten the drain plug to 25 Nm (18 lb.ft).
• Install a new seal.
8. Fill the engine with oil.

Specifications
10. Start engine and run at idle speed until the oil pressure warning light extinguishes.
• Stop the engine.
• Check for leaks.
11. Install the engine undershield.

12. Check and top-up the engine oil.

Engine
EXTERNAL VIEW
INTRODUCTION
The V8 petrol engine is a 4.2 liter, 8 cylinder, 90 degrees 'V' unit, with 4 valves per cylinder, operated
by 2 overhead camshafts per cylinder head. The engine emissions comply with ECD4 (European
Commission Directive) and US Federal Tier2 Bin 5 legislative requirements and employs catalytic
converters, electronic engine management control and positive crankcase ventilation to limit the
emission of pollutants. The cooling system is a low volume, high velocity system. The Engine Control
Module (ECM) controls the fuel injection system, the ignition system and the electric throttle.
The cylinder block is of aluminium alloy construction with cast iron liners. A cast aluminium bedplate
is bolted to the bottom of the block to improve lower structure rigidity. The cylinder heads are cast
aluminium with thermo-plastic camshaft covers. A pressed steel sump pan is bolted to the cast
aluminium structural sump. The fabricated stainless steel twin skin exhaust manifolds are unique for
each cylinder bank. A moulded plastic acoustic cover is fitted over the upper engine to reduce
engine-generated noise.
Engine Structure
1 Cylinder head (2 off)
2 Cylinder block
3 Bedplate
4 Structural sump
5 Sump pan
Technical Features
• An 8-cylinder 90-degree 'V' configuration liquid cooled aluminium cylinder block with cast
iron liners
• Pistons are of open-ended skirt design, with two compression rings and a three-piece oil
control ring
• Two aluminium cylinder heads, each incorporating two camshafts manufactured in chilled
cast iron
• Four valves per cylinder
• Graded valve lifters (shimless)
• Top fed, 8-hole fuel injectors
• Engine front cover manufactured from aluminium, accommodating the crankshaft front oil
seal
• Primary and secondary chain drive for the camshafts
• An aluminium bedplate
• A cast iron crankshaft
• Fracture-split connecting rods in sintered-forged steel
• A twin multi-vee belt, driving the front-end accessories
• Fabricated stainless steel twin skin exhaust manifolds
• An advanced engine management system incorporating electronic throttle control
• Meets with the fault handling requirements, as detailed in the European On-Board
Diagnostic (EOBD) III, US Federal OBD and California OBDII legislation.
CYLINDER BLOCK COMPONENTS
1 Piston rings
2 Piston
3 Circlip
4 Connecting rod
5 Bolts (16 off)
6 Connecting rod bearing shells
7 Bearing
8 Gudgeon pin
9 Circlip
10 Cylinder block
11 Pistons
12 Bolts (8 off)
13 Flywheel
14 Seal
15 Dowel
16 Crankshaft
17 Thrust washer
18 Thrust washer
19 Bearing shells - upper
20 Bearing shells - lower
21 Oil level gage tube
22 Oil level gage
23 Bedplate
24 Bolts (10 off)
25 Bolts (10 off)
26 Bolts (12 off)
27 Bolt
28 Bolts (8 off)
29 Windage tray
30 Sump
32 Flange
33 Bolts (11 off)
34 Clip
35 Bolts (2 off)
36 Stud
37 Oil pick-up pipe
38 Bolts (17 off)
39 Sump pan
40 Gasket
41 Bolts (3 off)
43 Engine oil cooler
44 Oil filter
46 Engine coolant temperature sensor
47 Seal
48 Bolts (4 off)
49 Oil pump
50 Crankshaft sprocket
51 Crankshaft pulley
52 Taper collet
53 Crankshaft bolt
Cylinder Block
The cylinder block is an 'Enclosed V' design, which provides an inherently 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 right hand cylinder bank is designated as 'A' bank, and
the left hand as 'B' bank. The cylinder bores are numbered from 1 to 4, for bank 'A' and 5 to 8 for
bank 'B', starting from the front of the engine.
Engine Data Locations
Part
Item Description
Number
1 Engine part number
Engine data (main bearing diameters, cylinder bore diameters, etc), emissions
2
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 a label displaying the engine number. Component diameters are represented by alpha
and numeric codes; keys to the codes are in the Service Repair Procedures (SRP) sections of this
manual.
Connecting Rods and Pistons
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
aluminium/tin split plain bearings.
The pistons are of the open-ended skirt design with a dished crown. Three piston rings, two
compression and one three-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 and Piston Installation

1 Bank A (RHS)
2 Bank B (LHS)
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 'A' - piston grade number and the thick flange of the connecting rod must face the front
of the engine
• Bank 'B' - piston grade number and the thin flange of the connecting rod must face the front
of the engine

The CKP sensor is installed at the rear of the sump. It is a variable reluctance sensor that provides an
input of engine crankshaft speed and position. For additional information, For additional information,
refer to Electronic Engine Controls (303-14 Electronic Engine Controls - 4.2L)
Knock Sensors
1 Bolts (2 off)
2 Knock sensor
The knock sensors are installed in the cylinder block on the inboard side of each cylinder bank. They
are piezo-electric sensors that provide inputs to detect and locate detonation during combustion. For
additional information, For additional information, refer to Electronic Engine Controls (303-14
Electronic Engine Controls - 4.2L)
Starter Motor
1 Bolt
2 Starter motor
3 Bolt
The engine starter motor is installed at the rear right side of the engine, at the cylinder block to
bedplate split line. For additional information, For additional information, refer to Starting
System (303-06 Starting System)
Coolant Drain Plug/Block Heater
A coolant drain plug is installed on the rear left side of the cylinder block. On vehicles with the cold
climate package, the cylinder block heater replaces the drain plug.
On vehicles destined for Canada, the coolant heater is installed during engine manufacture. For
Scandinavian vehicles the heater is supplied in kit form to be installed at the dealership.
Coolant Pump
1 Coolant pump
2 Bolts (4 off)
3 Pulley
4 Bolts (3 off)
The coolant pump is installed between the 2 cylinder banks, on the front face of the cylinder block.
Coolant Inlet and Outlet Assembly
1 Coolant outlet elbow
2 Coolant hose
The thermostat housing and coolant outlet duct are combined into an aluminium alloy coolant outlet
assembly, which is installed between the 2 cylinder banks, immediately above the coolant pump. A
hose connects the coolant outlet assembly to a coolant inlet housing attached to the coolant pump
intake on the cylinder block. The thermostat controls the flow of coolant through the radiator.
CRANKSHAFT AND SUMP COMPONENTS
1 Bedplate
2 Main bearings - lower (5 off)

Crankshaft and Main Bearings
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 aluminium/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
aluminium/tin thrust washer is installed each side of the top half of the centre 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, minimise 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.
Sump
1 Pressed steel oil pan
2 Aluminium alloy structural sump
The aluminium 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
aluminium alloy structural sump.
A bead of sealant seals the joint between the structural sump and the bedplate.
Oil Pump
with oil passages in the bedplate (See lubrication section for more information).
Starter Drive Plate
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 sensor, is
spot welded to the front face of the drive plate.
CAMSHAFT TIMING COMPONENTS
1 Secondary chain tensioner
2 Secondary chain
3 Variable valve timing unit
4 Primary chain
5 Primary chain tensioner
Timing Gear
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.
Timing Cover
The aluminium alloy timing cover accommodates the crankshaft front oil seal (a PTFE lip seal). Silicon
rubber in-groove gaskets seal the joint between the timing cover and the front face of the engine.
CYLINDER HEAD COMPONENTS
1 Camshaft bearing cap
2 Tappet (shimless)
3 Collet
4 Valve spring cap
5 Valve spring
6 Valve stem oil seal
7 Valve
8 Inlet camshaft
9 Exhaust camshaft
Cylinder Heads
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 14 mm (0.55 in) spark plugs, one 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.
Camshaft Covers
The camshaft covers are manufactured from thermo-plastic. The A bank camshaft cover incorporates
an outlet for the part load engine breather and the Pressure Control Valve (PCV). The B bank
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. For additional
information, For additional information, refer to Electronic Engine Controls (303-14 Electronic
Engine Controls - 4.2L)
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.
Cylinder Head Gasket

The multi-layered steel cylinder head gasket has cylinder specific water flow cross-sections for
uniform coolant flow.
Camshafts
The camshafts are manufactured in chilled cast iron. Five aluminium 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 Ring
1 Inlet camshaft
2 Sensor ring
Timing rings for each camshaft position sensor are 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 Position Sensor
The camshaft position sensors are installed in each cylinder head at the rear of the intake camshaft.
It is a variable reluctance sensor that provides an input to the ECM regarding the position of the
camshaft. For additional information, For additional information, refer to Electronic Engine
Controls (303-14 Electronic Engine Controls - 4.2L)
Inlet and Exhaust Valves
Each cylinder head incorporates dual overhead camshafts operating 4 valves per cylinder via solid
shimless 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.
CAUTION: Due to slight variations in length, the valves are not interchangeable between
marques (Land Rover, Jaguar and Aston Martin).
Fuel Injectors
Eight, top fed, twelve-hole, fuel injectors are installed in the fuel rails. The injectors are
electromagnetic solenoid valves controlled by the ECM. Two O-rings seal each injector to manifold
interface. The fuel jets from the injectors are directed onto the back of the intake valves. For
additional information, For additional information, refer to Electronic Engine Controls (303-14
Electronic Engine Controls - 4.2L)
The continuously VVT unit turns the intake camshaft in relation to the primary chain to advance and
retard the timing.
The system improves low and high-speed engine performance, engine idle quality and exhaust
emission.
The VVT system changes the phasing of the intake valves, relative to the fixed timing of the exhaust
valves, to alter:
• the mass of air flow into the engine's cylinders,

• and the engine's torque response and emissions.
The VVT unit uses a vane device to control the camshaft angle (refer to VVT operation). The system
operates over a range of 48 degrees and is advanced or retarded to the optimum angle within this
range.
The ECM controls the VVT, using engine speed and load, and engine oil temperature signals to
calculate the appropriate camshaft position. For additional information, For additional information,
refer to Electronic Engine Controls (303-14 Electronic Engine Controls - 4.2L)
The continuous VVT system provides the following advantages:
• Reduces engine emissions and fuel consumption by further optimising the camshaft timing,
this improves the engine's internal exhaust gas re-circulation (EGR) effect over a wider
operating range
• Improves full-load torque characteristics as the camshaft timing is optimised at all engine
speeds for superior volumetric efficiency
• Improves fuel economy by optimising torque over the engine's speed range.
This system also has the added benefits of operating at a lower oil-pressure and faster response time
when compared to a non-VVT system.
PRINCIPLES OF OPERATION - VARIABLE VALVE TIMING
A Retarded
B Advanced
1 Engine oil pressure
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 three 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.
When 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. When 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.
When directed by the ECM, the VVT 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
energising 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 assess any decrease in shuttle-
valve oil-pressure, via signals from the camshaft position sensor. The ECM will increase the
energizing signal, when required, to maintain the shuttle-valve hold 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. 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 psi), 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.
LUBRICATION SYSTEM
Oil is drawn from the reservoir in the oil pan and pressurised 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. Pressurised 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 psi).
Oil Filter Housing Assembly
3 Adapter
4 Seal
5 Filter
6 Engine oil cooler
The oil filter is a replaceable cartridge installed on an adapter via the oil cooler. An internal bypass
facility permits full flow bypass if the filter is blocked.
The oil pressure switch connects a ground input to the instrument cluster when oil pressure is
present. The switch operates at a pressure of 0.14 to 0.3 bar (2.0 to 4.5 psi).
Oil Level Gauge
1 Oil level gage
The oil level gage locates along the left side of the oil pan, supported in a tube installed in the sump.
Two holes in the end of the gauge indicate the minimum and maximum oil levels. There is a
difference of approximately 1.0 litres between the 2 levels.
EXHAUST MANIFOLD
1 Cylinder head
2 Gasket
3 Heat shield
4 Bolt
5 Gasket
7 Spacer (8 off)
8 Connector for Secondary Air Injection (SAI)
9 Bolt (8 off)
10 Heat shield
11 Bolt (4 off)
The fabricated stainless steel twin skin exhaust manifolds are unique for each cylinder bank.
Each exhaust manifold assembly includes 2 metal gaskets, located either side of the inner heat shield,
2 heat shields and a connection for the Secondary Air Injection (SAI) system. For additional
information, refer to Engine Emission Control (303-08 Engine Emission Control)
Spacers on the securing bolts allow the manifolds to expand and retract with changes of temperature
while maintaining the clamping loads.
Engine
For additional information, refer to <<303-00>>

Bolts and spacers

303-191-04
Holding Tool Crankshaft Pulley

303-893(LRT-12-080)
Remover, crankshaft seal

303-D121
Timing Setting tool

303-645
303-530

303-538
Seal installer
303-750
Seal extractor
303-751

303-191/02
Removal
2
3 . Remove the engine.

For additional information, refer to Engine (12.41.01)
4 . Mount the engine to an engine stand.
5 . Disconnect the 2 oil cooler hoses.
6 . Remove the exhaust manifold heat shield.
Remove the 2 bolts.

.
drive wrench.
Remove the bolt.

9 . NOTE:
Note the fitted position of the accessory drive belt.
Remove the accessory drive belt.
Remove the bolt.
11 . NOTE:
Using the special tool, remove the coolant pump pulley.

12 . Remove the coolant pump.
Remove the 5 bolts.
13 . NOTE:
Remove both the engine mounts and brackets.
Remove the 4 bolts.
14 . Remove the air conditioning (A/C) compressor.
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.
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 electrical

connector.
26 . NOTE:
NOTE:

Remove the 3 bolts.
30 . NOTE:
Release the 2 heated oxygen sensor (HO2S) harness brackets.
31 . Disconnect the crankshaft position (CKP) sensor electrical connector.
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.

36
37 . NOTE:
Using the special tools, remove the crankshaft pulley bolt.
Discard the bolt.
38 . NOTE:
Using the special tools, remove the crankshaft pulley.

39 . Using the special tool, remove and discard the crankshaft front seal.
40 . NOTE:
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.

45 . Disconnect the LH variable camshaft timing ( VCT) oil solenoid electrical connector.
46 . Disconnect the valve cover breather hose.
47 . Release the engine wiring harness from the retaining bracket.
48 . Disconnect the RH variable camshaft timing (VCT) oil solenoid electrical connector.
49 . NOTE:
Remove the RH valve cover.
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.
55 . Release the engine wiring harness from the retaining bracket.
56 . NOTE:
Remove the LH valve cover.

57 . Remove and discard the LH valve cover gaskets.
Remove and discard the seals.
58 . NOTE:
Install the special tool to the crankshaft sensor aperture.
Install the bolt.


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.
Remove the 2 bolts.

70 . NOTE:

72
. CAUTION: The bolts can only be used 3 times, mark the bolts with a center punch.
If 2 punch marks are visible, discard the bolts.
Remove the 8 bolts.
73 .
CAUTION: Note the position of the bolts, prior to removal.
Remove the oil pan.

74 . Remove the oil strainer pick-up assembly.
Remove the 2 bolts.
75 . Remove the oil pan extension.

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:
Remove the crankshaft main bearing carrier.
Remove the crankshaft main bearing carrier retaining bolts in the indicated
sequence.
Installation
1
. CAUTION: Use only a plastic scraper when removing the sealing material.
CAUTION: 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.
2 NOTE:
.
Install the crankshaft main bearing carrier and tighten bolts to specification within
twenty minutes of applying the sealant.
Apply a 2 mm (0.08in) 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 (0.039in) bead of sealant to the cylinder block in the area shown.
Use WSS-M4G323-A4-RTV sealant.

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 (11 lb.ft).

Stage 5: Bolts 1 to 10, tighten to 35 Nm (26 lb.ft), then a further 135
5)
degrees.

6)
degrees.

7)
degrees.

8)
degrees.
9) Stage 9: Center punch each of the bolt heads to indicate it has been reused.

7 . Install the baffle plate.
Tighten the 6 bolts to 6 Nm ( 4 lb.ft).
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.
11 . Install the special tool.
Install the bolt.

12 . NOTE:
Install the oil pump assembly.
Install the gasket.
13 . NOTE:
14 . NOTE:
Install the oil strainer pick-up assembly.
Install the O-ring seal.

.
chain.
18
Using a 3 mm (0.118 in) diameter rod, retain the chain tensioner piston.

19 .
NOTE:
Install the LH VCT control solenoid housing.

.
chain.
21 . Install the RH primary timing chain tensioner guide.
22
Using a 3 mm (0.118 in) diameter rod, retain the chain tensioner piston.
23 . NOTE:
NOTE:
Make sure that new bolts are installed.
Install the RH VCT control solenoid housing.

26 . Install the oil pan extension.
Apply a 3 mm (0.118 in) diameter bead of sealant, to the area indicated.
27 . Tighten the oil pan bolts in the sequence shown to 20 Nm (15 lb.ft).
Remove the bolt.
Tighten the bolt to 8 Nm (6 lb.ft)
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.
33 NOTE:
.
NOTE:
Install the engine front cover.
Apply a 3 mm (0.118 in) diameter bead of sealant 12mm (0.47 in) long, to
the 8 places indicated.
Install the gasket.

Secure the clips.
36 . NOTE:
Install new seals.
Install the LH valve cover plug aperture seals.
37 NOTE:
.
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 LH valve cover.

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 (9 lb.ft).
39 . Connect the LH VCT oil solenoid electrical connector.
40 . Attach the engine wiring harness to the retaining bracket.
41 . NOTE:
With assistance, install the oil level indicator and tube.

42 . NOTE:
Install the 4 LH ignition coil-on-plugs.
Install the 4 ignition coil-on-plugs.
43 . Connect the 4 electrical connectors.
44 . Install the LH ignition coil-on-plug cover.
45 . NOTE:
Install new seals.
Install new RH valve cover plug aperture seals.
46 NOTE:
.
NOTE:
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 RH valve cover.
Install the gasket.
47 . Install the RH valve cover bolts.
Install the RH valve cover bolts to the positons previously noted.
Tighten the bolts in the sequence shown to 12 Nm (9 lb.ft).
48 . NOTE:
Install the 4 RH ignition coil-on-plugs.
Install the 4 ignition coil-on-plugs.
50 . Connect the RH VCT oil solenoid electrical connector.
51 . Attach the engine wiring harness to the retaining bracket.
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
58
Using the special tools, tighten the crankshaft pulley bolt.

59 . NOTE:
Install the oil filter housing.
60 NOTE:
.
Install a new engine oil filter.
Install the engine oil filter.
lb.ft).
64 . NOTE:
Install the coolant manifold.
Connect the 4 coolant hoses and install the clips.
Attach the wiring harness bracket.
Tighten the Torx screws to 10 Nm (7 lb.ft).
65 . Connect the starter motor solenoid electrical connector.
66 . Connect the battery positive cable to the starter motor.
Secure the cover.

Secure the clips.
70 . Connect the battery positive cable and generator electrical connector.
Secure the cover.
Tighten the 2 bolts.

76 . Install both engine mounts and brackets.
77 . NOTE:
Install the coolant pump.
78 . NOTE:
Make sure that new bolts are installed.
Using the special tool, install the coolant pump pulley.

Clean and inspect the drive pulleys for damage.
Tighten the tensioner bolt to 40 Nm (30 lb.ft).
83 . Remove the engine from the engine stand.

84 . Install the engine.
For additional information, refer to Engine (12.41.01)

Removal
Engine (12.41.01)

303-536

303-749
Removal
2 . Evacuate the A/C system.




7 . Using the special tool, disconnect the fuel line.

8
contamination.
9 . Disconnect the brake booster vacuum hose from the intake manifold.
Remove the nut.
Release the clip.

Release the clip.

Remove the 2 bolts.
18 . Disconnect the power steering supply hose.
19 . Disconnect the coolant expansion tank to thermostat housing coolant hose.
Release the clip.

20

22 . Disconnect the coolant hoses from the engine oil cooler.
23 . Disconnect the LH catalytic converter from the exhaust manifold.

24 . Disconnect the RH catalytic converter from the exhaust manifold.
25
the fluid.
Release the clip.

26 .
Disconnect the high pressure line from the power steering gear.
27 . Release the transmission fluid lines from the engine.
Remove the nut.
Release the clip.


Release the cover.
Remove the nut.
31
moisture.
Disconnect the A/C high-pressure line from the intermediate joint.

Remove the nut.
32 . NOTE:
33
. CAUTION: The transmission ground cable must be replaced if disconnected from
the vehicle body.
Disconnect the transmission ground cable.
Remove the bolt.

Remove the 6 bolts.
36 . Install the special tools to the engine.
Support the engine.

37 .
CAUTION: Make sure the torque converter remains connected to the
transmission.
Release the transmission from the engine.
Support the transmission.
38
. CAUTION: Protect the suspension turrets to prevent damage upon engine
removal.
With assistance, carefully remove the engine.

Installation
Engine (12.41.01)
Installation
2.
With assistance, carefully install the engine.
3 . Carefully lower the engine onto the engine mounts.
5

Secure the cover.
Secure the clips.
10 . Attach the transmission fluid lines to the engine.
11 . Connect the transmission ground cable.
12 .
Connect the A/C high-pressure line intermediate joint.
13 . Attach the power steering gear high-pressure line.
Secure in the clip.
14 . Connect the low pressure line to the power steering pump.
16 . Connect the coolant expansion tank to thermostat housing coolant hose.
18 . Connect the engine oil cooler, coolant hoses.

Install the hoses and secure with the clips.
24 . Connect the brake booster vacuum hose to the intake manifold.
25 . Connect the purge inlet line.

Tighten the 4 Torx bolts to 25 Nm (18 lb.ft).





In vehicle repair

303-530
Crankshaft locking tool

303-645

303-532

303-540
303-540/02

303-590
Removal
2

5
NOTE:
Installation

.

(7 lb.ft).
3 . NOTE:
4 . NOTE:


7
10
13
NOTE:
14
camshaft.
shim.
.


303-530
Timing Setting tool

303-645

303-532

303-540
303-540/02

303-590
Removal
2


5
Install the screw.
Remove the 3 bolts.

.
Remove the 2 bolts.

Remove the 2 bolts.
12 .

Remove the 3 bolts.
15
NOTE:
Remove the camshaft bearing caps. Note: their position, orientation and markings.
Each is marked with its position (number) and an orientation (arrow).

Installation

.

Nm.
4
rotate.
NOTE:


.
chain.
8

9
not followed.

Remove the screw.


17

20

23
NOTE:
24
camshaft.
. shim.


Removal
Installation
Crankshaft pulley locking tool

303-191

303-191/02

303-588
Seal extractor
303-751
Seal installer
303-750
Removal
2


.
drive wrench.
5
NOTE:

Using the special tool, retain the crankshaft front pulley.
Remove and discard the crankshaft pulley retaining bolt.
6 . Using the special tools, remove the crankshaft pulley.
7 . Check the crankshaft pulley and locking ring for damage.
8 . Using the special tool, remove the crankshaft front seal.

Installation
1.
CAUTION: Make sure the crankshaft seal mating faces are clean and dry.
CAUTION: Do not remove the seal protector at this stage.
Using the special tool, install the crankshaft front seal.
2 . Remove the seal protector.
Install the locking ring.
4

5



303-538
Removal
2
3 . Remove the torque converter flexplate.

4 . Install the special tools.
Tighten the 2 nuts to retain the special tool.

5 . Using the special tool, pierce the seal to create holes for the 6 self-tapping screws.
6 . Using the special tools, remove and discard the crankshaft rear oil seal.
Install the 6 self-tapping screws.
Adjust the 2 nuts.

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.
2
. CAUTION: Make sure the seal is installed parallel
Using the special tool, install the crankshaft rear oil seal.
Tighten the special tool nuts evenly and progressively to fully install the
seal.
3 . Install the torque converter flexplate.


Removal
2

For additional information, refer to Intake Manifold (30.15.01)

6
NOTE:

8 . NOTE:
NOTE:
Make sure the shim remains with the tappet.
Remove the 16 tappets.

10 . Release the LH catalytic converter.

12
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. Failure to
With assistance remove the cylinder head.
14 . Remove and discard the cylinder head gasket.
Clean the cylinder head locating dowels.
Clean and inspect the cylinder head and cylinder block.

15 . NOTE:
Remove the LH heat shield.
16 . NOTE:
Remove the exhaust manifold.

Remove the bolt.
Installation
1 . Clean the component mating faces.
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.
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.

.
24 Nm (18 lb.ft).
Tighten the screws.
8.
CAUTION: The head gasket must be installed over the cylinder block dowels.
Install a new cylinder head gasket.
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 M8 bolts 11 and 12, to 25 Nm (18 lb.ft).
12 . Attach the catalytic coverter.
Tighten the nuts to 40Nm (30 lb.ft).

14 . Install the tappets.
Lubricate the components with clean engine oil.
Lubricate the journals and camshaft lobes with clean engine oil.

.

Nm (7 lb.ft).
17 . NOTE:

18 . NOTE:


For additional information, refer to Intake Manifold (30.15.01)
21
24

www.JagDocs.com
27
NOTE:
28
camshaft.
. shim.

Removal
3

5 Vehicles with secondary air injection: Remove the air control valve to exhaust manifold tube.
Manifold Tube

For additional information, refer to Thermostat Housing - Vehicles Without: Supercharger
Release the clip.

9 . Remove the RH valve cover.


Release the clip.

For additional information, refer to Power Steering Pump - 4.2L NA V8 - AJV8 (57.20.14)
13 . NOTE:
Remove the 3 bolts.
Remove the bolt.
Remove the bolt.

16
moisture.
Remove the 2 bolts.
17 . Position the A/C compressor aside to access the A/C compressor mounting bracket.
Remove the 4 bolts.

Remove the 4 bolts.
20 . LH side: Release the wiring harness.
21 . RH side: Release the wiring harness.

Remove the bolt.
Release the clip.

Installation
1 Install the engine front cover.
.
Install the gaskets.
Apply a bead of sealant 3 mm diameter, by 12 mm long, to the 8 places

indicated.
2 Install the engine front cover bolts.

.
(9 lb.ft).
Secure the clip.

Secure the clips.
7.


Secure the clip.

14 . Install the RH valve cover.


Secure the clip.

18 Vehicles with secondary air injection: Install the air control valve to exhaust manifold tube.
Manifold Tube


Removal
All vehicles
2



5 . NOTE:

Remove the 3 bolts.
All vehicles
Support the engine.

Raise the engine.
Remove the 4 bolts.
9 . NOTE:
Installation
All vehicles

Lower the engine.

All vehicles


Removal
All vehicles
2


4 . NOTE:

Remove the 3 bolts.
All vehicles
Support the engine.

Raise the engine.
Remove the 4 bolts.
9 . NOTE:

Installation
All vehicles
Lower the engine.
Tighten the screws.


All vehicles

Exhaust Manifold LH - Vehicles Without:
Removal
2



6 . Remove the LH heat shield.

Remove the bolt.

Installation

.
24 Nm (18 lb.ft).
Tighten the screws.




Exhaust Manifold LH - Vehicles With:
Removal
2




8 . Remove the LH exhaust manifold heat shield.
Remove the bolt.

Installation

.
24 Nm (18 lb.ft).

Tighten the screws.




Exhaust Manifold RH - Vehicles Without:
Removal
2

Remove the 2 nuts.

7 . Remove the RH heat shield.
Remove the bolt.

Installation

.
24 Nm (18 lb.ft).
Tighten the screws.




Exhaust Manifold RH - Vehicles With:
Removal
2

Remove the 2 nuts.

9 . Remove the RH exhaust manifold heat shield.

Remove the bolt.
Installation

.
Evenly and progressively, tighten the new bolts in the sequence shown to
24 Nm (18 lb.ft).
Tighten the screws.




Removal
2
3 . Remove the transmission.

4
. CAUTION: The bolts can only be used 3 times, mark the bolts with a center punch. If
2 punch marks are visible, discard the bolts.
NOTE:
Remove the 8 bolts.

Installation
1 . NOTE:
2 . Install the transmission.


Intake Manifold (30.15.01)
Removal

3 . Remove the RH engine cover bracket.
Remove the 2 nuts.
4 . Remove the LH engine cover bracket.
Remove the 2 nuts.
Release the 2 electrical connectors.
Remove the purge valve bolt.

5 . Release the engine wiring harness from the intake manifold.
6 . Release the wiring harness from the rear of the engine.
Remove the 2 bolts.
7 . Release the RH camshaft position (CMP) sensor electrical connector.

8 . Release the purge valve.

10 . Disconnect the MAP sensor electrical connector.

11 . Disconnect the fuel rail pressure (FRP) sensor electrical connector.
12 . Disconnect the FRP sensor vacuum line.
13 . Disconnect the knock sensors (KS) electrical connector.
14 . Disconnect the 8 fuel injector electrical connectors.

16 . Disconnnect the throttle body elbow vacuum line.
17 . Disconnect the positive crankcase ventilation (PCV) line from the throttle body elbow.
18 . Disconnect the brake booster vacuum hose from the intake manifold.
19 . Release the exhaust gas recirculation (EGR) valve.
Remove the 2 bolts.
20 .
Remove the intake manifold.

21 . NOTE:
Remove the foam pad.
22 . Remove the throttle body elbow.
Remove the 4 bolts.

23 . Remove the intake manifold MAP sensor housing.
Remove the 7 bolts.

25 . Remove the 2 intake manifold housings.
Installation
1 . Install the intake manifold housings.

3 . Install the intake manifold MAP sensor housing.
4 . Install the throttle body elbow.
5 . Install the foam pad.
Install new gaskets.
Evenly and progressively tighten the bolts to 20 Nm (15 lb.ft).
7 . Attach the EGR valve.

8 . Connect the brake booster vacuum hose.
10 . Connect the throttle body elbow vacuum line.
11 . Connect the FRP sensor vacuum line.
14 . Connect the KS electrical connector.
15 . Connect the FRP sensor electrical connector.
16 . Connect the MAP sensor electrical connector.

18 . Attach the purge valve.

19 . Attach the CMP sensor electrical connector.
21 . Install the LH engine cover bracket.
Attach the purge valve, align the peg and tighten the bolt to 6 Nm (4
lb.ft).
Secure the electrical connectors.
22 . Install the RH engine cover bracket.


Oil Pan (12.60.44)
Removal
1

3 . Remove the oil pan drain plug.
Discard the oil pan drain plug seal.
Position a container to collect the oil spillage.

Installation
Install the new gasket.
3 . Tighten the drain plug to 25 Nm (18 lb.ft).
Install a new seal.

5 . Fill the engine with the recommended oil to the correct level.
Oil Pump (12.60.26)
Removal
2


5 . NOTE:
Remove the oil strainer pick-up assembly.
Remove the 2 bolts.

Remove the 4 bolts.
Installation
1 . Install the oil pump assembly.
2 . Install the oil strainer pick-up assembly.

4 . Install the timing drive components.



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.

2


5
Install the screw.

Remove the 3 bolts.

.
Remove the 2 bolts.

Remove the 2 bolts.
11 . Remove the LH variable camshaft timing (VCT) control solenoid housing.
Remove the 2 bolts.
Remove the nut.

Remove the 2 bolts.

Remove the 2 bolts.
16 .
Release the LH camshaft sprocket assembly.

17 . Remove the LH secondary timing chain, tensioner and sprocket assembly.
Remove the 2 bolts.
18 .

20 . NOTE:
Installation
2
rotate.
NOTE:
Install the LH secondary timing chain, tensioner and sprocket assembly.
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.
4 . Install the LH secondary timing chain tensioner retaining bolts.

.
chain.
7
NOTE:

8
not followed.
Install the special tool to the LH exhaust camshaft sprocket.
9 . Install the LH VCT control solenoid housing.

10
. CAUTION: Make sure the secondary timing chain and camshaft sprockets are free
to rotate.

.
chain.
14

15
not followed.

Remove the 3 bolts.
Remove the 3 bolts.

Remove the screw.


Removal

For additional information, refer to Ignition Coil-On-Plug - 4.2L NA V8 - AJV8 (18.20.40)
Remove the nut.
5 . Release the clip and disconnect the purge inlet line.

Remove the 2 nuts.
Position the bracket aside.
7 . Release the 3 wiring harness clips.
8 . Disconnect the variable camshaft timing ( VCT) oil solenoid electrical connector.
9 . Disconnect the valve cover breather hose.

Release the clip.
11 . NOTE:
Remove the valve cover assembly.
13 . Remove the valve cover plug aperture seals.

14 . Remove the VCT control solenoid seal.
15 . NOTE:
Remove the oil filler pipe.
16 . NOTE:
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.
5 . Install the VCT control solenoid seal.
6 NOTE:
.
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.
7 . Install the valve cover retaining bolts.
8 . Install the engine cover mounting bracket.
9 . Connect the purge line.

Secure the clip.
12 . Connect the VCT oil solenoid electrical connector.


Removal

5 . Release the 3 wiring harness clips.
6 . Disconnect the variable camshaft timing ( VCT) oil solenoid electrical connector.
Remove the 2 nuts.
Position the bracket aside.
8 . Remove the valve cover assembly.

10 . Remove the valve cover plug aperture seals.
11 . Remove the VCTcontrol solenoid seal.
12 . Remove the PCV valve.
13 . NOTE:
Remove the bolts, remove and discard the seals.

Installation
1 . NOTE:
Install the components to their original fitted positions.
Install the seals and bolts.
3 . Install the VCT control solenoid seal.
4 . Install new valve cover plug aperture gaskets.
6 NOTE:
.
8 . Connect the VCT oil solenoid electrical connector.
9 . Install the ignition coil-on-plugs.

11 . Install the engine cover mounting bracket.


Oil Filter Housing
Wrench, Oil filter

303-752
Removal
2

4 Drain the coolant.

. For additional information, refer to Cooling System Draining, Filling and Bleeding - 4.2L NA V8
- AJV8

7 . NOTE:
NOTE:

8 . Disconnect the 2 oil cooler hoses.
Remove the 3 bolts.

10 . NOTE:
Remove the engine oil temperature sensor.
Installation
2 . Install the engine oil temperature sensor.

5 Using the special tool, install the oil filter.

.
lb.ft).



11 Top-up and bleed the coolant.

. For additional information, refer to Cooling System Draining, Filling and Bleeding - 4.2L NA
V8 - AJV8
Disassembly
Engine

303-191
Adapter
303-191-02

303-588

303-645
Camshaft setting
303-530

303-D055

303-535
Disassembly
1 . Disconnect the oil cooler hoses.

2 . Detach the supercharger belt.
• Detach the supercharger belt.
3 . Release the accessory drive belt tension.
• Detach the accessory drive belt.
• Remove the accessory drive belt.

7 . Detach the generator battery positive cable protective cover.

8 . Disconnect the generator battery positive cable.
9 . Disconnect the generator electrical connector.

13 . Detach the right-hand oxygen sensor retaining bracket.

17 . Remove the heat shield.
18 . Remove the heat shield retaining bolt.
19 . Remove the left-hand exhaust manifold.

20 . Remove the left-hand engine mount.
21 . Remove the left-hand engine mounting bracket.

24 . Remove the air conditioning compressor mounting bracket.

27 . Disconnect the crankshaft position sensor electrical connector.
28 . Remove the crankshaft position sensor.

1. Disconnect the variable valve timing (VVT) solenoid electrical connector.

35 . Detach the hoses.
36 . Detach the supercharger outlet pipe coolant hose.
• Cap the coolant ports.
37 .
Remove the supercharger outlet pipe
38 . Remove and discard the supercharger outlet pipe gasket.
39 . Remove and discard the supercharger outlet pipe retaining bolt seals.
40 . Remove and discard the supercharger outlet pipe to charge air coolers ducts.
41 . Disconnect the thermostat housing hoses


48 . Remove the thermostat housing retaining bolts.
• Remove and discard the thermostat housing O-ring seals.

50 . Disconnect the charge air cooler coolant pipes.
52 . Disconnect the electrical connectors.

53 . NOTE:
Detach the coolant hose from the throttle body.
56 . NOTE:
Disconnect the coolant hoses.
57 . Remove the EGR valve and the exhaust manifold to EGR valve tube.
• Remove the retaining bolts.
• Remove and discard the exhaust manifold to EGR valve tube gasket.
• Remove and discard the EGR valve to air intake elbow gasket.
58 . Disconnect the air intake elbow pipes.

59 . NOTE:
Make sure correct location of the ground strap is noted.
Remove the air intake elbow retaining bracket lower retaining bolts.
60 . Detach the air intake elbow.
• Remove and discard the retaining bolt seals.
61 . Remove the air intake elbow.
• Disconnect the manifold absolute pressure (MAP) sensor.

63 .
CAUTION: Make sure no foreign matter enters the cylinder head ports.
NOTE:
Remove the charge air coolers.
• Remove and discard the charge air cooler gasket.

64 . Disconnect the knock sensor electrical connectors.
65 . NOTE:
Remove the ignition coil cover.

68 . NOTE:
Detach the engine wiring harness.
69 . NOTE:
Disconnect the fuel injector electrical connectors.


• Detach the ground cable.
• Disconnect the variable valve timing (VVT) solenoid electrical connector.
• Remove the retaining bolt.

77 . Disconnect the positive crankcase ventilation pipe.
78 . Disconnect the fuel pressure regulator electrical connector.
79 . Disconnect the exhaust gas recirculation valve electrical connector.
80 . Disconnect the exhaust gas recirculation valve coolant hose.


87 . Detach the engine wiring harness

90 . Remove the lower intake manifold.
91 . NOTE:
Place a suitable container underneath the filter to prevent oil spillage.
Remove the oil filter element.

93 . Disconnect the oil pressure switch and oil temperature sensor electrical connectors.
95 . Detach the right-hand oxygen sensor.

96 . Detach the engine wiring harness retaining clips.
97 . Remove the engine wiring harness
98 . Remove the noise and vibration insulating pad.
99 . Remove the intake manifold heater coolant hose.
4. Remove the knock sensors.
5. Remove the intake manifold heater coolant hose.

100 . Remove the engine block insulation grommet.
101 . Remove the water pump pulley.
• Using the special tool, retain the water pump pulley.
102 . Remove the water pump.

104 . NOTE:
Remove the ignition coils.

106 . Remove the right-hand camshaft position (CMP) sensor.
107 . Remove the left-hand camshaft position (CMP) sensor.
108
NOTE:
The crankshaft retaining bolt will be very tight.
• Remove and discard the crankshaft pulley bolt.

110 . NOTE:
Using special tools, remove the crankshaft pulley.
• Collect the locking ring.

112
. CAUTION: Make sure the spark plugs are removed to enable the engine to rotate
freely.
CAUTION: Do not rotate the crankshaft counterclockwise. The timing chains may
bind causing engine damage.
CAUTION: Rotate the crankshaft clockwise to position the engine to top dead
center (TDC) No. 1 cylinder.
Install the special tool 303-645.
113 . Remove the right-hand valve cover.

114 . Remove the left-hand valve cover.

116 . Remove the right-hand variable camshaft timing oil control unit housing.
117 . Remove the left-hand variable camshaft timing oil control unit housing.

118 . Install the special tool to the left-hand cylinder head.
119 . Install the special tool to the right-hand cylinder head.

123 . Remove the primary timing chain guide.

.
camshaft sprockets.

129 . Remove the crankshaft sprocket.

.
camshaft sprockets.

.
136 . Remove the right-hand exhaust camshaft.

.
138 . Remove the right-hand intake camshaft.

.
140 . Remove the left-hand exhaust camshaft.

.
142 . Remove the left-hand inlet camshaft.
143
Remove the right-hand cylinder head.

144
Remove the left-hand cylinder head.
145 . Remove the crankshaft setting peg 303-645 from the crankshaft position sensor location.
146 . Remove the flexplate.
6. Remove the flexplate retaining bolts.
7. Remove the flexplate.
147 . Remove the lower oil pan.

148 . Remove the oil strainer.
149 . Remove the upper oil pan.

150 . Remove the oil pump.
151 Inspect the tops of the cylinder bores. As necessary remove ridge and carbon build up from
. each cylinder.
152 . Remove the piston cooling jets.
153
. CAUTION: Pistons, connecting rods and connecting rod bearings should be
numbered to make sure they are reassembled in the same position.
NOTE:
Mark the position of the connecting rod caps to the connecting rods to make sure of
correct installation.
NOTE:
Discard the connecting rod bolts after removal.
Remove the connecting rod bolts, the connecting rod caps and the lower connecting rod
bearings.
154
155
. CAUTION: Care should be taken not to damage the connecting rod and cap joint
face surfaces or possible engine damage may occur. Avoid contaminating the fractured
joint surfaces with dirt or grease.
NOTE:
Attach the connecting rods and caps after removal to avoid mismatch.
Remove the pistons.
• Rotate the crankshaft to locate pistons at the bottom of travel.
• Push the piston, connecting rod and upper bearing through the top of the cylinder.
156 . NOTE:
Remove the lower cylinder block bolts in the indicated sequence.
NOTE:
Mark the position of the upper and lower crankshaft main bearings for reassembly.
Remove the lower cylinder block.
• Remove the lower cylinder block retaining bolts in the indicated sequence.
158
. CAUTION: Avoid damage to any crankshaft bearing surfaces.
NOTE:
Never remove any pipe, plugs or dowels unless they are to be newly installed or the
cylinder block is to be washed.
Remove the crankshaft.
159 . Remove the upper crankshaft main bearings.
8. Remove the upper crankshaft thrust washers.
9. Remove the upper crankshaft main bearings.
160 Clean the cylinder block with a soap and water solution. Dry the cylinder block completely
. with compressed air.
Disassembly/assembly of subassemblies

Valve Spring Compressor

303-252
Disassembly
1
. CAUTION: Do not use a magnet to remove shims. Failure to follow these instructions
CAUTION: If the cylinder head valve components are to be reused, mark the
position of the valve components to make sure they are reassembled in the same position.
Remove the bucket tappet and shim assemblies.

2 . Remove the camshaft position (CMP) sensor.
• Remove and discard the 'O' ring seal.
• Remove the valve collets.
4 . Remove the valve spring retainers and valve springs.
1. Remove the valve spring retainers.
2. Remove the valve springs.
3. Remove the valve stem oil seals.

5 . Remove the valves from the cylinder head.
4. Remove the intake valves.
5. Remove the exhaust valves.
6 Inspect the cylinder heads and related components. For additional information, refer to
. <<303-00>>
7 . Remove the pipe plugs and alignment dowels as necessary to clean the cylinder heads.
Assembly
1
. WARNING: Eye protection is required during use of compressed air. Failure to follow
CAUTION: The cylinder head surface finish is measured in microns. For correct head
gasket sealing, avoid any contact of finish with metallic objects.
Clean gasket material, dirt and foreign material from cylinder heads. Wash with a suitable
soap and water solution and dry the cylinder head completely using compressed air if pipe
plugs have been removed.
2 . Install the pipe plugs and alignment dowels to cylinder heads.
• Apply pipe sealant to plugs prior to installation.
3 . NOTE:
Lubricate the valve stems before assembly.
Install the valves into the cylinder heads.
6. Install the intake valves.
7. Install the exhaust valves.
4 . Install the valve spring retainers and valve springs.
8. Install the valve stem oil seals.

9. Install the valve springs.
10. Install the valve spring retainers.
• Install the valve collets.
6 . Install the camshaft position (CMP) sensor.
• Install a new 'O' ring seal.
7
. CAUTION: Do not use a magnet to install shims. Failure to follow these instructions
Install the bucket tappet and shim assemblies.

Assembly
Engine

303-191
Adapter
303-191-02

303-645
Camshaft setting
303-530
303-532

303-535
Piston Ring Compressor

303-372
Crankshaft rear oil seal remover/replacer

303-538
Crankshaft front seal installer

303-538
303-D055
Assembly
1
. CAUTION: Use only a plastic scraper when removing old gasket material.
• If gasket material remains on the cylinder head after cleaning, use a plastic tipped
scraper to remove remaining material.
2 . NOTE:
Never remove pipe plugs or alignment dowels unless they are to be serviced.
Reseal oil passage blanking plugs, as necessary.
3 . NOTE:
NOTE:
Lubricate the upper crankshaft main bearings and thrust washers.
Install the upper crankshaft main bearings.

For additional information, refer to Camshaft Bearing Journal Clearance
1. Install the upper crankshaft thrust washers.
2. Install the upper crankshaft main bearings.
4.
CAUTION: Avoid damage to any crankshaft bearing surfaces.
Install the crankshaft.
5 NOTE:
.
NOTE:
Install lower cylinder block and tighten bolts to specification within twenty minutes of
applying sealer.
Apply a bead of sealant to the cylinder block housing.

• Use WSS-M4G320-A3-RTV sealant.
6
. CAUTION: Make sure all dowels are fully seated into lower cylinder block prior to
tightening the bolts.
CAUTION: Do not lubricate the lower cylinder block bolts.
CAUTION: Do not rotate crankshaft until all bolts are tightened to specification.
CAUTION: Bolts must be tightened within twenty minutes of applying sealer.
CAUTION: Tighten the bolts in the sequence shown.
Install the lower cylinder block to the upper cylinder block.
9.
CAUTION: Do not use any lubricant on the seal, the transit sleeve or the crankshaft.
CAUTION: Make sure all components are clean and dry.
Make sure the transit sleeve is correctly in place and install the new seal over the crankshaft.
10 . Carefully remove the transit sleeve, leaving the seal in place.
11 . Install the special tool to the crankshaft.
12 Reposition the nuts to hold the special tool against the crankshaft rear seal. Check that the
. crankshaft rear seal and the special tool are parallel to the rear of the engine.
13 .
CAUTION: Alternate nut tightening to correctly seat the crankshaft rear seal.
Using the special tool, install the crankshaft rear seal.

14 . Remove the special tool from the crankshaft.
• Check that the seal is located correctly.
15
• Position the crankshaft journal at the bottom of the stroke.
16
. CAUTION: Make sure the piston rings are positioned at different positions opposite
the thrust side of the piston before installation.
CAUTION: Install pistons with arrow to front of engine.
Using the special tool compress the rings and install the piston and connecting rod.
• Lubricate all piston components.

17
. CAUTION: When assembling the connecting rods and connecting rod caps it is
imperative that bearing slots and tangs be located on the same side of the connecting
rods.
CAUTION: Connecting rod bolts are torqued to yield and must be replaced.
CAUTION: Bolts must be tightened equally.
NOTE:
Remove the special tools from the connecting rods.
Position the connecting rod cap on the appropriate connecting rod.
13. Tighten to 90°

19 . Install the piston cooling jets.
• Tighten to 9 Nm
20 . Install the oil pump.
21 . Install the upper oil pan.
22 . Install the oil strainer.
• Install, but do not fully tighten the retaining bolts.

24 Tighten to 12 Nm.
.
• A new oil pan is supplied with the drain plug installed. Check that the drain plug is
tightened to 25 Nm.
25 . Install the flexplate.

14. Install the flexplate.
15. Install the flexplate retaining bolts.
26 . Reposition the crankshaft.
• Install the crankshaft setting peg 303-645 to the crankshaft position sensor location.
27 . Install a new left-hand cylinder head gasket.

28
Install the left-hand cylinder head.

29 . Install a new right-hand cylinder head gasket.
30
Install the right-hand cylinder head.

31 . NOTE:
32 . Install the left-hand inlet camshaft.

33 .
34 . NOTE:
35 . Install the left-hand exhaust camshaft.

36 .
37 . NOTE:

38 . Install the right-hand inlet camshaft.
39 .
40 . NOTE:

41 . Install the right-hand exhaust camshaft.
42 .
45
to rotate.

camshaft sprockets.
46 . Using a suitable tool, retain the left-hand timing chain tensioner piston.
48 . Install the secondary timing chain tensioner.
.
tool.

52
chain.
54
Using a suitable tool, hold the left-hand timing chain tensioner ratchet lock mechanism away
from the ratchet stem.
55 NOTE:
.
Slowly compress the left-hand timing chain tensioner.
56 NOTE:
.
Using a suitable tool, retain the left-hand timing chain tensioner piston.
59
sprocket bolt.
60
sprocket bolt.
61
to rotate.
camshaft sprockets.
62 . Using a suitable tool, retain the right-hand timing chain tensioner piston.
63 . Install the secondary timing chain tensioner retaining bolts.
.
tool.
66 . Install the primary timing chain guide.
67
chain.
69
Using a suitable tool, hold the right-hand timing chain tensioner ratchet lock mechanism
away from the ratchet stem.
70 NOTE:
.
Slowly compress the right-hand timing chain tensioner.
71 NOTE:
.
Using a suitable tool, retain the right-hand timing chain tensioner piston.
74
sprocket bolt.
75
sprocket bolt.
76 . Remove the special tool from the right-hand cylinder head.

77 . Remove the special tool from the left-hand cylinder head.
78 . Install the left-hand variable camshaft timing oil control unit housing.
79 . Install the right-hand variable camshaft timing oil control unit housing.
81 . Install the crankshaft position sensor.
82 . Install new seals to the timing cover.
26. Install the new seal to the inner groove on the face of the timing cover.
27. Install the new seal to the outer groove on the face of the timing cover.
83 Apply sealant to the eight joints on the engine face.

. • Sealant beads to be 3mm diameter and 12mm long. Cut the nozzle of the sealant tube
to produce a 3 mm bead. (Install and tighten the securing bolts within twenty minutes of
sealant application).
84 . Install the timing cover.
85 .
CAUTION: Make sure the crankshaft front seal mating faces are clean and dry.
CAUTION: Do not remove the crankshaft front seal protector.
Using the special tool, install a new crankshaft front seal.
86 . Remove the crankshaft seal protector.
87 . Install a new O-ring seal to the crankshaft pulley.
• Lubricate the new O-ring.
88
. CAUTION: The screw thread in the crankshaft must be cleaned out before a new
crankshaft pulley bolt is installed.
CAUTION: A new crankshaft pulley bolt must be used.
Install, but do not tighten, a new crankshaft pulley retaining bolt.

• Install the crankshaft pulley and locking ring to the crankshaft.
89
• Tighten the crankshaft pulley retaining bolt to 375 Nm.
91 . Carry out a valve clearance check.

For additional information, refer to Valve Clearance Check (12.29.47)
92 NOTE:
.
Install the left-hand valve cover.
93 NOTE:
.
Install the right-hand valve cover.
95 . Install the left-hand camshaft position (CMP) sensor.
96 . Install the right-hand camshaft position (CMP) sensor.
97 . NOTE:

Install the ignition coils.
99 . Install the water pump.
• Install new O-ring seals and gaskets.
100 . Install the water pump pulley.
• Using special tool, retain the water pump pulley.
• Tighten to 10 Nm + 45°.
101 . Install the engine block insulation grommet.
102 . Install the intake manifold heater coolant hose.
28. Install the knock sensors.
29. Install the intake manifold heater coolant hose.
103 . Install the noise and vibration insulating pad.
105 . Attach the engine wiring harness retaining clips.
106 . Attach the right-hand oxygen sensor.
108 . Connect the oil pressure switch and oil temperature sensor electrical connectors.
110 . NOTE:
Apply a suitable amount of clean engine oil to lubricate the oil filter O-ring seal.
Install a new oil filter.
111 .
114 . NOTE:
Left-hand shown, right-hand simular.
Install the lower intake manifold.

122 . Connect the exhaust gas recirculation valve coolant hose.

123 . Connect the exhaust gas recirculation valve electrical connector.
124 . Connect the fuel pressure regulator electrical connector.
125 . Connect the positive crankcase ventilation pipe.

128 . Attach the engine harness.
30. Connect the earth wire.
• Attach the engine harness.

133 . NOTE:
Left-hand shown, right hand similar.
Connect the fuel injector electrical connectors.


137 . NOTE:
Install the ignition coil cover.
138 . Connect the knock sensor electrical connectors.
139 . NOTE:
Install the charge air coolers.
• Install a new charge air cooler gasket.
141 . Connect the manifold absolute pressure (MAP) sensor.
142 . Install the air intake elbow.
• Install new retaining bolt seals.
143 . NOTE:
Make sure ground strap is correctly installed to the location noted.
Install the air intake elbow retaining bracket lower retaining bolts.
144 . Connect the air intake elbow pipes.
145
. 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.
Install the throttle body.
• Install a new throttle body gasket.
146 . NOTE:
Un-cap the coolant hose.
Attach the coolant hose to the throttle body.

148 . Install the EGR valve and the exhaust manifold to EGR valve tube.
• Install a new exhaust manifold to EGR valve tube gasket.
• Install a new EGR valve to air intake elbow gasket.
150 . NOTE:
Un-cap the exposed ports.

Connect the coolant hoses.
151 . Connect the exhaust gas recirculation (EGR) valve electrical connector.
153 . Connect the charge air cooler coolant pipes.

154 . Install new O-ring seals to the thermostat housing.
155 . Install thermostat housing.


164 . Connect the thermostat housing hoses
165 . Install new supercharger outlet pipe to charge air coolers ducts.
166 . Install a new supercharger outlet pipe gasket.
167 . Install new seals to the supercharger outlet pipe retaining bolts
168 .
Install the supercharger outlet pipe
169 . NOTE:
Un-cap the coolant ports.
Attach the supercharger outlet pipe coolant hose.
170 . Attach the hoses.

33. Attach the engine wiring harness.

177 . Connect the crankshaft position sensor electrical connector.

180 . Install the air conditioning compressor mounting bracket.
182 . Connect the air conditioning compressor electrical connector.
183 . Install the left-hand engine mounting bracket.
184 . Install the left-hand engine mount.
185
. CAUTION: Make sure the exhaust manifold and gasket are correctly aligned to
the cylinder head.
CAUTION: Make sure the exhaust manifold torque is checked after initial tighten.
Install the left-hand exhaust manifold.
186 . Install the heat shield retaining bolt.

191 . Attach the right hand oxygen sensor retaining bracket.
• Tighten the generator upper retaining bolt to 21 Nm.
• Tighten the generator lower retaining bolt to 40 Nm.

196 . Connect the generator electrical connector.
197 . Attach the generator battery positive cable.
• Tighten to 12 Nm
198 . Attach the generator battery positive cable protective cover.

• Install the accessory drive belt.

• Attach the accessory drive belt.

303-03A : Engine Cooling – 4.2L NA V8 – AJV8/4.2L SC
V8 – AJV8
Specifications
Specifications
Capacities
Liters
Naturally aspirated models 9.5
Supercharged models 11.5
Specifications
WSS M97B44-
Coolant fluid
D
Coolant concentration - will provide frost protection to -40°C (-40°F) 50%
Specific gravity of coolant at 20°C (68°F), to protect against frost down to -
1.068
40°C (-40°F)
NOTE:
The coolant is of the Organic Acid Technology (OAT) type and must not be mixed with
other types of coolant.
Item Specification
Pressurised, thermostatically controlled with remote
Cooling system type
header tank
Radiator Cross flow with integral transmission fluid cooler
Remote - fitted with a bleed screw and low coolant
Expansion tank
level sensor
Pressure cap rating 1.2 bar (120 kPa) (17 lbf/in²)
Thermostat:
Starts to open 88° C (190° F)
Fully open 95° C (203° F)
Cooling fan Electronically controlled
Coolant pump Centrifugal flow impellor, belt driven from crankshaft
Low temperature radiator (Intercooler Cross flow, single pass, located in front of A/C
circuit) condenser
Auxiliary water pump (Intercooler
Centrifugal type, 35w 12V DC electric motor
circuit)
Engine oil cooler (Supercharged
Twin oil-air coolers, connected in series
models)
Item Nm lb-ft lb-in

Block heater 56 41 -
Coolant expansion tank - bolt 7 5 62
Coolant inlet housing to engine - bolt 9 7 80
6+ 71 +
Coolant pump - bolt 8 + 90º
90º 90º
10 + 7+ 88 +
Coolant pump pulley - bolt
45º 45º 45º
Radiator upper mounting bracket - bolt - Naturally aspirated
27 20 -
models
Radiator upper mounting bracket - bolt - Supercharged models 30 22 -
Thermostat to coolant outlet pipe assembly - bolt 4 3 35
Thermostat and coolant outlet pipe assembly to engine - bolt 9 7 80
Engine oil cooler support brackets 7 5 62
Oil cooler feed tubes 7 5 62
Oil cooler return tubes 7 5 62
Auxiliary water pump (Intercooler circuit) securing bolt 5 4 44
General procedure
Cooling System Draining, Filling and

Bleeding - 4.2L NA V8 - AJV8
WARNING: Never remove the coolant pressure cap under any circumstances
while the engine is operating. Failure to follow this instruction may result in personal
injury.
WARNING: 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.
CAUTION: The engine cooling system must be maintained with the correct
concentration and type of anti-freeze solution to prevent corrosion and frost damage.
Failure to follow this instruction may result in damage to the engine
CAUTION: Never remove the coolant pressure cap under any circumstances
while the engine is operating. Failure to follow this instruction may result in damage to
the engine.
1. Open the hood.
2.

3.
WARNING: 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 result in
personal injury.
Release the cooling system pressure.

• Remove the coolant expansion tank cap.
4. Drain the coolant.

• Remove the drain plug.
5. Install the drain plug.
6. Loosen the coolant expansion tank bleed screw.
7.
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.
8. Install the coolant expansion tank cap.
9. Set the heater controls to maximum.
10. Start the engine and idle until hot air is emited at the face registers.
11. Switch the engine off and allow to cool.
12. Check and top-up the coolant if required.
13. Close the hood.

Cooling System Draining, Filling and
Bleeding - 4.2L SC V8 - AJV8
injury.
Failure to follow this instruction may result in damage to the engine
the engine.
1. Open the hood.
2.

3.
WARNING: 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 result in
personal injury.
Release the cooling system pressure.

• Remove the coolant expansion tank cap.
4. Drain the coolant.
• Remove the drain plug.
5. Install the drain plug.
6. Loosen the coolant expansion tank bleed screw.
7.
Refill the cooling system.

• When coolant runs from the expansion tank bleed point bubble-free, tighten the bleed
screw.
9. Remove the engine cover.

10. Remove the supercharger coolant filler plug.

• Remove and discard the sealing washer.
11.
CAUTION: Coolant may spill from the supercharger fill port when the ignition is
switched on.
Switch the ignition on.
12.
CAUTION: Do not allow the supercharger coolant pump to run dry for more
than one minute. Failure to follow this instruction may result in damage to the vehicle.
Allow the supercharger pump to run and top-up the coolant through the supercharger fill port.
• Switch the ignition off.
13. Install the supercharger coolant fill plug and tighten to 45 Nm (33 lb.ft).
• Install a new sealing washer.
14. Install the engine cover.

15. Set the heater controls to maximum.
16. Start the engine and idle until hot air is emited at the face registers.
19. Close the hood.

Cooling System Draining and Vacuum
Filling
injury.
Failure to follow this instruction may result in damage to the engine.
the engine.
NOTE:
Vehicles fitted with supercharged engines shown, V8 NA and V6 engines similar.
1. Set the heater controls to maximum HOT.
2. Open the hood.
3.
WARNING: Relieve the cooling system pressure by unscrewing the coolant

pressure cap. Failure to follow this instruction may result in personal injury.
Remove the coolant expansion tank cap.

4.

5. Remove the radiator undertray.

6. NOTE:
Remove the coolant drain plug.

• Drain the coolant into a suitable container.
7. Disconnect the coolant lower hose from the supercharger radiator.

• Release the clip.
• Allow the coolant to drain.
8.
CAUTION: Do not over tighten the drain plug. Failure to follow this instruction
NOTE:
Install the drain plug.

• Remove the drain tray.
9. Connect the supercharger radiator lower coolant hose.
10. Install the radiator undertray.

11. Lower the vehicle.
12. Prepare a sufficient amount of coolant to the specified concentration.
13. Install the cooling system vacuum refill adaptor to the expansion tank.
14. Install the vacuum filler gauge to the cooling system vacuum refill adaptor.
15. Install the venturi tube assembly to the vacuum filler gauge.
16. NOTE:
Make sure both valves are in the closed position on the vacuum filler gauge assembly.
NOTE:
The coolant vacuum fill tool needs an air pressure of 6 to 8 bar (87 to 116 psi) to operate
correctly.
NOTE:
Small diameter or long airlines may restrict airflow to the coolant vacuum fill tool.
Connect a regulated compressed air supply to the venturi tube assembly.
17. Position the evacuated air hose into a container.
18. Open the air supply valve.
19. NOTE:
Make sure the coolant supply hose is positioned into a container of fifty percent mixture
of Jaguar Premium Cooling System Fluid or equivalent, meeting Jaguar specification
WSS M97B44-D and fifty percent water. Make sure no air can enter the coolant supply
hose.
Open the coolant supply valve for 2 seconds to prime the coolant supply hose.
20. Apply air pressure progressively until the arrow on the vacuum filler gauge reaches the
green segment.
• Allow the vacuum to rebuild.
• Close the air supply valve.
• Allow one minute to check the vacuum is held.
21. Disconnect the compressed air supply line.
22. NOTE:
Close the coolant supply valve when the coolant expansion tank MAX mark is reached or
coolant movement has ceased.
Open the coolant supply valve and allow the coolant to be drawn into the system.
23. Remove the vacuum filler gauge and cooling system vacuum refill adaptor assembly.

25. Remove the engine cover.
26. Remove the supercharger coolant fill plug.

27.
CAUTION: Coolant may spill from the supercharger fill port when the ignition is
switched on.
28.
CAUTION: Do not allow the supercharger coolant pump to run dry for more
than one minute. Failure to follow this instruction may result in damage to the vehicle.
Allow the supercharger pump to run and top-up the coolant through the supercharger fill port.
• Switch the ignition off.
29. Install the supercharger coolant fill plug.

• Tighten to 45 Nm (33 lb.ft).
30. Install the engine cover.
31.
CAUTION: Observe the engine temperature gauge. If the engine starts to over-
heat switch off immediately and allow to cool. Failure to follow this instruction may
cause damage to the vehicle.
Start the engine and idle until hot air is emitted at the face registers.
34. Close the hood.

Cooling System Flushing
1. Remove the air cleaner. <<303-12A>>
2. Remove the air cleaner. <<303-12B>>
3. Remove the thermostat.
4. Detach the lower coolant hose from the radiator and position to one side.
5. Detach the upper coolant hose from the radiator.
NOTE:
To remove rust, sludge and other foreign material from the cooling system, use Premium
Cooling System flush, meeting Jaguar specification EGR-M14P7-A, which is safe for use
with aluminium cooling systems. This cleaning restores cooling system efficiency and
helps prevent overheating.
NOTE:
In severe cases where cleaning solvents will not properly clean the cooling system, it will
be necessary to use the pressure flushing method using Cooling System Flusher, 164-
R3670 to restore efficient operation.
NOTE:
A pulsating or reversed direction of flushing water will loosen sediment more quickly
than a steady flow in the normal coolant flow direction.
NOTE:
Dispose of old coolant and flushing water contaminated with coolant and cleaning
chemicals in accordance with local, state and federal laws.
6. Connect a hose pipe to the radiator upper coolant hose connection using a suitable
connector.
7.
CAUTION: Radiator internal pressure must not exceed 100 kPa (14.5 psi).
Failure to follow this instruction may cause damage to the radiator.
Flush the radiator using the hose pipe until the coolant flowing from the radiator lower
coolant hose connection is clear.
8. Remove the hose pipe from the radiator upper coolant hose connection.
9. Connect a hose pipe to the upper coolant hose using a suitable connector.
10. Flush the engine using the hose pipe until the coolant flowing from the radiator lower
coolant hose is clear.
11. Remove the hose pipe from the upper coolant hose connection.
12. Connect the upper coolant hose to the radiator.
13. Connect the lower coolant hose to the radiator.
14. Install the thermostat.
15. Fill the cooling system.

16. Install the air cleaner. <<303-12A>>
17. Install the air cleaner. <<303-12B>>


COMPONENT LOCATION
1 Transmission oil cooler inlet
2 Engine coolant outlet
3 Vent hose
4 Auxiliary coolant flow pump
5 Cap
6 Fan harness connector
7 Expansion tank
8 Heater return pipe
9 Heater feed pipe
10 Bleed screw
11 Engine oil cooler connections
12 Transmission oil cooler outlet

13 Engine coolant inlet
INTRODUCTION
WARNING: Never remove the coolant pressure cap under any circumstances while the
engine is operating. Failure to follow this instruction may result in personal injury. To avoid having
scalding hot coolant or steam blow out of the cooling system, use extreme care when removing the
coolant pressure cap from a hot cooling system. Wait until the engine has cooled, then wrap a
thick cloth around the coolant pressure cap and turn it slowly until the pressure begins to release.
Step back while the pressure is released from the system. When certain all the pressure has been
released turn and remove the coolant pressure cap (still with a cloth) from the coolant expansion
tank. Failure to follow these instructions may result in personal injury.
WARNING: 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.
WARNING: Remove fuse 38 from the Battery Junction Box (BJB) prior to performing any
under hood service in the area of the cooling fan when the engine is hot, since the cooling fan
motor could operate if the engine has been switched OFF. Failure to follow this instruction may
CAUTION: The engine cooling system must be maintained with the correct concentration
and type of anti-freeze solution to prevent corrosion and frost damage.
CAUTION: Never remove the coolant pressure cap under any circumstances while the
engine is operating. Failure to follow this instruction may result in damage to the engine.
Engine cooling is via a low volume, high velocity system, which achieves a very fast warm up. The
temperature of the combustion chambers is reduced along with a more even temperature
distribution.
The coolant expansion tank has an integral bleed screw and coolant-level sensor. The auxiliary
coolant-flow pump is fitted as standard.
The cooling-fan speed is controlled directly by the Engine Control Module (ECM) based on input data
measured by the Engine Coolant Temperature (ECT) sensor, the climate control pressure-transducer
and the transmission oil temperature sensor. The ECM processes this input data and outputs a Pulse
Width Modulated (PWM) signal, which determines the fan speed. Should the output signal fall
outside predetermined parameters, maximum fan-speed is initiated to protect the engine. High
engine temperature is indicated by the illumination of the engine over-temperature warning light,
located in the instrument cluster.
Where appropriate, to provide an extended period of engine cooling, the ECM continues to control
the fan speed after the ignition has been turned off. For additional information, refer to Electronic
Engine Controls (303-14 Electronic Engine Controls - 4.2L)
A coolant drain plug is located at the rear of the cylinder block behind the starter motor.
COOLANT PUMP
1 Pulley
2 Hub
3 Pump body
4 Impeller
5 Adapter casting
The coolant pump is fitted between the 2 cylinder banks, on the front face of the cylinder block.
The pump consists of a housing containing a shaft, with a shrouded plastic impeller on one end and a
drive pulley on the other.
A pair of roller bearings supports the shaft in the housing. A seal behind the impeller prevents
coolant from contaminating the bearings. Should this seal fail, coolant escapes from a witness hole in
the housing indicating that immediate action is required.
An O-ring and an aluminum-alloy gasket, seal the ports between the pump and the cylinder banks.
From the pump, coolant flows into each bank of the cylinder block. In each bank, approximately 50%
of the coolant cools the cylinder bores and the remainder is diverted through the bypass gallery to
the cylinder head.
With the thermostat closed, coolant returns directly to the pump through the bypass on the
thermostat housing.
With the thermostat open, coolant returns to the pump via the radiator.
COOLANT OUTLET ASSEMBLY

1 Bypass to coolant pump
3 ECT sensor
4 Vent to expansion tank
5 Engine coolant outlet
6 Thermostat cover
7 Bottom hose connection
A coolant outlet plastic pipe connects to the outlet port of each cylinder head to provide a common
connection point for the radiator top hose. It also incorporates the ECT sensor, which provides a
signal representing coolant temperature at the cylinder heads. Controlling the coolant flow through
the radiator, the thermostat starts to open at 80°C (176°F) to 84°C (183°F) and is fully open at 96°C
(205°F). The outlet pipe has connections to supply the heater core and the bypass flow to the
thermostat housing. An in-groove gasket seals each of the outlet-to-cylinder head joints. An
aluminium gasket seals the ECT sensor to thermostat housing.
RADIATOR
A Front view
B Rear view
1 Receiver dryer (condenser assembly)
2 Radiator assembly
3 Auxiliary radiator
5 Fan
6 Fan motor
7 Shroud
The cooling pack incorporates the radiator assembly with integral transmission oil cooler (located in
the radiator outlet tank), an air conditioning condenser, and the twin fan and motor assembly.
The radiator is mounted on 4 rubber mounts, one on each end of the upper and lower face. A closing
panel, which retains the radiator assembly, fits over the top of the radiator and is secured to the
vehicle body.
COOLING FANS
The 2 radiator cooling fans are mounted in a twin fan and motor assembly between the radiator and
the engine.
The fan control module controls the fans dependent on the demand from the cooling system
(temperature) or the air conditioning system (pressure).
The fan control module is located on the twin fan and motor shroud. The variable PWM module
controls the fan speeds.
Under hot operating conditions, the fans may continue to operate for some time after the engine has
been switched off, but will stop automatically when the coolant temperature has been sufficiently
reduced. For additional information, refer to Electronic Engine Controls (303-14 Electronic Engine
Controls - 4.2L)
ENGINE BLOCK HEATER
1 Engine block heater
For vehicle markets subject to very cold climate conditions, an engine block heater for connection to
an external mains power supply, is fitted in place of the engine block drain plug.
ENGINE OIL COOLER

1 Engine oil cooler
The engine oil cooler is a Modine oil to water type. The oil cooler is located at the front of the engine
and is fitted between the oil filter housing and the oil filter.
The coolant supply for the engine oil cooler is through the radiator bottom hose.
COOLANT RECOVERY SYSTEM

A pressurized coolant expansion tank system is used which continuously separates the air from the
cooling system and replenishes the system through the coolant expansion tank outlet hose, attached
to the heater return hose.
A continuous vent from the engine and radiator to the coolant expansion tank prevents air locks
from forming in the cooling system.
Manual bleed points are provided on the coolant reservoir.
The coolant expansion tank serves as the location for:
• Service fill
• Coolant expansion during warm-up
• Air separation during operation
• System pressurization by the coolant pressure cap
• The coolant expansion tank is designed to have approximately 0.5 to 1 liter of air when cold
to allow for coolant expansion
ENGINE COOLANT TEMPERATURE (ECT) SENSOR

The ECT sensor is located in the coolant outlet pipe and reacts to engine coolant temperature
changes, providing an input to the ECM. The sensor is a Negative Temperature Coefficient (NTC)
thermistor, decreasing in resistance as the temperature rises. For additional information, refer to
Electronic Engine Controls (303-14 Electronic Engine Controls - 4.2L)
ENGINE COOLANT
The long life engine coolant is formulated to last for 5 years or 240,000 km (150,000 miles). The
coolant is silicate free and orange in color. The long life engine coolant must not be mixed with
conventional engine coolant.
COOLANT FLOW
1 Dual coolant flow valve
2 EGR valve
3 Throttle body
4 Heater core
5 Water pump
6 Engine bank (left-hand)
7 Thermostat
8 Engine oil cooler
9 Lower hose
10 Coolant expansion tank
11 Radiator
13 Upper hose
Engine Cooling - 4.2L SC V8 - AJV8
Authoring Template
COMPONENT LOCATION
A Single engine oil cooler variant
B Twin engine oil cooler variant
1 Radiator assembly
2 Cooling fan shroud
3 Condenser
4 Right Hand (RH) engine oil cooler
5 Left Hand (LH) engine oil cooler
6 Engine oil cooler
7 Intercooler pump
8 Intercooler
9 Power steering oil cooler
OVERVIEW
The cooling system employed for the supercharged engine is very similar to the normally aspirated
engine. The system is of the pressure relief by-pass type, which allows coolant to circulate around
the engine and the heater circuit while the thermostat main valve is closed. The primary function of
the cooling system is to maintain the engine within an optimum temperature range under changing
ambient and engine operating conditions. Secondary functions are to provide heating for the
passenger compartment and cooling for the transmission fluid and engine oil.
The cooling system comprises:
• A cooling module including common radiator, condenser, transmission oil cooler with
additional water cooled, intake charge air radiator
• A passenger compartment heater matrix
• An engine driven coolant pump
• An electric coolant pump
• A thermostat
• An degas tank
• An electro-viscous cooling fan
• Transmission oil pipes
• Single or twin engine oil coolers
• Two charge air cooler assemblies (heat exchangers)
• Connecting hoses and pipes
ENGINE COOLING SYSTEM

A centrifugal pump mounted on the front of the engine and driven by an ancillary drive 'polyvee' belt
circulates the coolant. The engine driven coolant pump circulates coolant through the cylinder block
and cylinder heads via a chamber located in the 'vee' of the engine. Having passed through the
engine the coolant returns to the thermostat housing. The coolant then progresses down the 'top
hose' to the heater pipe. The heater pipes lead to the bulkhead and return to the engine side of the
thermostat.
The engine contains a conventional thermostat, which is positioned such that the wax's temperature
is controlled by both the coolant from the radiator and the bypass. This results in the thermostat
being able to vary its opening temperature dependant on ambient conditions. The thermostat
housing also contains a sprung loaded valve, which limits the amount flow using the bypass. This
means that the engine can run without coolant flowing through the bypass temporarily, to improve
heater performance.
The engine radiator is a cross-flow type with an aluminium matrix and has a drain tap on the lower
RH rear face. There is an additional charge air radiator, located in front of the engine radiator, to
support the water charge air coolers (heat exchangers) on the engine.
The coolant for the charge air cooling is driven by an electric pump at constant speed and is mounted
on the engine radiator end tank. This circuit shares the engine coolant via a vortex connection, in the
engine to radiator hose. The lower engine radiator mountings are located part way up the end tanks.
The mountings are fitted with rubber bushes, which sit on the upper chassis rails. The radiator upper
is mounted by pins, which are pushed through rubber bushes mounted in the front end carrier above
the radiator. The radiator also incorporates 2 connections for the transmission oil pipes.
The top and bottom hoses are mounted to the inlet and outlet sides of the thermostat housing.
The degas tank is fitted forward of the LH suspension turret in the engine compartment. The degas
tank allows for the expansion of the coolant as the engine gets hot and also supplies the engine with
coolant as the coolant in the engine contracts. The tank also allows any air trapped in the coolant to
be removed.
The liquid cooled transmission fluid cooler is located behind the engine cooling radiator and is
connected to the transmission via flexible hoses and metal pipes
There are 2 variations of engine oil coolers available. One variant uses a single cooler located in front
of the intercooler, whereas the second variant utilizes 2 coolers, 1 for each cylinder bank, also
located in front of the intercooler.
The viscous fan unit is electronically controlled by the ECM to optimise fan speed for all operating
conditions.
NOTE:
If the electrical connections to the viscous fan are disconnected the fan will 'idle' and
overheating may result. The ECM stores the appropriate fault codes in this case.
ENGINE COOLING SYSTEM OPERATION
Part
Item Description
Number
A Hot coolant
B Cold coolant
1 Radiator bottom hose
2 Hose assembly - Feed from intercooler radiator to LH and RH intercoolers
Hose assembly - Return from LH and RH intercoolers to intercooler radiator, via

3
electric pump
4 Radiator top hose

5 Hose - Feed from RH intercooler to supercharger
6 Hose - Return from degas tank to intercooler radiator
7 Heater return pipe
8 Heater feed pipe
9 Hose - EGR coolant inlet
10 Hose - Feed to throttle heating assembly
11 Hose - Return from throttle heating assembly
12 Transmission oil cooler feed pipe
13 Transmission oil cooler return pipe
14 Hose - Power steering cooler return
15 Transmission oil cooler return pipe
16 Hose - Power steering cooler to reservoir feed
17 Hose - Power steering pump feed
When the engine is running the coolant pump is driven by the ancillary drive belt. This forces coolant
to circulate around the engine and heater, while the thermostat and bypass valve are shut. As the
temperature and pressure increases the bypass valve is forced open allowing coolant to circulate
through the bypass valve. When the temperature reaches 82°C (180°F) the main thermostat begins
to open allowing coolant to circulate through the main radiator. As the thermostat progressively
opens (fully open at 95°C (203°F)), the bypass valve progressively closes forcing any coolant through
the heater or radiator. Once coolant is allowed to circulate through the radiator, the transmission
fluid and the engine oil coolers begin to receive coolant flow.
The increased coolant volume, created by heat expansion, is directed to the expansion tank through
a bleed hose from the top of the radiator. The expansion tank has an outlet hose, which is connected
into the coolant circuit. This outlet hose returns the coolant to the system when the engine cools.
Coolant flows through the radiator from the top right hand tank to the bottom left hand tank and is
cooled by air passing through the matrix. The temperature of the cooling system is monitored by the
ECM via the Engine Coolant temperature (ECT) sensor located in the cylinder head. The ECM uses
signals from this sensor to control the cooling fan operation and adjust fuelling according to engine
temperature.
To control the cooling fan, the ECM sends a Pulse Width Modulated (PWM) signal to the cooling fan
module (integral to the ECM). The frequency of the PWM signal is used by the cooling fan module to
determine the output voltage supplied to the fan motor.
The ECM varies the duty cycle of the PWM signal between 0 and 100% to vary the fan speed. If the
PWM signal is outside the 0 to 100% range, the cooling fan module interprets the signal as an open
or short circuit and runs the fans at maximum speed to ensure the engine and gearbox do not
overheat.
The ECM operates the fan in response to inputs from the ECT sensor, the transmission oil
temperature sensor, the A/C switch and the A/C pressure sensor.
The speed of the cooling fan is also influenced by vehicle road speed. The ECM adjusts the speed of
the cooling fans, to compensate for the ram effect of vehicle speed, using the Controller Area
Network (CAN) road speed signal received from the Anti-lock Braking System (ABS) module.
Engine Cooling
For a detailed description of the cooling system operation, refer to the relevant Description and

• Leaks • Fuse
• Coolant expansion tank • Wiring harness
• Electric fan • Loose or corroded connector(s)
• Radiator • Engine Coolant Temperature (ECT) sensor
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
• Hoses
• Hose connections
• Radiator
• Coolant pump • GO to Pinpoint Test
Coolant loss • Heater core G552274p1.
• Gaskets
• Engine casting cracks
• Engine block core plugs
• Engine coolant
• GO to Pinpoint Test
Engine overheating (level/condition)
G552274p2.
• Thermostat
• Fan motor
• Fan motor fuses and/or
circuits
• ECT sensor
• Engine control module
(ECM)
• Fan speed module
• Thermostat
Engine not reaching normal • GO to Pinpoint Test
• Electric fan
operating temperature G552274p3.
• Fan speed module
DTC Index
NOTE:
fault (the last two digits give extra information read by the manufacturer approved diagnostic
system).
NOTE:
three decimal places, and with a current calibration certificate. When testing resistance, always
NOTE:
NOTE:
terminals.
• Fill cooling system

to correct level
and specification.
Specifications
• Carry out any
pinpoint tests
associated with
this DTC using the
manufacturer
approved
Engine Coolant • Low coolant level diagnostic system
Temperature (ECT) • ECT sensor sensing circuit - • Check and install
P011623 sensor circuit - intermittent high resistance new engine
range/performance - • Engine thermostat failure thermostat as
• ECT sensor failure necessary.
signal stuck low
Thermostat -
Vehicles Without:
Supercharger
(26.45.07)
• Install a new ECT
sensor as
necessary.
Engine Coolant
Temperature (ECT)
Sensor (18.30.10)

to correct level
and specification.
Specifications
• Carry out any
pinpoint tests
associated with
this DTC using the
Engine Coolant manufacturer
• Low coolant level
approved
Temperature (ECT) • ECT sensor sensing circuit -
diagnostic system
P011624 sensor circuit - intermittent high resistance
• Check and install
range/performance - • Engine thermostat failure
new engine
• ECT sensor failure
signal stuck high thermostat as
necessary.
Thermostat -
Vehicles Without:
Supercharger
(26.45.07)
sensor as
necessary.
Engine Coolant
Temperature (ECT)
Sensor (18.30.10)

to correct level
and specification.
Specifications
• Carry out any
pinpoint tests
associated with
this DTC using the
manufacturer
approved
Engine Coolant • Low coolant level diagnostic system
Temperature (ECT) • ECT sensor sensing circuit - • Check and install
P011629 sensor circuit - intermittent high resistance new engine
range/performance - • Engine thermostat failure thermostat as
signal invalid
Thermostat -
Vehicles Without:
Supercharger
(26.45.07)
sensor as
necessary.
Engine Coolant
Temperature (ECT)
Sensor (18.30.10)
• Carry out any

pinpoint tests
associated with
this DTC using the
• ECT sensor sensing circuit - manufacturer
Engine Coolant short to power, high approved
P011700 Temperature (ECT) resistance, open circuit, diagnostic system
sensor circuit - low input disconnected • Install a new ECT
• ECT sensor failure sensor as
necessary.
Engine Coolant
Temperature (ECT)
Sensor (18.30.10)
• Check for cooling

• Engine overheat
Engine Coolant fan circuit DTCs
condition/cooling fan failure
and refer to
P011800 Temperature (ECT) • ECT sensor sensing circuit -
relevant action
sensor circuit - high input short to ground
specified in DTC
Index
• Carry out any
pinpoint tests
associated with
this DTC using the
manufacturer
approved
diagnostic system
sensor as
necessary.
Engine Coolant
Temperature (ECT)
Sensor (18.30.10)

to correct level
and specification.
Specifications
• Carry out any
pinpoint tests
associated with
this DTC using the
manufacturer
approved
• Low coolant level diagnostic system
Insufficient coolant • ECT sensor sensing circuit - • Check and install
P012500 temperature for closed intermittent high resistance new engine
loop fuel control • Engine thermostat failure thermostat as
Thermostat -
Vehicles Without:
Supercharger
(26.45.07)
sensor as
necessary.
Engine Coolant
Temperature (ECT)
Sensor (18.30.10)
Coolant Thermostat • Low/contaminated coolant

(Coolant Temperature • Thermostat GO to Pinpoint Test
P012800
Below Thermostat • Cooling fan G552274p3.
Regulating Temperature) circuit(s)/module
• Carry out any

• Electric fan control circuit - pinpoint tests
Electric fan control
P048023 short to ground, high associated with
circuit low resistance this DTC using the
manufacturer
approved
diagnostic system
• Carry out any

pinpoint tests
associated with
Electric fan control • Electric fan control circuit -
P048024 this DTC using the
circuit high short to power
manufacturer
approved
diagnostic system
• Carry out any

pinpoint tests
associated with
this DTC using the
manufacturer
approved
diagnostic system
• Cooling fan obstructed • CLEAR any
P048309 Fan rationality check
• Fan/motor damaged obstruction and
INSTALL a new fan
as necessary.
Cooling Fan Motor
and Shroud -
Vehicles Without:
Supercharger
(26.25.25)
• Carry out any

pinpoint tests
associated with
this DTC using the
manufacturer
• Fan control module reports
approved
P048316 Fan rationality check battery voltage less than
diagnostic system
nine volts
• CHECK the battery
condition
• CHECK the
charging system
and fan circuits
• Carry out any

pinpoint tests
associated with
• Fan control module reports
this DTC using the
P048317 Fan rationality check battery voltage greater than
manufacturer
18 volts
approved
diagnostic system
• CHECK the
charging system
and fan circuits
• Carry out any

pinpoint tests
associated with
this DTC using the
manufacturer
approved
diagnostic system
• CLEAR any
P048397 Fan rationality check • Cooling fan jammed
obstruction and
INSTALL a new fan
as necessary.
Cooling Fan Motor
and Shroud -
Vehicles Without:
Supercharger
(26.25.25)
Pinpoint Tests
PINPOINT TEST G552274p1 : LOSS OF

COOLANT
G552274t2 : 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.
Specifications
Cooling System Draining, Filling and Bleeding - 4.2L NA V8 - AJV8 TEST the system for correct
operation.
-> No
Verify the customer complaint.

ENGINE OVERHEATS
G552274t3 : CHECK COOLANT
1. Check the coolant level and condition.
• Does the system contain sufficient coolant of the correct specification?
-> Yes
-> No
Top-up and fill the cooling system to the correct level with the correct specification fluid as
necessary.
Specifications
Cooling System Draining, Filling and Bleeding - 4.2L NA V8 - AJV8 Check for coolant loss. GO to
Pinpoint Test G552274p1.
G552274t1 : 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
-> No
INSTALL a new coolant expansion tank pressure cap. TEST the system for correct operation.
G552274t4 : 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.
-> No
INSTALL a new thermostat.
Thermostat - Vehicles Without: Supercharger (26.45.07) TEST the system for correct operation.
ENGINE DOES NOT REACH NORMAL
OPERATING TEMPERATURE
G552274t5 : 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.
-> No
INSTALL a new thermostat.
Thermostat - Vehicles Without: Supercharger (26.45.07) TEST the system for correct operation.
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 . Switch the engine off.
2 . Open the hood and install protective fender covers.
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 . 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 . Pressurize the cooling system to the coolant expansion tank pressure cap lower limit.
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 . Release the system pressure and remove the pressure test equipment. Check the coolant level.
Replenish as necessary with the correct coolant solution.
Specifications
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 . Conduct the coolant expansion tank pressure cap pressure test in this section.
Coolant Expansion Tank Pressure Cap 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 . Remove the expansion tank pressure cap from the coolant expansion tank.
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.
Slowly pressurise the system until the pressure gauge reading stops increasing, and note highest
pressure reading obtained.
4 . Release pressure and repeat Step 3 at least twice to make sure the pressure test reading is
repeatable and within specification.
5 . If the pressure test gauge readings are not within specification, install a new coolant expansion
tank pressure cap.
Thermostat Test
Remove the thermostat
Thermostat - Vehicles Without: Supercharger (26.45.07) 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.
Thermostat - Vehicles Without: Supercharger (26.45.07) 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.
Thermostat - Vehicles Without: Supercharger (26.45.07)
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.
Coolant Expansion Tank (26.15.01)

Removal
WARNING: 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.
CAUTION: Correct installation of the coolant expansion tank cap can be obtained by
tightening the cap until an audible click is heard.
1
. WARNING: 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 result in personal
injury.
Remove the coolant expansion tank cap.
2 . Clamp the relevant hoses, to minimise the coolant loss.
3
. CAUTION: Engine coolant will damage the paint finished surfaces. If spilt,
immediately remove the coolant and clean the area with water.
NOTE:
Disconnect the 2 hoses from the coolant expansion tank.
Release the clips.
Remove the bolt.
Installation
2 . Disconnect the 2 hoses from the coolant expansion tank.
Remove the container.
Position and secure the clips.
3 . Remove the coolant hose clamps.

4 . Top-up the coolant.
5
. CAUTION: Correct installation of the coolant expansion tank cap can be obtained by
Install the coolant expansion tank cap.

Cooling Fan Motor and Shroud - Vehicles
With: Supercharger (26.25.25)
Removal


5 . Remove the fan cowl.
Remove the 15 clips.
Remove the 2 bolts.

7 . Disconnect the 2 front impact sensor electrical connectors.
8 . Remove the radiator upper mountings.
Remove the 4 bolts.
9 . Release the headlamp to front crossmember bracket.
Remove the 2 bolts.

10 . Release the wiring harness.
11 . Disconnect the secondary air injection (AIR) reservoir vacuum line.
Release the clip.
12 . Remove the front crossmember.


- AJV8

Remove the 7 clips.

17 . Release the auxiliary coolant pump.
Release from the rubber mounting.
18 . Release the cooling fan motor and shroud.

19 . Remove the cooling fan motor and shroud.
Remove the 2 bolts.
Release from the 3 retainers.
Installation
1 . Install the cooling fan motor and shroud.
Secure in the retainers.
Tighten the bolts.
2 . Secure the cooling fan motor and shroud.

3 . Install the auxiliary coolant pump.
Secure in the rubber mounting.
6 . Install the front crossmember.
7 . Tighten the front crossmember to apron panel front extension bolts to 20 Nm (15 lb.ft).
8 . Tighten the front crossmember to fender apron panel reinforcement bolts to 30 Nm (22 lb.ft).
9 . Tighten the front crossmember to front side member extension bolts to 25 Nm (18 lb.ft).
10 . Secure the headlamps.

11 . Connect the AIR reservoir vacuum line.

Secure the clips.
14 . Install the radiator upper mountings.
15 . Connect the 2 front impact sensor electrical connectors.
17 . Install the fan cowl.





- AJV8
Radiator - Vehicles Without: Supercharger
(26.40.01)
Removal

4 . Release the A/C condenser.
Remove the 2 bolts.
Release from the 2 retainers and tie aside.

Remove the 7 clips.
7
. WARNING: 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.

For additional information, refer to Cooling System Draining, Filling and Bleeding - 4.2L NA V8
- AJV8
Release the breather hose.
Remove the bolt.

Remove the 4 bolts.
Release the clip.

Release the clip.
12 .
Disconnect the transmission cooler hoses.
Disconnect the 2 unions.

14 . Release the radiator assembly.
15 . NOTE:
NOTE:
The radiator is removed from beneath the vehicle.

Remove the radiator assembly.
Protect the elements from damage.
Lift the radiator clear of its mountings.
16 . Remove the radiator rubber mountings
17 . Remove the cooling fan.
Remove the 2 bolts.
Installation
1 . Install the cooling fan.
Tighten the bolts.
2 . Install the radiator rubber mountings
3 . Install the radiator assembly.
Lift the radiator onto its mountings.
6 . Connect the transmission cooler hoses.
Tighten the unions to 20 Nm (15 lb.ft).
7 . Connect the radiator lower hose.
8 . Connect the radiator upper hose.

Connect the breather hose.
11 Refill the cooling system.

V8 - AJV8

14 . Secure the A/C condenser.


17 . Check and top-up the transmission fluid level.

For additional information, refer to Transmission Fluid Level Check
Radiator - Vehicles With: Supercharger
(26.40.01)
Removal

4 . Release the trim panel.
Release the LH headlamp washer hose.
Release the 2 wiring harness retaining clips.
Remove the scrivet.

5 . Release the clip.
7 . Remove the air conditioning (A/C) condenser.

For additional information, refer to Condenser Core - 4.2L SC V8 - AJV8 (82.15.07)
Remove the 4 bolts.

Release the clip.
Release the clip.
12 .
Disconnect the 2 transmission cooler lines.
Disconnect the 2 unions.

15 . Remove the trim panel.
Remove the scrivet.
Release the wiring harness fir tree clip.
17 . Mark the position of the power steering fluid cooler pipes.

Remove the 2 bolts.
20 . Release the radiator assembly.
21 . NOTE:
The radiator is removed from beneath the vehicle.
Remove the radiator assembly.
Lift the radiator clear of its mountings.

22 . NOTE:
Remove the radiator rubber mountings
23 . Remove the cooling fan.
Remove the 2 bolts.
Installation
1 . Install the cooling fan.
Tighten the bolts.
2 . Install the radiator rubber mountings
3 . Install the radiator assembly.
Lift the radiator onto its mountings.
5 Attach the power steering fluid cooler.

.
Align the power steering fluid cooler pipes clamp to the marks made
previously.
7 . Connect the transmission cooler lines.

8 . Connect the radiator lower hose.
9 . Connect the radiator upper hose.
12 . Install the trim panel.
Install the scrivet.
13 . Install the A/C condenser.

For additional information, refer to Condenser Core - 4.2L SC V8 - AJV8 (82.15.07)
15 . Secure the trim panel.
Install the scrivet.

Secure the 2 wiring harness clips.
Secure the LH headlamp washer hose.



Thermostat - Vehicles With: Supercharger
(26.45.07)
Removal
2

- AJV8
4 . Disconnect the thermostat housing coolant hose.
Release the clip.
Remove the 3 bolts.

6.
WARNING: Eye protection must be worn.
NOTE:
Release and remove the thermostat.
Position the thermostat housing in a vice.
Installation
1 . Install the thermostat.

3 . Connect the thermostat housing coolant hose.

- AJV8
6 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
Thermostat - Vehicles Without:
Removal
CAUTION: Engine coolant will damage the paint finished surfaces. If spilt, immediately
remove the coolant and clean the area with water.


3
hot.

- AJV8
4 . Disconnect the thermostat housing coolant hose.
Release the clip.

6 . Release and remove the thermostat.
Installation
3 . Connect the thermostat housing coolant hose.


- AJV8


7 NOTE:
.

Test
Thermostat Housing - Vehicles Without:
Supercharger
Removal

2
hot.

- AJV8

4 . Release the clips and disconnect the 5 coolant hoses.

Disconnect the ECT sensor electrical connector.
6 . NOTE:
Remove the ECT sensor.

7 . Remove the thermostat.
8 . Remove and discard the 3 O-ring seals.
9 . Release and remove the thermostat.
Installation
1 . Install the O-ring seals.
3 . Install the ECT sensor.
Connect and secure the coolant hoses.


- AJV8

Coolant Manifold - Vehicles With:
Supercharger
Removal

2

- AJV8
4 . Remove the supercharger belt.

For additional information, refer to Supercharger Belt (18.50.08)
Remove the 2 bolts.

6 . Disconnect the coolant manifold to radiator hose.
Remove the clip.
7 . Disconnect the thermostat housing to radiator hose.
Release the clip.
8 . Disconnect the coolant manifold to coolant reservoir hose.
Release the clip.
9 . Disconnect the coolant manifold bleed hose.
Release the clip.
10 . Disconnect the engine coolant temperature (ECT) sensor electrical connector.

11 . Disconnect the cylinder block coolant hose.
Release the clip.
12
. 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.
Release the coolant manifold.
Position the wiring harness bracket aside.
13 . Disconnect the coolant manifold rear hose.

Rotate the coolant manifold.
Release the clip.
15 . NOTE:
Remove the clip.
Remove the 3 bolts.

Installation
Connect the rear hose and secure with the clip.
Connect the cylinder block hose and secure with the clip.
Attach the wiring harness bracket.

4 . Connect the remaining coolant hoses.
5 . Connect the ECT sensor electrical connector.


9 Refill and bleed the cooling system.

- AJV8
Coolant Pump - Vehicles Without:
Supercharger
Removal
2
hot.

- AJV8

4 . Loosen the 3 coolant pump pulley bolts.
5 . Release the accessory drive belt.
Release the tension from the belt.
6 . Remove the coolant pump drive pulley.
Remove the 3 bolts.

Remove the 5 bolts.
Discard the gasket.
Installation
1 . Install the coolant pump.
Tighten the 5 bolts to 8 Nm (6 lb.ft), then a further 90 degrees.
2 . Install the coolant pump drive pulley.
Install, and lightly tighten the bolts.

4 . Tighten the pulley bolts to 10 Nm (7 lb.ft), then a further 45 degrees.


- AJV8

Coolant Pump - Vehicles With:
Supercharger
Removal
2
3
hot.

For additional information, refer to Cooling System Draining, Filling and Bleeding - 4.2L SC V8 -
AJV8

5 . Disconnect the coolant manifold to coolant reservoir hose.
Release the clip.

6 . NOTE:
7
. CAUTION: Engine coolant will damage the paint finished surfaces. If spilt,
NOTE:
Remove the coolant pump.
Remove the 5 bolts.

Discard the gasket.
Installation
Stage 1: Tighten the bolts to 8 Nm (6 lb.ft).
Stage 2: Tighten a further 90 degrees.
Stage 1: Tighten the bolts to 10 Nm (7 lb.ft).
Stage 2: Tighten a further 45 degrees.
3 . Connect and secure the coolant hose.

- AJV8

303-03B : Supercharged Cooling – 4.2L NA V8 –
AJV8/4.2L SC V8 – AJV8
Coolant Pump
Removal
1

- AJV8
4 . Disconnect the 2 coolant hoses.

Release the clip.
5 . Release the coolant pump.
Remove the bolt.

Remove the 7 clips.

Installation
Connect the coolant hoses and secure with the clips.

4 . Secure the coolant pump.
5 . Connect the coolant hoses.

- AJV8
8 NOTE:
.

Test
Radiator
Removal
1

- AJV8
3 . Vehicles with single oil cooler: Remove the oil cooler.

For additional information, refer to Oil Cooler (12.60.68)
4 . Vehicles with twin oil coolers: Remove the twin oil coolers.
For additional information, refer to Twin Oil Coolers

6.
CAUTION: Protect the surrounding components.
Release the supercharger radiator.
Remove the 2 bolts.
Tie the A/C condenser aside.
7 . Remove the intake air duct.
Release the clip.

8 . LH side: Disconnect the supercharger radiator hose.
Release the clip.
9 . RH side: Disconnect the 3 supercharger radiator hoses.
10 . Disconnect the coolant pump electrical connector.

11 . Remove the supercharger radiator.
12 . NOTE:
Remove the coolant pump.
Release the clip and disconnect the hose.
Remove the bolt.
Installation
Connect the hose and secure with the clip.

2 . Install the supercharger radiator.
3 . Install the intake air duct.
Secure the clip.
4 . Secure the supercharger radiator and A/C condenser.
5 . Attach the power steering fluid cooler.
6 . Vehicles with twin oil coolers: Install the twin oil coolers.
For additional information, refer to Twin Oil Coolers
7 . Vehicles with single oil cooler: Install the oil cooler.

For additional information, refer to Oil Cooler (12.60.68)

- AJV8
303-04A : Fuel charging and controls – 4.2L SC V8 –
AJV8
Specifications
Specifications
Item Nm lb-ft lb-in

Fuel rail bolts (NA models) 10 7 88
Fuel rail bolts (SC models) 21 15 -
Fuel rail pressure sensor 5 4 44
Fuel temperature sensor 7 5 62
Throttle body bolts 10 7 88

No Data Available


310-D005
Removal
2
3
. WARNING: 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.
WARNING: 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.
WARNING: The spilling of fuel is unavoidable during this operation. Ensure that all
necessary precautions are taken to prevent fire and explosion.
Using the special tool, disconnect the fuel line.

4 . Remove the LH charge air cooler.

For additional information, refer to Charge Air Cooler LH (18.50.19)
5 . Remove the RH charge air cooler.

For additional information, refer to Charge Air Cooler RH (18.50.18)
7 . Release the fuel injector wiring harness.

Remove and discard the fuel injector O-ring seals.

10 . NOTE:
Release and remove the fuel injectors.
Remove the 8 clips.
Discard the O-ring seals.

11 . Remove the fuel pressure sensor.
Remove the 2 bolts.
12
. CAUTION: To prevent damage to components, use an additional wrench when
loosening or tightening unions.
Remove the fuel temperature sensor.
Installation
1 . Install the fuel temperature sensor.
Apply sealant to the sensor thread.

2 . Install the fuel pressure sensor.
3 . Install the fuel injectors.
5 . Attach the fuel injector wiring harness.
Secure the clips.
7 . Install the RH charge air cooler.

For additional information, refer to Charge Air Cooler RH (18.50.18)
8 . Install the LH charge air cooler.
For additional information, refer to Charge Air Cooler LH (18.50.19)
9 . Connect the fuel line to the fuel rail.


Removal

3 . Remove the fuel injector.
Remove the clip.
Installation
1 . Install the fuel injector.



Removal

3 . Disconnect the throttle position (TP) sensor electrical connector.
4
hot.
NOTE:
Position cloth to collect fluid spillage.
Disconnect the coolant hoses from the throttle body.
Clamp the throttle body coolant hoses to minimize coolant loss.

Release the throttle body hose clips
5.
Remove the throttle body.
Remove the 4 bolts.
Remove and discard the throttle body gasket.
Installation

2 . Connect the coolant hoses and secure with the clips.
Remove the hose clamps from the throttle body hoses.
3 . Connect the TP sensor electrical connector.

5 . Remove the supercharger coolant fill plug.
Remove and discard the sealing washer.
6
. CAUTION: Coolant may spill from the supercharger fill port when the ignition is
switched on.

7
. CAUTION: Do not allow the supercharger coolant pump to run dry for more than
one minute. Failure to follow this instruction may result in damage to the vehicle.
Allow the supercharger pump to run and top-up the coolant through the supercharger fill
port.
Switch the ignition off.
8 . Install the supercharger coolant fill plug and tighten to 45 Nm (33 lb.ft).
Install a new sealing washer.
9 . Switch the ignition off.

11 . Check and top-up the coolant.

303-04B : Fuel Charging and Controls – 4.2L NA V8 –
AJV8
Specifications
Specifications
Item Nm lb-ft lb-in

Fuel rail - bolt 10 7 88
Throttle body - bolt 10 7 88

COMPONENT LOCATIONS
1 RH (right-hand) fuel rail
2 LH (left-hand) fuel rail
3 Injectors (8 off)
4 Fuel supply pipe

5 Electric throttle body
6 Fuel supply cross over pipe
INTRODUCTION
The major components of the fuel charging and control system comprise a fuel pump and FPDM (fuel
pump driver module) , fuel rails and eight injectors. The fuel pump supplies fuel from the tank, via a
pipe routed along the side of the transmission, 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 Management
System (EMS), 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 (310-01 )
For additional information, refer to Electronic Engine Controls (303-14 )
COMPONENT LOCATIONS
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

INTRODUCTION
The major components of the fuel charging and control system comprise a fuel pump and Fuel Pump
Driver Module (FPDM), fuel rails and eight injectors. The fuel pump supplies fuel from the tank, via a
pipe routed along the side of the transmission, 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 Management
System (EMS), 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 (310-01 Fuel Tank and Lines)
For additional information, refer to Electronic Engine Controls (303-14 Electronic Engine Controls -
4.2L)
FUEL PUMP
1 Electrical connector
2 Fuel pump module
3 Fuel level sensor
4 Fuel level float
The fuel pump module is mounted in the RH 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, which is controlled by the EMS. For additional information, refer
to Fuel Tank and Lines (310-01)
FUEL PUMP DRIVER MODULE
The Fuel Pump Driver Module (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 fuel rail
pressure sensor, MAP and the Mass Air Flow (MAF)/Intake Air Temperature (IAT) sensor. The FPDM
is located on the RH end of the charcoal cannister and is attached by 2 scrivet fasteners.
The ECM sends a PWM 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 the 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 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
Integrated Diagnostic System (IDS). The FPDM cannot be interrogated for diagnostic purposes.
INJECTORS
Eight, top fed, 12 hole, fuel injectors are installed in the fuel rails. Two 'O' rings seal each injector to
the fuel rails and should be renewed whenever an injector is refitted to an engine. A small amount of
engine oil can be applied to the 'O' rings to aid installation. No other form of lubrication should be
used. 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 injectors have a resistance of 13.8 Ohms ± 0.7 Ohms @ 20 Degrees Celsius.
ELECTRIC THROTTLE
The electronic throttle body 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, Accelerator Pedal
Position (APP) sensor and the Engine Control Module (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. For additional information, refer to Electronic Engine Controls (303-14 Electronic
Engine Controls - 4.2L)
FUEL RAILS
1 Fuel rail pressure sensor
2 Fuel rail pressure damper
3 Fuel rail
4 Fuel rail temperature sensor
5 Fuel rail
6 Fuel rail pressure damper
7 Fuel rail inlet
8 Fuel rail connection pipe
9 Fuel injector
Each fuel rail maintains a fuel pressure of typically 4.5bar (65 psi), 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 injectors to
the fuel rails.
FUEL PRESSURE DAMPER
A fuel pressure damper is attached centrally to each of the fuel rails. The damper acts to damp
pressure pulses from the fuel pump.
FUEL TEMPERATURE SENSOR
The fuel temperature sensor is located in the rear of the RH fuel rail. The sensor is an NTC sensor,
which is connected to the ECM by two wires. For additional information, refer to Electronic Engine
Controls (303-14 Electronic Engine Controls - 4.2L)
FUEL RAIL PRESSURE SENSOR
The fuel pressure 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 For additional information, refer to Electronic Engine Controls (303-14 Electronic Engine
Controls - 4.2L)
.
Fuel Charging and Controls - 4.2L NA V8 -

For a detailed description of fuel charging and controls, refer to the relevant Description and

• Fuel level
• Fuel leaks
• Fuses
• Damaged fuel lines
• Loose or corroded electrical connectors
• Damaged push connect fittings
• Harnesses
• Fuel contamination/grade/quality
• Sensor(s)
• Throttle body
• Engine Control Module (ECM)
• Damaged fuel tank filler pipe cap
• Damaged fuel tank filler pipe
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
• Ensure the engine

• Engine breather system breather system is
disconnected/restricted free from restriction
Engine cranks, but does not fire • Ignition system and is correctly
• Fuel system installed
• Electronic engine control • For ignition system
tests.
Engine Ignition
• For fuel system tests.
Fuel Tank and Lines
• Read DTCs and refer
to DTC Index for
electronic engine
control tests.
Electronic Engine
Controls
• Evaporative emissions
• For purge valve tests.
purge valve
• Fuel pump
Engine cranks and fires, but will • Spark plugs
Fuel Tank and Lines
not start • HT short to ground
• For ignition system
(tracking) check rubber
tests.
boots for cracks/damage
Engine Ignition
• Ignition system
• Check the engine

coolant level and
condition.
Specifications
• Ensure the battery is
in a fully charged and
• Engine coolant level/anti- serviceable condition
freeze content • Read DTCs and refer
• Battery to DTC Index for
• Electronic engine controls electronic engine
Difficult cold start
• Exhaust Gas Recirculation control tests.
(EGR) valve stuck open Electronic Engine
• Fuel pump Controls
• Purge valve • For EGR system tests.
Engine Emission
Control
Fuel Tank and Lines
• Check for injector

leak, install new
• Injector leak injector as necessary.
• Electronic engine control Fuel Injector
• Purge valve (18.10.01)
Difficult hot start • Fuel pump • Read DTCs and refer
• Ignition system to DTC Index for
• EGR valve stuck open electronic engine
control tests.
Electronic Engine
Controls
Fuel Tank and Lines
tests.
Engine Ignition
• For EGR system tests.
Engine Emission
Control

leak, install new
injector as necessary.
Fuel Injector
(18.10.01)
to DTC Index for
electronic engine
• Injector leak
control tests.
Difficult to start after hot soak • Electronic engine control
Electronic Engine
(vehicle standing, engine off, • Purge valve
Controls
after engine has reached • Fuel pump
operating temperature) • Ignition system
• EGR valve stuck open
Fuel Tank and Lines
tests.
Engine Ignition
Engine Emission
Control

breather system is
free from restriction
and is correctly
• Breather system installed
disconnected/restricted • Read DTCs and refer
• ECM relay to DTC Index for
• Electronic engine control electronic engine
Engine stalls soon after start • Ignition system control tests.
• Air intake system restricted Electronic Engine
• Air leakage Controls
• Fuel lines • For ignition system
tests.
Engine Ignition
• Check for blockage in
air filter element and
air intake system
• Check for air leakage
in air intake system
Fuel Tank and Lines

Fuel Tank and Lines
leak, install new
injector as necessary.
Fuel Injector
(18.10.01)
in air intake system
• Fuel pressure, fuel pump,
to DTC Index for
fuel lines
electronic engine
• Injector leak
control tests.
• Air leakage
Electronic Engine
• Electronic engine control
Engine hesitates/poor Controls
• Throttle motor
acceleration • Read DTCs and refer
• Restricted accelerator pedal
to the DTC Index in
travel (carpet, etc)
this section for
• Ignition system
throttle motor tests
• Ensure accelerator
• Transmission malfunction
pedal is free from
restriction
tests.
Engine Ignition
Engine Emission
Control
• For transmission tests.
Diagnostic Strategy

Fuel Tank and Lines
in intake air system
• Fuel pump/lines
• Air leakage
to DTC Index for
• Electronic engine controls
Engine backfires electronic engine
• Ignition system
control tests.
• Sticking variable camshaft
Electronic Engine
timing (VCT) hub
Controls
tests.
Engine Ignition
to DTC Index for VCT
tests.
Electronic Engine
Controls

Fuel Tank and Lines
to DTC Index for
electronic engine
control tests.
• Fuel pump/lines
Electronic Engine
Engine surges Controls
• Throttle motor
• Ignition system
to DTC Index in this
section for throttle
motor tests.
tests.
Engine Ignition

to DTC Index for
electronic engine
control tests.
Electronic Engine
Controls
• Fuel pump/lines
Engine detonates/knocks Fuel Tank and Lines
• Air leakage
• Sticking VCT hub
to DTC Index for VCT
tests.
Electronic Engine
Controls

to DTC Index for
electronic engine
control tests.
• Electronic engine controls Electronic Engine
No throttle response
• Throttle motor Controls
section for throttle
motor tests.
Poor throttle response • Breather system • Ensure the engine

disconnected/restricted breather system is
• Electronic engine control free from restriction
• Transmission malfunction and is correctly
• Traction control event installed
• Air leakage • Read DTCs and refer
to DTC Index for
electronic engine
control tests.
Electronic Engine
Controls
• For transmission
system tests.
Diagnostic Strategy
DTC Index
NOTE:
If the control module/component is suspect and the vehicle remains under manufacturer
module/component.
NOTE:
system).
NOTE:
NOTE:
Check and rectify basic faults before beginning diagnostic routines that involve pinpoint tests.
NOTE:
terminals.

tests associated with
• Fuel rail pressure (FRP) this DTC using the
sensor, sensing circuit - manufacturer
short to ground, open approved diagnostic
circuit system
Fuel rail/system
P008700 • FRP sensor supply circuit - • Install a new FRP
pressure - too low high resistance sensor as necessary.
• FRP sensor failure Fuel Rail Pressure
• Fuel pump failure (FRP) Sensor
• Fuel line leak, restriction (18.30.98)
Fuel Tank and Lines

• FRP sensor supply/sensing tests associated with
circuits - short to each this DTC using the
other manufacturer
• FRP sensor sensing circuit - approved diagnostic
short to power system
Fuel rail/system
P008800 • FRP sensor ground circuit - • Install a new FRP
pressure - too high high resistance sensor as necessary.
• FRP sensor failure Fuel Rail Pressure
• Restricted fuel line (FRP) Sensor
• Fuel pump short circuit to (18.30.98)
power • For fuel system tests.
Fuel Tank and Lines
• Air intake leak between • Check for leak from air

MAF sensor and cylinder intake system
head • For fuel system tests.
System too lean (bank
P017100 • Fuel filter, injector, system Fuel Tank and Lines
1) restriction • Read DTCs and refer
• MAF sensor fault (low to DTC Index in this
intake air flow) section for MAF sensor
• Exhaust leak (forward of tests
catalytic converter) • Check and rectify any
exhaust leak prior to
catalytic converter
• Check air cleaner

element is free from
restriction
• Check for leaking
injectors, install new
• Restricted air cleaner injector(s) as
• Leaking fuel injector(s) necessary.
• Engine oil contaminated Fuel Injector
with fuel (too many cold (18.10.01)
System too rich (bank starts with vehicle • Check for
P017200
1) subsequently not getting contaminated engine
hot enough for long oil, drain and refill
enough) engine oil as
• MAF sensor fault (high necessary.
intake air flow) Engine Oil Draining
and Filling
section for MAF sensor
tests
• Check for leak from air

• Air intake leak between intake system
MAF sensor and cylinder • For fuel system tests.
head Fuel Tank and Lines
• Fuel filter, injector, system • Read DTCs and refer
System too lean (bank
P017400 restriction to DTC Index in this
2) • MAF sensor fault (low section for MAF sensor
intake air flow) tests
• Exhaust leak (forward of • Check and rectify any
catalytic converter) exhaust leak prior to
catalytic converter

• Restricted air cleaner element is free from
• Leaking fuel injector(s) restriction
• Engine oil contaminated • Check for leaking
with fuel (too many cold injectors, install new
System too rich (bank starts with vehicle injector(s) as
P017500 subsequently not getting
2) necessary.
hot enough for long Fuel Injector
enough) (18.10.01)
• MAF sensor fault (high • Check for
intake air flow) contaminated engine
oil, drain and refill
engine oil as
necessary.
Engine Oil Draining
and Filling
section for MAF sensor
tests

this DTC using the
• Injector circuit - short to manufacturer
Cylinder 1 injector ground, high resistance, approved diagnostic
P020100
circuit - malfunction disconnected system
• Injector failure • Install a new injector
as necessary.
Fuel Injector
(18.10.01)

this DTC using the
P020200
as necessary.
Fuel Injector
(18.10.01)

this DTC using the
P020300
as necessary.
Fuel Injector
(18.10.01)

• Injector circuit - short to this DTC using the
Cylinder 4 injector ground, high resistance, manufacturer
P020400
circuit - malfunction disconnected approved diagnostic
• Injector failure system
• Install a new injector
as necessary.
Fuel Injector
(18.10.01)

this DTC using the
P020500
as necessary.
Fuel Injector
(18.10.01)

this DTC using the
P020600
as necessary.
Fuel Injector
(18.10.01)

this DTC using the
P020700 disconnected system
circuit - malfunction
as necessary.
Fuel Injector
(18.10.01)

this DTC using the
P020800 disconnected system
circuit - malfunction
as necessary.
Fuel Injector
(18.10.01)
• ECM to ignition coil • Check for cylinder mis-

P131500 Persistent misfire
primary circuit fault fire, ignition and
(cylinder misfire detected injector DTCs and refer
DTC also flagged) to the DTC Index
• Fuel injector circuit fault(s) • For fuel system tests.
(injector DTCs also flagged) Fuel Tank and Lines
• Fuel delivery pressure low • For spark plug tests.
• Spark plug Engine Ignition
failure/fouled/incorrect • For cylinder
gap compression tests.
• Cylinder compression low Engine
• Check for individual

Misfire rate exceeds • Misfire rate exceeds cylinder misfire DTCs
P131600
emissions thresholds emissions thresholds and refer to DTC Index
in this section

this DTC using the
manufacturer
Throttle actuator approved diagnostic
• Jammed throttle blade,
P210129 control motor circuit system
gearing or motor
range/performance • Install a new throttle
body. Refer to the new
module/component
• Install a new throttle

Throttle actuator body. Refer to the new
P210162 control motor circuit module/component
gearing or motor
range/performance installation note at the

this DTC using the
manufacturer
Throttle actuator approved diagnostic
P210164 control motor circuit system
gearing or motor
range/performance • Install a new throttle
body. Refer to the new
module/component
• Check for throttle

Throttle actuator
• Throttle blade stuck open related DTCs and refer
P210177 motor control circuit
• Intake air system leak to DTC Index in this
range/performance section
• Check intake air
system for leaks

this DTC using the
manufacturer
Throttle actuator • Throttle motor control
approved diagnostic
P210329 motor control circuit circuit - short to power
system
high • ECM fault
• Refer to new
module/component
installation note at top
of DTC Index

this DTC using the
Throttle actuator manufacturer
• Throttle motor control
motor control circuit approved diagnostic
P210364 circuit - short to power
high - signal system
• ECM fault
plausibility failure • Refer to new
module/component
of DTC Index

Throttle actuator
• Throttle MIL request due this DTC using the
P210500 control system - forced to fuel cut manufacturer
engine shutdown approved diagnostic
system

body.
Throttle Body
Throttle actuator
(19.70.04) Refer to
P210629 control system - forced • Signal invalid
new
limited power module/component
of DTC Index

body.
Throttle Body
Throttle actuator
(19.70.04) Refer to
P210664 control system - forced • Signal plausibility failure
new
limited power module/component
of DTC Index
Throttle actuator • Throttle motor control
this DTC using the
P211800 motor control current circuit - short to ground,
manufacturer
range/performance power, high resistance
approved diagnostic
system

body.
Throttle Body
Throttle actuator
(19.70.04) Refer to
P211900 control throttle body • Throttle spring faulty
new
range/performance module/component
of DTC Index


310-D005
Removal
WARNING: This procedure involves fuel handling. Be prepared for fuel spillage at all times
and always observe fuel handling precautions. Failure to follow these instructions may result in
personal injury.
WARNING: After carrying out repairs, the fuel system must be checked visually for leaks.
WARNING: 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


3 . Remove the engine RH cover bracket.
Remove the 2 nuts.
4 . Remove the engine LH cover bracket.
Remove the 2 nuts.

6 . Release the purge valve.

9 . Disconnect the FRP sensor vacuum line.


12
contamination.
Remove the fuel injection supply manifold.
13 . NOTE:
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 . Install the FRP sensor.
3 . Install the fuel injectors.
Install the clips.

7 . Connect the FRP sensor vacuum line.

Secure the clips.
12 . Install the LH engine cover bracket.
lb.ft).

13 . Install the RH engine cover bracket.


Removal
personal injury.


3 . Remove the fuel injector.
Remove the clip.

Installation
1 . Install the fuel injector.
Install the clip.


Removal

Remove the bolt.
5
hot.
Disconnect the coolant hoses from the throttle body.
Clamp the throttle body coolant hoses to minimize coolant loss.
Release the throttle body hose clips
Remove the 4 bolts.
Remove and discard the throttle body gasket.
Installation
2 . 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 clips.



303-05 : Accessory Drive – 4.2L NA V8 – AJV8/4.2L SV
V8 – AJV8
Specifications
Specifications
Item Nm lb-ft lb-in

Accessory drive belt, tensioner - bolt 40 30 -
Accessory drive belt, idler pulley - bolt 25 18 -
Accessory drive belt - bolt (Supercharged models) 40 30 -

COMPONENT LOCATION

1 Engine coolant pump
3 Air Conditioning (A/C) compressor
4 Automatic tensioner
5 Crankshaft damper
6 Idler
7 Generator
8 Drive belt
INTRODUCTION
A single belt drives the following primary engine mounted accessories:
• Engine coolant pump

• Power steering pump
• Air Conditioning (A/C) compressor
• Generator.
A secondary belt drives the engine driven cooling fan.
Both the primary and secondary belts are crankshaft driven with an automatic tensioner
keeping the belt at the correct tension. The crankshaft incorporates a torsional vibration
damper to absorb vibration and shock loads.
Accessory Drive - 4.2L SC V8 - AJV8
COMPONENT LOCATION

A Primary accessory drive
B Secondary accessory drive
1 Routing idler
2 Coolant pump
3 Primary accessory drive belt
4 Primary tensioner assembly
6 Air Conditioning (AC) compressor
7 Crankshaft pulley
8 Generator
9 Supercharger pulley
10 Secondary accessory drive belt
11 Routing idler
12 Secondary tensioner assembly
OVERVIEW
A single six-ribbed belt drives all the primary engine mounted accessories and a secondary
single eight-ribbed belt drives the supercharger.
Both the primary and secondary belts are crankshaft driven via the torsional vibration damper.
An automatic tensioner, located on the Left Hand (LH) accessory-mounting bracket, keeps the
primary accessory belt at the correct tension. A routing idler on the Right Hand (RH)
accessory-mounting bracket increases the wrap angle around the generator pulley.
A second automatic tensioner, located on the generator mounting bracket, keeps the
secondary accessory belt at the correct tension. A routing idler located on a timing cover
mounting bracket increases the wrap angle around the supercharger pulley.
The automatic tensioner's consist of a routing idler on the end of a spring loaded pivot arm.
The pivot arm can be turned counter-clockwise (viewed from the front of the engine) for
removal and installation of the belt.
The torsional vibration damper incorporates compressed rubber between its inner and outer
diameters to absorb vibration and shock loads.
Accessory Drive
For a detailed description of the Front End Accessory Drive (FEAD), refer to the relevant
Description and Operation section in the workshop manual.

2 . Visually inspect for obvious signs of mechanical damage and system integrity.
Mechanical
• FEAD belt
• FEAD belt tension
• FEAD belt tensioner
• FEAD belt pulleys
3 . If an obvious cause for an observed or reported concern is found, correct the cause (if
possible) before proceeding to the next step.
Symptom Chart
FEAD belt noise or squeal
Possible Source(s):
• FEAD belt pulley(s)
• Lubricant or other contamination
• FEAD belt
Action(s) to take:
• DETERMINE where the noise is coming from. CHECK for pulley alignment,
freedom of rotation and damage. REPAIR or INSTALL new parts as necessary.
Accessory Drive Belt Idler Pulley - 4.2L NA V8 - AJV8 (12.10.43)
• CHECK FEAD belt for contamination. If contaminated, INSTALL a new belt.
• CHECK FEAD belt for correct application
FEAD belt does not hold tension

Possible Source(s):
• FEAD belt cracking or damaged
• Tensioner worn or damaged
Action(s) to take:
• INSPECT FEAD belt for cracking or damage. INSTALL a new belt as necessary.
• CHECK FEAD belt tensioner for damage and correct operation. INSTALL a new
FEAD belt tensioner as necessary.
Accessory Drive Belt Tensioner - 4.2L NA V8 - AJV8 (12.10.41)
Component Tests
FEAD belt tensioner
Static
The only checks required for the FEAD belt tensioner are for stick, grab or bind.
1 . Remove the drive belt in the area of the tensioner.
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 . 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.
Dynamic
The FEAD belt tensioner can be checked dynamically as follows:
1 . 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.
FEAD belt
1 . With the engine off, check routing of the drive belt.
2 . Inspect the drive belt tensioner wear indicator to confirm the drive belt is within operating
range. Install a new drive belt as necessary .
Accessory Drive Belt - 4.2L NA V8 - AJV8

(12.10.40)
Removal
2
. WARNING: Do not work on or under a vehicle supported only by a jack.
Always support the vehicle on safety stands.



Remove the bolt.

. Rotate the accessory drive belt tensioner counter-clockwise, using a
3/8 " drive wrench.
7 . NOTE:
Installation

Tighten the clips.


Accessory Drive Belt - 4.2L SC V8 - AJV8
(12.10.40)
Removal
2


3/8 " drive wrench.

Remove the bolt.
6 . NOTE:
Installation



Accessory Drive Belt Tensioner - 4.2L NA
V8 - AJV8 (12.10.41)
Removal
2


Remove the bolt.

3/8 " drive wrench.
Remove the bolt.
Installation

Tighten the clips.


Accessory Drive Belt Tensioner - 4.2L SC
V8 - AJV8 (12.10.41)
Removal
2



Remove the 2 nuts.

3/8 " drive wrench.
Remove the bolt.
Installation

Tighten the nuts.



Accessory Drive Belt Idler Pulley - 4.2L NA
V8 - AJV8 (12.10.43)
Removal
All vehicles
2

Vehicles with secondary air injection (AIR)

4 . Release the AIR control valve.
Remove the 2 bolts.
All vehicles
Remove the bolt.
Installation
All vehicles
Tighten the bolt to 25 Nm.

2 . Secure the AIR control valve.
All vehicles

Accessory Drive Belt Idler Pulley - 4.2L SC
V8 - AJV8 (12.10.43)
Removal
All vehicles
2

4 . Release the supercharger belt tensioner.
Loosen the bolt.
Vehicles without secondary air injection (AIR)

Remove the bolt.

6
. CAUTION: Take care when removing the idler pulley, as damage to the secondary
air injection pipes may occur.
Remove the accessory drive belt idler pulley.
Loosen the bolt and pulley assembly by approximately 15 mm.
Using suitable tools, apply gentle pressure to the pulley assembly until the
pulley separates from the bolt.
Remove the bolt.
Installation
Vehicles without secondary air injection (AIR)

2
. CAUTION: Make sure that the pulley is correctly centred on the bolt prior to
tightening the bolt, failure to follow this instruction may result in damage to the vehicle.
Install the accessory drive belt idler pulley.
Using a suitable tool, release the bolt from the new pulley assembly.
Loosely install the pulley and bolt.
Check that the pulley is correctly centered on the bolt.
All vehicles
3 . Secure the supercharger belt tensioner.


Supercharger Belt (18.50.08)
Removal
2


Remove the 2 nuts.
5 NOTE:
. Note the fitted position.
Release the supercharger belt.

Rotate the supercharger belt tensioner clockwise, using a 1/2 " drive
wrench.
Installation

Tighten the nuts.


Supercharger Belt Tensioner (18.50.24)
Removal
2



Remove the 2 nuts.

7 . Release the engine mounts.
Support the engine.
8 NOTE:

wrench.
9 . Remove the supercharger belt tensioner.

Raise the engine.
Remove the bolt.
Remove the O-ring seal.
Installation
1 . Install the supercharger belt tensioner.
Lower the engine onto its mounts.
2 . Secure the engine mounts.

3 . Attach the supercharger belt.

Tighten the screws.

Tighten the nuts.



Supercharger Belt Idler Pulley (18.50.09)
Removal
2



Remove the 2 nuts.
6 NOTE:

wrench.
7 . Remove the supercharger belt idler pulley.
Remove the bolt.
Installation
1 . Install the supercharger belt idler pulley.
2 . Attach the supercharger belt.

Tighten the nuts.



303-06 : Starting System – 4.2L NA V8 – AJV8/4.2L SV
V8 – AJV8
Specifications
Specifications
Item Nm lb-ft lb-in

Keyless start control module to floor console bracket - screw 6 4 53
Keyless start control module, trim to floor console bracket - screw 6 4 53
Starter motor - bolt/stud 43 32 -
Solenoid terminal connector - nut 7 5 62
Starting System
COMPONENT LOCATION
INTRODUCTION
The starter motor is rated at 1.8kW and is a Denso level three-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.
The starter solenoid is energised by a signal from the Engine Control Module (ECM) when
the starter switch is pressed. When engine cranking is requested, the ECM checks that a valid
mobilisation code has been received before granting the crank request. For additional
information, refer to Anti-Theft - Active (419-01A Anti-Theft - Active)
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 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
For a detailed description of the starting system, refer to the relevant Description and
Starting System

• Battery
• Fuses
• Gear selector lever cable adjustment
• Wiring harness
• Starter Motor
• Damaged, loose or corroded connectors
• Battery
• Starter relay
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
• Gear selector not in P or
Make sure the gear selector is in the P or
N position
N position and correctly adjusted.
• Battery
The engine does Selector Lever Cable Adjustment
• Harness/Connectors
not crank (starter (44.15.07) Check the battery condition
• Starter motor
motor does not and state of charge.
• Starter relay
turn) Battery Check the starter motor and
• Start switch
harness. Check for DTCs and refer to
• Transmission control
the DTC Index
module (TCM)
• Engine control module
(ECM)
• Engine seized
• Starter motor installation Check the starter motor installation

The engine does
• Starter motor (fasteners tight, starter motor square to
not crank (starter
• Ring gear engine, etc). Check the ring gear teeth
motor does turn)
for damage, foreign objects, etc.
• Battery Check the battery condition and state of
• Harness/Connectors charge.
Engine cranks
• Starter motor Battery Refer to the electrical circuit
too slowly
• Engine oil incorrect grade diagrams and test the starter motor and
starter motor circuits
Engine cranks • Low engine compression Check the engine compressions.
too fast Engine
• Starter motor Check the starter motor installation
• Starter motor (fasteners tight, motor square to engine,
Excessive starter
installation/casing etc). Check the starter motor casing
motor noise
• Ring gear condition. Check the ring gear teeth for
damage, foreign objects, etc.
DTC Index
CAUTION: When probing connectors to take measurements in the course of the

pinpoint tests, use the adaptor kit, part number 3548-1358-00. Failure to follow this
instruction may result in damage to the vehicle.
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
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
NOTE:
Check and rectify basic faults before beginning diagnostic routines involving pinpoint
tests.
NOTE:
If DTCs are recorded and, after performing the pinpoint tests, the fault is not present, an
terminals.

Starter relay • Starter relay control
P081700 circuit (break circuit - high resistance
wire)
• Starter relay control
Starter relay associated with this DTC
P081A00 circuit - short to ground
circuit low using the manufacturer
Starter relay associated with this DTC
P081B00 circuit - short to power
circuit high using the manufacturer
Check ignition, power and
ground supplies to CJB and
• Faulty instrument cluster
instrument cluster. Re-
• Target SID re-
synchronize ID by re-
Ignition synchronisation error
B100951 configuring the instrument
authorisation following programming
cluster as a new module.
• CAN fault
Check CAN communications
between instrument cluster
and tester
between CJB and instrument
• Low speed CAN fault
cluster. Check ignition,
• CJB fault
power and ground supplies to
• Instrument cluster fault
CJB and instrument cluster.
Ignition • Incorrect module installed
Confirm correct module is
authorisation (CJB/Instrument cluster)
B100962 installed. Re-synchronise ID
signal compare • Target SID
by re-configuring the
failure synchronisation error
instrument cluster as a new
following re-programming
module. Check CAN
• Noise/EMC related error
network for
interference/EMC related
issues
Check Power and Ground
supplies to CJB and
• CJB fault instrument cluster. Check
Ignition • Low speed CAN fault CAN communications
B100963 authorisation • Instrument cluster fault between CJB and instrument
time-out • Low battery voltage <9V cluster. Check battery is in
fully charged and serviceable
condition, refer to the battery
care manual
Check power and ground
Ignition
• CJB fault supplies to CJB and
authorisation
• Low speed CAN fault instrument cluster. Check
B100964 signal
• Instrument cluster fault CAN communications
plausibility
failure
cluster
supplies to CJB and
• CJB fault instrument cluster. Check
• Low speed CAN fault CAN network between CJB
Ignition
B100987 • Instrument cluster fault and instrument cluster.
authorisation
• Low battery voltage <9V Check battery is fully
charged and in serviceable
care manual
Fuel pump • RJB fault supplies to RJB. Check CAN
authorisation • Low speed CAN fault communications between
B100A51
target ID not • Instrument cluster fault RJB and instrument cluster.
stored Check power and ground
supplies to instrument cluster
• Low speed CAN fault between RJB and instrument
• RJB fault cluster. Check power and
• Instrument cluster fault ground supplies to RJB and
Fuel pump • Incorrect module installed instrument cluster. Confirm
authorisation (RJB/Instrument cluster) correct module installed. Re-
B100A62
signal compare • Write target SID synchronise ID by re-
failure synchronisation error configuring the RJB as a new
following re-programming module. Check CAN
• Noise/EMC related error network for
issues
supplies to RJB and
• RJB fault instrument cluster. Check
Fuel Pump • Low speed CAN fault CAN communications
B100A63 Authorisation • Instrument cluster fault between RJB and instrument
Time Out • Low battery voltage <9V cluster. Check battery is in
care manual
• Write target SID Re-synchronise ID by re-
synchronisation error configuring the RJB as a new
Fuel Pump following re-programming module. Check ignition,
B100A64
authorisation • RJB fault power and ground supplies to
• Low speed CAN fault RJB and instrument cluster.
Check CAN network
between RJB and instrument
cluster
supplies to RJB and
• RJB fault
instrument cluster. Check
CAN network between RJB
Fuel pump • Instrument cluster fault
B100A87 and instrument cluster.
authorisation • Low battery voltage < 9
Check battery is fully
volts
charged and in serviceable
care manual
• RJB fault
• Vehicle speed present
supplies to RJB and
when attempting to power
Column lock steering column lock
CAN network between RJB
B100B67 ground • Engine speed present
and instrument cluster.
authorisation when attempting to power
Check ABS, ECM and CJB
steering column lock
for DTCs and refer to the
• Power mode status > four
relevant DTC Index
when attempting to
perform lock action

Column lock supplies to RJB and
B100B87 ground instrument cluster. Check
• RJB fault
authorisation CAN network between RJB
and instrument cluster
• CJB fault
• Vehicle speed present
supplies to CJB and
when attempting to power
Column lock steering column lock
CAN network between CJB
B100C67 supply • Engine speed present
and instrument cluster.
authorisation when attempting to power
Check ABS, ECM and CJB
steering column lock
relevant DTC Index
when attempting to
perform lock action

Column lock supplies to CJB and
B100C87 supply instrument cluster. Check
• CJB fault
authorisation CAN network between CJB
ground supplies to steering
Column lock • Not programmed column lock and instrument
B100D51
authorisation cluster. Re-synchronise ID
by re-configuring the steering
column lock as a new module
Check CAN network
• CAN fault between steering column
• Steering column lock fault lock and instrument cluster.
• Instrument cluster fault Check power and ground
• Incorrect module installed supplies to steering column
Column lock
(Steering column lock and instrument cluster.
authorisation -
B100D62 lock/Instrument cluster) Confirm the correct modules
signal compare
• Target ID synchronisation are installed. Re-synchronize
failure
error following re- ID by re-configuring the
programming steering column lock as new.
• Noise/EMC related error Check CAN network for
issues
Column lock Check CAN network to
• CAN fault
authorisation - steering column lock. Check
B100D64 signal power and ground supplies to
plausibility steering column lock and
failure instrument cluster
• CAN fault Check CAN network
• Steering column lock fault between steering column
Column lock
• Instrument cluster fault lock and instrument cluster.
B100D87 authorisation -
• Low voltage at steering Check power and ground
missing message
column lock < 8V supplies to steering column
lock and instrument cluster
Check CAN network
• CAN fault
lock and instrument cluster.
Column lock • Low temperature < -30 °
B100D96 supplies to steering column
authorisation • Low voltage at steering
lock and instrument cluster.
column lock < 8 volts
Check there is no torque
• Restricted bolt movement
applied to the steering
column/wheel
Steering column
Refer to the electrical circuit
lock power
• Circuit short to ground diagrams and test steering
B102611 circuit short to
column lock power circuit
ground or over
for short to ground
temperature
Steering column • Steering column lock Refer to the electrical circuit
lock ground ground circuit - short to diagrams and test steering
B102612
circuit short to power column lock ground circuit
power for short to power
Steering column
• Circuit open diagrams and test steering
B102613 lock power
column lock power circuit
circuit open load
for high resistance
• CJB fault Check power and ground
• Low speed CAN fault supplies to CJB and RKE
Passive key • Remote Keyless Entry module. Check CAN
authorisation (RKE) module fault communications between
B102B67
signal incorrect • Write target SID CJB and RKE module. Re-
after event synchronisation error synchronise ID by re-
following re-programming configuring the RKE module
as a new module
• CJB fault
supplies to CJB, RKE
module and receiver. Check
• RKE module fault
CAN communications
• Key fob battery
low/battery contact issue
cluster. Check key fob
• Interference from other
battery. Confirm vehicle
RF signal
surroundings, move vehicle.
• EMC/noise
Check CAN network for
Passive key • Receiver fault
B102B87 authorisation • Receiver not programmed
issues. Disconnect battery,
missing message correctly
then re-connect - confirm
• Serial communications
operation by re-programming
fault (between receiver
keys. Check serial circuit
and RKE module)
between receiver and RKE
• Key fault
module. Confirm spare key
• Passive antenna fault
works. Refer to the electrical
• Confirm placement of key
circuit diagrams and test
within vehicle
circuits to all 3 antennas.
Check whereabouts of key
• Signal stuck low associated with this DTC
B108A23 Start button stuck
• Signal invalid associated with this DTC
B108A29 Start button fault
Engine crank
• Engine crank Carry out any pinpoint tests
authorisation
authorisation circuit short associated with this DTC
to ground using the manufacturer
ground or over
temperature
Engine crank Carry out any pinpoint tests
• Engine crank
B114013 authorisation associated with this DTC
authorisation circuit high
circuit open load using the manufacturer
resistance approved diagnostic system
• Operator only cycles one

key during programming
• Instrument cluster, start Ensure all keys to be
Key transponder control unit or key loses programmed are available.
- number of keys power or circuit failure Check power and ground
B1B0100 stored below during programming supplies to all relevant
minimum • Faulty key modules. Replace faulty key.
number required • Unable to programme key Check CAN network for
due to noise/EMC related noise/EMC related issues
issues
Re-synchronize ID by re-
configuring the start control
• Error following start
unit as new module. Check
Key transponder control unit replacement
- start control • Start control unit fault
B1B0105 start control unit and
unit already • LIN fault
programmed • Instrument cluster fault
LIN circuit between start
control unit and instrument
cluster
Check LIN circuit between
• LIN fault
start control unit and
Key transponder • Instrument cluster fault
- start control • Faulty key
B1B0151 unit • Start control unit fault
programming • Attempted to programme
instrument cluster. Ensure
error a non-default key
new keys are from a known
good source
• Un-programmed key
inserted in start control
Key transponder
unit Confirm correct keys are
B1B0155 - transponder not
• Non-default key inserted being used
programmed
during key programming

• Instrument cluster fault associated with this DTC
• Start control unit fault using the manufacturer
• Incorrect module installed approved diagnostic system.
Key transponder (instrument cluster/start Check power and ground
- start control control unit) supplies to start control unit
B1B0162
unit challenge • Error during or following and instrument cluster.
response error the write target SID Check correct modules are
routine installed. Re-synchronize ID
• Noise/EMC related issues by re-configuring the start
control unit as a new module.
issues
• LIN fault
Key transponder Check LIN circuit between
• Key fault
- transponder start control unit and
B1B0164 • Start control unit fault
challenge instrument cluster. Check
• Error occurred during key
response error power and ground supplies to
programming
instrument cluster. Confirm
correct key operation. Re-run
key programming
• LIN fault Carry out any pinpoint tests
• Instrument cluster fault associated with this DTC
• Key fault using the manufacturer
• Start control unit fault approved diagnostic system.
• Another key in close Check LIN circuit between
proximity start control unit and
• Attempted to programme instrument cluster. Check
a non default key ignition, power and ground
• IPK Cold initialisation supplies to start control unit
Key transponder whilst in Ignition On state, and instrument cluster.
- start control without key being present Confirm correct key
B1B0167
unit invalid in the SCU operation. Confirm single
response • Race condition caused by key operation. Ensure new
closing driver door and keys are from a known good
pressing start button source. Check for
within a small time intermittent power and
window ground at instrument cluster.
• Passive Key search Design condition - advise
function from last door customer of correct starting
closed and key inserted in sequence. Design condition -
the SCU determine customer
transponder key usage
• LIN fault approved diagnostic system.
Key transponder • Instrument cluster fault Check LIN circuit between
B1B0187
- timer expired • Start control unit fault start control unit and
instrument cluster
Target I.D. • CAN fault Check CAN network
B1B3305
transfer - system • ECM fault between ECM and
programming • Instrument cluster fault instrument cluster. Check
failures • ECM or instrument cluster ignition, power and grounds
incorrectly configured to ECM and instrument
cluster. Re-synchronise ID
module
Check CAN network
between ECM and
• CAN fault
ignition, power and grounds
• ECM fault
to ECM and instrument
cluster. Check correct ECM
Target I.D. • Incorrect module installed
B1B3362 transfer - signal (ECM/instrument cluster)
installed. Re-synchronise ID
compare failure • Synchronisation error
• Noise/EMC related error
module. Check CAN
network for
issues
• CAN fault
Check CAN network
• ECM fault
between ECM and
Target I.D. ignition, power and grounds
status incomplete
transfer - signal to ECM and instrument
B1B3364 • Race condition caused by
plausibility cluster. Check steering
closing driver door and
failure column lock operation.
pressing start button
Design condition - advise
within a small time
customer of correct start
window
sequence
Check CAN network

between ECM and
• CAN fault instrument cluster. Check
Target I.D. • ECM fault ignition, power and grounds
B1B3387 transfer - missing • Instrument cluster fault to ECM and instrument
message • Low battery voltage cluster. Check battery is in
care manual
High speed CAN • Vehicle CAN bus off
U000188 communication condition
bus
Internal control • Invalid configuration Re-configure the RJB using
U030000 module software message is received the manufacturer approved
incompatibility diagnostic system. Clear the
DTC and retest. If the DTC is
steering column lock, refer to
the new module installation
note at the top of the DTC
Index
Install a new steering column
• Internal electronic failure lock, refer to the new module
U300049 Control Module
the DTC Index
diagnostic system. Check
steering column lock for
• Missing message
U300087 Control Module DTCs and refer to the DTC
integrity using the
diagnostic system
Vehicle Install original module,
being transmitted, module
U300281 Identification check for DTCs and refer to
previously installed to
Number (VIN) relevant DTC Index
other vehicle
Starter Motor (86.60.01)

Removal
2

Release the cover.
Remove the nut.


Remove the 2 bolts.
Installation


Secure the cover.

Start Control Unit
Removal
1 . Remove the rear seat armrest.
For additional information, refer to Rear Seat Armrest (76.70.39)

3 . Remove the floor console rear panel.

4 . Remove the floor console side panel trim.

Carefully release 11 clips.
5 . Remove the keyless start control module trim cover.

6 . Remove the keyless start control module.
Installation
1 . Install the keyless start control module.
2 . Install the keyless start control module trim cover.

3 . Install the floor console side panel trim.
Install the opposite hand.
4 . Install the floor console rear panel.


6 . Install the rear seat armrest.


303-07 : Engine Ignition – 4.2L NA V8 – AJV8/4.2L SC
V8 – AJV8
Specifications
Specifications
Engine Firing Order
Firing Order
1:2:7:3:4:5:6:8
Item Specification
Spark plug AJ8 4575
Spark plug gap 0.9 - 1.0 mm
Item Nm lb-ft lb-in

Ignition coil - bolt 5 4 44
Spark plug 28 21 -
Engine Ignition
COMPONENT LOCATION

1 - Ignition coils (8 off)
2 Spark plugs (8 off)
3 - ECM
INTRODUCTION
The 4.2L 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.
IGNITION COILS
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 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.
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.
CONTROL DIAGRAM
NOTE:
A = Hardwired connections; D = High speed CAN bus; N=Medium speed CAN bus
1 - Battery
2 TCM
3 ABS control module
5 Keyless vehicle module
6 RCM
7 Park brake module
8 - ECM
9 - Ignition coils (8 off)
10 - Auxiliary junction box
11 - CJB
12 - Mega fuse
Engine Ignition
For a detailed description of the Engine Ignition System, refer to the relevant Description and
Engine Ignition

• Fuses
• Engine oil level • Wiring harness
• Cooling system coolant level • Loose or corroded electrical connectors
• Fuel level • Ignition coils
• Fuel contamination/grade/quality • Sensor(s)
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
breather system is
• Engine breather system free from restriction
disconnected/restricted and is correctly
Engine cranks, but does not • Engine ignition system installed
fire • Fuel system • Read DTCs and
• Electronic engine controls refer to DTC Index
in this section for
engine ignition
system tests
• For fuel system
tests.
Fuel Tank and
Lines
• Read DTCs and
refer to the DTC
Index for electronic
engine controls.
Electronic Engine
Controls
• For purge valve

tests.
Evaporative
Emissions
• Evaporative emissions • For fuel system
purge valve tests.
• Fuel pump Fuel Tank and
• Spark plugs Lines
Engine cranks and fires, but
• HT short to ground • For spark plug tests,
will not start
(tracking) check rubber GO to Pinpoint Test
boots for cracks/damage G553827p2.
• Ignition coil failure(s) • For engine ignition
coil circuit tests,
check for DTCs and
refer to the DTC
Index

coolant level and
anti-freeze content.
Specifications
• Ensure the battery is
in a fully charged
• Engine coolant level-anti- and serviceable
freeze content condition
• Battery • Read DTCs and
Difficult cold start • Exhaust gas recirculation for electronic engine
(EGR) valve stuck open controls.
• Fuel pump Electronic Engine
• Purge valve Controls
• For EGR system
tests.
Engine Emission
Control
• For fuel system
tests.
Fuel Tank and
Lines
• For purge valve
tests.
Evaporative
Emissions

injectors
• Read DTCs and
refer to the DTC
Index for electronic
engine controls.
Electronic Engine
Controls
• For purge valve
• Injector leak tests.
• Electronic engine controls Evaporative
• Purge valve Emissions
Difficult hot start • Fuel pump • For fuel system
• Engine ignition system tests.
• EGR valve stuck open Fuel Tank and
Lines
• Read DTCs and
refer to DTC Index
in this section for
engine ignition
system tests
• For EGR valve tests.
Engine Emission
Control

injectors
• Read DTCs and
refer to DTC Index
for electronic engine
control tests.
• Injector leak
Electronic Engine
Difficult to start after hot • Electronic engine controls
Controls
soak (vehicle standing, • Purge valve
• For purge valve
engine off, after engine has • Fuel pump
tests.
reached operating • Engine ignition system
Evaporative
temperature) • EGR valve stuck open
Emissions
• For fuel system
tests.
Evaporative
Emissions
• Read DTCs and
refer to DTC Index
in this section for
engine ignition
system tests
Engine Emission
Control

breather system is
and is correctly
installed
• Read DTCs and
refer to DTC Index
• Breather system control.
disconnected/restricted Electronic Engine
• Electronic engine control Controls
• Engine ignition system • Read DTCs and
Engine stalls soon after start • Air intake system refer to DTC Index
restricted in this section for
• Air leakage engine ignition
• Fuel lines system tests
• Check for blockage
in air filter element
and air intake
system
• For fuel system
tests.
Fuel Tank and
Lines
• For fuel system

tests.
Fuel Tank and
• Fuel pressure, pump and Lines
lines • Check for injector
• Injector leak leak
• Air leakage • Check for leakage
• Electronic engine controls from air intake
Engine hesitates/poor
• Engine ignition system system
acceleration
• EGR valve stuck open • Read DTCs and
• Transmission malfunction refer to DTC Index
• Restricted pedal travel for electronic engine
(carpet, etc) control tests.
Electronic Engine
Controls
• Read DTCs and
refer to DTC Index
in this section for
engine ignition
system tests
• For EGR system
tests.
Engine Emission
Control
tests.
Diagnostic Strategy
pedal is free from
restriction
• For fuel system

tests.
Fuel Tank and
Lines
• Check for leakage in
air intake system
• Read DTCs and
refer to DTC Index
• Fuel pump and lines
• Air leakage
controls.
Electronic Engine
• Engine ignition system
Engine backfires Controls
• Sticking Variable
• Read DTCs and
Camshaft Timing (VCT)
refer to DTC Index
hub
in this section for
engine ignition
system tests
• Read DTCs and
refer to DTC Index
for VCT tests.
Electronic Engine
Controls
• For fuel system

tests.
Fuel Tank and
Lines
• Fuel pump and lines • Read DTCs and
Engine surges
• Engine ignition system for electronic engine
controls.
Electronic Engine
Controls
• Read DTCs and
refer to DTC Index
in this section for
engine ignition
system tests
• Read DTCs and

refer to DTC Index
controls
• For fuel system
tests.
• Electronic engine controls Fuel Tank and
• Fuel pump and lines Lines
Engine detonates/knocks • Air leakage • Check for leakage
• Sticking VCT hub from air intake
system
• Read DTCs and
refer to DTC Index
for VCT tests.
Electronic Engine
Controls
• Read DTCs and

refer to DTC Index
No throttle response for electronic engine
control tests

breather system is
and is correctly
installed
• Read DTCs and
• Breather system
refer to DTC Index
disconnected/restricted
control tests.
Poor throttle response • Transmission malfunction
Electronic Engine
• Traction control event
Controls
• Air leakage
tests.
Diagnostic Strategy
• Check for leakage
from air intake
system
DTC Index
pinpoint tests, use the adaptor kit, part number 3548-1358-00.
NOTE:
identify the fault (the last two digits give extra information read by the manufacturer-
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:
tests.
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.

• Carry out any
pinpoint tests
Cylinder 1 ignition • Engine ignition coil associated with this
coil circuit - short to ground, DTC using the
P035100
primary/secondary power, open circuit manufacturer
circuit approved
diagnostic system
• Carry out any

pinpoint tests
P035200
circuit approved
diagnostic system
• Carry out any

Cylinder 3 ignition • Engine ignition coil pinpoint tests
coil circuit - short to ground, associated with this
P035300
primary/secondary power, open circuit DTC using the
circuit manufacturer
approved
diagnostic system
• Carry out any

pinpoint tests
P035400
circuit approved
diagnostic system
• Carry out any

pinpoint tests
P035500
circuit approved
diagnostic system
• Carry out any

pinpoint tests
P035600
circuit approved
diagnostic system
• Carry out any

pinpoint tests
P035700
circuit approved
diagnostic system
• Carry out any

pinpoint tests
P035800
circuit approved
diagnostic system
• ECM to ignition coil • Check for cylinder

primary circuit fault mis-fire, ignition
(cylinder misfire detected and injector DTCs
DTC also flagged) and refer to the
• Fuel injector circuit DTC Index
fault(s) (injector DTCs • For fuel system
also flagged) tests.
• Fuel delivery pressure Fuel Tank and
low Lines
• Spark plug • For spark plug
failure/fouled/incorrect tests.
gap Engine Ignition
• Cylinder compression low • For cylinder
compression tests.
Engine
• Carry out any

pinpoint tests
• Ignition module/coil
associated with this
monitoring circuit - short
Ignition amplifier DTC using the
P136700 to ground, short to power,
group A manufacturer
high resistance
approved
diagnostic system
• Carry out any

pinpoint tests
monitoring circuit - short
Ignition amplifier DTC using the
P136800 to ground, short to power,
group B manufacturer
high resistance
approved
diagnostic system
Pinpoint Tests
PINPOINT TEST G553827p2 : CHECK

SPARK PLUG RESISTANCE
G553827t9 : CHECK SPARK PLUG RESISTANCE
1. Remove the suspect spark plug(s). 2. Measure the resistance between:
Spark plug Spark plug
Center electrode tip HT contact
• Is the resistance between 8,000 and 12,000 ohms? (nominal 10,000 ohms)
-> Yes
Check ignition coil and circuits. Refer to the DTC Index for ignition coil and circuit tests.
-> No
INSTALL new spark plug(s). CLEAR the DTC and test the system for normal operation.
Spark Plugs - 4.2L NA V8 - AJV8 (18.20.02)

Removal
2 Remove the ignition coil-on-plugs.

. For additional information, refer to Ignition Coil-On-Plug - 4.2L NA V8 - AJV8
(18.20.40)
4.
Clean the area surrounding the spark plugs.
Installation
Tighten the spark plugs to 28 Nm (21 lb.ft).
2 . Install the remaining coil-on-plugs.
3 Install the ignition coil-on-plug.

. For additional information, refer to Ignition Coil-On-Plug - 4.2L NA V8 - AJV8
(18.20.40)

Spark Plugs - 4.2L SC V8 - AJV8 (18.20.02)
Removal
1 Remove the ignition coil-on-plugs.
. For additional information, refer to Ignition Coil-On-Plug - 4.2L SC V8 - AJV8
(18.20.40)
3.
Clean the area surrounding the spark plugs.
Installation
Tighten the spark plugs to 25 Nm (18 lb.ft).
2 . Install the remaining coil-on-plugs.
3 Install the ignition coil-on-plug.

. For additional information, refer to Ignition Coil-On-Plug - 4.2L SC V8 - AJV8
(18.20.40)
Ignition Coil-On-Plug - 4.2L NA V8 - AJV8
(18.20.40)
Removal

3 . NOTE:
Left hand engine bank only.
Remove the dipstick.
4 . Remove the ignition coil cover.

5 . Disconnect the ignition coil-on-plug electrical connector.

Remove the bolt.
Installation
3 . Install the ignition coil-on-plug cover.

4 . NOTE:
Install the dipstick.


Ignition Coil-On-Plug - 4.2L SC V8 - AJV8
(18.20.40)
Removal

3 . NOTE:
Remove the oil level indicator.
4 . Remove the ignition coil cover.

5 . Disconnect the ignition coil-on-plug electrical connector.

Remove the bolt.
Installation
2 . Install the ignition coil-on-plug cover.

3 . NOTE:
Install the oil level indicator.


303-08A : Engine Emission Control – 4.2L SC V8 – AJV8
Specifications
Specifications
lb- lb-
Item Nm
ft in
Exhaust gas recirculation (EGR) tube to EGR valve - bolt 21 15 -
EGR tube to exhaust manifold - nut 21 15 -
EGR valve to throttle body elbow - bolt 10 7 88
Positive crankcase ventilation (PCV) valve - screw 5 4 44
Secondary air injection, air pipe - union nut 35 26 -
Secondary air injection, blanking plug 35 26 -
Secondary air injection, control valve bracket to engine - bolt 8 6 71
Secondary air injection, manifold absolute pressure sensor to bonnet hinge
11 8 -
panel - bolt
Secondary air injection, pump to bracket - nut 8 6 71

For additional information, refer to Engine Emission Control (303-08 Engine Emission
Control - Vehicles Without: Supercharger)

No Data Available
Exhaust Gas Recirculation (EGR) Valve

(17.45.01)
Removal

3 . Disconnect the EGR valve electrical connector.
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.
Disconnect the 2 EGR valve coolant hoses.

Clamp the EGR coolant hose to minimize coolant loss.
Remove the 2 bolts.
6 . NOTE:
Remove the EGR valve.

Installation
1 . Install the EGR valve.


Remove the coolant hose clamps.
4 . Connect the EGR valve electrical connector.


7 NOTE:
. For NAS vehicles only.

For additional information, refer to Powertrain Control Module (PCM) Long Drive
Cycle Self-Test
Removal
2 . RH side: Remove the intake air resonator.

Remove the bolt.
3.
Remove the positive crankcase ventilation (PCV) valve.

Disconnect the PCV hose.
Installation
Connect the hose.


Secondary Air Injection (AIR) Control
Valve to Exhaust Manifold Tube

303-749

303-021
Removal
2

- AJV8




9 . Remove the coolant expansion tank support bracket.
Remove the 3 nuts.


13 . Remove the coolant rail.
Remove the bolt.
Disconnect the 3 quick release connectors.
14 .
15 . NOTE:

Raise the engine.

20 . Release the AIR tube from the AIR control valve.
21 . Remove the AIR tube.
Installation
1 . Install the AIR tube.
2 . Attach the AIR tube to the exhaust manifolds.
3 . Attach the AIR tube to the AIR control valve.
4 . Install the LH exhaust manifold heat shield.

Tighten the screws.
5 . Install the RH exhaust manifold heat shield.
Tighten the screws.
7 . Install the coolant rail.
Connect the quick release connectors.
11 . Install the coolant expansion tank support bracket.








- AJV8
Valve
Removal


Disconnect the vacuum hose.
Remove the 2 bolts.
5 . Remove the AIR control valve.

Installation
1 . Attach the AIR control valve hose.

Connect the vacuum hose.


6 NOTE:

Cycle Self-Test
Removal
2 . Remove the RH headlamp assembly.

For additional information, refer to Headlamp Assembly (86.41.33)
3 . Release the washer jet hose.

Remove the clip.
4 . Disconnect the AIR pump hose.
5 . Release the AIR pump.

Remove the 3 nuts.
6 . Remove the AIR pump.

7 . NOTE:
Remove the AIR pump bracket.

Installation
1 . Install the AIR pump bracket.
2 . Install the AIR pump.

Connect the hose.
3 . Attach the washer jet hose.

4 . Install the RH headlamp assembly.


6 NOTE:
If required, carry out a short drive cycle.

For additional information, refer to Powertrain Control Module (PCM) Short Drive
Cycle Self-Test
Secondary Air Injection Manifold Absolute
Pressure Sensor
No Data Available
303-08B : Engine Emission Control – 4.2L NA V8 – AJV8
Specifications
Specifications
lb- lb-
Item Nm
ft in
Exhaust gas recirculation (EGR) tube to EGR valve - bolt 21 15 -
EGR tube to exhaust manifold - nut 21 15 -
EGR valve to throttle body elbow - bolt 10 7 88
Positive crankcase ventilation (PCV) valve - screw 5 4 44
Secondary air injection, air pipe - union nut 35 26 -
Secondary air injection, blanking plug 35 26 -
Secondary air injection, control valve bracket to engine - bolt 8 6 71
Secondary air injection, manifold absolute pressure sensor to bonnet hinge
11 8 -
panel - bolt
Secondary air injection, pump to bracket - nut 8 6 71

COMPONENT LOCATION

1 PCV (positive crankcase ventilation) valve
2 EGR (exhaust gas recirculation) gas transfer pipe
3 Part load valve
4 Electric throttle
5 EGR (exhaust gas recirculation) valve
INTRODUCTION
The engine emission control system comprises:
• EGR (exhaust gas recirculation) system

• Crankcase ventilation system
The EGR (exhaust gas recirculation) system is controlled by a PWM (pulse width
modulation) signal from the ECM (engine control module) . The system comprises an EGR
(exhaust gas recirculation) valve and a gas transfer pipe.
The crankcase ventilation system is ventilated through a part load and a full load breather.
The part load breather is connected through a PCV (positive crankcase ventilation) valve,
which prevents air flow back into the engine.
The engine emission control system also features a Secondary Air Injection (SAI) system,
comprising a pump, solenoid control valve and associated pipes. The pumps operation is
controlled by the engine management system. For additional information, refer to Electronic
Engine Controls (303-14 )
COMPONENT LOCATION (NA)

1 PCV valve
2 EGR gas transfer pipe
3 Part load valve
4 Electric throttle
5 EGR valve
COMPONENT LOCATION (SC)

1 PCV valve
2 Exhaust manifold
3 EGR gas transfer pipe
4 EGR valve
5 Crankcase ventilation pipes
INTRODUCTION
The engine emission control system comprises:
• EGR system
• Crankcase ventilation system
• Secondary Air Injection (SAI) system
The EGR system is controlled by a PWM signal from the ECM. The system comprises an
EGR valve and a gas transfer pipe.
The crankcase ventilation system is ventilated through a part load and a full load breather.
The part load breather is connected through a PCV valve, which prevents air flow back into
the engine.
The engine emission control system also features a Secondary Air Injection (SAI) system,
comprising a pump, solenoid control valve and associated pipes. The pumps operation is
controlled by the engine management system.
EGR SYSTEM
The EGR (exhaust gas recirculation) system is controlled by a PWM signal from the ECM
(engine control module) . The system comprises an EGR (exhaust gas recirculation) valve and
a gas transfer pipe.
The EGR (exhaust gas recirculation) valve 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 (exhaust gas
recirculation) valve receive four 12 Volt signals from the ECM (engine control module) . The
EGR (exhaust gas recirculation) valve is cooled by the return coolant flow from the electric
throttle.
The EGR (exhaust gas recirculation) valve is connected to the LH exhaust manifold via the
gas transfer pipe.
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 bank A camshaft cover and the induction elbow. The
PCV (positive crankcase ventilation) valve prevents reverse flow into the crankcase.
The full load breather is a flexible hose connected between the oil separator in the bank B
camshaft cover and the air intake duct.
The ends of the breather hoses incorporate quick release connectors.
The oil separators consist of wire gauze packed into an open ended enclosure below the
breather outlet in each camshaft cover.
SECONDARY AIR INJECTION COMPONENT

LOCATION (NA SHOWN SC SIMILAR)
1 SAI hose bracket
2 SAI pressure sensor (NAS only)
3 Vacuum pipe
4 SAI vacuum control valve
5 SAI to exhaust manifold pipe
6 SAI control valve
7 SAI Vacuum reservoir
8 SAI pump
SECONDARY AIR INJECTION

Secondary Air Injection (SAI) is fitted to the vehicle to reduce exhaust emissions to meet
European Union (EU) Stage 4 and Federal Petrol Emission standards. The SAI system
comprises:
• SAI pump
• SAI valve
• Associated pipes
• SAI Absolute Pressure (MAP) sensor (NAS only)
The SAI pump is used to provide a supply of air into the exhaust manifolds during the cold
start period of the engine. The SAI 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) and
hydrocarbon (HC) 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 250°C (482°F) and need to be between
temperatures of 400°C (752°F) and 800°C (1472°F) for optimum efficiency. Consequently,
the heat produced by the SAI 'afterburning' reduces the time delay before the catalysts reach
an efficient operating temperature.
SAI Pump
The sai pump is located behind the right-hand side of the front bumper cover. The pump is
fitted on rubber mountings to help prevent noise which is generated by SAI pump operation.
The SAI 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 20°C (68°F).
Air is drawn into the SAI pump through vents in its front cover and is then passed through a
non serviceable paper element 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 SAI pump is energized, the ECM switches on the SAI switching valve,
which opens to allow vacuum from the SAI vacuum reservoir to be applied to the vacuum
operated SAI control valve. When the vacuum is applied to the SAI control valve, it opens to
allow the air from the SAI pump through to the exhaust manifolds.
When the ECM switches off the SAI switching valve, the vacuum supply to the SAI 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 SAI switching valve is closed,
the ECM removes power from the SAI pump relay, and this in turn stops the SAI pump from
operating.
SAI Switching Valve
The ECM switches on the SAI switching valve with a one second delay after initiating SAI
pump operation. When the SAI switching valve is open, a steady vacuum supply is allowed
through to open the vacuum operated SAI control valve. When the ECM switches off the SAI
switching valve, the valve closes and immediately shuts off the vacuum supply to the SAI
control valve. The pump continues to operate for a further five seconds for system diagnostic
purposes.
When the SAI switching valve is switched off, the vacuum supply line opens to atmosphere,
and this causes the SAI switching valve to close automatically to prevent any further injection
of air.
SAI control Valve

The injected air from the SAI pump is controlled by the SAI control valve. This allows the
correct amount of air to be injected directly into the exhaust manifolds via tuned restrictors on
each bank of cylinders. The SAI control valve prevents exhaust gasses from blowing back
into the SAI pump.
The SAI control valve is assisted in operation by a vacuum source from the SAI vacuum
reservoir located in the left hand side at the front of the engine. This assistance allows the
actuation of the SAI control valve independently from the intake manifold vacuum levels
available.
When the pressure in the exhaust system is higher than in the SAI system, the SAI control
valve closes the circuit, and this protects the SAI system from exhaust gasses blowing back
into the SAI system.
Vacuum to the SAI switching valve is provided from the intake manifold vacuum by the SAI
vacuum reservoir. A small bore vacuum hose provides the vacuum route between the SAI
vacuum reservoir and SAI switching valve. A further small bore vacuum hose is used to
connect the SAI switching valve to the SAI control valve.
SAI Pressure Sensor - NAS only

The SAI system is monitored by measuring the system pressure by using the SAI pressure
sensor at several instances during its cycle of operation.
The SAI system pressure is measured before operation of the SAI pump. The SAI pump is
then switched on and with a one second delay, the SAI 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 SAI pressure reading then a failure will be flagged.
A second pressure measurement is made after the requirement for SAI into the exhaust system
has expired, but continuing on from the same period of SAI pump operation, i.e. the pump is
left running, against a closed SAI 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 SAI then a
failure will be flagged.
A final pressure reading is taken after the SAI system has been switched off to ensure the
system shuts down.
SAI Vacuum Reservoir

The SAI vacuum reservoir is located on the LH side of the engine at the front.
The SAI vacuum reservoir is included in the vacuum supply line between the intake manifold
and the SAI switching valve.
The SAI vacuum reservoir contains a one-way valve to stop vacuum leaking back towards the
intake manifold side. The SAI vacuum reservoir holds a constant vacuum so that the SAI
control valve opens as soon as the SAI switching valve is switched on.

For a detailed description of the Engine Emission Control system, refer to the relevant

• Fuses
• Wiring harness
• Loose or corroded electrical
• Engine breather hoses connectors
• Cyclone separator • Sensor(s)
• Exhaust gas recirculation (EGR) pipes • Stepper motor(s)
(check for cracks) • Secondary air injection (AIR)
• EGR valve pump
• Secondary air injection (AIR)
valve
• Engine control module (ECM)
4 . If the cause is not visually evident, verify the customer concern and refer to the Symptom
Chart below, alternatively, check for Diagnostic Trouble Codes (DTCs) and refer to the DTC
Index.
Symptom Chart
• Engine breather system • Ensure the engine breather
Engine cranks, but does
disconnected/restricted system is free from
not fire
restriction and is correctly
installed
• Read DTCs and refer to

• Exhaust gas recirculation
DTC Index in this section
Difficult to start cold (EGR) valve stuck open
for EGR valve tests
• Ensure the engine breather

• Breather system system is free from
Engine stalls soon after
disconnected/restricted restriction and is correctly
start
installed

• EGR valve stuck open DTC Index in this section
Engine stops/stalls
for EGR valve tests

Poor idle quality
for EGR valve tests

Engine hesitates/poor • EGR valve stuck open DTC Index in this section
acceleration for EGR valve tests

• Breather system system is free from
Poor throttle response disconnected/restricted restriction and is correctly
installed

• Excessive fuel
consumption
• EGR system not for EGR system tests
• Excessive black
operating • Ensure the engine breather
smoke
• Engine breather system system is free from
• Excessive
restricted restriction and is correctly
emissions
installed
• Inspect the EGR pipes,

paying particular attention
Loud 'ticking' noise with • EGR pipes cracked
to the ribbed sections.
engine running
Replace as necessary

• Engine breather system system is free from
Engine oil leaks restricted restriction and is correctly
installed
DTC Index

NOTE:
identify the fault (the last two digits give extra information read by the manufacturer-
NOTE:
NOTE:
tests.
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.
DTC Description Possible Causes Action

• Check the installation
• EGR valve and for
incorrectly installed restriction/mechanical
or loose failure of the EGR
• EGR valve stuck valve.
P040100 EGR flow insufficient closed, blocked Exhaust Gas
• EGR valve Recirculation (EGR)
mechanical failure Valve (17.45.01)
• EGR pipe blocked • Check the EGR
pipework for restriction

Secondary Air tests associated with
• AIR check valve
Injection (AIR) this DTC using the
P041300 control circuit high
switching valve circuit manufacturer approved
open diagnostic system
Secondary Air • AIR check valve • Carry out any pinpoint

P041400 Injection (AIR) control circuit low tests associated with
switching valve circuit this DTC using the
shorted manufacturer approved
diagnostic system

• EGR valve power
Exhaust Gas supply circuit -
this DTC using the
P048900 Recirculation (EGR) short to ground,
control circuit low high resistance
diagnostic system

• EGR valve control tests associated with
Exhaust Gas
circuit - short to this DTC using the
P049000 Recirculation (EGR)
power manufacturer approved
control circuit high
diagnostic system
• Check the secondary air

• Secondary air
injection system for
injection system
leaks
Secondary air injection leaks
manifold absolute • Secondary air
P243100 tests associated with
pressure sensor circuit injection pump
this DTC using the
range/performance • Secondary air
injection valve
diagnostic system
• Secondary air
injection manifold
Secondary air injection tests associated with
absolute pressure
manifold absolute this DTC using the
P243200 sensor circuit -
pressure sensor circuit manufacturer approved
short to ground,
low diagnostic system
high resistance
• Secondary air • Carry out any pinpoint

Secondary air injection injection manifold tests associated with
manifold absolute pressure (MAP) this DTC using the
P243300
pressure sensor circuit sensor circuit - manufacturer approved
high short to power diagnostic system

• Secondary air
Secondary air injection injection pump
this DTC using the
P244400 system pump stuck control circuit -
ON short to ground
diagnostic system

Secondary air injection • Secondary air
P244500 system pump stuck injection pump
this DTC using the
OFF control circuit -
short to power diagnostic system

(17.45.01)
Removal

3 . Disconnect the EGR valve electrical connector.
4
this procedure.
Disconnect the 2 EGR valve coolant hoses.

Clamp the EGR coolant hoses to minimize coolant loss.
Remove the 2 nuts.
6 . Release the EGR valve from the throttle body elbow.

Remove the 2 bolts.
7 . Remove the EGR valve.

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.


4 . Connect the coolant hoses.

5 . Connect the electrical connector.



Removal

3.
Remove the positive crankcase ventilation (PCV) valve.

Disconnect the PCV hose.
Release the PCV valve.
Installation


Valve to Exhaust Manifold Tube

303-749

303-021
Removal
2

- AJV8




9 . Remove the coolant expansion tank support bracket.
Remove the 3 nuts.


13 . Remove the coolant rail.
Remove the bolt.
Disconnect the 3 quick release connectors.
14 .
15 . NOTE:

Raise the engine.

21 . Remove the AIR tube.
Installation
1 . Install the AIR tube.
2 . Attach the AIR tube to the exhaust manifolds.
4 . Install the LH exhaust manifold heat shield.

Tighten the screws.
5 . Install the RH exhaust manifold heat shield.
Tighten the screws.
7 . Install the coolant rail.
Connect the quick release connectors.
11 . Install the coolant expansion tank support bracket.








V8 - AJV8
Valve
Removal


Remove the bolt.

Remove the 2 bolts.
6 . Remove the AIR control valve.

Installation
1 . Attach the AIR control valve hose.



Tighten the clips.


7 NOTE:

Cycle Self-Test
Removal
1

3 . Disconnect the AIR pump electrical connector.
4 . Disconnect the AIR pump hose.
5 . Remove the AIR pump.

Remove the 3 nuts.
6 . NOTE:
Remove the AIR pump bracket.
Installation
1 . Install the AIR pump bracket.
2 . Install the AIR pump.

Connect the hose.

4 NOTE:

Cycle Self-Test
Secondary Air Injection Manifold Absolute
Pressure Sensor
Removal
1 . Remove the secondary air injection manifold absolute pressure sensor.
Disconnect the hose.
Installation
303-12A : Intake Air Distribution and Filtering – 4.2L SC
V8 – AJV8
Specifications
Specifications
Item Nm lb-ft lb-in

Air cleaner and MAF duct assy bracket to front crash structure 8 6 71
Air ducting band clamps 4 3 35
Air intake and resonator tube assy to engine 8 6 71
Air cleaner front support bracket 8 6 71
Resonator to dash and cowl panel 9 7 80

COMPONENT LOCATION

1 Dirty air intake
2 Air cleaner box
3 Clean air duct
4 Mass air flow sensor
5 RH bank charge air cooler
6 Supercharger outlet manifold
7 LH bank charge air cooler
8 Mass air flow sensor
9 Clean air duct
10 Electric throttle
11 Induction elbow
12 Air cleaner box
13 Supercharger
OVERVIEW
The engine air intake and distribution system comprises:
• Two air cleaner boxes

• Two air intakes
• Electric throttle
• A supercharger
• Two Mass Air Flow (MAF) 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 Mass Air flow sensor is fitted at the outlet of each air cleaner box. The sensor provides an
input to the engine control module (ECM). 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.

No Data Available

Removal
NOTE:
LH air cleaner procedure shown, RH is similar.
1


4 . Release the front ot the LH fender splash shield.


Remove the 7 clips.
6 . Disconnect the intake air resonator.
Release the clip.
7 . Disconnect the mass air flow (MAF) sensor electrical connector.
8 . Disconnect the intake air duct.
9 . Remove the air cleaner housing.

Remove the bolt.
Release from the locating grommet.
10 . NOTE:
Remove the mass air flow (MAF) sensor assembly.

11 . NOTE:
Make sure that this component is installed to the noted removal position.
Remove the air cleaner insert.

Installation
1 . Install the air cleaner insert.
2 . Install the MAF sensor assembly.

Tighten the screws.
3 . Install the air cleaner housing.

Secure in the grommet.
4 . Connect the intake air duct.
5 . Connect the MAF sensor electrical connector.
6 . Connect the intake air resonator.

7 . Install the air ducting.

Install the clips.
Secure the clips.
8 . Secure the fender splash shield.



Removal
NOTE:
LH air cleaner element procedure shown, RH is similar.
1



5 . Remove the air cleaner element.
Installation
1 . Install the air cleaner element.



Intake Air Resonator
Removal
2 . LH side: Release the intake air resonator.

Remove the bolt.
3 . RH side: Release the intake air resonator.

Remove the bolt.
Release the clip.
Installation

Charge Air Cooler LH (18.50.19)
Removal
2

For additional information, refer to Supercharger (18.50.15)
4
. CAUTION: Before disconnecting or removing the components, ensure the
area around the joint faces and connections are clean. Plug open connections to
prevent contamination.
Disconnect the charge air cooler, coolant hose.

Release the clip.
5 . Release the purge valve assembly.

Remove the nut.
Remove the bolt.
6 . Remove the charge air cooler.
Discard the gasket.
Installation
1 . Install the charge air cooler.

3 . Connect the charge air cooler, coolant hose.


Removal
2


For additional information, refer to Throttle Body Elbow (19.70.28)
5 . Remove the supercharger outlet pipe.

For additional information, refer to Supercharger Outlet Pipe (18.50.16)
6 . Disconnect the charge air cooler, coolant hose.

Release the clip.
7 . NOTE:
This step requires the aid of another technician.
Remove the supercharger.

Remove the 3 bolts.
Installation
Clean the locating dowels.
2 . Connect the charge air cooler, coolant hose.

3 . Install the supercharger outlet pipe.

For additional information, refer to Supercharger Outlet Pipe (18.50.16)

For additional information, refer to Throttle Body Elbow (19.70.28)


7 . Refill and bleed the cooling system.

Supercharger Outlet Pipe (18.50.16)
Removal

3.
NOTE:
Disconnect the 2 supercharger outlet pipe coolant hoses.

Clamp the hoses to minimize coolant loss.
4 . Release the supercharger outlet pipe.

Remove the 4 bolts.
5.
Remove the supercharger oultet pipe.

Remove the 4 bolts.
6 . Remove the supercharger coolant filler plug.

Remove and discard the sealing washer.
7 . NOTE:
Remove the spacer.

Remove the 3 bolts.
Installation
1 . Install the spacer.
2 . Install the supercharger outlet pipe.

Install new seals.
Remove the hose clamps.


6
. CAUTION: Coolant may spill from the supercharger fill port when the
ignition is switched on.
7
. CAUTION: Do not allow the supercharger coolant pump to run dry for
more than one minute. Failure to follow this instruction may result in damage to
the vehicle.
Allow the supercharger pump to run and top-up the coolant through the supercharger
fill port.
8 . Install the supercharger coolant fill plug and tighten to 45 Nm (33 lb.ft).
Install a new sealing washer.
9 . Switch the ignition off.

Throttle Body Elbow (19.70.28)
Removal
CAUTION: Before disconnecting or removing components, ensure the area

contamination.

2 Remove the EGR valve.

. For additional information, refer to Exhaust Gas Recirculation (EGR) Valve
(17.45.01)
3 . Disconnect the purge outlet line.
4 . Disconnect the brake booster vacuum hose quick release connector.
5 . Remove the EGR valve transfer pipe.

Remove the 2 nuts.
6 . Release the engine breather line.
7 . Disconnect the manifold absolute pressure (MAP) sensor electrical connector.
8 . Remove the MAP sensor.

9 . Remove the NVH pads from each cylinder bank.

10 . Release the charge air coolers from the throttle body elbow.
11 . Release the throttle body elbow.

Remove the 2 bolts.
12 . Remove the supercharger pressure relief actuator.

Disconnect the vacuum line.
Remove the 2 bolts.
Installation
2 . Install the supercharger pressure relief actuator.

Connect the vacuum line.
3 . Secure the throttle body elbow.

4 . Secure the charge air coolers to the throttle body elbow.

5 . Install the NVH pads on the cylinder banks.
6 . Install the MAP sensor.

7 . Connect the engine breather line.
8 . Install the EGR valve transfer pipe.

9 . Connect the brake booster vacuum hose quick release connector.
10 . Connect the purge outlet line.
11 Install the EGR valve.

. For additional information, refer to Exhaust Gas Recirculation (EGR) Valve
(17.45.01)

303-12B : Intake Air Distribution and Filtering – 4.2L NA
V8 – AJV8
Specifications
Specifications
Item Nm lb-ft lb-in

Air cleaner housing bracket - bolt 8 6 71
Air cleaner intake pipe bracket - bolt 8 6 71
Air cleaner outlet pipe bracket - bolt 8 6 71
Band clamp 4 3 35
Resonator to bulkhead - nut 9 7 80

COMPONENT LOCATION

1 Intake noise tube
2 Electric throttle
3 Air intake manifold
4 Resonator
5 Resonator
6 Air filter box
7 Clean air intake
INTRODUCTION
The 4.2 Liter V8 engine air intake and distribution system comprises:
• Air filter box

• Air intake
• Intake manifold
• Electronic throttle
The air filter box is located in front of the LH (left-hand) front wheel, behind the wheel arch
liner 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
(left-hand) 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.
COMPONENT LOCATION

1 Intake noise tube
2 Electric throttle
4 Resonator
5 Resonator
6 Air filter box
7 Clean air intake
INTRODUCTION
The 4.2 Liter V8 engine air intake and distribution system comprises:
• Air filter box

• Air intake
• Intake manifold
• Electronic throttle
The air filter box is located in front of the LH front wheel, behind the wheel arch liner 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 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.

For a detailed description of the Intake Air Distribution and Filtering system, refer to the
relevant Description and Operation section in the workshop manual.

• Hoses and ducts • Mass Air Flow (MAF) sensor
(damage/connections) • Secondary Air Injection (AIR) Manifold
• Air cleaner element Absolute Pressure (MAP) sensor
(contaminated/blocked) • Throttle body
• Restricted air intake • Harness (security/damage)
• Seals and gaskets • Connections (security/damage)
Index.
Symptom Chart
• Ensure the air intake
system is free from
blockage and is correctly
Vehicle does not • Restricted/blocked air intake
installed
start/hard • Restricted/blocked air cleaner
• Install a new air cleaner
starting/poor element
element as necessary.
performance
Air Cleaner Element
(19.10.08)
• Check for correct
• Intake pipe installation and integrity
disconnected/damaged after of air intake system
the air cleaner • Check for correct
Excessive intake
• Air cleaner assembly installation and integrity
noise
incorrectly of the air cleaner
assembled/damaged assembly.
DTC Index

NOTE:
identify the fault (the last two digits give additional information read by the
NOTE:
NOTE:
tests.
NOTE:
If DTCs are logged and, after performing the pinpoint tests, a fault is not present, an
terminals.

• Blocked air cleaner • Check air cleaner
element element is free
• Leakage from air intake from restriction
Mass Air Flow (MAF) system • Check for leak
P010100 circuit - • Engine breather leak from air intake
range/performance • MAF sensor sensing system, rectify as
circuit - high resistance, necessary
intermittent short to • Ensure the engine
ground breather system is
• MAF sensor supply correctly installed
circuit - high resistance and in serviceable
• MAF sensor failure condition
• Carry out any
pinpoint tests
DTC using the
manufacturer
approved
diagnostic system
• Install a new MAF
sensor as necessary.
Mass Air Flow
(MAF) Sensor
(18.30.15)
• Carry out any

pinpoint tests
• MAF sensor supply DTC using the
circuit - short to ground, manufacturer
high resistance approved
Mass Air Flow (MAF)
P010200 • MAF sensor ground diagnostic system
circuit - low input
circuit - high resistance • Install a new MAF
• MAF sensor failure sensor as necessary.
Mass Air Flow
(MAF) Sensor
(18.30.15)
• Carry out any

pinpoint tests
DTC using the
• MAF sensor sensing
manufacturer
approved
Mass Air Flow (MAF) • MAF sensor ground
P010300 diagnostic system
circuit - high input circuit - high resistance
• MAF sensor failure
Mass Air Flow
(MAF) Sensor
(18.30.15)
• Intake manifold air leak • Check for correct

(loose or missing installation and
Manifold Absolute
component) serviceability of
Pressure (MAP)
P010600 • MAP sensor signal intake manifold and
sensor -
circuit fault associated
range/performance
• MAP sensor failure components
• Carry out any
pinpoint tests
DTC using the
manufacturer
approved
diagnostic system
• Install a new MAP
Manifold Absolute
Pressure (MAP)
Sensor (18.30.86)
• Check for leak

from air intake
system
• Air intake leak between • For fuel system
MAF sensor and tests.
cylinder head Fuel Tank and
• Fuel filter, injector, Lines
System too lean (bank system restriction • Read DTCs and
P017100
1) • MAF sensor fault (low refer to DTC Index
intake air flow) in this section for
• Exhaust leak (forward MAF sensor tests
of catalytic converter) • Check and rectify
any exhaust leak
prior to catalytic
converter

element is free
from restriction
injectors, install
• Restricted air cleaner
new injector(s) as
• Leaking fuel injector(s)
necessary.
• Engine oil contaminated
Fuel Injector
with fuel (too many
(18.10.01)
cold starts with vehicle
System too rich (bank • Check for
1) contaminated
hot enough for long
engine oil, drain
enough)
and refill engine oil
• MAF sensor fault (high
as necessary.
intake air flow)
Engine Oil
Draining and
Filling
• Read DTCs and
refer to DTC Index
in this section for
MAF sensor tests
• Check for leak

from air intake
system
P017400
any exhaust leak
prior to catalytic
converter

element is free
from restriction
injectors, install
new injector(s) as
necessary.
Fuel Injector
• Engine oil contaminated
(18.10.01)
with fuel (too many
• Check for
cold starts with vehicle
System too rich (bank contaminated
2) engine oil, drain
hot enough for long
enough)
as necessary.
Engine Oil
intake air flow)
Draining and
Filling
• Read DTCs and
refer to DTC Index
in this section for
MAF sensor tests
• Ensure the air

intake system is
• Air intake restriction
free from
Idle air control system restriction
Drive (FEAD) overload
P050600 RPM lower than • Check the FEAD
(defective/seized
expected belt and
component)
components.
Accessory Drive
and correct
installation of air
• Intake air leak between
intake system
Idle air control system MAF sensor and engine
P050700 RPM higher than • Engine crankcase
and correct
expected breather leak
installation of
engine crankcase
breather system

Removal
2


5 . Release the front ot the LH fender splash shield.


Remove the 7 clips.
Release the clip.
8 . Disconnect the mass air flow (MAF) sensor.

Release the clip.
Remove the bolt.
Release the clip.
10 . NOTE:
Remove the mass air flow (MAF) sensor.

Installation
1 . Install the MAF sensor.
Tighten the screws.

Secure in the clip.

Secure in the clip.
5 . Install the air ducting.

Install the clips.
Secure the clips.




Removal
1



5 . Remove the air cleaner element.
Installation
1 . Install the air cleaner element.



Air Cleaner Outlet Pipe (19.10.31)
Removal
2

4 . Open the hood.

6 . Release and tie aside the power steering reservoir.

Remove the 2 bolts.
7 . Remove the air cleaner outlet pipe.
Remove the bolt.
Release the electrical connector.
Installation
1 . Install the air cleaner outlet pipe.
Install the electrical connector.
2 . Install the power steering fluid reservoir.




303-13 : Evaporative Emission – 4.2L NA V8 –
Specifications
Specifications
Item Nm lb-ft lb-in

Evaporative emission, canister bracket to vehicle - nut 7 5 62
Purge valve to engine cover bracket - bolt 4 3 35
Vapour/fuel tube bracket to vehicle - bolt 9 7 80
Evaporative Emissions - 4.2L NA V8 -

AJV8
COMPONENT LOCATION
Part
Item Description
Number
1 - Fuel filler pipe/cap
2 - DMTL pump filter (NAS only)
3 - Charcoal canister
4 - Fuel pump
5 - DMTL pump (NAS only)
6 - Breather hose from tank
7 - Fuel tank
8 Fuel filter
Charcoal canister vent hose (All except NAS) or DMTL pump vent hose
9 -
(NAS)
10 - Fuel delivery hose
11 - Purge valve
INTRODUCTION
The evaporative emission (EVAP) 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.
DMTL
The DMTL system is a legislative requirement for NAS vehicles. The DMTL system
periodically checks the EVAP system and the fuel tank for leaks when the ignition is switched
off. The DMTL system comprises the previously described components of the EVAP system
with the following additional components; a DMTL pump and a DMTL filter.
DMTL Pump
The DMTL pump is connected to the atmospheric vent of the charcoal canister and
incorporates a Positive Temperature Co-efficient (PTC) heating element, a normally open
valve and a reference orifice. The DMTL 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 DMTL 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 DMTL
pump by a hose.
The DMTL 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 0°C (32°F) and less than 40°C (104°F) and the vehicle was not started for at least
3hrs prior to this run.
The DMTL 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.
DMTL Operation
To check the fuel tank and the EVAP system for leaks, the ECM operates the DMTL 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
DMTL test is running) or until after the DMTL 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 40°C (32 and 104°F)
• 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 IDS. 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 DMTL 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 Malfunction
Indicator Lamp (MIL) 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.
CHARCOAL CANNISTER
1 Charcoal cannister
2 DMTL pump
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 DMTL 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
1 Hose and connection-purge valve to electric throttle
3 Hose-charcoal cannister to purge valve
4 Purge valve
The purge valve is located LH 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 Engine Control Module (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 Pulse Width Modulated (PWM) 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).
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 waits until the engine is running above 40°C (104°F) 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 DMTL
valve atmospheric vent connection and its filter on NAS vehicles or, via the vent hose
connection and the spider trap on non NAS vehicles.
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.
Evaporative Emissions - 4.2L SC V8 -
AJV8
COMPONENT LOCATION
Part
Item Description
Number
1 Fuel filler pipe/cap
2 fuel tank leakage monitoring pump filter (NAS only)
3 Charcoal canister
4 Fuel pump
5 fuel tank leakage monitoring pump (NAS only)
6 Breather hose from tank
7 Fuel tank
8 Fuel filter
Charcoal canister vent hose (All except NAS) or fuel tank leakage
9
monitoring pump vent hose (NAS)
10 Fuel delivery hose
11 Purge valve
OVERVIEW
The evaporative emission (EVAP) 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.
FUEL TANK LEAKAGE MONITORING

The fuel tank leakage monitoring system is a legislative requirement for NAS vehicles. 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 additional of a
fuel tank leakage monitoring pump and a fuel tank leakage monitoring filter.
Fuel Tank Leakage Monitoring Pump

The fuel tank leakage monitoring pump is connected to the atmospheric vent of the charcoal
canister and incorporates a Positive Temperature Co-efficient (PTC) heating element, a
normally open valve and a reference orifice. The fuel tank leakage monitoring 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 fuel tank leakage monitoring 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 fuel tank leakage monitoring pump by a hose.
The fuel tank leakage monitoring 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 0°C (32°F) and less than 40°C (104°F) and the vehicle was not started
for at least 3hrs prior to this run.
The fuel tank leakage monitoring 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.
Fuel Tank Leakage Monitoring Operation

To check the fuel tank and the EVAP system for leaks, the ECM operates the fuel tank
leakage monitoring 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 fuel
tank leakage monitoring test is running) or until after the fuel tank leakage monitoring 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 altitude is below 2500 m (8200 feet)
• The ambient temperature is between 4 and 35°C (32 and 104°F)
• 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 20 minutes
• The battery voltage is between 11 and 14.5 volts
• The last engine off time was more than 20 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 recommended diagnostic tool. 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 14 major leak check or after refueling
is not detected.
When the leak check is complete, the ECM stops the fuel tank leakage monitoring 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 Malfunction
Indicator Lamp (MIL) 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.
CHARCOAL CANNISTER
2 Fuel tank leakage monitoring pump
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.
Variant Capacity
NAS 3000cc (183 in³)
ROW 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. On NAS vehicles the atmospheric vent hose connection
allows for the attachment of the fuel tank leakage monitoring 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
1 Electric throttle
2 Purge valve
air intake manifold, to the elbow assembly which locates the electric throttle. The purge valve
is controlled by the Engine Control Module (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.
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 valve is Pulse Width Modulated (PWM) 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).
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 waits until the engine is running above 40°C (104°F) 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 fuel
tank leakage monitoring valve atmospheric vent connection and its filter on NAS vehicles or,
via the vent hose connection and the spider trap on non NAS vehicles.
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.
For a detailed description of the Evaporative emissions system, refer to the relevant
Description and Operation section of the workshop manual.
Evaporative Emissions - 4.2L NA V8 - AJV8

• Fuel filler cap and seal
• Fuel filler neck
• Diagnostic Monitoring of Tank Leakage (DMTL) fresh air • Fuses
filter (restriction, etc) • Connectors
• Fuel tank (leaks, damage, etc) • Harnesses
• Fuel lines and joints, etc • Purge valve
• Carbon canister • DMTL pump
• Purge valve
• DMTL pump module
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.
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
• Restriction in the vapor line
• Check for
between the fuel tank and the
Difficulty in restrictions/damage, etc (see
carbon canister
filling fuel tank visual inspection)
outlet/atmospheric port
• Check for leaks, check the

• System leak
purge valve operation. GO to
Fuel smell • Purge valve inoperative
'Check Fuel Filler • Fuel filler cap missing/not • Check the fuel filler cap and
Cap' displayed on tightened after refuelling seal
Message Center
DTC Index

diagnostic tests, use the adaptor kit, part number 3548-1358-00.
NOTE:
If the module is suspect and the vehicle remains under the manufacturer 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.
NOTE:
NOTE:
NOTE:
tests.
NOTE:
terminals.
• Evaporative canister
purge pipe restricted,
leaking, disconnected For basic checks. GO to
• Evaporative canister Pinpoint Test
vent restricted G556798p1.
• Evaporative canister Carry out any pinpoint
P044100 Incorrect purge flow
purge valve to engine tests associated with this
pipe(s) restricted, DTC using the
leaking, disconnected manufacturer approved
• Evaporative canister diagnostic system
purge valve failure
Carry out any pinpoint

Evaporative Emission • DMTL COV circuit - tests associated with this
P044700 (EVAP) system vent short to ground DTC using the
control circuit open manufacturer approved
diagnostic system
Evaporative Emission • DMTL COV circuit - tests associated with this
P044800 (EVAP) system vent short to power DTC using the
control circuit shorted manufacturer approved
diagnostic system
Check the fuel system
Evaporative Emission • DMTL system has integrity (see visual
P045600 (EVAP) system leak detected a leak inspection). Carry out K
detected (very small leak) line or Vacutec tests to
identify the leak
• Carry out any
pinpoint tests
associated with
this DTC using
the manufacturer
• EVAP canister purge approved
valve control circuit - diagnostic system
Evaporative Emission short to ground, high • Install a new
P045800 (EVAP) canister purge resistance EVAP canister
valve circuit low • EVAP canister purge purge valve as
valve failure necessary.
Evaporative
Emission Canister
Purge Valve -
4.2L NA V8 -
AJV8 (17.15.30)
Evaporative Emission Carry out any pinpoint

• EVAP canister purge
P045900 (EVAP) canister purge tests associated with this
valve control circuit -
valve circuit high DTC using the
short to power manufacturer approved
diagnostic system
Evaporative emission
• DMTL pump circuit - tests associated with this
(EVAP) system leak
P240100 short to ground DTC using the
detection pump control
circuit low
diagnostic system
• DMTL pump circuit - tests associated with this
(EVAP) system leak
P240200 short to power DTC using the
detection pump control
circuit high
diagnostic system
• DMTL reference leak
• DMTL pump circuit -
Check the DMTL
Evaporative emission short to ground,
pipework. For DMTL
(EVAP) system leak power, high
P240429 pump tests, GO to
detection pump sensing resistance
Pinpoint Test
circuit range/performance • DMTL pipework
G556798p4.
blocked/leaking

Evaporative emission Check the DMTL
short to ground,
(EVAP) system leak pipework. For DMTL
power, high
P24042F detection pump sensing pump tests, GO to
resistance
circuit range/performance Pinpoint Test
• DMTL pipework
- signal erratic G556798p4.
blocked/leaking

short to ground, For DMTL pump tests,
(EVAP) system leak
P240500 power, high GO to Pinpoint Test
detection pump sensing
resistance G556798p4.
circuit low

short to ground, For DMTL pump tests,
(EVAP) system leak
P240600 power, high GO to Pinpoint Test
detection pump sensing
resistance G556798p4.
circuit high

• DMTL heater control tests associated with this
(EVAP) system leak
P240B00 circuit low DTC using the
detection pump heater
circuit low
diagnostic system
Evaporative emission Carry out any pinpoint
• DMTL heater control
(EVAP) system leak tests associated with this
P240C00 circuit high
detection pump heater DTC using the
circuit high manufacturer approved
diagnostic system
• DMTL system circuit Carry out any pinpoint
- short to ground, tests associated with this
(EVAP) system change-
P245000 power, high DTC using the
over valve (COV)
resistance manufacturer approved
performance/stuck open
diagnostic system
• DMTL system circuit Carry out any pinpoint
- short to ground, tests associated with this
(EVAP) system change-
P245100 power, high DTC using the
over valve (COV)
resistance manufacturer approved
performance/stuck closed
diagnostic system
Pinpoint Tests

EVAPORATIVE SYSTEM INCORRECT
PURGE FLOW
G556798t1 : CHECK FUEL FILLER CAP
INSTALLATION AND CONDITION OF CANISTER,
PIPES AND CONNECTORS
1. Make sure that the fuel filler cap is correctly installed and tightened. 2. Check the condition
of the carbon canister. 3. Check the condition of all accessible pipes and connectors in the
vapor line.
• Are the canister and all pipes and connectors in good condition?
-> Yes
-> No
REPAIR as necessary. CLEAR the DTC, test the system for normal operation.
G556798t2 : CHECK THAT THE PURGE VALVE IS

OPERATING
1. Disconnect the vapor pipe from the inlet port of the evaporative purge valve. 2. RUN the
engine for 2 minutes, making sure that the engine reaches normal operating temperature. 3.
Check that the evaporative purge valve is operating, by touch or by sound (using a
stethoscope, it will be possible to hear the valve operating).
• Is the valve operating?
-> Yes
CHECK for related DTCs. Refer to the DTC Index above.
-> No
CHECK the purge valve circuits. GO to Pinpoint Test G556798p3.
PINPOINT TEST G556798p2 : CHANGE-

OVER VALVE (COV) CONTROL
CIRCUIT
G556798t3 : CHECK THE COV CONTROL CIRCUIT
FOR SHORT CIRCUIT TO GROUND
1. Set ignition status to OFF. 2. Disconnect the DMTL electrical connector, CV011. 3.
DMTL connector CV011, harness side Battery
-> Yes
REPAIR the short circuit. For additional information, refer to the wiring diagrams. Clear the
DTC, test the system for normal operation.
-> No

FOR SHORT CIRCUIT TO POWER
DMTL connector CV011, harness side Battery

-> Yes
-> No

FOR HIGH RESISTANCE
1. Disconnect the ECM electrical connector, FL072. 2. Measure the resistance between:
DMTL connector CV011, harness side ECM connector FL072, harness side
Pin 03 Pin 48
-> Yes
REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams.
Clear the DTC, test the system for normal operation.
-> No
INSTALL a new DMTL assembly. If the DTC is repeated, refer to the new ECM installation
notes at the top of the DTC Index.
PINPOINT TEST G556798p3 : PURGE

VALVE CONTROL CIRCUIT
G556798t6 : CHECK THE POWER SUPPLY TO THE
PURGE VALVE
1. Disconnect the purge valve connector, PI304. 2. Set ignition status to ON, engine OFF. 3.
Measure the voltage between:
Purge valve connector PI304, harness side Battery
• Is the voltage less than 10 volts?
-> Yes
REPAIR the circuit between the purge valve and battery. This circuit includes harness splices
and fuse 14 of the engine junction box. For additional information, refer to the wiring
diagrams. Clear the DTC, test the system for normal operation.
-> No
G556798t7 : CHECK THE PURGE VALVE CONTROL

CIRCUIT FOR SHORT CIRCUIT TO GROUND
1. Set ignition status to OFF. 2. Measure the resistance between:
-> Yes
-> No

CIRCUIT FOR SHORT CIRCUIT TO POWER
-> Yes
-> No

CIRCUIT FOR HIGH RESISTANCE
1. Disconnect the ECM electrical connector, PI300. 2. Measure the resistance between:
Purge valve connector PI304, harness side ECM connector PI300, harness side
Pin 02 Pin 92
-> Yes
-> No
INSTALL a new purge valve. Clear the DTC, test the system for normal operation. If the
DTC is repeated, refer to the new ECM installation notes at the top of the DTC Index.

DIAGNOSTIC MONITORING OF FUEL
TANK LEAKAGE (DMTL) PUMP
CONTROL CIRCUIT
DMTL PUMP
1. Set the ignition status to OFF. 2. Disconnect the DMTL pump electrical connector, CV011.
3. Set ignition status to ON, engine OFF. 4. Measure the voltage between:
DMTL pump connector CV011, harness side Battery
-> Yes
REPAIR the circuit between the DMTL pump and battery. This circuit includes harness splice
FLS05 and fuse 14 of the engine junction box. For additional information, refer to the wiring
-> No
G556798t11 : CHECK THE DMTL PUMP CONTROL

-> Yes
-> No

-> Yes
-> No

DMTL pump connector CV011, harness side ECM connector FL072, harness side
Pin 01 Pin 33
-> Yes
-> No
INSTALL a new DMTL pump. Clear the DTC, test the system for normal operation. If the
DTC is repeated, refer to the new ECM installation note at the top of the DTC Index.

DIAGNOSTIC MONITORING OF FUEL
TANK LEAKAGE (DMTL) HEATER
CIRCUIT
DMTL PUMP
1. Set ignition status to OFF. 2. Disconnect the DMTL pump electrical connector, CV011. 3.
Set ignition status to ON, engine OFF. 4. Measure the voltage between:
-> Yes
REPAIR the circuit between the DMTL pump and battery. This circuit includes harness splice
FLS05 and fuse 14 of the engine junction box. For additional information, refer to the wiring
-> No
G556798t15 : CHECK THE DMTL HEATER CONTROL


-> Yes
-> No

-> Yes
-> No

DMTL pump connector CV011, harness side ECM connector FL072, harness side
Pin 02 Pin 23
-> Yes
-> No
INSTALL a new DMTL pump. Clear the DTC, test the system for normal operation. If the
DTC is repeated, refer to the new ECM installation note at the top of the DTC Index.

Evaporative Emission Canister - 4.2L NA
V8 - AJV8/4.2L SC V8 - AJV8 (17.15.13)
Removal
WARNING: 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.
1
2 Remove the rear differential.

. For additional information, refer to Axle Assembly - 4.2L NA V8 - AJV8/4.2L SC V8
- AJV8, Vehicles Without: Differential Drain Plug (51.25.13)
3.
NOTE:
Sub-frame shown removed for clarity.
Disconnect the evaporative emissions canister.

Disconnect the 3 lines.
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 - 4.2L NA V8 - AJV8/4.2L SC V8
- AJV8, Vehicles Without: Differential Drain Plug (51.25.13)
Evaporative Emission Canister Purge Valve
- 4.2L NA V8 - AJV8 (17.15.30)
Removal

3 . Release the 2 electrical connectors.
4
Release the clip and disconnect purge outlet line at the intake elbow.
5

6 . Remove the purge valve assembly.
Remove the 2 nuts.
7 . NOTE:
NOTE:
Remove the purge valve.

Remove the bolt.
Installation
1 . Install the purge valve, align the peg and tighten the bolt to 6 Nm (4 lb.ft).
2 . Install the purge valve.

3 . Connect the purge lines.

4 . Secure the electrical connectors.


Evaporative Emission Canister Purge Valve
- 4.2L SC V8 - AJV8 (17.15.30)
Removal
2
Disconnect the purge outlet line.
3
Disconnect the purge inlet line.
4 . Remove the purge valve assembly.

Remove the nut.
Remove the bolt.
5 . NOTE:
NOTE:
Remove the purge valve.

Remove the bolt.
Installation
1 . Install the purge valve, align the peg and tighten the bolt to 6 Nm (4 lb.ft).
2 . Install the purge valve.

3 . Connect the purge lines.

303-14A : Electronic Engine Controls – 4.2L SC V8 –
AJV8
Specifications
Specifications
Item Nm lb-ft lb-in

Camshaft position sensor - bolt 7 5 62
Catalyst monitor sensor 45 33 -
Crankshaft position sensor - screw 7 5 62
Engine control module 10 7 88
Heated oxygen sensor 45 33 -
Knock sensor - nut 20 15 -
Knock sensor - stud 10 7 88
Oil pressure sensor 15 11 -
Oil temperature sensor 15 11 -
Variable camshaft timing, oil control solenoid - bolt 10 7 88
General procedure
Powertrain Control Module (PCM) Long

Drive Cycle Self-Test
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.
Carry out a road test and perform the following operations.

• Accelerate to 55 mph (88 km/h) in 5th gear and cruise for 2 minutes with the engine
speed at or above 1800rpm.
• Lift off the throttle and allow the vehicle to decelerate until the engine speed is less than
1000 rpm.
• Stop the vehicle.
• Release brake, allow the vehicle to move with no throttle for 1 minute.
• 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
NOTE:
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 70ºC
(158 ºF) is achieved.
• Switch off the engine.
5. NOTE:
claimed against.


COMPONENT LOCATION SHEET 1 of 2

2 Injector
4 Knock sensor
5 Camshaft Position (CMP) sensor
6 Electric throttle
7 Exhaust Gas Recirculation (EGR) valve
8 Manifold Absolute Pressure sensor
9 Purge valve
11 Engine Control Module (ECM)
13 Downstream Heated Oxygen Sensor (HO2S)
14 Upstream Heated Oxygen Sensor (HO2S)
15 Mass Air Flow(MAF)/Intake Air Temperature (IAT) sensor
16 Secondary air injection valve
18 Oil pressure sensor
19 Secondary air injection pump
21 Variable valve timing solenoid
22 Ignition coil
23 Positive Crankcase Ventilation (PCV) valve

2 Adaptive speed control sensor (where fitted)
3 Accelerator Pedal Position (APP) sensor
4 Adaptive speed control module (where fitted)
5 Fuel Pump Driver Module (FPDM)
9 Battery Junction Box (BJB)
OVERVIEW
The V8 supercharged engine is controlled by an ECM. 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 (OBD)
• 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 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.).
ENGINE CONTROL MODULE (ECM)

1 ECM
2 Mounting bracket
The ECM and bracket assembly are attached to the vehicle on the left hand side in the
secondary bulkhead area using 3 m6 nuts, 2 off onto the longitudinal and 1 off to the wheel
arch apron panel.
System ECM has the following inputs:
• RCM
• Park/neutral switch
• Ignition coil feedback x8
• Fuel rail temperature
• Fuel rail pressure
• Supercharger inlet pressure
• Mass air flow
• Engine speed
• Camshaft position x2
• Driver demand
• Brake pedal position switch
• Speed control switches
• Generator load
• Oxygen sensors pre catalyst x2
• Oxygen sensors post catalyst x2
• Throttle position
• Cooling fan speed
• Ignition switch position
• Knock sensors x2
• Manifold Absolute pressure (MAP)
• Intercooler temperature
• Coolant temperature
• Engine oil temperature
The ECM outputs to the following:
• Electric throttle Actuator

• Brake vacuum pump relay
• Ignition coils (x8)
• Oxygen sensor heaters (4)
• Fuel injectors (8)
• Purge Valve
• Engine Cooling Fan
• Fuel pump relay
• Starter Relay
• EMS Main Relay
• Electric Fan Control
• Generator Control
• Fuel tank leakage monitoring (NAS Only)
• Fuel Pump Driver Module (FPDM)
CRANKSHAFT POSITION SENSOR (CKP)
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
degrees 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 30 degrees BTDC No.1 cylinder. Because of the crankshaft sensor's
orientation, the target wheel uses windows stamped 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.
CAMSHAFT POSITION SENSOR (CMP)
Two sensors are located at the rear of the engine, in the cylinder head (one per bank), above
the rear cylinders. The sensors are Variable Reluctor Sensor (VRS) type, producing four
pulses for every two engine crankshaft revolutions. The sensing element is positioned
between 0 and 2mm from the side of the cam gear wheel.
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:
• 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.
ENGINE OIL TEMPERATURE SENSOR
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.
FUEL RAIL TEMPERATURE SENSOR
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. The sensors operating
range is -40 Degrees Celsius to 150 Degrees Celsius. The fuel rail temperature sensor is fitted
on the rear of the right hand bank fuel rail.
FUEL RAIL PRESSURE SENSOR
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.
FUEL TANK LEAKAGE MONITORING - NAS ONLY

Charcoal Canister with fuel tank leakage monitoring
Pump (NAS only)
2 Fuel tank leakage monitoring pump
The fuel tank leakage monitoring system periodically checks the evaporative system and the
fuel tank for leaks when the ignition is switched off. The fuel tank leakage monitoring 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 fuel tank leakage monitoring
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 fuel tank leakage
monitoring 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. For
additional information, refer to Evaporative Emissions - Vehicles With: Supercharger (303-
13 Evaporative Emissions)
PURGE VALVE
Purge Valve and Hoses location
1 Purge hose
2 Purge valve
3 Electric throttle
The purge valve is located on the LH side of the engine on a bracket which is attached to the
cylinder head. The purge valve is a solenoid operated valve which is closed when de-
energized. The purge valve is controlled by a 10Hz PWM signal from the ECM. When 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 fuel tank leakage monitoring pump fresh air vent. For additional
information, refer to Evaporative Emissions - Vehicles With: Supercharger (303-13
Evaporative Emissions)
MASS AIR FLOW/INLET AIR TEMPERATURE

SENSOR (MAF/IAT)
Two MAF/IAT sensors are located in the clean air duct immediately after the air cleaner box.
The air mass flow is determined by the cooling effect of inlet 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 MAF 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 sensor is integrated into the MAF meter. 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)-

SUPERCHARGER INLET PRESSURE
The MAP sensor is located in the LH side of the throttle elbow.
The MAP sensor provides a voltage proportional to the absolute pressure in the supercharger
intake. This signal allows the load on the engine to be calculated and used within the internal
calculations of the MAP. The sensor is located below the electric throttle on the induction
elbow.
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.
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 Land Rover
recommended diagnostic tool.
MANIFOLD ABSOLUTE PRESSURE AND

TEMPERATURE SENSOR (MAPT)
The MAPT is located to the front of the RH engine bank intercooler and is secured with a
single bolt. The sensor measures the pressure and temperature of the inducted air prior to it
entering the cylinders.
The sensor fits and seals using a radial ‘O’ ring seal directly to the inlet manifold.
The MAPT signal is used to retard the ignition timing relative to boost pressure. The
intercooler temperature is used for air charge density calculations and for intercooler
diagnostic purposes.
KNOCK SENSORS
The V8 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). 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 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.
ELECTRONIC THROTTLE
The V8 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 EAPP 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.
• Provide differing responses for differing Terrain response modes.
A software strategy within the ECM enables the throttle position to be calibrated each ignition
cycle. When the ignition is turned ON, the ECM performs a self test and calibration routine
on the electronic throttle by closing the throttle full, then opening again. This tests the default
position springs.
Accelerator Pedal Position Sensor (APP)

The APP sensors are located on the accelerator pedal assembly.
The APP sensors are used to determine the driver's request for vehicle speed, acceleration and
deceleration. This value is used by the ECM and the throttle is opened to the correct angle by
an electric motor integrated into the throttle body.
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 'limp – home'
input. In limp home mode due to an APP signal failure the ECM will limit the maximum
engine speed to 2000 rpm.
OXYGEN SENSORS
There are four oxygen sensors located in the exhaust system. Two upstream before the
catalytic converter and two down stream after the catalytic converter. 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.
Oxygen Sensors
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 sensor’s readiness for closed loop control and influences emissions. The
PWM duty cycle is carefully controlled to prevent thermal shock to cold sensors.
Heated oxygen sensors also known as Linear or "Wide 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 heated oxygen 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 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 with a calibrated torque
wrench For additional information, refer to Specifications (303-14)
. 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 reading.
• Strong smell of H02S (rotten eggs) 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 fewer holes in the protection tube
than the down stream sensors.
STOPLAMP SWITCH
The stoplamp switch is mounted on the brake pedal bracket and is connected to the vehicle
harness via a 4 pin multiplug.
When the brake pedal is pressed, the switch contacts close allowing 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.
GENERATOR
The Generator has a multifunction voltage regulator for use in a 14V charging system with
6÷12 zener diode bridge rectifiers.
The ECM monitors the load on the electrical system via PWM 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.
FUEL INJECTORS
The engine has 8 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 ‘return less’ 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. 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 eight 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.
The individual cylinder spark timing is calculated from a variety of inputs:
• Engine speed and load.

• Knock control.
• Auto gearbox shift control.
• Idle speed control.
FUEL PUMP CONTROL MODULE

The fuel pump control module is located in the rear LH quarter adjacent to the parking aid
control module.
The fuel pump is control by the ECM. The ECM sends a PWM signal to the fuel pump
control module from pin B20 of the ECM, 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 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 fuel pump control module is monitored by the ECM. Any errors can be
retrieved from the ECM by the Jaguar recommended diagnostic tool. The fuel pump control
module cannot be interrogated for diagnostic purposes.
The MAP controls the fuel pump control module in response to inputs from the fuel rail
pressure sensor, MAP and the MAF/IAT sensor.
FUEL PUMP RELAY

The ECM controls the fuel pump relay which in turn controls the power supply to the fuel
pump control module. The ECM energizes the relay ON with ignition ON.
COOLING FAN CONTROL

The ECM controls an electric cooling fan via a control module to provide engine cooling. The
ECM supplies the fan with a PWM signal that controls the duty cycle of the fan, providing the
correct amount of cooling fan speed and airflow.

Variable valve timing is used on the V8 engine to enhance low and high speed engine
performance and idle speed quality.
For each inlet camshaft the VVT 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
The VVT unit is a hydraulic actuator mounted on the end of the inlet camshaft. The unit
advances or retards the camshaft timing to alter the camshaft to crankshaft phase. The ECM
controls the VVT timing unit via a 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.
VVT 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. While 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.
CONTROL DIAGRAM SHEET 1 of 3

NOTE:
A = Hardwired connection
1 Fuse
2 Battery
4 Door module
5 Door module
6 knock sensors
7 MAP sensor
9 CKP sensor
10 APP
11 Stop lamp switch
12 CMP sensor
15 Air temperature sensor
17 MAF/IAT sensor
18 Automatic Speed Limiter switch
19 ECM
20 Start/Stop switch

NOTE:
1 FPDM
2 Generator
3 HO2S (upstream)
4 HO2S (downstream)
5 Electric throttle
6 Purge valve
7 fuel tank leakage monitoring pump
8 EGR valve
9 Engine cooling fan
10 VCT solenoid
12 ECM
13 Injector (8 off)
14 Ignition coil (8 off)

NOTE:
D = High speed CAN bus; N=Medium speed CAN bus; O = LIN (local interconnect
network) bus
1 Diagnostic socket
2 Steering column lock
3 Park brake module
4 TCM
5 ECM
6 Integrated control panel
7 Steering wheel speed control switches
8 Rotary coupler
12 RCM
13 Adaptive front lighting system control module
14 Gear shift module
16 Pedestrian protection module
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 HO2S
• The MAF/IAT sensor
• The CKP sensor
• Electric throttle body.
Oxygen 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.

The characteristics of the signal supplied by the CKP are learned 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 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 crankshaft position sensor 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 crankshaft position 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 T4. 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).
T4 Diagnostics
The ECM stores faults as DTC, referred to as 'P' codes. The 'P' codes are defined by OBD
legislation and, together with their associated environmental and freeze frame data, can be
read using a third party scan tool or T4. T4 can also read real time data from each sensor, the
adaptive values currently being employed and the current fueling, ignition and idle settings.

For a detailed description of electronic engine controls, refer to the relevant Description and

• Engine oil level • Fuses
• Cooling system coolant level • Wiring harness
• Fuel level • Electrical connector(s)
• Throttle body • Engine Control Module (ECM)
• Poly-vee belt • Transmission Control Module (TCM)
possible) before proceeding to the next step
Index.
Symptom Chart
Engine non-start
• Security system • Check that the security
/Immobilizer engaged system is disarmed
• Engine in shut-down • Read DTCs and refer to
mode DTC Index in this
Engine does not crank
• ECM relay section for ECM relay
• Battery tests
• Park/Neutral switch • Ensure the battery is in
• Starting system fully charged and
• Engine seized serviceable condition
• For Park/Neutral switch
tests.
External Controls
• For starting system
tests.
Starting System
• For engine system tests.
Engine

breather system is free
from restriction and is
correctly installed
• Engine breather system • For ignition system
disconnected/restricted tests.
• Ignition system Engine Ignition
Engine cranks, but does not
• Fuel system • For fuel system tests.
fire
• Electronic engine Fuel Charging and
controls Controls
DTC Index in this
section for electronic
engine control tests

• Evaporative emissions Evaporative Emissions
purge valve • For fuel system tests.
Engine cranks and fires, but • Fuel pump Fuel Tank and Lines
will not start • Spark plugs • For ignition system
• Ignition coil failure(s) tests.
Engine Ignition
Difficult to start
• Check engine coolant
coolant level and
level/anti-freeze
condition.
content
Specifications
• Battery
• Ensure the battery is in
• Electronic engine
a fully charged and
controls
serviceable condition
Difficult cold start • Exhaust gas
recirculation (EGR)
DTC Index in this
valve stuck open
• Fuel pump
purge valve
Engine Emission
Control
Fuel Tank and Lines
• Carry out injector leak

tests, install new
injectors as necessary.
Fuel Injector
(18.10.01)
• Injector leak
DTC Index in this
controls
Difficult hot start purge valve
• Fuel pump
• Ignition system
Fuel Tank and Lines
tests.
Engine Ignition
Engine Emission
Control

tests, install new
Fuel Injector
(18.10.01)
• Injector leak
DTC Index in this
Difficult to start after hot controls
soak (vehicle standing, • Evaporative emissions
engine off, after engine has purge valve
reached operating • Fuel pump
temperature) • Ignition system
Fuel Tank and Lines
tests.
Engine Ignition
Engine Emission
Control
• Compressions high/low • Carry out compression

• Battery tests.
Engine cranks too fast/slow
• Starting system Engine
• Ensure battery is in a
fully charged and
tests.
Starting System
Engine stalls
correctly installed
DTC Index in this
• Breather system section for ECM relay
disconnected/restricted tests
• ECM relay • Read DTCs and refer to
• Electronic engine DTC Index in this
controls section for electronic
Engine stalls soon after start • Ignition system engine control tests
• Air intake system • For ignition system
restricted tests.
• Air leakage Engine Ignition
• Fuel lines • Check for blockage in
air cleaner element and
air intake system
• Check for leakage in air
intake system
Fuel Tank and Lines

DTC Index in this
section for ECM relay
• ECM relay
tests
• Throttle position (TP)
Engine stalls on overrun • Read DTCs and refer to
sensors
DTC Index in this
section for TP sensor
tests

• ECM relay DTC Index in this
• CKP sensor section for ECM relay,
Engine stalls at steady speed
• TP sensors CKP, and TP sensor
tests

Engine stalls with speed • ECM relay
DTC Index in this
control enabled
tests

DTC Index in this
section for ECM relay,
and TP sensor tests
• ECM relay
• Check for excessive
• TP sensors
loads being placed on
• Additional engine loads
the engine from PAS,
(PAS, air conditioning,
Engine stalls when air conditioning
etc)
manoeuvring systems etc.
• Transmission
• For transmission system
malfunction
tests.
• CAN malfunction
Diagnostic Strategy
• For CAN network tests.
Communications
Network
Poor driveability
Fuel Tank and Lines
• Carry out fuel injector
leak tests, install new
Fuel Injector
(18.10.01)
• Fuel pressure, fuel
• Check for leakage from
pump, fuel lines
air intake system
• Injector leak
• Air leakage
DTC Index in this
controls
Engine hesitates/poor engine control tests
• Ignition system
acceleration • For ignition system
• EGR valve stuck
tests.
• Transmission
Engine Ignition
malfunction
• Restricted pedal travel
Engine Emission
(carpet, etc)
Control
tests.
Diagnostic Strategy
pedal is free from
restriction
• Fuel pump, fuel lines • For fuel system tests.

Engine backfires • Air leakage Fuel Tank and Lines
• Electronic engine • Check for leakage from
controls air intake system
• Ignition system • Read DTCs and refer to
• Sticking variable DTC Index in this
camshaft timing (VCT) section for electronic
hub engine control tests
tests.
Engine Ignition
DTC Index in this
section for VCT system
tests

Fuel Tank and Lines
• Fuel pump, fuel lines
DTC Index in this
Engine surges controls
• Ignition system
tests.
Engine Ignition

DTC Index in this
• Electronic engine engine control tests
controls • For fuel system tests.
• Fuel pump, fuel lines, Fuel Tank and Lines
Engine detonates/knocks fuel quality • Check for leakage from
• Air leakage air intake system
• Sticking VCT hub • Read DTCs and refer to
DTC Index in this
tests

No throttle response controls section for electronic
• Default mode enabled • Check message center

• Speed control, brake for default message,
switch read DTCs and refer to
Speed control inhibited or
• Electronic engine DTC Index
disabled
controls • For speed control, and
• CAN fault brake switch tests.
Speed Control
DTC Index in this
Communications
Network
• Ensure engine breather

system is free from
restriction and is
• Breather system
correctly installed
DTC Index in this
controls
Poor throttle response • Transmission
malfunction
tests.
• Air leakage
Diagnostic Strategy
intake system

tests.
• Park/Neutral switch External Controls
Engine defaults, warning
• Electronic engine • Read DTCs and refer to
light and messages. Refer to
controls DTC Index in this
the owner handbook
DTC Index

NOTE:
If the module/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.
NOTE:
NOTE:
NOTE:
tests.
NOTE:
terminals.

• Check anti-lock
control -
stability assist
• Invalid data received module for
Left front wheel speed from ABS - left front DTCs and refer
C003100
sensor wheel speed signal to DTC Index.
Anti-Lock
Control -
Stability Assist
• Check anti-lock
control -
stability assist
Right front wheel speed from ABS - right front DTCs and refer
C003400
Anti-Lock
Control -
Stability Assist
• Check anti-lock
control -
• Invalid data received stability assist
Left rear wheel speed from ABS - left rear module for
C003700
sensor wheel speed signal DTCs and refer
to DTC Index.
Anti-Lock
Control -
Stability Assist
• Check anti-lock
control -
stability assist
Right rear wheel speed from ABS - right rear DTCs and refer
C003A00
Anti-Lock
Control -
Stability Assist
• Carry out the

pinpoint tests
associated with
this DTC using
• Variable Camshaft
the
Timing (VCT) circuit
manufacturer
fault
Intake camshaft position - approved
• Valve timing
P001100 timing over-advanced diagnostic
incorrectly set
(bank 1) system
• Timing chain has
• Check the valve
slipped
timing.
Timing Drive
Components
(12.65.13)
• Carry out the

pinpoint tests
associated with
this DTC using
the
manufacturer
fault
• Valve timing
P001200 timing over-retarded (bank diagnostic
incorrectly set
1) system
• Check the valve
slipped
timing.
Timing Drive
Components
(12.65.13)
• The relative positions • Reset the

Crankshaft position of the CKP and CMP sensor
(CKP)/Camshaft position teeth are not correct positions.
P001600
(CMP) sensor correlation, Sensors incorrectly Camshaft
right hand bank aligned on rebuild Position (CMP)
Sensor LH
(18.31.12)
Camshaft
Position (CMP)
Sensor RH
(18.31.11)
Crankshaft
Position (CKP)
Sensor
(18.30.12)
• Reset the
sensor
positions.
Camshaft
Position (CMP)
Sensor LH
(18.31.12)
• The relative positions
Camshaft
Crankshaft position of the CKP and CMP
Position (CMP)
(CKP)/Camshaft position teeth are not correct
P001800 Sensor RH
(CMP) sensor correlation, Sensors incorrectly
(18.31.11)
left hand bank aligned on rebuild
Crankshaft
Position (CKP)
Sensor
(18.30.12)
Timing Drive
Components
(12.65.13)
• Carry out the

pinpoint tests
associated with
this DTC using
the
manufacturer
fault
• Valve timing
P002100 timing over-advanced diagnostic
incorrectly set
(bank 2) system
• Check the valve
slipped
timing.
Timing Drive
Components
(12.65.13)
• Variable Camshaft • Carry out the

Intake camshaft position - Timing (VCT) circuit pinpoint tests
P002200 timing over-retarded (bank fault associated with
2) • Valve timing this DTC using
incorrectly set the
• Timing chain has manufacturer
slipped approved
diagnostic
system
• Check the valve
timing.
Timing Drive
Components
(12.65.13)
• Carry out the

pinpoint tests
associated with
this DTC using
the
manufacturer
• VCT solenoid fault
Variable Camshaft Timing approved
• Oil contamination
(VCT) control solenoid diagnostic
• VCT oil flow fault
P002672 (bank 1) circuit system
• VCT/Camshaft
range/performance - • Check the oil
mechanical failure
actuator stuck open condition and
flow
• Check for
mechanical
failure of
components
• Carry out the

pinpoint tests
associated with
this DTC using
the
manufacturer
Variable Camshaft Timing • VCT solenoid fault
approved
(VCT) control solenoid • Oil contamination
diagnostic
(bank 1) circuit • VCT oil flow fault
P002677 system
range/performance - • VCT/Camshaft
• Check the oil
commanded position not mechanical failure
condition and
achievable
flow
• Check for
mechanical
failure of
components
Variable Camshaft Timing • Carry out the

(VCT) control solenoid pinpoint tests
P002872 (bank 2) circuit associated with
range/performance - this DTC using
• VCT/Camshaft
actuator stuck open the
mechanical failure manufacturer
approved
diagnostic
system
• Check the oil
condition and
flow
• Check for
mechanical
failure of
components
• Carry out the

pinpoint tests
associated with
this DTC using
the
manufacturer
Variable Camshaft Timing • VCT solenoid fault
approved
(VCT) control solenoid • Oil contamination
diagnostic
(bank 2) circuit • VCT oil flow fault
P002877 system
range/performance - • VCT/Camshaft
• Check the oil
commanded position not mechanical failure
condition and
achievable
flow
• Check for
mechanical
failure of
components
• Carry out the

pinpoint tests
associated with
this DTC using
the
manufacturer
• HO2S heater circuit -
approved
HO2S heater control circuit circuit fault
P003100 diagnostic
low (bank 1) • HO2S heater failure
system
• Install a new
HO2S as
necessary.
Heated Oxygen
Sensor (HO2S)
• Carry out the

pinpoint tests
P003200 associated with
high (bank 1) • HO2S heater failure
this DTC using
the
manufacturer
approved
diagnostic
system
• Install a new
HO2S as
necessary.
Heated Oxygen
Sensor (HO2S)
• Carry out the

pinpoint tests
associated with
this DTC using
the
manufacturer
• Catalyst monitor
approved
sensor heater circuit -
Catalyst monitor sensor diagnostic
circuit fault
P003600 heater control circuit (bank system
1) • Install new
sensor heater failure
catalyst monitor
sensor as
necessary.
Catalyst
Monitor Sensor
(18.30.66)
• Carry out the

pinpoint tests
associated with
this DTC using
the
manufacturer
approved
P005100 diagnostic
low (bank 2) • HO2S heater failure
system
• Install a new
HO2S as
necessary.
Heated Oxygen
Sensor (HO2S)
• Carry out the

pinpoint tests
associated with
P005200 this DTC using
high (bank 2) • HO2S heater failure
the
manufacturer
approved
diagnostic
system
• Install a new
HO2S as
necessary.
Heated Oxygen
Sensor (HO2S)
• Carry out the

pinpoint tests
associated with
this DTC using
the
manufacturer
approved
sensor heater circuit -
circuit fault
P005600 heater control circuit (bank system
2) • Install new
sensor heater failure
catalyst monitor
sensor as
necessary.
Catalyst
Monitor Sensor
(18.30.66)
• Check for MAP

sensor related
DTCs and refer
to the DTC
Index in this
• MAP sensor failure section
Manifold absolute pressure
• BARO sensor failure • Install a new
P006900 (MAP)/Barometric
(internal ECM fault) ECM. Refer to
pressure correlation
new
module/compo
nent installation
Note at top of
DTC Index
• Carry out the

pinpoint tests
associated with
• Ambient temperature this DTC using
Ambient air temperature value missing from the
P007100
sensor range/performance CAN bus manufacturer
approved
diagnostic
system
• Carry out the
• Ambient air
pinpoint tests
temperature sensor
associated with
circuit - high
this DTC using
resistance
Ambient air temperature the
P007200 • Ambient air
sensor circuit low manufacturer
temperature sensor
approved
circuit - short to
diagnostic
ground
system
• Carry out the

pinpoint tests
associated with
• Ambient air
this DTC using
temperature sensor
Ambient air temperature the
P007300 circuit - short to
sensor circuit high manufacturer
power
approved
diagnostic
system
• Carry out the

pinpoint tests
associated with
this DTC using
the
manufacturer
approved
• VCT control solenoid diagnostic
circuit - high system
Variable Camshaft Timing
resistance, • Install a new
P007500 (VCT) control circuit (bank
disconnected VCT control
1)
• VCT solenoid failure solenoid as
necessary.
Variable
Camshaft
Timing (VCT)
Oil Control
Solenoid
(18.30.90)
• Carry out the

pinpoint tests
• VCT control solenoid associated with
Variable Camshaft Timing circuit - short to this DTC using
P007600 (VCT) control circuit low ground, disconnected the
(bank 1) • VCT solenoid failure manufacturer
approved
diagnostic
system
• Install a new
VCT control
solenoid as
necessary.
Variable
Camshaft
Timing (VCT)
Oil Control
Solenoid
(18.30.90)
• Carry out the

pinpoint tests
associated with
this DTC using
the
manufacturer
approved
diagnostic
• VCT control solenoid
system
Variable Camshaft Timing circuit - short to
• Install a new
P007700 (VCT) control circuit high power
VCT control
(bank 1) • VCT solenoid failure
solenoid as
necessary.
Variable
Camshaft
Timing (VCT)
Oil Control
Solenoid
(18.30.90)
• Carry out the

pinpoint tests
associated with
this DTC using
the
manufacturer
• VCT control solenoid approved
circuit - high diagnostic
Variable Camshaft Timing
resistance, system
P008100 (VCT) control circuit (bank
disconnected • Install a new
2)
• VCT solenoid failure VCT control
solenoid as
necessary.
Variable
Camshaft
Timing (VCT)
Oil Control
Solenoid
(18.30.90)
• Carry out the

pinpoint tests
associated with
this DTC using
the
manufacturer
approved
diagnostic
system
• Install a new
P008200 (VCT) control circuit low ground, disconnected
VCT control
solenoid as
necessary.
Variable
Camshaft
Timing (VCT)
Oil Control
Solenoid
(18.30.90)
• Carry out the

pinpoint tests
associated with
this DTC using
the
manufacturer
approved
diagnostic
system
• Install a new
P008300 (VCT) control circuit high power
VCT control
solenoid as
necessary.
Variable
Camshaft
Timing (VCT)
Oil Control
Solenoid
(18.30.90)
• Fuel rail pressure • Carry out the

(FRP) sensor, sensing pinpoint tests
circuit - short to associated with
Fuel rail/system pressure -
P008700 ground, open circuit this DTC using
too low
• FRP sensor supply the
circuit - high manufacturer
resistance approved
• FRP sensor failure diagnostic
• Fuel pump failure system
• Fuel line leak, • Install a new
restriction FRP sensor as
necessary.
Fuel Rail
Pressure (FRP)
Sensor
(18.30.98)
• For fuel system
tests.
Fuel Tank and
Lines
• Carry out the

pinpoint tests
associated with
• FRP sensor this DTC using
supply/sensing the
circuits - short to each manufacturer
other approved
• FRP sensor sensing diagnostic
circuit - short to system
power • Install a new
Fuel rail/system pressure -
P008800 • FRP sensor ground FRP sensor as
too high
circuit - high necessary.
resistance Fuel Rail
• FRP sensor failure Pressure (FRP)
• Restricted fuel line Sensor
• Fuel pump short (18.30.98)
circuit to power • For fuel system
tests.
Fuel Tank and
Lines
• Carry out the

NOTE: pinpoint tests
Intercooler air associated with
temperature sensor is this DTC using
integral to primary MAP the
sensor manufacturer
Intake Air Temperature
approved
P009623 Sensor 2 Circuit
diagnostic
Range/Performance
• Intercooler air system. Refer
temperature sensor to electrical
circuit - short to circuit diagrams
ground and check
Intercooler air
temperature
sensor circuit
for short to
ground
• Carry out the

pinpoint tests
associated with
NOTE: this DTC using
Intercooler air the
temperature sensor is manufacturer
integral to primary MAP approved
sensor diagnostic
system. Refer
to electrical
Range/Performance
• Intercooler air circuit diagrams
temperature sensor and check
circuit - short to Intercooler air
power temperature
sensor circuit
for short to
power
• Carry out the

pinpoint tests
associated with
Intercooler air the
sensor diagnostic
system. Refer
to electrical
Range/Performance
circuit - high Intercooler air
resistance temperature
sensor circuit
for high
resistance
NOTE: • Carry out the

pinpoint tests
Intercooler air
associated with
temperature sensor is
this DTC using
Intake Air Temperature integral to primary MAP
P009700 the
Sensor 2 Circuit Low Input sensor
manufacturer
approved
diagnostic
• Intercooler air system. Refer
temperature sensor to electrical
circuit - short to circuit diagrams
ground, high and check
resistance primary MAP
sensor
intercooler air
temperature
sensor circuit
for short to
ground, high
resistance
• Carry out the

pinpoint tests
associated with
this DTC using
NOTE: the
Intercooler air manufacturer
temperature sensor is approved
integral to primary MAP diagnostic
sensor system. Refer
Intake Air Temperature to the electrical
P009800
Sensor 2 Circuit High Input circuit diagrams
• Intercooler air and check
temperature sensor primary MAP
circuit - short to sensor
power intercooler air
temperature
sensor circuit
for short to
power
• Check air
• Blocked air cleaner cleaner element
element is free from
• Leakage from air restriction
intake system • Check for leak
• Engine breather leak from air intake
• MAF sensor sensing system, rectify
circuit - high as necessary
Mass Air Flow (MAF)
P010100 resistance, • Ensure the
circuit - range/performance
intermittent short to engine breather
ground system is
• MAF sensor supply correctly
circuit - high installed and in
resistance serviceable
• MAF sensor failure condition
• Carry out the
pinpoint tests
associated with
this DTC using
the
manufacturer
approved
diagnostic
system
• Install a new
MAF sensor as
necessary.
Mass Air Flow
(MAF) Sensor
(18.30.15)
• Carry out the

pinpoint tests
associated with
this DTC using
• MAF sensor supply
the
circuit - short to
manufacturer
ground, high
approved
resistance
Mass Air Flow (MAF) diagnostic
P010200 • MAF sensor ground
circuit - low input system
circuit - high
• Install a new
resistance
MAF sensor as
necessary.
Mass Air Flow
(MAF) Sensor
(18.30.15)
• Carry out the

pinpoint tests
associated with
this DTC using
• MAF sensor sensing the
circuit - short to manufacturer
power approved
Mass Air Flow (MAF) • MAF sensor ground diagnostic
P010300
circuit - high input circuit - high system
resistance • Install a new
• MAF sensor failure MAF sensor as
necessary.
Mass Air Flow
(MAF) Sensor
(18.30.15)
Manifold Absolute • Intake manifold air • Check for

P010600 Pressure (MAP) sensor - leak (loose or missing correct
range/performance component) installation and
• MAP sensor signal serviceability of
circuit fault intake manifold
• MAP sensor failure and associated
components
• Carry out the
pinpoint tests
associated with
this DTC using
the
manufacturer
approved
diagnostic
system
• Install a new
MAP sensor as
necessary.
Manifold
Absolute
Pressure (MAP)
Sensor
(18.30.86)
• Carry out the

pinpoint tests
associated with
• MAP sensor signal this DTC using
Manifold Absolute
circuit - short to the
P010700 Pressure/Barometric
ground manufacturer
Pressure Circuit Low Input
approved
diagnostic
system
• Carry out the

pinpoint tests
associated with
• MAP sensor signal this DTC using
Manifold Absolute
P010800 Pressure/Barometric
power manufacturer
Pressure Circuit High Input
approved
diagnostic
system
• Blocked air cleaner • Check air

element cleaner element
Mass or Volume Air Flow • Leakage from air is free from
P010B00 B Circuit intake system restriction
Range/Performance • Engine breather leak • Check for leak
• MAF sensor 2 sensing from air intake
circuit - high system, rectify
resistance, as necessary
intermittent short to • Ensure the
ground engine breather
• MAF sensor 2 supply system is
circuit - high correctly
resistance installed and in
• MAF sensor 2 failure serviceable
condition
• Carry out the
pinpoint tests
associated with
this DTC using
the
manufacturer
approved
diagnostic
system
• Install a new
MAF sensor as
necessary.
Mass Air Flow
(MAF) Sensor
(18.30.15)
• Carry out the

pinpoint tests
associated with
this DTC using
• MAF sensor 2 supply
the
circuit - short to
manufacturer
ground, high
approved
resistance
Mass or Volume Air Flow diagnostic
P010C00 • MAF sensor 2 ground
Circuit 2 Low Input system
circuit - high
• Install a new
resistance
MAF sensor as
• MAF sensor 2 failure
necessary.
Mass Air Flow
(MAF) Sensor
(18.30.15)
• Carry out the

• MAF sensor 2 sensing
pinpoint tests
circuit - short to
associated with
power
this DTC using
Mass or Volume Air Flow • MAF sensor 2 ground
P010D00 the
Circuit 2 High Input circuit - high
manufacturer
resistance
approved
• MAF sensor 2 failure
diagnostic
system
• Install a new
MAF sensor as
necessary.
Mass Air Flow
(MAF) Sensor
(18.30.15)
• Carry out the

pinpoint tests
associated with
this DTC using
the
manufacturer
• IAT sensor sensing
Intake Air Temperature approved
circuit - high
(IAT) sensor circuit - diagnostic
P011123 resistance
range/performance - signal system
• IAT sensor failure
stuck low • Install a new
MAF sensor as
necessary.
Mass Air Flow
(MAF) Sensor
(18.30.15)
• Carry out the

pinpoint tests
associated with
this DTC using
the
manufacturer
Intake Air Temperature approved
circuit - high
(IAT) sensor circuit - diagnostic
P011124 resistance
range/performance - signal system
stuck high • Install a new
MAF sensor as
necessary.
Mass Air Flow
(MAF) Sensor
(18.30.15)
• Carry out the

pinpoint tests
associated with
Intake Air Temperature this DTC using
circuit - high
(IAT) sensor circuit - the
P011129 resistance
range/performance - signal manufacturer
invalid approved
diagnostic
system
• Install a new
MAF sensor as
necessary.
Mass Air Flow
(MAF) Sensor
(18.30.15)
• Carry out the

pinpoint tests
associated with
this DTC using
the
• IAT sensor sensing manufacturer
circuit - high approved
resistance, diagnostic
P011200 (IAT) sensor circuit - low
disconnected system
input
• IAT sensor failure • Install a new
MAF sensor as
necessary.
Mass Air Flow
(MAF) Sensor
(18.30.15)
• Carry out the

pinpoint tests
associated with
this DTC using
the
circuit - short to approved
ground, short to diagnostic
P011300 (IAT) sensor circuit - high
power system
input
• IAT sensor failure • Install a new
MAF sensor as
necessary.
Mass Air Flow
(MAF) Sensor
(18.30.15)
• Fill cooling
system to
correct level
• ECT sensor sensing
and
Engine Coolant circuit - intermittent
specification.
Temperature (ECT) sensor high resistance
P011623 Specifications
circuit - range/performance • Engine thermostat
• Carry out the
- signal stuck low failure
pinpoint tests
associated with
this DTC using
the
manufacturer
approved
diagnostic
system
• Check and
install new
engine
thermostat as
necessary.
Thermostat -
Vehicles With:
Supercharger
(26.45.07)
• Install a new
ECT sensor as
necessary.
Engine Coolant
Temperature
(ECT) Sensor
(18.30.10)
• Fill cooling
system to
correct level
and
specification.
Specifications
• Carry out the
pinpoint tests
associated with
this DTC using
• Low coolant level the
• ECT sensor sensing manufacturer
Engine Coolant circuit - intermittent approved
Temperature (ECT) sensor high resistance diagnostic
P011624
circuit - range/performance • Engine thermostat system
- signal stuck high failure • Check and
• ECT sensor failure install new
engine
thermostat as
necessary.
Thermostat -
Vehicles With:
Supercharger
(26.45.07)
• Install a new
ECT sensor as
necessary.
Engine Coolant
Temperature
(ECT) Sensor
(18.30.10)
• Fill cooling
system to
correct level
and
specification.
Specifications
• Carry out the
pinpoint tests
associated with
this DTC using
the
manufacturer
• Low coolant level approved
• ECT sensor sensing diagnostic
Engine Coolant circuit - intermittent system
Temperature (ECT) sensor high resistance • Check and
P011629
circuit - range/performance • Engine thermostat install new
- signal invalid failure engine
• ECT sensor failure thermostat as
necessary.
Thermostat -
Vehicles With:
Supercharger
(26.45.07)
• Install a new
ECT sensor as
necessary.
Engine Coolant
Temperature
(ECT) Sensor
(18.30.10)
• Carry out the

pinpoint tests
associated with
• ECT sensor sensing this DTC using
Engine Coolant power, high manufacturer
P011700 Temperature (ECT) sensor resistance, open approved
circuit - low input circuit, disconnected diagnostic
• ECT sensor failure system
• Install a new
ECT sensor as
necessary.
Engine Coolant
Temperature
(ECT) Sensor
(18.30.10)
• Check for
cooling fan
circuit DTCs
and refer to
relevant action
specified in
DTC Index
• Carry out the
• Engine overheat pinpoint tests
condition/cooling fan associated with
failure this DTC using
Engine Coolant
• ECT sensor sensing the
P011800 Temperature (ECT) sensor
circuit - high input
ground approved
• ECT sensor failure diagnostic
system
• Install a new
ECT sensor as
necessary.
Engine Coolant
Temperature
(ECT) Sensor
(18.30.10)
• Carry out the

pinpoint tests
associated with
this DTC using
the
• TP sensor sensing
manufacturer
circuits TP 1 and TP 2
Throttle Position (TP) approved
- short to battery, high
P012100 sensor circuits TP 1 and TP diagnostic
resistance
2 - range/performance system
• TP sensor failure
• Install a new
throttle body as
necessary.
Throttle Body
(19.70.04)
• TP sensor sensing • Carry out the

circuit TP 1 - short to pinpoint tests
Throttle Position (TP)
ground, high associated with
P012200 sensor circuit TP 1 - low
resistance this DTC using
input
• TP sensor failure the
manufacturer
approved
diagnostic
system
• Install a new
throttle body as
necessary.
Throttle Body
(19.70.04)
• Carry out the

pinpoint tests
associated with
this DTC using
the
• TP sensor sensing manufacturer
Throttle Position (TP) circuit TP1 - short to approved
P012300 sensor circuit TP 1 - high power diagnostic
input • TP sensor failure system
• Install a new
throttle body as
necessary.
Throttle Body
(19.70.04)
• Fill cooling
system to
correct level
and
specification.
Specifications
• Carry out the
pinpoint tests
associated with
this DTC using
the
circuit - intermittent
Insufficient coolant manufacturer
high resistance
P012500 temperature for closed loop approved
• Engine thermostat
fuel control diagnostic
failure
system
• Check and
install new
engine
thermostat as
necessary.
Thermostat -
Vehicles With:
Supercharger
(26.45.07)
• Install a new
ECT sensor as
necessary.
Engine Coolant
Temperature
(ECT) Sensor
(18.30.10)
• Drain and re-

fill cooling
system to
correct level
and
specification.
Specifications
Cooling System
Draining,
Filling and
Bleeding - 4.2L
SC V8 - AJV8
• Low/contaminated
• Check and
Coolant Thermostat coolant
install a new
(Coolant Temperature • Thermostat
P012800 engine
Below Thermostat • Cooling fan
thermostat as
Regulating Temperature) circuit(s)/module
necessary.
Thermostat -
Vehicles With:
Supercharger
(26.45.07)
• Check for
correct
operation of
cooling fan,
check for DTCs
and refer to
DTC Index
• Check for and

rectify any
exhaust leak
• Exhaust gas leakage between
• H02S cylinder head
Heated Oxygen Sensor variable/constant and catalytic
P01311A (H02S) circuit - low circuit - circuit fault, converter (e.g.
voltage (bank 1) disconnected manifolds,
• H02S failure EGR system
etc.)
• Carry out the
pinpoint tests
associated with
this DTC using
the
manufacturer
approved
diagnostic
system
• Install a new
HO2S as
necessary.
Heated Oxygen
Sensor (HO2S)
• Check for and

rectify any
exhaust leak
between
cylinder head
and catalytic
converter (e.g.
manifolds,
EGR system
• Exhaust gas leakage etc.)
• H02S • Carry out the
Heated Oxygen Sensor variable/constant pinpoint tests
P01321B (H02S) circuit - high circuit - circuit fault, associated with
voltage (bank 1) disconnected this DTC using
• H02S failure the
manufacturer
approved
diagnostic
system
• Install a new
HO2S as
necessary.
Heated Oxygen
Sensor (HO2S)
• Carry out the

pinpoint tests
associated with
• HO2S to ECM wiring
this DTC using
shield high resistance
the
Heated Oxygen Sensor • Exhaust leak
manufacturer
P013300 (H02S) circuit - slow • Fuel control system
approved
response (bank 1) fault
diagnostic
• HO2 sensor failure
system
• Check for and
rectify any
exhaust leak
between
cylinder head
and catalytic
converter (e.g.
manifolds,
EGR system
etc.)
• For fuel
charging and
controls tests.
Fuel Charging
and Controls
• Install a new
HO2S as
necessary.
Heated Oxygen
Sensor (HO2S)
• Carry out the

pinpoint tests
associated with
this DTC using
Heated Oxygen Sensor
• HO2S slow activation the
P013400 (H02S) circuit - no activity
manufacturer
detected (bank 1)
approved
diagnostic
system
• Carry out the

pinpoint tests
associated with
this DTC using
the
manufacturer
sensor sensing circuit
approved
- short to ground, high
resistance,
P013700 circuit - low voltage (bank system
disconnected
1) • Install new
catalyst monitor
sensor failure
sensor as
necessary.
Catalyst
Monitor Sensor
(18.30.66)
• Catalyst monitor • Carry out the

Catalyst monitor sensor
sensor sensing circuit pinpoint tests
P013800 circuit - high voltage (bank
- short to power associated with
1)
• Catalyst monitor this DTC using
sensor ground braided the
shield - high manufacturer
resistance approved
• Catalyst monitor diagnostic
sensor failure system
• Install new
catalyst monitor
sensor as
necessary.
Catalyst
Monitor Sensor
(18.30.66)
• Carry out the

pinpoint tests
associated with
this DTC using
Catalyst monitor sensor • Catalyst monitor
the
P013900 circuit - slow response sensor slow response
manufacturer
(bank 1)
approved
diagnostic
system
• Carry out the

pinpoint tests
associated with
sensing circuit - short
this DTC using
to ground, short to
the
power, high
manufacturer
resistance,
approved
disconnected
P014000 circuit - no activity system
sensor ground braided
detected (bank 1) • Install a new
shield - high
catalyst monitor
resistance
sensor as
necessary.
sensor - mechanical
Catalyst
damage
Monitor Sensor
(18.30.66)
• Carry out the

• Catalyst monitor pinpoint tests
sensor heater control associated with
circuit - high this DTC using
Catalyst monitor heater
P014100 resistance the
circuit (bank 1)
• Catalyst monitor manufacturer
sensor heater failure approved
diagnostic
system
• Install a new
catalyst monitor
sensor as
necessary.
Catalyst
Monitor Sensor
(18.30.66)
• Carry out the

pinpoint tests
associated with
this DTC using
the
• HO2S sensing circuit
manufacturer
- short to ground,
Heated Oxygen Sensor approved
short to power, high
P01511A (H02S) circuit - low diagnostic
resistance
voltage (bank 2) system
• HO2S failure
• Install a new
HO2S as
necessary.
Heated Oxygen
Sensor (HO2S)
• Carry out the

pinpoint tests
associated with
this DTC using
the
• H02S sensing circuit -
manufacturer
short to ground, short
Heated Oxygen Sensor approved
to power, high
P01521B (H02S) circuit - high diagnostic
resistance
voltage (bank 2) system
• H02S failure
• Install a new
HO2S as
necessary.
Heated Oxygen
Sensor (HO2S)
• Carry out the

pinpoint tests
• HO2S to ECM wiring associated with
shield high resistance this DTC using
Heated Oxygen Sensor • Exhaust leak the
P015300 (H02S) circuit - slow • Fuel control system manufacturer
response (bank 2) fault approved
• HO2 sensor failure diagnostic
system
• Check for and
rectify any
exhaust leak
between
cylinder head
and catalytic
converter (e.g.
manifolds,
EGR system
etc.)
• For fuel system
and controls
tests.
Fuel Charging
and Controls
• Install a new
HO2S as
necessary.
Heated Oxygen
Sensor (HO2S)
• Carry out the

pinpoint tests
associated with
this DTC using
Heated Oxygen Sensor
• H02S slow activation the
P015400 (H02S) circuit - no activity
manufacturer
detected (bank 2)
approved
diagnostic
system
• Carry out the

pinpoint tests
associated with
this DTC using
the
manufacturer
sensor sensing circuit
approved
- short to ground, high
resistance,
P015700 circuit - low voltage (bank system
disconnected
2) • Install a new
catalyst monitor
sensor failure
sensor as
necessary.
Catalyst
Monitor Sensor
(18.30.66)
Catalyst monitor sensor • Catalyst monitor • Carry out the

P015800 circuit - high voltage (bank sensor sensing circuit pinpoint tests
2) - short to power associated with
• Catalyst monitor this DTC using
sensor ground braided the
shield - high manufacturer
resistance approved
• Catalyst monitor diagnostic
sensor failure system
• Install a new
catalyst monitor
sensor as
necessary.
Catalyst
Monitor Sensor
(18.30.66)
• Carry out the

pinpoint tests
associated with
this DTC using
Catalyst monitor sensor • Catalyst monitor
the
P015900 circuit - slow response sensor slow response
manufacturer
(bank 2)
approved
diagnostic
system
• Carry out the

pinpoint tests
associated with
this DTC using
to ground, short to
the
power, high
manufacturer
resistance,
approved
disconnected
P016000 circuit - no activity system
sensor ground braided
detected (bank 2) • Install a new
shield - high
catalyst monitor
resistance
sensor as
necessary.
sensor - mechanical
Catalyst
damage
Monitor Sensor
(18.30.66)
• Carry out the

pinpoint tests
• Catalyst monitor associated with
Catalyst monitor sensor sensor heater control this DTC using
P016100
heater circuit (bank 2) circuit malfunction the
manufacturer
approved
diagnostic
system
• Check for leak

from air intake
system
• For fuel system
tests.
• Air intake leak Fuel Tank and
between MAF sensor Lines
and cylinder head • Read DTCs and
• Fuel filter, injector, refer to DTC
system restriction Index in this
P017100 System too lean (bank 1)
• MAF sensor fault section for
(low intake air flow) MAF sensor
• Exhaust leak (forward tests
of catalytic converter) • Check and
rectify any
exhaust leak
prior to
catalytic
converter
• Check air
cleaner element
is free from
restriction
• Check for
leaking
injectors, install
• Restricted air cleaner new injector(s)
• Leaking fuel as necessary.
injector(s) Fuel Injector
• Engine oil (18.10.01)
contaminated with • Check for
fuel (too many cold contaminated
P017200 System too rich (bank 1) starts with vehicle engine oil,
subsequently not drain and refill
getting hot enough for engine oil as
long enough) necessary.
• MAF sensor fault Engine Oil
(high intake air flow) Draining and
Filling
• Read DTCs and
refer to DTC
Index in this
section for
MAF sensor
tests
• Check for leak
from air intake
system
• For fuel system
tests.
• Air intake leak Fuel Tank and
between MAF sensor Lines
and cylinder head • Read DTCs and
• Fuel filter, injector, refer to DTC
system restriction Index in this
P017400 System too lean (bank 2)
• MAF sensor fault section for
(low intake air flow) MAF sensor
• Exhaust leak (forward tests
of catalytic converter) • Check and
rectify any
exhaust leak
prior to
catalytic
converter
• Check air
cleaner element
is free from
restriction
• Check for
leaking
injectors, install
• Restricted air cleaner new injector(s)
• Leaking fuel as necessary.
injector(s) Fuel Injector
• Engine oil (18.10.01)
contaminated with • Check for
fuel (too many cold contaminated
P017500 System too rich (bank 2) starts with vehicle engine oil,
subsequently not drain and refill
getting hot enough for engine oil as
long enough) necessary.
• MAF sensor fault Engine Oil
(high intake air flow) Draining and
Filling
• Read DTCs and
refer to DTC
Index in this
section for
MAF sensor
tests
Engine Fuel Temperature • EFT sensor sensing • Carry out the

P018123
(EFT) sensor circuit - circuit - short to pinpoint tests
range/performance - signal ground, short to associated with
stuck low power, high resistance this DTC using
• EFT sensor ground the
circuit - high manufacturer
resistance approved
• EFT sensor failure diagnostic
system
• Install a new
EFT sensor as
necessary.
Fuel
Temperature
Sensor
(18.30.99)
• Carry out the

pinpoint tests
associated with
this DTC using
• EFT sensor sensing the
ground, short to approved
Engine Fuel Temperature
power, high resistance diagnostic
(EFT) sensor circuit -
P018124 • EFT sensor ground system
range/performance - signal
circuit - high • Install a new
stuck high
resistance EFT sensor as
• EFT sensor failure necessary.
Fuel
Temperature
Sensor
(18.30.99)
• Carry out the

pinpoint tests
associated with
this DTC using
• EFT sensor sensing the
ground, short to approved
Engine Fuel Temperature
power, high resistance diagnostic
(EFT) sensor circuit -
P018129 • EFT sensor ground system
circuit - high • Install a new
invalid
resistance EFT sensor as
• EFT sensor failure necessary.
Fuel
Temperature
Sensor
(18.30.99)
• Carry out the
pinpoint tests
associated with
this DTC using
the
• EFT sensor sensing manufacturer
Engine Fuel Temperature ground diagnostic
P018200 (EFT) sensor circuit - low • EFT sensor ground system
input circuit - short circuit • Install a new
• EFT sensor failure EFT sensor as
necessary.
Fuel
Temperature
Sensor
(18.30.99)
• Carry out the

pinpoint tests
associated with
this DTC using
• EFT sensor sensing
the
circuit - short to
manufacturer
power, high
approved
resistance,
Engine Fuel Temperature diagnostic
disconnected
P018300 (EFT) sensor circuit - high system
• EFT sensor ground
input • Install a new
circuit - high
EFT sensor as
resistance
necessary.
• EFT sensor failure
Fuel
Temperature
Sensor
(18.30.99)
• Carry out the

pinpoint tests
associated with
this DTC using
Fuel Rail Pressure (FRP) • FRP sensor range and
the
P019100 sensor circuit - performance
manufacturer
range/performance
approved
diagnostic
system
• FRP sensor sensing • Carry out the

circuit - short to pinpoint tests
Fuel Rail Pressure (FRP)
P019200 ground, high associated with
sensor circuit - low input
resistance, this DTC using
disconnected the
• FRP sensor 5V supply manufacturer
circuit - high approved
resistance diagnostic
• FRP sensor failure system
• Install a new
FRP sensor as
necessary.
Fuel Rail
Pressure (FRP)
Sensor
(18.30.98)
• Carry out the

pinpoint tests
associated with
• FRP sensor
this DTC using
supply/sensing
the
circuits - short circuit
manufacturer
to each other
approved
• FRP sensor sensing
diagnostic
Fuel Rail Pressure (FRP) circuit - short to
P019300 system
sensor circuit - high input power
• Install a new
• FRP sensor ground
FRP sensor as
circuit - high
necessary.
resistance
Fuel Rail
• FRP sensor failure
Pressure (FRP)
Sensor
(18.30.98)
• Carry out the

pinpoint tests
associated with
this DTC using
the
manufacturer
• EOT sensor sensing approved
Engine Oil Temperature
circuit - intermittent diagnostic
(EOT) sensor circuit -
P019623 high resistance system
• EOT sensor failure • Install a new
stuck low
EOT sensor as
necessary.
Oil
Temperature
Sensor
(18.31.01)
Engine Oil Temperature • EOT sensor sensing • Carry out the

P019624 (EOT) sensor circuit - circuit - intermittent pinpoint tests
range/performance - signal high resistance associated with
stuck high • EOT sensor failure this DTC using
the
manufacturer
approved
diagnostic
system
• Install a new
EOT sensor as
necessary.
Oil
Temperature
Sensor
(18.31.01)
• Carry out the

pinpoint tests
associated with
this DTC using
the
manufacturer
Engine Oil Temperature
circuit - intermittent diagnostic
(EOT) sensor circuit -
P019629 high resistance system
• EOT sensor failure • Install a new
invalid
EOT sensor as
necessary.
Oil
Temperature
Sensor
(18.31.01)
• Carry out the

pinpoint tests
associated with
this DTC using
the
manufacturer
Engine Oil Temperature circuit - short to diagnostic
P019700 (EOT) sensor circuit - low ground system
input • EOT sensor failure • Install a new
EOT sensor as
necessary.
Oil
Temperature
Sensor
(18.31.01)
P019800 Engine Oil Temperature • EOT sensor sensing • Carry out the
(EOT) sensor circuit - high circuit - short to pinpoint tests
input power, high associated with
disconnected the
• EOT sensor failure manufacturer
approved
diagnostic
system
• Install a new
EOT sensor as
necessary.
Oil
Temperature
Sensor
(18.31.01)
• Carry out the

pinpoint tests
associated with
this DTC using
the
• Injector circuit - short
manufacturer
to ground, high
approved
Cylinder 1 injector circuit - resistance,
P020100 diagnostic
malfunction disconnected
system
• Injector failure
• Install a new
injector as
necessary.
Fuel Injector
(18.10.01)
• Carry out the

pinpoint tests
associated with
this DTC using
the
manufacturer
to ground, high
approved
P020200 diagnostic
system
• Install a new
injector as
necessary.
Fuel Injector
(18.10.01)
• Injector circuit - short • Carry out the

Cylinder 3 injector circuit -
P020300 to ground, high pinpoint tests
malfunction
resistance, associated with
disconnected this DTC using
• Injector failure the
manufacturer
approved
diagnostic
system
• Install a new
injector as
necessary.
Fuel Injector
(18.10.01)
• Carry out the

pinpoint tests
associated with
this DTC using
the
manufacturer
to ground, high
approved
P020400 diagnostic
system
• Install a new
injector as
necessary.
Fuel Injector
(18.10.01)
• Carry out the

pinpoint tests
associated with
this DTC using
the
manufacturer
to ground, high
approved
P020500 diagnostic
system
• Install a new
injector as
necessary.
Fuel Injector
(18.10.01)
• Carry out the

pinpoint tests
to ground, high
associated with
P020600 this DTC using
the
manufacturer
approved
diagnostic
system
• Install a new
injector as
necessary.
Fuel Injector
(18.10.01)
• Carry out the

pinpoint tests
associated with
this DTC using
the
manufacturer
to ground, high
approved
P020700 diagnostic
system
• Install a new
injector as
necessary.
Fuel Injector
(18.10.01)
• Carry out the

pinpoint tests
associated with
this DTC using
the
manufacturer
to ground, high
approved
P020800 diagnostic
system
• Install a new
injector as
necessary.
Fuel Injector
(18.10.01)
• Carry out the

pinpoint tests
associated with
this DTC using
circuit TP 2 - short to
Throttle Position (TP) the
ground, high
P022200 sensor circuit TP 2 - low manufacturer
resistance
input approved
diagnostic
system
• Install a new
throttle body as
necessary.
Throttle Body
(19.70.04)
• Carry out the

pinpoint tests
associated with
this DTC using
the
Throttle Position (TP) circuit TP 2- short to approved
P022300 sensor circuit TP 2 - high power diagnostic
input • TP sensor failure system
• Install a new
throttle body as
necessary.
Throttle Body
(19.70.04)
• Carry out the

pinpoint tests
associated with
• APP sensor circuit
this DTC using
Accelerator Pedal Position APP 1 - short to
the
P022700 (APP) sensor circuit APP 1 ground, high
manufacturer
- low input resistance
approved
diagnostic
system
• Carry out the

pinpoint tests
associated with
• APP sensor circuit this DTC using
Accelerator pedal position
APP 1 - short to the
P022800 (APP) sensor circuit APP 1
power manufacturer
high input
approved
diagnostic
system
• Carry out the

pinpoint tests
• Post supercharger associated with
Turbocharger/Supercharger MAP sensor circuit - this DTC using
P023700 Boost Sensor A Circuit short to ground, high the
Low resistance manufacturer
approved
diagnostic
system. Refer
to electrical
circuit diagrams
and check Post
supercharger
MAP sensor
circuit for short
to ground, high
resistance
• Carry out the

pinpoint tests
associated with
this DTC using
the
manufacturer
approved
• Post supercharger
Turbocharger/Supercharger diagnostic
MAP sensor circuit -
P023800 Boost Sensor A Circuit system. Refer
short to power
High to electrical
circuit diagrams
and check Post
supercharger
MAP sensor
circuit for short
to power
• Carry out the

pinpoint tests
associated with
• Charge air cooler
this DTC using
coolant pump relay
Charge Air Cooler Coolant the
P023B13 control circuit - open
Pump Control Circuit Low manufacturer
circuit
approved
diagnostic
system
• Carry out the

pinpoint tests
associated with
• Charge air cooler
this DTC using
coolant pump relay
Charge Air Cooler Coolant the
P023C12 control circuit - short
Pump Control Circuit High manufacturer
to power
approved
diagnostic
system
Random/multiple cylinder • ECM to ignition coil • If specific

P030000
misfire detected primary circuit faults cylinder misfire
(cylinder misfire or injector
detected DTCs also DTCs are also
logged) logged refer to
• Fuel injector circuit the tests
fault(s) (injector associated to
DTCs also logged) those DTCs
• Ignition coil failure first
• Spark plug • For ignition
failure/fouled/incorrec coil test.
t gap Engine
• Fuel delivery pressure Ignition
(low/high) • Check and
• Fuel contamination install new
• Fuel injectors sparkplugs as
restricted, leaking, necessary.
continuously open Spark Plugs -
• Cylinder compression 4.2L SC V8 -
low AJV8
• Worn (18.20.02)
camshaft/broken valve • For fuel system
springs tests.
• Valve clearance Fuel Tank and
adjustment Lines
• For injector
tests.
Fuel Charging
and Controls
• Check cylinder
compressions.
Engine
• Check for
worn/broken
engine
components
and valve
clearance
adjustment.
Engine
Valve
Clearance
Adjustment
(12.29.48)
• Refer to
Refer to P030000 possible P030000
P030100 Cylinder 1 misfire detected
causes actions
Refer to P030000 possible • Refer to

causes P030000
actions
• Refer to
causes actions
• Refer to
causes actions
• Refer to
causes actions
• Refer to
causes actions
• Refer to
causes actions
• Refer to
causes actions
• Check for fuel

level sensor
DTCs and refer
• Misfire detected
to DTC Index
Misfire detected with low during low fuel level
P031300 • Add fuel, clear
fuel condition
the DTC and
test for normal
operation
• Check for
specific
• Misfire detected on cylinder misfire
Engine misfire detected on
P031600 first 1000 revs DTCs and refer
startup
to the DTC
Index
• Poor sensor contact • Ensure a good

with the cylinder electrical
Knock sensor (KS) 1
P032700 block contact with the
circuit - low input (bank 1)
• KS circuit - short to cylinder block
ground • Carry out the
• KS failure pinpoint tests
associated with
this DTC using
the
manufacturer
approved
diagnostic
system
• Install a new
KS as
necessary.
Knock Sensor
(KS)
(18.30.69)
• Ensure a good
electrical
contact with the
cylinder block
• Carry out the
pinpoint tests
• Poor sensor contact associated with
with the cylinder this DTC using
block the
Knock sensor (KS) 1 • KS circuit - high manufacturer
P032800
circuit - high input (bank 1) resistance, short to approved
power diagnostic
• KS failure system
• Install a new
KS as
necessary.
Knock Sensor
(KS)
(18.30.69)
• Ensure a good
electrical
contact with the
cylinder block
• Poor sensor contact
• Carry out the
with the cylinder
pinpoint tests
block
Knock sensor (KS) 2 associated with
P033200 • KS circuit - short to
circuit - low input (bank 2) this DTC using
ground
the
• KS failure
manufacturer
approved
diagnostic
system
• Install a new
KS as
necessary.
Knock Sensor
(KS)
(18.30.69)
• Ensure a good
electrical
contact with the
cylinder block
• Carry out the
pinpoint tests
• Poor sensor contact associated with
with the cylinder this DTC using
block the
Knock sensor (KS) 2 • KS circuit - high manufacturer
P033300
circuit - high input (bank 2) resistance, short to approved
power diagnostic
• KS failure system
• Install a new
KS as
necessary.
Knock Sensor
(KS)
(18.30.69)
• Carry out the

pinpoint tests
associated with
this DTC using
the
manufacturer
• CKP sensor circuit -
approved
diagnostic
to power, high
system
resistance,
• Check CKP
Crankshaft Position (CKP) disconnected
sensor for
sensor circuit - • CKP sensor gap
P033592 damage and
performance or incorrect incorrect, foreign
check air gap
operation matter on sensor face,
(check at 90°
damaged teeth on
intervals,
rotor
should be no
• CKP sensor failure
greater than
4.5mm)
• Install a new
CKP sensor as
necessary.
Crankshaft
Position (CKP)
Sensor
(18.30.12)
• Carry out the

pinpoint tests
associated with
this DTC using
the
manufacturer
approved
• CKP sensor circuit - diagnostic
short to ground, short system
to power, high • Check CKP
resistance, sensor for
disconnected damage and
Crankshaft Position (CKP)
• CKP sensor gap check air gap
P033594 sensor circuit - unexpected
incorrect, foreign (check at 90°
operation
matter on sensor face, intervals,
damaged teeth on should be no
rotor greater than
• CKP sensor failure 4.5mm)
• Install a new
CKP sensor as
necessary.
Crankshaft
Position (CKP)
Sensor
(18.30.12)
• Carry out the

pinpoint tests
associated with
this DTC using
• CKP sensor circuit - the
short to ground, short manufacturer
to power, high approved
resistance, diagnostic
disconnected system
Crankshaft Position (CKP)
• CKP sensor gap • Check CKP
incorrect, foreign sensor for
range/performance
matter on sensor face, damage and
damaged teeth on check air gap
rotor (check at 90°
• CKP sensor failure intervals,
should be no
greater than
4.5mm)
• Install a new
CKP sensor as
necessary.
Crankshaft
Position (CKP)
Sensor
(18.30.12)
• Carry out the

pinpoint tests
associated with
this DTC using
the
manufacturer
• CMP sensor circuit -
approved
diagnostic
to power, high
system
resistance,
Camshaft Position (CMP) • Check CMP
disconnected
sensor circuit (bank 1) - sensor for
P034092 • CMP sensor gap
performance or incorrect correct
incorrect, foreign
operation installation and
matter on sensor face,
damage
damaged rotor
• Install a new
• CMP sensor failure
CMP sensor as
necessary.
Camshaft
Position (CMP)
Sensor RH
(18.31.11)
• Carry out the

pinpoint tests
associated with
this DTC using
the
manufacturer
approved
to power, high
diagnostic
resistance,
system
Camshaft Position (CMP) disconnected
• Check CMP
P034094 sensor circuit (bank 1) - • CMP sensor gap
sensor for
unexpected operation incorrect, foreign
correct
installation and
damaged rotor
damage
• Install a new
CMP sensor as
necessary.
Camshaft
Position (CMP)
Sensor RH
(18.31.11)
• Carry out the

pinpoint tests
associated with
this DTC using
the
manufacturer
approved
diagnostic
to power, high
system
resistance,
• Check CMP
sensor for
correct
range/performance incorrect, foreign
installation and
damage
damaged rotor
• Install a new
CMP sensor as
necessary.
Camshaft
Position (CMP)
Sensor RH
(18.31.11)
• Carry out the

pinpoint tests
associated with
this DTC using
the
manufacturer
approved
diagnostic
to power, high
system
resistance,
Camshaft Position (CMP) • Check CMP
disconnected
sensor circuit (bank 2) - sensor for
performance or incorrect correct
incorrect, foreign
operation installation and
damage
damaged rotor
• Install a new
CMP sensor as
necessary.
Camshaft
Position (CMP)
Sensor LH
(18.31.12)
Camshaft Position (CMP) • CMP sensor circuit - • Carry out the

P034594 sensor circuit (bank 2) - short to ground, short pinpoint tests
unexpected operation to power, high associated with
disconnected the
• CMP sensor gap manufacturer
incorrect, foreign approved
matter on sensor face, diagnostic
damaged rotor system
• CMP sensor failure • Check CMP
sensor for
correct
installation and
damage
• Install a new
CMP sensor as
necessary.
Camshaft
Position (CMP)
Sensor LH
(18.31.12)
• Carry out the

pinpoint tests
associated with
this DTC using
the
manufacturer
approved
diagnostic
to power, high
system
resistance,
• Check CMP
sensor for
correct
range/performance incorrect, foreign
installation and
damage
damaged rotor
• Install a new
CMP sensor as
necessary.
Camshaft
Position (CMP)
Sensor LH
(18.31.12)
• Carry out the

pinpoint tests
associated with
circuits - short to
Ignition coil 1 this DTC using
P035100 ground, power, high
primary/secondary circuit the
resistance
manufacturer
approved
diagnostic
system
• Carry out the

pinpoint tests
associated with
this DTC using
circuits - short to
Ignition coil 2 the
primary/secondary circuit manufacturer
resistance
approved
diagnostic
system
• Carry out the

pinpoint tests
associated with
this DTC using
circuits - short to
Ignition coil 3 the
resistance
approved
diagnostic
system
• Carry out the

pinpoint tests
associated with
this DTC using
circuits - short to
Ignition coil 4 the
resistance
approved
diagnostic
system
• Carry out the

pinpoint tests
associated with
this DTC using
circuits - short to
Ignition coil 5 the
resistance
approved
diagnostic
system
• Carry out the

pinpoint tests
circuits - short to
Ignition coil 6 associated with
primary/secondary circuit this DTC using
resistance
the
manufacturer
approved
diagnostic
system
• Carry out the

pinpoint tests
associated with
this DTC using
circuits - short to
Ignition coil 7 the
resistance
approved
diagnostic
system
• Carry out the

pinpoint tests
associated with
this DTC using
circuits - short to
Ignition coil 8 the
resistance
approved
diagnostic
system
• EGR valve incorrectly

• For EGR
installed or loose
system tests.
Exhaust Gas Recirculation • EGR pipe blocked
Engine
P040100 (EGR) flow insufficient • EGR valve stuck
Emission
detected closed, blocked
Control
• EGR valve failure
• Carry out the

pinpoint tests
associated with
this DTC using
Secondary Air Injection • AIR check valve
the
P041300 (AIR) switching valve control circuit high
manufacturer
circuit open
approved
diagnostic
system
• Carry out the

pinpoint tests
Secondary Air Injection • AIR check valve associated with
P041400 (AIR) switching valve control circuit low this DTC using
circuit shorted the
manufacturer
approved
diagnostic
system
• Check for
misfire/lean
• Catalyst failure due to
combustion
overheating damage
DTCs and refer
caused by misfire
to DTC Index
and/or lean
in this section
combustion
Catalyst system efficiency • Check the oil
P042000 • Catalyst failure due to
below threshold (bank 1) and fuel
poisoning caused by
condition/level.
excessive oil
Check the
consumption and/or
catalytic
contaminated fuel
converter for
damage
• Check for
misfire/lean
combustion
overheating damage
DTCs and refer
caused by misfire
to DTC Index
and/or lean
in this section
combustion
Catalyst system efficiency • Check the oil
P043000 • Catalyst failure due to
below threshold (bank 2) and fuel
poisoning caused by
condition/level.
excessive oil
Check the
consumption and/or
catalytic
contaminated fuel
converter for
damage
• Carry out the

pinpoint tests
associated with
this DTC using
Evaporative Emission • Purge valve -
the
P044100 (EVAP) system incorrect range/performance
manufacturer
purge flow
approved
diagnostic
system
• Carry out the

pinpoint tests
Evaporative Emission • DMTL COV circuit - associated with
P044700 (EVAP) system vent short to ground this DTC using
control circuit open the
manufacturer
approved
diagnostic
system
• Carry out the

pinpoint tests
associated with
this DTC using
Evaporative Emission • DMTL COV circuit -
the
P044800 (EVAP) system vent short to power
manufacturer
control circuit shorted
approved
diagnostic
system
• For evaporative
Evaporative Emission • DMTL system has emissions tests.
P045600 (EVAP) system leak detected a leak Evaporative
detected (very small leak) Emissions
• Carry out the

pinpoint tests
associated with
this DTC using
the
• EVAP canister purge
manufacturer
valve control circuit -
approved
Evaporative Emission short to ground, high
diagnostic
P045800 (EVAP) canister purge resistance
system
valve circuit low • EVAP canister purge
• Install a new
valve failure
EVAP canister
purge valve as
necessary.
Evaporative
Emissions
• Carry out the

pinpoint tests
associated with
• EVAP canister purge this DTC using
Evaporative Emission
valve control circuit - the
P045900 (EVAP) canister purge
short to power manufacturer
valve circuit high
approved
diagnostic
system
• For fuel level

• Fuel level sensor
Fuel level sensor A circuit - sensor pinpoint
P046129 failure
range/performance - stuck tests for this
DTC.
Fuel Tank and
Lines
• For fuel level

sensor pinpoint
Fuel level sensor A circuit - • Fuel level sensor tests for this
P04612F range/performance - signal failure DTC.
erratic Fuel Tank and
Lines
• For fuel level

sensor pinpoint
• Fuel level sensor tests for this
Fuel level sensor A circuit -
P046200 failure DTC.
low input
Fuel Tank and
Lines
• For fuel level

sensor pinpoint
• Fuel level sensor tests for this
Fuel level sensor A circuit -
P046300 failure DTC.
high input
Fuel Tank and
Lines
• Carry out the

pinpoint tests
associated with
• Electric fan control
this DTC using
circuit - short to
the
P048023 Fan 1 control circuit low ground, high
manufacturer
resistance
approved
diagnostic
system
• Carry out the

pinpoint tests
associated with
• Electric fan control this DTC using
P048024 Fan 1 control circuit high
power manufacturer
approved
diagnostic
system
• Cooling fan difficult • Carry out the

to turn/obstructed pinpoint tests
• Fan/Motor damaged associated with
this DTC using
the
manufacturer
approved
diagnostic
system
• CLEAR any
obstruction and
INSTALL a
new fan as
necessary.
Cooling Fan
Motor and
Shroud -
Vehicles With:
Supercharger
(26.25.25)
• Carry out the

pinpoint tests
associated with
this DTC using
the
manufacturer
approved
• Fan control module
diagnostic
reports battery voltage
P048316 Fan rationality check system
less than nine volts
• CHECK the
battery
condition
• CHECK the
charging
system and fan
circuits
• Carry out the

pinpoint tests
associated with
this DTC using
the
• Fan control module manufacturer
reports battery voltage approved
greater than 18 volts diagnostic
system
• CHECK the
charging
system and fan
circuits
• Carry out the
pinpoint tests
associated with
this DTC using
the
manufacturer
approved
diagnostic
system
• CLEAR any
• Cooling fan jammed
P048397 Fan rationality check obstruction and
INSTALL a
new fan as
necessary.
Cooling Fan
Motor and
Shroud -
Vehicles With:
Supercharger
(26.25.25)
• Carry out the

pinpoint tests
associated with
• EGR valve power
this DTC using
supply circuit - short
Exhaust Gas Recirculation the
P048900 to ground, high
(EGR) control circuit low manufacturer
resistance
approved
diagnostic
system
• Carry out the

pinpoint tests
associated with
• EGR valve control this DTC using
Exhaust Gas Recirculation circuit - short to the
P049000
(EGR) control circuit high power manufacturer
approved
diagnostic
system
• Check ABS for

DTCs and refer
• Vehicle speed -
to DTC Index.
Vehicle speed sensor invalid signal received
P050082 Anti-Lock
malfunction over CAN
Control -
Stability Assist
• Check ABS for
DTCs and refer
• Vehicle speed -
to DTC Index.
Vehicle speed sensor invalid signal received
P050086 Anti-Lock
malfunction over CAN
Control -
Stability Assist
• Check for
ABS/TCM
DTCs and refer
to DTC Index
for speed
Vehicle speed sensor - • Vehicle speed - range
sensor tests.
P050162 range/performance - signal performance
Anti-Lock
plausibility failure
Control -
Stability Assist
Diagnostic
Strategy
• Carry out the

pinpoint tests
associated with
• The brake pressure
this DTC using
reading does not agree
Brake switch A/B the
P050400 with the brake light
correlation manufacturer
switch value
approved
diagnostic
system
• Brake switch high

fault: Brake lights • Carry out the
stuck on Gearshift pinpoint tests
interlock inoperative associated with
Speed control this DTC using
Brake switch A/B inoperative the
P050401
correlation • Brake switch low manufacturer
fault: Brake lights approved
inoperative Gearshift diagnostic
stuck in Park Reduced system
engine braking
• Air intake restriction • Ensure the air

• Front End Accessory intake system is
Drive (FEAD) free from
Idle air control system
P050600 overload restriction
RPM lower than expected
(defective/seized • Check the
component) FEAD belt and
components.
Accessory
Drive
• Ensure the air

intake system is
free from
restriction
Drive (FEAD)
Idle air control system • Check the
P050624 overload
RPM lower than expected FEAD belt and
(defective/seized
components.
component)
Accessory
Drive
• Check for
leakage and
correct
installation of
• Intake air leak air intake
between MAF sensor system
Idle air control system and engine • Check for
P050700
RPM higher than expected • Engine crankcase leakage and
breather leak correct
installation of
engine
crankcase
breather system
• Check for
leakage and
correct
installation of
• Intake air leak air intake
between MAF sensor system
Idle air control system and engine • Check for
P050723
RPM higher than expected • Engine crankcase leakage and
breather leak correct
installation of
engine
crankcase
breather system
• Check for any

• Cold start emission engine ignition
reduction strategy related DTCs
Cold start ignition timing
P050B84 engine spark timing also logged and
performance
too retarded refer to the
DTC Index
• Check for any
• Cold start emission engine ignition
reduction strategy related DTCs
Cold start ignition timing
P050B85 engine spark timing also logged and
performance
too advanced refer to the
DTC Index
• Carry out the

pinpoint tests
associated with
this DTC using
• Crank request circuit -
the
P05120C Starter request circuit high input
manufacturer
approved
diagnostic
system
• Carry out the

pinpoint tests
associated with
this DTC using
the
P05120E Starter request circuit low input
manufacturer
approved
diagnostic
system
• Check for CAN

network
interference/E
MC related
error. Re-
synchronise ID
• Security key invalid
P051300 Incorrect immobilizer key by re-
configuring the
ECM and
instrument
cluster as new
modules
• Carry out the

pinpoint tests
associated with
• Battery back-up
this DTC using
P056013 System voltage malfunction
the
manufacturer
approved
diagnostic
system
• Check for
sensor 5 volt
• System voltage supply related
P056100 System voltage unstable comparison DTCs and refer
to DTC Index
in this section
• Carry out the

pinpoint tests
associated with
• Sensor 5 volt power this DTC using
supply circuit - low the
P056200 System voltage low
input manufacturer
approved
diagnostic
system
• Carry out the

pinpoint tests
associated with
• Sensor 5 volt power this DTC using
supply circuit - high the
P056300 System voltage high
input manufacturer
approved
diagnostic
system
• Check speed
control system
• Speed control cancel
Speed control cancel button for DTCs and
P057501 button fault
fault refer to DTC
Index
• Check speed
control system
Speed control multi- • Active speed limiter
for DTCs and
P059000 function input B circuit fault
refer to DTC
stuck
Index
• Refer to new
module/compo
Internal control module • CPU communication -
nent installation
P060143 memory check sum error - sub
Note at top of
special memory failure
DTC Index
• Refer to new
module/compo
Internal control module
• CPU communication nent installation
P060145 memory check sum error -
Note at top of
program memory failure
DTC Index
• Refer to new
Internal control module module/compo
Random Access Memory • Initial RAM test nent installation
P060442
(RAM) error - general Note at top of
memory failure DTC Index
• Refer to new
Random Access Memory • Shut off RAM test nent installation
P060443
(RAM) error - special Note at top of
• Refer to new
Random Access Memory • RAM check sum nent installation
P060444
(RAM) error - data Note at top of
• Refer to new
Random Access Memory • Initial RAM test nent installation
P060445
(RAM) error - program Note at top of
• Configure the
module using
Internal control module • EEPROM/flash the Jaguar
P060500 Read Only Memory checksum error approved
(ROM) error diagnostic
system
• Refer to new
module/compo
• ROM error nent installation
P060529 Read Only Memory
Note at top of
(ROM) error
DTC Index
Internal control module • Refer to new

Read Only Memory • ROM check sum module/compo
P060542
(ROM) error - general nent installation
memory failure Note at top of
DTC Index
• Refer to new
Read Only Memory • Shut off ROM test nent installation
P060543
(ROM) error - special Note at top of
• Refer to new
Read Only Memory • Initial ROM test nent installation
P060544
(ROM) error - data Note at top of
• Refer to new
Read Only Memory • Continuous ROM test nent installation
P060545
(ROM) error - program Note at top of
• Refer to new
module/compo
• Continuous ROM test nent installation
Note at top of
(ROM) error
DTC Index
• Refer to new
Read Only Memory • Shut off ROM test nent installation
P060548
(ROM) error - supervision Note at top of
software failure DTC Index
• Refer to new
module/compo
• ROM error - sub nent installation
Note at top of
(ROM) error
DTC Index
• Refer to new
module/compo
• Watchdog error nent installation
P060600 ECM/PCM processor fault
Note at top of
DTC Index
• Refer to new
ECM/PCM processor fault • Controller test - sub
P060601 module/compo
- general electrical failure
nent installation
Note at top of
DTC Index
• Refer to new
module/compo
• System internal
nent installation
P060604 ECM/PCM processor fault failures
Note at top of
DTC Index
• Refer to new
• Throttle return spring module/compo
ECM/PCM processor fault
failure (throttle body nent installation
P060605 - system programming
failure) Note at top of
failures
DTC Index
• Refer to new
module/compo
• Watch dog timer fault
ECM/PCM processor fault nent installation
P060641 - sub
- general checksum failure Note at top of
DTC Index
• Refer to new
module/compo
• Error capturing
P060642 instructions
- general memory failure Note at top of
DTC Index
• Refer to new
module/compo
• Duplication memory
P060643 fault
- special memory failure Note at top of
DTC Index
• Refer to new
module/compo
• Duplication memory
P060644 fault - sub
- data memory failure Note at top of
DTC Index
• Refer to new
module/compo
• Detection of write to
P060645 internal ROM
- program memory failure Note at top of
DTC Index
ECM/PCM processor fault • Configure the

P060646 • Detection of write to
- calibration/parameter module using
memory failure internal ROM - sub the Jaguar
approved
diagnostic
system
• Configure the
module using
the Jaguar
• Watch dog timer fault
P060647 ECM/PCM processor fault approved
diagnostic
system
• Configure the
module using
ECM/PCM processor fault • Scheduling sequence the Jaguar
P060648 - supervision software check approved
failure diagnostic
system
• Refer to new
module/compo
ECM/PCM processor fault • Controller test nent installation
P060649
- internal electronic failure Note at top of
DTC Index
• Refer to new
module/compo
Control module • Sub - CPU watch dog nent installation
P060700
performance Note at top of
DTC Index
• Carry out the

pinpoint tests
associated with
this DTC using
• APS Communication the
P060D00 accelerator pedal position
manufacturer
performance
approved
diagnostic
system
• Refer to new
• Throttle motor
amplifier failure for
throttle position nent installation
P060E62 valve sensor
performance - signal Note at top of
malfunction
compare failure DTC Index
• Refer to new
throttle position • TPS Communication nent installation
P060E64
performance - signal Note at top of
plausibility failure DTC Index
• Clear the DTC

and retest. If
• Internal control the DTC resets,
Internal control module module monitoring refer to new
P060A64 monitoring processor processor module/compo
performance performance nent installation
Note at top of
DTC Index
• Clear the DTC

and retest. If
• Internal control the DTC resets,
Internal control module module monitoring refer to new
P060A67 monitoring processor processor module/compo
performance performance nent installation
Note at top of
DTC Index
• Re-configure
the RJB using
the
• Car configuration data
Control module vehicle manufacturer
P061000 mismatch
options error approved
diagnostic
system
• Refer to new
module/compo
Internal control module • Pedal follower error nent installation
P061A00
torque performance Note at top of
DTC Index
• Refer to new
• Absolute engine module/compo
torque calculation nent installation
P061A29 torque performance - signal
failure - sub-processor Note at top of
invalid
DTC Index
• Absolute engine • Refer to new

torque calculation module/compo
P061A64 torque performance - signal
failure nent installation
Note at top of
DTC Index
• Refer to new
Internal control module • Absolute and dynamic module/compo
torque calculation engine torque nent installation
P061B29
performance - signal calculation failure Note at top of
invalid DTC Index
• Refer to new
Internal control module • Absolute and dynamic module/compo
torque calculation engine torque nent installation
P061B64
performance - signal calculation failure Note at top of
plausibility failure DTC Index
• Refer to the
electrical circuit
diagrams and
• Fuel pump control check the
Fuel pump A control circuit fault (FPDM to FPDM to Fuel
P062700
circuit/open fuel pump) Pump circuit
for short to
ground, power,
open circuit
• Refer to the
electrical circuit
diagrams and
• Invalid fuel pump test the ECM to
Fuel pump A control duty requested by the FPDM monitor
P062A00
circuit range/performance ECM circuit for short
to ground,
power, open
circuit
• Configure the
module using
the Jaguar
approved
diagnostic
system, clear
• CCF to CAN VIN
VIN not programmed or DTC and re-
P063000 mismatch
incompatible - ECM/PCM test, if DTC
remains suspect
the ECM. Refer
to the new
module/compo
nent installation
note at the top
of the DTC
Index
• Carry out the

pinpoint tests
associated with
this DTC using
• EMS control relay
EMS control relay control the
P068773 malfunction
circuit high manufacturer
approved
diagnostic
system
• For
• TCM Output shaft transmission
Output speed sensor circuit speed sensor error tests.
P072186
range/performance received Diagnostic
Strategy
• Carry out the

pinpoint tests
associated with
this DTC using
• Starter relay circuit
Starter relay circuit (break the
P08170D (break wire)
wire) manufacturer
approved
diagnostic
system
• Carry out the

pinpoint tests
associated with
this DTC using
the
P081A0B Starter relay circuit low low
manufacturer
approved
diagnostic
system
• Carry out the

pinpoint tests
associated with
this DTC using
P081B0C Starter relay circuit high high
the
manufacturer
approved
diagnostic
system
• Carry out the

pinpoint tests
associated with
this DTC using
• Park/Neutral switch
Park/Neutral switch input the
P08510E input circuit - low
circuit low manufacturer
approved
diagnostic
system
• Carry out the

pinpoint tests
associated with
this DTC using
Park/Neutral switch input the
P08520C input circuit - high
circuit high manufacturer
approved
diagnostic
system
• Carry out the

pinpoint tests
associated with
Intercooler air the
sensor diagnostic
system. Refer
to electrical
Range/Performance
circuit - short, open Intercooler air
circuit temperature
sensor circuit
for short, open
circuit
NOTE: • Carry out the

Intercooler air pinpoint tests
temperature sensor is associated with
integral to primary MAP this DTC using
sensor the
Range/Performance
manufacturer
approved
• Intercooler air diagnostic
temperature sensor system. Refer
circuit - short, open to electrical
circuit circuit diagrams
and check
Intercooler air
temperature
sensor circuit
for short, open
circuit
• Carry out the

pinpoint tests
associated with
Intercooler air the
sensor diagnostic
system. Refer
to electrical
Range/Performance
circuit - short, open Intercooler air
circuit temperature
sensor circuit
for short, open
circuit
• Re-configure
the instrument
cluster using
• Incorrect ID received
the
Immobilizer to ECM signal from instrument
P125900 manufacturer
error cluster
approved
diagnostic
system
• ECM to ignition coil • Check for

primary circuit fault cylinder mis-
(cylinder misfire fire, ignition
detected DTC also and injector
flagged) DTCs and refer
• Fuel injector circuit to the DTC
fault(s) (injector Index
DTCs also flagged) • For fuel system
• Fuel delivery pressure tests.
low Fuel Tank and
• Spark plug Lines
failure/fouled/incorrec • For spark plug
t gap tests.
• Cylinder compression Engine
low Ignition
• For cylinder
compression
tests.
Engine
• Check for
individual
• Misfire rate exceeds cylinder misfire
Misfire rate exceeds
P131600 emissions thresholds DTCs and refer
emissions thresholds
to DTC Index
in this section
• Carry out the

pinpoint tests
• Ignition module/coil associated with
monitoring circuit - this DTC using
short to ground, short the
P136700 Ignition amplifier group A
to power, high manufacturer
resistance approved
diagnostic
system
• Carry out the

pinpoint tests
• Ignition module/coil associated with
monitoring circuit - this DTC using
short to ground, short the
P136800 Ignition amplifier group B
to power, high manufacturer
resistance approved
diagnostic
system
• Refer to new
module/compo
• ECM fault nent installation
P160300 EEPROM error
note at top of
DTC Index
• Suspect the
ECM, refer to
ECM electronic throttle • Dynamic torque
new
P162600 monitoring/self test - monitoring error
module/compo
torque monitoring problem
nent installation
note at top of
DTC Index
• Check integrity
and correct
installation of
air intake
• Heated Oxygen system
Sensor (HO2S) fuel • Check for any
P209600 Fuel trim too lean, bank 1
adaption - lean HO2S codes
also logged and
refer to DTC
Index in this
section
• Check integrity
and correct
installation of
air intake
P209700 Fuel trim too rich, bank 1
adaption - rich HO2S codes
also logged and
refer to DTC
Index in this
section
• Check integrity
and correct
installation of
air intake
P209800 Fuel trim too lean, bank 2
adaption - lean HO2S codes
also logged and
refer to DTC
Index in this
section
• Check integrity
and correct
installation of
• Heated Oxygen air intake
Sensor (HO2S) fuel system
P209900 Fuel trim too rich, bank 2
adaption - rich • Check for any
HO2S codes
also logged and
refer to DTC
Index in this
section
• Carry out the

pinpoint tests
associated with
this DTC using
the
manufacturer
approved
diagnostic
• Jammed throttle
Throttle actuator control system
blade, gearing or
P210129 motor circuit • Install a new
motor
range/performance throttle body.
Refer to the
new
module/compo
nent installation
note at the top
of the DTC
Index
• Refer to the
electrical circuit
diagrams and
test throttle
actuator control
motor circuit
for short to
ground, power,
high resistance.
• Jammed throttle
Throttle actuator control Compare
blade, gearing or
P210162 motor circuit throttle position
motor
range/performance sensor 1 and 2
datalogger
signals, if
signals are
comparable
install a new
throttle body.
Throttle Body
(19.70.04)
• Carry out the

pinpoint tests
• Jammed throttle
Throttle actuator control associated with
blade, gearing or
P210164 motor circuit this DTC using
motor
range/performance the
manufacturer
approved
diagnostic
system
• Install a new
throttle body.
Refer to the
new
module/compo
nent installation
note at the top
of the DTC
Index
• Check for
throttle related
DTCs and refer
• Throttle blade stuck
Throttle actuator motor to DTC Index
open
P210177 control circuit in this section
• Intake air system leak
range/performance • Check intake
air system for
leaks
• Carry out the

pinpoint tests
associated with
this DTC using
the
• Throttle motor control manufacturer
Throttle actuator motor
P210329 power diagnostic
• ECM fault system
• Refer to new
module/compo
nent installation
note at top of
DTC Index
• Carry out the

pinpoint tests
associated with
this DTC using
• Throttle motor control the
Throttle actuator motor circuit - short to manufacturer
P210364 control circuit high - signal power approved
plausibility failure • ECM fault diagnostic
system
• Refer to new
module/compo
nent installation
note at top of
DTC Index
• Carry out the

pinpoint tests
associated with
this DTC using
Throttle actuator control • Throttle MIL request
the
P210500 system - forced engine due to fuel cut
manufacturer
shutdown
approved
diagnostic
system
• Install a new
throttle body.
Throttle Body
(19.70.04)
Throttle actuator control
• Signal invalid Refer to new
P210629 system - forced limited
module/compo
power
nent installation
note at top of
DTC Index
• Install a new
throttle body.
Throttle Body
(19.70.04)
Throttle actuator control • Signal plausibility
Refer to new
P210664 system - forced limited failure
module/compo
power
nent installation
note at top of
DTC Index
• Carry out the

pinpoint tests
associated with
this DTC using
Throttle actuator motor circuit - short to
the
P211800 control current ground, power, high
manufacturer
range/performance resistance
approved
diagnostic
system
• Install a new
throttle body.
Throttle actuator control
• Throttle spring faulty Throttle Body
P211900 throttle body
(19.70.04)
range/performance
Refer to new
module/compo
nent installation
note at top of
DTC Index
• Carry out the

pinpoint tests
associated with
this DTC using
Accelerator pedal position • APP sensor circuit 2 -
the
P212200 (APP) sensor D circuit low low input
manufacturer
input
approved
diagnostic
system
• Carry out the

pinpoint tests
associated with
this DTC using
Accelerator pedal position • APP sensor circuit 2 -
the
P212300 (APP) sensor D circuit high high input
manufacturer
input
approved
diagnostic
system
• Check APP
sensor circuits
1 and 2 for
short to ground,
• APP sensor circuit 1 power and high
Accelerator pedal position and 2 range resistance.
P213528 (APP) sensor 1 and 2 performance - sub- Clear the DTCs
voltage correlation processor and retest. If
the code
remains,
replace the APP
sensor
• Carry out the

pinpoint tests
• APP sensor - associated with
excessive difference this DTC using
between raw values of the
P213529 (APP) sensor 1 and 2
circuit 1 and 2 - sub- manufacturer
voltage correlation
processor approved
diagnostic
system
P213562 Accelerator pedal position • APP sensor circuit 1 • Check APP

(APP) sensor 1 and 2 and 2 range sensor circuits
voltage correlation performance - sub- 1 and 2 for
processor short to ground,
power and high
resistance.
Clear the DTCs
and retest. If
the code
remains,
replace the APP
sensor
• Carry out the

pinpoint tests
associated with
• APP sensor circuit 1 this DTC using
and 2 range the
P213564 (APP) sensor 1 and 2
performance manufacturer
voltage correlation
approved
diagnostic
system
• Refer to new
module/compo
• BARO sensor failure
Barometric pressure circuit nent installation
P222800 (internal ECM fault)
low input note at top of
DTC Index
• Refer to new
module/compo
• BARO sensor failure
Barometric pressure circuit nent installation
P222900 (internal ECM fault)
high input note at top of
DTC Index
• Carry out the

pinpoint tests
associated with
Evaporative emission this DTC using
(EVAP) system leak the
P240100 short to ground
detection pump control manufacturer
circuit low approved
diagnostic
system
Evaporative emission • Carry out the

(EVAP) system leak pinpoint tests
P240200 short to power
detection pump control associated with
circuit high this DTC using
the
manufacturer
approved
diagnostic
system

• For evaporative
Evaporative emission emissions
short to ground,
(EVAP) system leak system tests.
P240429 power, high resistance
detection pump sensing Evaporative
• DMTL pipework
circuit range/performance Emissions
blocked/leaking

• For evaporative
Evaporative emission • DMTL pump circuit -
emissions
(EVAP) system leak short to ground,
system tests.
P24042F detection pump sensing power, high resistance
Evaporative
circuit range/performance - • DMTL pipework
Emissions
signal erratic blocked/leaking
• For evaporative
Evaporative emission • DMTL pump circuit - emissions
(EVAP) system leak short to ground, system tests.
P240500
detection pump sensing power, high resistance Evaporative
circuit low Emissions
• For evaporative
Evaporative emission • DMTL pump circuit - emissions
(EVAP) system leak short to ground, system tests.
P240600
detection pump sensing power, high resistance Evaporative
circuit high Emissions
• Carry out the

pinpoint tests
associated with
Evaporative emission this DTC using
(EVAP) system leak the
P240B00 circuit low
detection pump heater manufacturer
diagnostic
system
• Carry out the

Evaporative emission pinpoint tests
(EVAP) system leak associated with
detection pump heater this DTC using
circuit high the
manufacturer
approved
diagnostic
system
• Check the
secondary air
injection
system for
• Secondary air leaks
injection system leaks • Carry out the
Secondary air injection
• Secondary air pinpoint tests
manifold absolute pressure
P243100 injection pump associated with
sensor circuit
• Secondary air this DTC using
range/performance
injection valve the
manufacturer
approved
diagnostic
system
• Carry out the

pinpoint tests
• Secondary air
associated with
injection manifold
this DTC using
Secondary air injection absolute pressure
the
P243200 manifold absolute pressure sensor circuit - short
manufacturer
sensor circuit low to ground, high
approved
resistance
diagnostic
system
• Carry out the

pinpoint tests
• Secondary air associated with
injection manifold this DTC using
Secondary air injection
pressure (MAP) the
P243300 manifold absolute pressure
sensor circuit - short manufacturer
sensor circuit high
to power approved
diagnostic
system
• Carry out the

pinpoint tests
• Secondary air
associated with
injection pump
Secondary air injection this DTC using
P244400 control circuit - short
system pump stuck ON the
to ground
manufacturer
approved
diagnostic
system
• Carry out the

pinpoint tests
associated with
• Secondary air
this DTC using
injection pump
Secondary air injection the
P244500 control circuit - short
system pump stuck OFF manufacturer
to power
approved
diagnostic
system
• Carry out the

pinpoint tests
associated with
Evaporative emission • DMTL system circuit this DTC using
(EVAP) system change- - short to ground, the
P245000
over valve (COV) power, high resistance manufacturer
performance/stuck open approved
diagnostic
system
• Carry out the

pinpoint tests
associated with
Evaporative emission • DMTL system circuit this DTC using
(EVAP) system change- - short to ground, the
P245100
over valve (COV) power, high resistance manufacturer
performance/stuck closed approved
diagnostic
system
• Carry out the

pinpoint tests
associated with
this DTC using
the
manufacturer
• Coolant Pump Control
approved
Coolant Pump Control Circuit
P260100 diagnostic
Circuit Range/Performance Range/Performance
system. Refer
to electrical
circuit diagrams
and check
coolant pump
control circuit
for short, open
circuit
• Check for
DTCs
• ECT sensor fault
indicating a
• Ambient temperature
fault with any
sensor fault
ECM/PCM Internal engine of the
P261064 • Body processor
off timer performance components
module fault (time)
listed, and refer
• CAN error
to relevant
DTC Index
• Check for
DTCs
indicating a
fault with any
sensor fault
ECM/PCM Internal engine of the
P261087 • Body processor
off timer performance components
module fault (time)
listed, and refer
• CAN error
to relevant
DTC Index
• Carry out the

pinpoint tests
associated with
this DTC using
• CAN Link circuit
Control module the
U007300 malfunction
communication bus off manufacturer
approved
diagnostic
system
• Carry out the

pinpoint tests
associated with
• CAN Link this DTC using
Lost communication with ECM/TCM network the
U010100
TCM malfunction manufacturer
approved
diagnostic
system
• Carry out the

• CAN Link ECM/gear pinpoint tests
Lost communication with shift network associated with
U010300
gear shift control module malfunction this DTC using
the
manufacturer
approved
diagnostic
system
• Carry out the

pinpoint tests
associated with
• CAN Link
this DTC using
ECM/speed control
Lost communication with the
U010400 module network
speed control module manufacturer
malfunction
approved
diagnostic
system
• Carry out the

pinpoint tests
associated with
• CAN Link ECM/ABS this DTC using
Lost communication with
module network the
U012100 anti-lock brake system
malfunction manufacturer
(ABS) control module
approved
diagnostic
system
• Carry out the

pinpoint tests
• CAN Link associated with
ECM/Electronic this DTC using
parking brake signal the
U012800 electronic parking brake
missing network manufacturer
control module
malfunction approved
diagnostic
system
• Carry out the

pinpoint tests
associated with
this DTC using
Lost communication with • Lost communication -
the
U015100 restraints control CAN or hardwired
manufacturer
module/inertia switch
approved
diagnostic
system
• Carry out the

pinpoint tests
U01511F restraints control SRS fault
associated with
this DTC using
the
manufacturer
approved
diagnostic
system
• Carry out the

pinpoint tests
associated with
this DTC using
the
U015157 restraints control CAN fault
manufacturer
approved
diagnostic
system
• Carry out the

pinpoint tests
associated with
• CAN Link
this DTC using
ECM/instrument
U015500 cluster network
instrument cluster manufacturer
malfunction
approved
diagnostic
system
• Carry out the

pinpoint tests
associated with
this DTC using
• Security challenge
U016700 response timeout
vehicle immobilizer manufacturer
approved
diagnostic
system
• Check TCM for

DTCs and refer
Invalid data received from • TCM engine speed
to DTC Index.
U040208 Transmission Control control monitor
Diagnostic
Module (TCM)
Strategy
• Check TCM for

DTCs and refer
Invalid data received from • Actual gear position
to DTC Index.
U040264 Transmission Control status
Diagnostic
Module (TCM)
Strategy
• Check TCM for
DTCs and refer
Invalid data received from • Selector lever position
to DTC Index.
U040267 Transmission Control status
Diagnostic
Module (TCM)
Strategy
• Check TCM for

DTCs and refer
Invalid data received from • Output shaft speed
to DTC Index.
U040281 Transmission Control signal
Diagnostic
Module (TCM)
Strategy
Check the transmission

control module for
related stored DTCs.
Using the manufacturer
approved diagnostic
system, complete a
CAN network integrity
Invalid Data Received • CAN Bus circuit fault
test. Refer to the
From Transmission Control • Circuit fault in supply
electrical circuit
Module - TCM engine voltage to
U040282 diagrams and check the
speed control monitor - transmission control
CAN network to the
plausibility (TCM alive module
transmission control
counter)
module. Refer to the
electrical circuit
diagrams and check the
power and ground
circuit to the
module
• Check TCM for
• TCM engine speed DTCs and refer
Invalid data received from
control monitor - to DTC Index.
U040283 Transmission Control
plausibility Diagnostic
Module (TCM)
Strategy
• Check TCM for

• TCM engine speed DTCs and refer
control monitor - to DTC Index.
U040286 Transmission Control
rationality Diagnostic
Module (TCM)
Strategy
• Check speed
• Invalid data received
control module
Invalid data received from from speed control
U040581 for DTCs and
speed control module module
refer to DTC
Index.
Speed Control
• Check speed
control module
for DTCs and
U040583 refer to DTC
Index.
Speed Control
• Check speed
control module
for DTCs and
U04058F refer to DTC
Index.
Speed Control
• Check anti-lock
control -
stability assist
module for
• Brake Position Switch DTCs and refer
U041500 Anti-lock Brake System
to DTC Index.
Anti-Lock
Control -
Stability Assist
• Check anti-lock
control -
stability assist
• Engine drag torque module for
control monitoring - DTCs and refer
plausibility to DTC Index.
Anti-Lock
Control -
Stability Assist
• Check anti-lock
control -
stability assist
• Engine drag torque module for
control monitoring - DTCs and refer
rationality to DTC Index.
Anti-Lock
Control -
Stability Assist
Invalid data received from • Battery voltage level • Check

U042386
instrument cluster - signal instrument
invalid cluster for
DTCs and refer
to DTC Index.
Instrument
Cluster
• Check
instrument
cluster for
• External ambient
Invalid data received from DTCs and refer
U042481 temperature
instrument cluster to DTC Index.
Instrument
Cluster
• Check CAN
network
between ECM
and instrument
cluster. Check
power and
grounds to
ECM and
instrument
cluster. Check
• Security code mis-
Invalid data received from correct ECM
U042600 match
vehicle immobilizer and instrument
cluster
installed. Re-
synchronise ID
by re-
configuring the
ECM and
instrument
cluster as new
modules
• Set ignition to
ON, then OFF
Warning indicator (wait 30
• Fuel Cut
U206400 requested by another seconds), then
control module ON (wait 4
seconds)

Camshaft Position (CMP) Sensor LH
(18.31.12)
Removal
2 . Disconnect the CMP sensor electrical connector.

Slide the red connector latch to one side.

Installation

Camshaft Position (CMP) Sensor RH
(18.31.11)
Removal

Remove the 2 bolts.

4 . Release the CMP sensor electrical connector.

Release the clip.

Installation


Removal
2

For additional information, refer to Catalytic Converter (17.50.05)
4 . Remove the catalyst monitor sensor.
Installation
1
. WARNING: Make sure the H02S wiring harness is not twisted more than
180 degrees and is not in contact with the exhaust.
CAUTION: Make sure the anti-seize compound does not contact the
catalyst monitor sensor tip.
Install the catalyst monitor sensor and tighten to 45 Nm (33 lb.ft).

Apply an anti-seize compound to the thread of the sensor.

4 NOTE:

Cycle Self-Test
Crankshaft Position (CKP) Sensor
(18.30.12)
Removal
2
3 . NOTE:
Remove the crankshaft position (CKP) sensor.

Installation
Tighten the Torx screw to 8 Nm (6 lb.ft).

Removal
2 . Remove the air intake cover.

Remove the 4 clips.
3 . Release the power distribution box and position aside.

4 . Disconnect the engine harness electrical connector.

Loosen the bolt.
5 . Release the electrical connector.

6 . NOTE:
Remove the engine control module (ECM).

Remove the 3 bolts.
Release and disconnect the 2 engine harness electrical connectors.
Installation
Connect the ECM electrical connectors.
2 . Install the electrical connector.


4 . Position and install the power distribution box.


7 . Using WDS, configure a new ECM.

Engine Coolant Temperature (ECT) Sensor
(18.30.10)
Removal
CAUTION: Engine coolant will damage the paint finished surfaces. If spilt,

3 . Disconnect the ECT sensor electrical connector.
4
this procedure.

Installation

3 . Top-up the coolant.

Removal
personal injury.

4
. WARNING: The spilling of fuel is unavoidable during this operation.
Ensure that all necessary precautions are taken to prevent fire and explosion.
Remove the FRP sensor.

Remove the 2 bolts.
Installation
1
. WARNING: After carrying out repairs, the fuel system must be checked
visually for leaks. Failure to follow this instruction may result in personal injury.
Install the FRP sensor.



Removal

3

Installation
Apply sealant to the sensor thread.


Removal
2
3 . Release and disconnect the heated oxygen sensor (HO2S) electrical connector.
4
. WARNING: Do not twist the HO2S wiring harness on removal. Failure to
Remove the HO2S.
Installation
1
HO2S tip.
Install the HO2S to the catalytic converter and tighten to 45 Nm (33 lb.ft).

4 NOTE:

Cycle Self-Test
Removal
2

4 . Remove the NVH pad.
5 . Remove the KS.

Remove the 2 nuts.
Installation
1 . Install the KS.
2 . Install the NVH pad.


Manifold Absolute Pressure (MAP) Sensor
(18.30.86)
Removal


Installation


4 NOTE:

Cycle Self-Test
Removal
NOTE:
LH MAF sensor procedure shown, RH is similar.
1
2 . Remove the air cleaner.

For additional information, refer to Air Cleaner (19.10.05)
Installation
1 . Install the air cleaner.
2 NOTE:

Cycle Self-Test
Variable Camshaft Timing (VCT) Oil
Control Solenoid (18.30.90)
Removal
NOTE:
Removal of the RH is similar to this procedure.

3 . Remove the VCT oil control solenoid.

Remove the bolt.
Installation
1 . Install the VCT oil control solenoid.

4 NOTE:
Cycle Self-Test
No Data Available
Removal
2

4 . Remove the oil temperature sensor.

Installation
1 . Install the oil temperature sensor.


Removal
2


Installation


Intake Air Temperature (IAT) Sensor
(18.30.52)
Removal

4 . Remove the IAT sensor.

Installation
1 . Install the IAT sensor.
Tighten the Torx screw.


303-14B : Electronic Engine Controls – 4.2L NA V8 –
AJV8
Specifications
Specifications
Item Nm lb-ft lb-in

Camshaft position sensor - bolt 7 5 62
Catalyst monitor sensor 45 33 -
Crankshaft position sensor - screw 7 5 62
Engine control module 10 7 88
Heated oxygen sensor 45 33 -
Knock sensor - nut 20 15 -
Knock sensor - stud 10 7 88
Oil pressure sensor 15 11 -
Oil temperature sensor 15 11 -
Variable camshaft timing, oil control solenoid - bolt 10 7 88
General procedures
Powertrain Control Module (PCM) Long

WARNING: Where possible, all road tests should be on well surfaced and dry
roads. Always comply with speed limits and local traffic regulations.
NOTE:
NOTE:
The vehicle must exceed 50mph (80 km/h) during the road test.
5. NOTE:
Make sure cruise control is not engaged.
Carry out a road test and perform the following operations.

• Accelerate to 55 mph (88 km/h) in 5th gear and cruise for 2 minutes with the engine
speed at or above 1800rpm.
• Lift off the throttle and allow the vehicle to decelerate until the engine speed is less than
1000 rpm.
• Stop the vehicle.
• Release brake, allow the vehicle to move with no throttle for 1 minute.
• Road test is now complete.

7. NOTE:
claimed against.

Powertrain Control Module (PCM) Short
NOTE:
4. Start the engine.

• Raise the engine speed to 1500 rpm and hold for 3 minutes until a temperature of 70ºC
(158 ºF) is achieved.
• Switch off the engine.
5. NOTE:
claimed against.



3 CMP (camshaft position) sensor
4 Injector
5 Purge valve
6 MAP (manifold absolute pressure) sensor
8 ECM (engine control module)
9 CKP (crankshaft position) sensor
10 MAF (mass air flow) /IAT (intake air temperature) sensor
11 Downstream HO2S (heated oxygen sensor)
12 Upstream HO2S (heated oxygen sensor)
19 Variable Vale timing solenoid
20 Ignition coil
21 Knock sensor
22 PCV (positive crankcase ventilation) valve

3 APP (accelerator pedal position) sensor
5 FPDM (fuel pump driver module)
7 CJB (central junction box)
9 BJB (battery junction box)
INTRODUCTION
The V8 4.2 Liter naturally aspirated engine is controlled by an ECM (engine control module)
manufactured by DENSO. The Engine Management System (EMS) controls the following:
• Engine fueling
• Ignition timing
• Knock control
• On Board Diagnostic
• Speed control
The ECM (engine control module) 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 (engine control module) 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 (engine control module) 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
The EMS comprises the following inputs:
• CMP (camshaft position) sensor

• CKP (crankshaft position) sensor
• Fuel rail pressure sensor
• 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
• Secondary Air Injection (SAI) MAP (manifold absolute pressure) sensor
• APP (accelerator pedal position) sensor
• DMTL (NAS only)
• Cooling fan speed feedback.
• Heated Exhaust Gas Oxygen (HEGO) sensors
• Universal Heated Exhaust Gas Oxygen (UHEGO) 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 fuel pump driver module
• VCT (variable camshaft timing) solenoids
• Purge valve
• EGR (exhaust gas recirculation) valve
• Secondary air injection pump
IGNITION MODES
The vehicle has a possible 4 ignition modes. The modes and systems that are active in each
mode are detailed in the following table.
Accessory
Ignition Mode Off On Crank
(convenience)
Exterior lamps Memory functions - Exterior lamps, fog Stability controls
headlamps (dip Seat, steering column lamps, direction
only), approach etc indicator lamps
lamps
Interior lighting Manual seat adjustment, Convertible hood Heated/cooled
steering column seats
Preheat - timed Interior lighting Wash/wipe Adaptive speed
in control
Electric park Brake lights HEVAC Adaptive damping
brake - On
Instrument Exterior lighting auto EMS TPMS
cluster - Stand headlamps, reversing
by, Clock, lamps, side lamps, tail
Odometer lamps
Hazard warning Infotainment previous Instrument cluster – Pedestrian
lamps condition (Preset dials and warnings, protection system
volume), radio standby, fuel gauge temperature
phone standby, steering gauge, lamp check
wheel switches
Locking and Instrument cluster – Electric windows Gearshift control &
Unlocking message center, trip TCM (transmission
computer control module)
Security system Horn EPB – power to EPB – power to
disengage (foot on disengage
break)
Cigar lighter/power Restraints system
socket check

NOTE:
1 Fuse
2 Battery
4 Door module
5 Door module
6 knock sensors
7 MAP (manifold absolute pressure) sensor
9 CKP (crankshaft position) sensor
10 Stop lamp switch
15 APP (accelerator pedal position)
17 MAF (mass air flow) /IAT (intake air temperature) sensor

NOTE:
1 FPDM (fuel pump driver module)
2 Generator
3 HO2S (heated oxygen sensor) (upstream)
4 HO2S (heated oxygen sensor) (downstream)
5 Electric throttle
6 Purge valve
7 DMTL pump
10 VCT (variable camshaft timing) solenoid
13 Injector (8 off)

NOTE:
D = High speed CAN (controller area network) bus; N=Medium speed CAN (controller
area network) bus; O = LIN (local interconnect network) bus
1 Diagnostic socket
3 Park brake module
4 TCM (transmission control module)
8 Rotary coupler
11 ABS (anti-lock brake system) control module
12 RCM (restraints control module)

4 Injector
5 Purge valve
6 Manifold Absolute Pressure sensor
11 Downstream Heated Oxygen Sensor (HO2S)
12 Upstream Heated Oxygen Sensor (HO2S)
16 Exhaust Gas Recirculation (EGR) valve
19 Variable Valve timing solenoid
20 Ignition coil
21 Knock sensor
22 Positive Crankcase Ventilation (PCV) valve

3 Accelerator Pedal Position (APP) sensor
5 Fuel Pump Driver Module (FPDM)
INTRODUCTION
The V8 4.2 Liter naturally aspirated engine is controlled by an electronic Engine Management
System (EMS). The EMS controls the following:
• Engine fueling
• Ignition timing
• Knock control
• On Board Diagnostic
• 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 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
The EMS comprises the following inputs:
• CMP sensor
• CKP sensor
• Fuel rail pressure sensor
• MAF sensor
• Knock sensors
• Fuel rail temperature sensor
• ECT sensor
• Engine oil temperature sensor
• MAP sensor
• Electric throttle feedback sensor
• Secondary Air Injection (SAI) MAP sensor
• APP sensor
• DMTL (NAS only)
• Cooling fan speed feedback.
• Heated Exhaust Gas Oxygen (HEGO) sensors
• Universal Heated Exhaust Gas Oxygen (UHEGO) sensors
• Brake switch
• Speed control cancel/suspend switch
• Automatic speed limiter switch
• Crank request signal
• IAT sensor
• External air temperature sensor
The EMS comprises the following outputs:
• Fuel injectors
• Ignition coils
• Engine cooling fan
• Electric fuel pump driver module
• VCT solenoids
• Purge valve
• EGR valve
• Secondary air injection pump
IGNITION MODES
The vehicle has a possible 4 ignition modes. The modes and systems that are active in each
mode are detailed in the following table.
Accessory
Ignition Mode Off On Crank
(convenience)
Exterior lamps Memory functions seat, Exterior lamps fog Stability
headlamps – column etc lamps directional controls
Dip only Indicators
approach lamps
Interior lighting Manual adjust seat Convertible hood Heated/cooled
column etc Seat
Preheat - timed Interior lighting Wash/wipe Adaptive speed
in control
Electric park Brake lights HVAC Adaptive
brake - On damping
cluster - stand headlamps, reversing
by, clock, lamps, side lamps, tail
odometer lamps
Hazard warning Auto infotainment Instrument cluster – Pedestrian
lamps previous condition (preset dials and warnings fuel Protection
volume), radio standby, gauge temperature system
phone standby, steering gauge lamp check
wheel switches
Locking and Instrument cluster – Windows Gearshift
unlocking message center, trip control & TCM
computer
Security Horn EPB – power to EPB – power to
disengage (foot on disengage
break)
Cigar lighter/power socket Restraints check
COMPONENTS
Engine Control Module (ECM)
The ECM is located in the plenum area on the passenger side of the engine compartment
attached to the bulkhead.
The ECM has the following inputs:
• RCM
• Park/neutral switch
• Ignition coil feedback x2
• Fuel rail temperature
• Mass air flow
• Engine speed
• Camshaft position x2
• Driver demand
• Brake pedal position switch
• Speed control switches
• Generator load
• Oxygen sensors pre catalyst x2
• Oxygen sensors post catalyst x2
• Throttle position
• Cooling fan speed
• Ignition switch position
• Knock sensors x2
• MAP
• Coolant temperature
• Engine oil temperature
The ECM outputs to the following:
• Throttle Actuator
• Brake vacuum pump relay
• Ignition coils (x8)
• Oxygen sensor heaters (4)
• Fuel injectors (8)
• Purge Valve
• Engine Cooling Fan
• Fuel pump relay
• Starter Relay
• EMS Main Relay
• Viscous Fan Control
• Generator Control
• Diagnostic Monitoring of Tank Leakage (DMTL) (NAS Only)
• E box fan
Crankshaft Position Sensor (CKP)
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
degrees 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 30 degrees BTDC (before top dead center) No.1 cylinder. Because of
the crankshaft sensor's orientation, the target wheel uses windows stamped 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.
Camshaft Position Sensor (CMP)

Two sensors are located at the rear of the engine, in the cylinder head (one per bank), above
the rear cylinders. The sensors are Variable Reluctor Sensor (VRS) type, 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 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:
• 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.
Engine Coolant Temperature Sensor (ECT)
The sensor is located at the front of the engine in the water pipe below the throttle body. The
ECT (engine coolant temperature) sensor is a thermistor used to monitor the engine coolant
temperature. The engine coolant temperature 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 -30 Degrees Celsius to 125 Degrees Celsius.
When a defective coolant sensor is detected, the ECM defaults to the oil temperature sensor
value.
Engine Oil Temperature Sensor
Oil temperature is monitored through a temperature sensor mounted in the oil system. This
component is a NTC (negative temperature coefficient) type. The sensor is mounted next to
the oil pressure sensor at the front of the engine and locates into the oil filter bracket.
Oil Pressure Sensor
The oil pressure sensor is located in the oil filter bracket adjacent to the oil temperature
sensor. The sensor is hardwired to the instrument cluster and is used to illuminate the oil
pressure warning indicator. The sensor switches on at pressures below 24.5kPa and is closed
circuit at zero oil pressure.
Fuel Rail Temperature Sensor
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.
Diagnostic Monitoring of Tank Leakage (DMTL) - NAS

ONLY
Charcoal Canister with DMTL Pump (NAS only)

2 DMTL pump
The DMTL system periodically checks the evaporative system and the fuel tank for leaks
when the ignition is switched off. The DMTL 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 DMTL 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 DMTL 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
Purge Valve and Hoses location
1 Hose and connection-purge valve to electric throttle
4 Purge valve
air intake manifold, to the elbow assembly which locates the electric throttle.
coupling to the purge line which runs parallel with the fuel feed line and around the rear of the
fuel tank to the charcoal canister.
The purge valve is a solenoid operated valve which is closed when de-energized. The purge
valve is controlled by a 10Hz PWM signal from the ECM. When 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 DMTL pump fresh air vent. For additional information, refer to Evaporative
Emissions (303-13 Evaporative Emissions)
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 inlet 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 MAF 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
calculate the required 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 meter. 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°C 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 ECM and provides an analogue signal to
the 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 Integrated Diagnostic
System (IDS).
Knock Sensors
The V8 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.
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 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 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 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 V8 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 sensor
• 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 speed control.
• Perform all dynamic stability control throttle control interventions.
• Monitor and carry out maximum engine and road speed cut out.
• Provide differing responses for differing Terrain response modes.
A software strategy within the ECM enables the throttle position to be calibrated each ignition
cycle. When the ignition is turned ON, the ECM performs a self test and calibration routine
on the electronic throttle by closing the throttle full, then opening again. This tests the default
position springs.
Accelerator Pedal Position Sensor (APP)
The APP sensors are located on the accelerator pedal assembly.
The APP sensors are used to determine the driver's request for vehicle speed, acceleration and
deceleration. This value is used by the ECM and the throttle is opened to the correct angle by
an electric motor integrated into the throttle body.
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 'limp – home'
input. In limp home mode due to an APP signal failure the ECM will limit the maximum
engine speed to 2000 rpm.
Stoplamp Switch
The stoplamp switch is mounted on the brake pedal bracket and is connected to the vehicle
harness via a 4 pin multiplug.
When the brake pedal is pressed, the switch contacts close allowing 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.
Oxygen Sensors
There are four oxygen sensors located in the exhaust system. Two upstream before the
catalytic converter and two down stream after the catalytic converter. 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.
Oxygen Sensors
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 sensor’s readiness for closed loop control and influences emissions. The
PWM duty cycle is carefully controlled to prevent thermal shock to cold sensors.
UHEGO (Universal Heated Exhaust Gas Oxygen) sensors also known as Linear or "Wide
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 HEGO 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 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.
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. The heater pins of HEGO and UHEGO sensor
electrical connections are tinned and the signal pins 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 reading.
• Strong smell of H02S (rotten eggs) 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 holes around the end of the shroud,
whereas the down stream sensors have holes arranged along the length the shroud.
Generator
The Generator has a multifunction voltage regulator for use in a 14V charging system with
6÷12 zener diode bridge rectifiers.
The ECM monitors the load on the electrical system via PWM 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 pack on the CAN bus to illuminate the charge warning lamp.
Fuel Injectors
The engine has 8 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 V8 engine is fitted with eight 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.
The individual cylinder spark timing is calculated from a variety of inputs:
• Engine speed and load.

• Knock control.
• Auto gearbox shift control.
• Idle speed control.
Fuel Pump Relay

The V8 engine has a returnless fuel system. The system pressure is maintained at a constant 4
bar (59 Psi), with no reference to intake manifold pressure. The fuel is supplied to the
injectors from a fuel pump fitted within the fuel tank. The electrical supply to this fuel pump
is controlled by the ECM via a relay and an Inertia Switch which will turn the fuel off upon a
vehicle impact. The fuel system is pressurized as soon as the ECM is powered up, the pump is
then switched off until engine start has been achieved.
Cooling Fan Control

The ECM controls an electric fan to provide engine cooling. The ECM supplies the fan with a
PWM signal that controls the speed of the fan, thus providing the correct amount of cooling
fan speed and airflow. The EMS uses a Hall effect sensor to determine the fan speed.
Variable Valve Control (VVC)

Variable valve timing is used on the V8 engine to enhance low and high speed engine
performance and idle speed quality.
For each inlet camshaft the VVC system comprises:
• VVC unit
• Valve timing solenoid
The VVC 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 VVC 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 VVC system is controlled by the ECM based on engine load and speed along with engine
oil temperature to calculate the appropriate camshaft position.
The VVC 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
The VVC unit is a hydraulic actuator mounted on the end of the inlet camshaft. The unit
advances or retards the camshaft timing to alter the camshaft to crankshaft phase. The ECM
controls the VVC timing unit via a oil control solenoid. The oil control solenoid routes oil
pressure to the advance or retard chambers either side of the vanes within the VVC unit.
The VVC 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 VVC unit whilst simultaneously allowing
oil pressure into the retard chambers.
The ECM controls the advancing and retarding of the VVC unit based on engine load and
speed. The ECM sends an energize signal to the oil control solenoid until the desired VVC
position is achieved. When the desired VVC position is reached, the energizing signal is
reduced to hold the oil control solenoid position and consequently desired VVC 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.
VVC operation can be affected by engine oil temperature and properties. At very low oil
temperatures the movement of the VVC mechanism will be slow due to the high viscosity of
the oil. While at high oil temperatures the low oil viscosity may impair the VVC 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 VVC advance in order
to prevent the engine from stalling when returning to idle speed.
VVC does not operate when engine oil pressure is below 1.25 bar. This is because there is
insufficient pressure to release the VVC units internal stopper pin. This occurs when the
engine is shut down and the VVC unit has returned to the retarded position. The stopper pin
locks the VVC unit to the camshaft to ensure camshaft stability during the next start up.
Valve Control 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.
The EGR valve is an electrically controlled valve that allows burned exhaust gas to be
recirculated back into the engine. The EGR valve consists of a stepper motor that opens and
closes the valve in steps. Since exhaust gas has much less oxygen than air, it is basically inert.
It takes the place of air in the cylinder and reduces combustion temperature. As the
combustion temperature is reduced, so are the oxides of nitrogen (NOx).
The EGR valve is located on the intake manifold with a pipe connecting the exhaust manifold
to the valve. Connection between the sensor and the harness is via a six-way connector.
Fuel Pump Driver Module
The Fuel Pump Driver Module (FPDM) is located in the rear LH quarter adjacent to the
parking aid control module.
The fuel pump is control by the ECM. The ECM sends a PWM 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 the FPDM
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 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 IDS. The FPDM cannot be interrogated for diagnostic purposes.
The MAP controls The FPDM in response to inputs from the fuel rail pressure sensor, MAP
and the MAF/IAT sensor.
Fuel Rail Pressure Sensor

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 FPDM to control the amount of fuel delivered to the fuel rail. The fuel rail
pressure sensor is a pressure transducer device. A vacuum pipe connects to the intake
manifold for manifold pressure. The ECM receives a voltage from the FRP sensor which is
proportional to the fuel pressure in the fuel injection supply manifold.
Central Junction Box
The ECM is connected to ignition switch I and II. 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.
When the ignition is turned OFF the ECM will maintain its powered up state for up to 20
minutes while it initiates its power down routine and on completion will turn off the ECM
main relay. The ECM will normally power down in approximately 60 seconds, do not
disconcert the battery until the ECM is completely powered down.
Secondary Air Injection

The secondary air injection system comprises:
• SAI pump
• SAI valve
• Associated pipes
• SAI Manifold Absolute Pressure (MAP) sensor (NAS only)
The ECM controls the SAI pump and SAI valve with a PWM signal and on NAS vehicles
measures the system pressure via the MAP sensor. For additional information, refer to
Engine Emission Control (303-08 Engine Emission Control)

NOTE:
1 Fuse
2 Battery
4 Door module
5 Door module
6 knock sensors
7 MAP sensor
9 CKP sensor
10 APP
11 Stop lamp switch
12 CMP sensor
17 MAF/IAT sensor
19 ECM

NOTE:
1 FPDM
2 Generator
3 HO2S (upstream)
4 HO2S (downstream)
5 Electric throttle
6 Purge valve
7 DMTL pump
8 EGR valve
10 VCT solenoid
12 ECM
13 Injector (8 off)

NOTE:
D = High speed CAN bus; N=Medium speed CAN bus; O = LIN (local interconnect
network) bus
1 Diagnostic socket
3 Park brake module
4 TCM
5 ECM
8 Rotary coupler
12 RCM
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 H02S
• The MAF/IAT sensor
• The CKP sensor
• Electric throttle body.
UHEGO/HEGO and MAF/IAT 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 (HEGO and UHEGO) 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.
CKP Sensor
The characteristics of the signal supplied by the CKP sensor are learned 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 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 crankshaft position sensor 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 crankshaft position 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 IDS. 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).
IDS Diagnostics
The ECM stores faults as DTC, referred to as 'P' codes. The 'P' codes are defined by OBD
legislation and, together with their associated environmental and freeze frame data, can be
read using a third party scan tool or IDS. IDS can also read real time data from each sensor,
the adaptive values currently being employed and the current fueling, ignition and idle
settings.

For a detailed description of electronic engine controls, refer to the relevant Description and

• Engine oil level • Fuses
• Cooling system coolant level • Wiring harness
• Fuel level • Electrical connector(s)
• Throttle body • Engine Control Module (ECM)
• Poly-vee belt • Transmission Control Module (TCM)
Index.
Symptom Chart
Engine non-start
• Security system • Check that the security
/Immobilizer engaged system is disarmed
• Engine in shut-down • Read DTCs and refer to
mode DTC Index in this
Engine does not crank
• ECM relay section for ECM relay
• Battery tests
• Park/Neutral switch • Ensure the battery is in
• Starting system fully charged and
• Engine seized serviceable condition
tests.
External Controls
tests.
Starting System
• For engine system tests.
Engine

correctly installed
• Engine breather system tests.
disconnected/restricted Engine Ignition
• Ignition system • For fuel system tests.
Engine cranks, but does not
• Fuel system Fuel Charging and
fire
• Electronic engine Controls - 4.2L NA V8
controls - AJV8/4.2L SC V8 -
AJV8
DTC Index in this

purge valve • For fuel system tests.
Engine cranks and fires, but • Fuel pump Fuel Tank and Lines
will not start • Spark plugs • For ignition system
• Ignition coil failure(s) tests.
Engine Ignition
Difficult to start
• Check engine coolant
coolant level and
level/anti-freeze
condition.
content
Specifications
• Battery
• Ensure the battery is in
a fully charged and
Difficult cold start controls
• Exhaust gas
recirculation (EGR)
DTC Index in this
valve stuck open
• Fuel pump
purge valve Engine Emission
Control
Fuel Tank and Lines

tests, install new
Fuel Injector
(18.10.01)
• Injector leak
DTC Index in this
controls
Difficult hot start purge valve
• Fuel pump
• Ignition system
Fuel Tank and Lines
tests.
Engine Ignition
Engine Emission
Control

tests, install new
Fuel Injector
(18.10.01)
• Injector leak
DTC Index in this
Difficult to start after hot controls
soak (vehicle standing, • Evaporative emissions
engine off, after engine has purge valve
reached operating • Fuel pump
temperature) • Ignition system
Fuel Tank and Lines
tests.
Engine Ignition
Engine Emission
Control
• Compressions high/low • Carry out compression

Engine cranks too fast/slow
• Battery tests.
• Starting system Engine
• Ensure battery is in a
fully charged and
tests.
Starting System
Engine stalls
correctly installed
DTC Index in this
• Breather system section for ECM relay
disconnected/restricted tests
• ECM relay • Read DTCs and refer to
controls section for electronic
Engine stalls soon after start • Ignition system engine control tests
• Air intake system • For ignition system
restricted tests.
• Air leakage Engine Ignition
• Fuel lines • Check for blockage in
air cleaner element and
air intake system
intake system
Fuel Tank and Lines

DTC Index in this
• ECM relay
tests
• Throttle position (TP)
Engine stalls on overrun • Read DTCs and refer to
sensors
DTC Index in this
section for TP sensor
tests

• ECM relay DTC Index in this
• CKP sensor section for ECM relay,
Engine stalls at steady speed
• TP sensors CKP, and TP sensor
tests
DTC Index in this
Engine stalls with speed • ECM relay
control enabled
tests

DTC Index in this
section for ECM relay,
and TP sensor tests
• ECM relay
• Check for excessive
• TP sensors
loads being placed on
• Additional engine loads
the engine from PAS,
(PAS, air conditioning,
Engine stalls when air conditioning
etc)
manoeuvring systems etc.
• Transmission
malfunction
tests.
• CAN malfunction
Diagnostic Strategy
Communications
Network
Poor driveability
Fuel Tank and Lines
• Carry out fuel injector
leak tests, install new
Fuel Injector
(18.10.01)
pump, fuel lines
air intake system
• Injector leak
• Air leakage
DTC Index in this
controls
Engine hesitates/poor engine control tests
• Ignition system
acceleration • For ignition system
• EGR valve stuck
tests.
• Transmission
Engine Ignition
malfunction
Engine Emission
(carpet, etc)
Control
tests.
Diagnostic Strategy
pedal is free from
restriction
Fuel Tank and Lines
air intake system
• Air leakage
DTC Index in this
controls
Engine backfires • Ignition system
• Sticking variable
tests.
camshaft timing (VCT)
Engine Ignition
hub
DTC Index in this
tests

Fuel Tank and Lines
DTC Index in this
Engine surges controls
• Ignition system
tests.
Engine Ignition

DTC Index in this
• Electronic engine engine control tests
controls • For fuel system tests.
• Fuel pump, fuel lines, Fuel Tank and Lines
Engine detonates/knocks fuel quality • Check for leakage from
• Air leakage air intake system
• Sticking VCT hub • Read DTCs and refer to
DTC Index in this
tests

No throttle response controls section for electronic
• Default mode enabled • Check message center

Speed control inhibited or • Speed control, brake for default message,
disabled switch read DTCs and refer to
• Electronic engine DTC Index
controls • For speed control, and
• CAN fault brake switch tests.
Speed Control
DTC Index in this
Communications
Network
• Ensure engine breather

system is free from
restriction and is
• Breather system
correctly installed
DTC Index in this
controls
Poor throttle response • Transmission
malfunction
tests.
• Air leakage
Diagnostic Strategy
intake system

tests.
• Park/Neutral switch External Controls
Engine defaults, warning
• Electronic engine • Read DTCs and refer to
light and messages. Refer to
controls DTC Index in this
the owner handbook
DTC Index

NOTE:
If the module/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.
NOTE:
NOTE:
NOTE:
tests.
NOTE:
terminals.

• Check anti-lock
control - stability
• Invalid data received assist module for
Left front wheel speed from ABS - left front DTCs and refer to
C003100
sensor wheel speed signal DTC Index.
Anti-Lock Control
- Stability Assist
• Check anti-lock
control - stability
Right front wheel from ABS - right front DTCs and refer to
C003400
speed sensor wheel speed signal DTC Index.
Anti-Lock Control
- Stability Assist
• Check anti-lock
control - stability
Left rear wheel speed from ABS - left rear DTCs and refer to
C003700
sensor wheel speed signal DTC Index.
Anti-Lock Control
- Stability Assist
• Check anti-lock
Right rear wheel • Invalid data received
C003A00 control - stability
speed sensor from ABS - right rear
assist module for
wheel speed signal DTCs and refer to
DTC Index.
Anti-Lock Control
- Stability Assist
• Carry out any

pinpoint tests
DTC using the
manufacturer
fault
Intake camshaft approved
• Valve timing
P001100 position - timing over- diagnostic system
incorrectly set
advanced (bank 1) • Check the valve
timing.
slipped
Timing Drive
Components
(12.65.13)
• Carry out any

pinpoint tests
DTC using the
manufacturer
fault
• Valve timing
incorrectly set
retarded (bank 1) • Check the valve
timing.
slipped
Timing Drive
Components
(12.65.13)

Crankshaft position Reset the sensor positions.
of the CKP and CMP
(CKP)/Camshaft Camshaft Position (CMP)
teeth are not correct
P001600 position (CMP) sensor Sensor RH (18.31.11)
Sensors incorrectly
correlation, right hand Crankshaft Position (CKP)
aligned on rebuild
bank Sensor (18.30.12)

Crankshaft position Reset the sensor positions.
of the CKP and CMP
(CKP)/Camshaft Camshaft Position (CMP)
teeth are not correct
P001800 position (CMP) sensor Sensor LH (18.31.12)
Sensors incorrectly
correlation, left hand Crankshaft Position (CKP)
aligned on rebuild
bank Sensor (18.30.12)
• Variable Camshaft • Carry out any

Intake camshaft Timing (VCT) circuit pinpoint tests
P002100 position - timing over- fault associated with this
advanced (bank 2) • Valve timing DTC using the
incorrectly set manufacturer
• Timing chain has approved
slipped diagnostic system
• Check the valve
timing.
Timing Drive
Components
(12.65.13)
• Carry out any

pinpoint tests
DTC using the
manufacturer
fault
• Valve timing
incorrectly set
retarded (bank 2) • Check the valve
timing.
slipped
Timing Drive
Components
(12.65.13)
• Carry out any

pinpoint tests
DTC using the
Variable Camshaft • VCT solenoid fault
manufacturer
Timing (VCT) control • Oil contamination
approved
solenoid (bank 1) • VCT oil flow fault
circuit • VCT/Camshaft
• Check the oil
range/performance - mechanical failure
condition and flow
actuator stuck open
• Check for
mechanical failure
of components
• Carry out any

pinpoint tests
Variable Camshaft DTC using the
Timing (VCT) control manufacturer
solenoid (bank 1) approved
P002677 circuit diagnostic system
• VCT/Camshaft
mechanical failure
commanded position condition and flow
not achievable • Check for
mechanical failure
of components
P002872 Variable Camshaft • VCT solenoid fault • Carry out any

Timing (VCT) control • Oil contamination pinpoint tests
solenoid (bank 2) • VCT oil flow fault associated with this
circuit • VCT/Camshaft DTC using the
range/performance - mechanical failure manufacturer
actuator stuck open approved
diagnostic system
• Check the oil
condition and flow
• Check for
mechanical failure
of components
• Carry out any

pinpoint tests
Variable Camshaft DTC using the
Timing (VCT) control manufacturer
solenoid (bank 2) approved
P002877 circuit diagnostic system
• VCT/Camshaft
mechanical failure
commanded position condition and flow
not achievable • Check for
mechanical failure
of components
• Carry out any

pinpoint tests
DTC using the
• HO2S heater circuit - manufacturer
HO2S heater control circuit fault approved
P003100
circuit low (bank 1) • HO2S heater failure diagnostic system
• Install a new HO2S
as necessary.
Heated Oxygen
Sensor (HO2S)
• Carry out any

pinpoint tests
DTC using the
P003200
circuit high (bank 1) • HO2S heater failure diagnostic system
as necessary.
Heated Oxygen
Sensor (HO2S)
• Carry out any
pinpoint tests
DTC using the
• Catalyst monitor sensor
manufacturer
heater circuit - circuit
Catalyst monitor approved
fault
P003600 sensor heater control diagnostic system
circuit (bank 1) • Install new catalyst
heater failure
monitor sensor as
necessary.
Catalyst Monitor
Sensor (18.30.66)
• Carry out any

pinpoint tests
DTC using the
P005100
circuit low (bank 2) • HO2S heater failure diagnostic system
as necessary.
Heated Oxygen
Sensor (HO2S)
• Carry out any

pinpoint tests
DTC using the
P005200
circuit high (bank 2) • HO2S heater failure diagnostic system
as necessary.
Heated Oxygen
Sensor (HO2S)
• Carry out any

pinpoint tests
DTC using the
heater circuit - circuit
Catalyst monitor manufacturer
fault
P005600 sensor heater control approved
circuit (bank 2) diagnostic system
heater failure
• Install new catalyst
monitor sensor as
necessary.
Catalyst Monitor
Sensor (18.30.66)
• Check for MAP

sensor related
DTCs and refer to
the DTC Index in
Manifold absolute • MAP sensor failure
this section
pressure • BARO sensor failure
P006900 • Install a new ECM.
(MAP)/Barometric (internal ECM fault)
Refer to new
pressure correlation
module/component
installation Note at
top of DTC Index
• Carry out any

pinpoint tests
• Ambient temperature associated with this
Ambient air
value missing from DTC using the
P007100 temperature sensor
CAN bus manufacturer
range/performance
approved
diagnostic system
• Carry out any

• Ambient air
pinpoint tests
temperature sensor
Ambient air circuit - high resistance
DTC using the
P007200 temperature sensor • Ambient air
manufacturer
circuit low temperature sensor
approved
diagnostic system
• Carry out any

pinpoint tests
• Ambient air associated with this
Ambient air
temperature sensor DTC using the
circuit - short to power manufacturer
circuit high
approved
diagnostic system
• Carry out any

pinpoint tests
DTC using the
circuit - high
Variable Camshaft manufacturer
resistance,
P007500 Timing (VCT) control approved
disconnected
circuit (bank 1) diagnostic system
• VCT solenoid failure
• Install a new VCT
control solenoid as
necessary.
Variable Camshaft
Timing (VCT) Oil
Control Solenoid
(18.30.90)
• Carry out any

pinpoint tests
DTC using the
manufacturer
Variable Camshaft circuit - short to diagnostic system
P007600 Timing (VCT) control ground, disconnected • Install a new VCT
circuit low (bank 1) • VCT solenoid failure control solenoid as
necessary.
Variable Camshaft
Timing (VCT) Oil
Control Solenoid
(18.30.90)
• Carry out any

pinpoint tests
DTC using the
manufacturer
approved
Variable Camshaft diagnostic system
P007700 Timing (VCT) control • Install a new VCT
circuit high (bank 1) control solenoid as
necessary.
Variable Camshaft
Timing (VCT) Oil
Control Solenoid
(18.30.90)
• Carry out any

pinpoint tests
DTC using the
manufacturer
approved
circuit - high
resistance,
disconnected
circuit (bank 2) control solenoid as
necessary.
Variable Camshaft
Timing (VCT) Oil
Control Solenoid
(18.30.90)
• Carry out any
pinpoint tests
DTC using the
manufacturer
Variable Camshaft circuit - short to diagnostic system
P008200 Timing (VCT) control ground, disconnected • Install a new VCT
circuit low (bank 2) • VCT solenoid failure control solenoid as
necessary.
Variable Camshaft
Timing (VCT) Oil
Control Solenoid
(18.30.90)
• Carry out any

pinpoint tests
DTC using the
manufacturer
approved
circuit high (bank 2) control solenoid as
necessary.
Variable Camshaft
Timing (VCT) Oil
Control Solenoid
(18.30.90)
• Carry out any

pinpoint tests
DTC using the
• Fuel rail pressure
manufacturer
(FRP) sensor, sensing
approved
circuit - short to
diagnostic system
• Install a new FRP
• FRP sensor supply
Fuel rail/system sensor as
P008700 circuit - high resistance
pressure - too low necessary.
Fuel Rail Pressure
• Fuel pump failure
(FRP) Sensor
• Fuel line leak,
(18.30.98)
restriction
• For fuel system
tests.
Fuel Tank and
Lines
P008800 Fuel rail/system • FRP sensor • Carry out any

pressure - too high supply/sensing circuits pinpoint tests
- short to each other associated with this
• FRP sensor sensing DTC using the
circuit - short to power manufacturer
• FRP sensor ground approved
circuit - high resistance diagnostic system
• FRP sensor failure • Install a new FRP
• Restricted fuel line sensor as
• Fuel pump short circuit necessary.
to power Fuel Rail Pressure
(FRP) Sensor
(18.30.98)
• For fuel system
tests.
Fuel Tank and
Lines

element is free
from restriction
• Check for leak
from air intake
system, rectify as
necessary
• Blocked air cleaner
element
breather system is
• Leakage from air intake
correctly installed
system
and in serviceable
• Engine breather leak
condition
Mass Air Flow (MAF) • MAF sensor sensing
• Carry out any
P010100 circuit - circuit - high
pinpoint tests
range/performance resistance, intermittent
short to ground
DTC using the
manufacturer
circuit - high resistance
approved
diagnostic system
sensor as
necessary.
Mass Air Flow
(MAF) Sensor
(18.30.15)
• Carry out any

pinpoint tests
circuit - short to
Mass Air Flow (MAF) associated with this
P010200 ground, high resistance
circuit - low input DTC using the
• MAF sensor ground
manufacturer
approved
• MAF sensor failure diagnostic system
sensor as
necessary.
Mass Air Flow
(MAF) Sensor
(18.30.15)
• Carry out any

pinpoint tests
DTC using the
• MAF sensor sensing manufacturer
circuit - short to power approved
Mass Air Flow (MAF) • MAF sensor ground diagnostic system
P010300
circuit - high input circuit - high resistance • Install a new MAF
• MAF sensor failure sensor as
necessary.
Mass Air Flow
(MAF) Sensor
(18.30.15)

installation and
serviceability of
intake manifold
and associated
components
• Carry out any
• Intake manifold air leak
pinpoint tests
(loose or missing
Manifold Absolute associated with this
component)
Pressure (MAP) DTC using the
P010600 • MAP sensor signal
sensor - manufacturer
circuit fault
range/performance approved
• MAP sensor failure
diagnostic system
• Install a new MAP
sensor as
necessary.
Manifold Absolute
Pressure (MAP)
Sensor (18.30.86)
• Carry out any

Intake Air pinpoint tests
Temperature (IAT) associated with this
P011123 sensor circuit - DTC using the
range/performance - manufacturer
signal stuck low approved
diagnostic system
sensor as
necessary.
Mass Air Flow
(MAF) Sensor
(18.30.15)
• Carry out any

pinpoint tests
DTC using the
manufacturer
Intake Air
• IAT sensor sensing approved
Temperature (IAT)
• IAT sensor failure • Install a new MAF
range/performance -
sensor as
signal stuck high
necessary.
Mass Air Flow
(MAF) Sensor
(18.30.15)
• Carry out any

pinpoint tests
DTC using the
manufacturer
Intake Air
• IAT sensor sensing approved
Temperature (IAT)
• IAT sensor failure • Install a new MAF
range/performance -
sensor as
signal invalid
necessary.
Mass Air Flow
(MAF) Sensor
(18.30.15)
• Carry out any

pinpoint tests
DTC using the
Intake Air circuit - high approved
Temperature (IAT) resistance, diagnostic system
P011200
sensor circuit - low disconnected • Install a new MAF
input • IAT sensor failure sensor as
necessary.
Mass Air Flow
(MAF) Sensor
(18.30.15)
• Carry out any
pinpoint tests
DTC using the
manufacturer
Intake Air approved
circuit - short to
Temperature (IAT) diagnostic system
P011300 ground, short to power
sensor circuit - high • Install a new MAF
input sensor as
necessary.
Mass Air Flow
(MAF) Sensor
(18.30.15)

to correct level and
specification.
Specifications
• Carry out any
pinpoint tests
DTC using the
manufacturer
• ECT sensor sensing diagnostic system
Engine Coolant
circuit - intermittent • Check and install
Temperature (ECT)
high resistance new engine
• Engine thermostat thermostat as
range/performance -
failure necessary.
signal stuck low
• ECT sensor failure Thermostat -
Vehicles Without:
Supercharger
(26.45.07)
sensor as
necessary.
Engine Coolant
Temperature (ECT)
Sensor (18.30.10)

Engine Coolant specification.
circuit - intermittent
Temperature (ECT) Specifications
high resistance
P011624 sensor circuit - • Carry out any
• Engine thermostat
range/performance - pinpoint tests
failure
signal stuck high associated with this
DTC using the
manufacturer
approved
diagnostic system
• Check and install
new engine
thermostat as
necessary.
Thermostat -
Vehicles Without:
Supercharger
(26.45.07)
sensor as
necessary.
Engine Coolant
Temperature (ECT)
Sensor (18.30.10)

specification.
Specifications
• Carry out any
pinpoint tests
DTC using the
manufacturer
Engine Coolant
Temperature (ECT)
range/performance -
failure necessary.
signal invalid
Vehicles Without:
Supercharger
(26.45.07)
sensor as
necessary.
Engine Coolant
Temperature (ECT)
Sensor (18.30.10)
• ECT sensor sensing • Carry out any

Engine Coolant circuit - short to power, pinpoint tests
Temperature (ECT) high resistance, open associated with this
P011700
sensor circuit - low circuit, disconnected DTC using the
input • ECT sensor failure manufacturer
approved
diagnostic system
sensor as
necessary.
Engine Coolant
Temperature (ECT)
Sensor (18.30.10)
• Check for cooling

fan circuit DTCs
and refer to
relevant action
specified in DTC
Index
• Carry out any
• Engine overheat
pinpoint tests
condition/cooling fan
Engine Coolant associated with this
failure
Temperature (ECT) DTC using the
P011800 • ECT sensor sensing
sensor circuit - high manufacturer
input approved
diagnostic system
sensor as
necessary.
Engine Coolant
Temperature (ECT)
Sensor (18.30.10)
• Carry out any

pinpoint tests
DTC using the
manufacturer
Throttle Position (TP) circuits TP 1 and TP 2 -
approved
sensor circuits TP 1 short to battery, high
and TP 2 - resistance
• Install a new
range/performance • TP sensor failure
throttle body as
necessary.
Throttle Body
(19.70.04)
• Carry out any

pinpoint tests
Throttle Position (TP) circuit TP 1 - short to
DTC using the
P012200 sensor circuit TP 1 - ground, high resistance
manufacturer
low input • TP sensor failure
approved
diagnostic system
• Install a new
throttle body as
necessary.
Throttle Body
(19.70.04)
• Carry out any

pinpoint tests
DTC using the
Throttle Position (TP) circuit TP1 - short to approved
P012300 sensor circuit TP 1 - power diagnostic system
high input • TP sensor failure • Install a new
throttle body as
necessary.
Throttle Body
(19.70.04)

specification.
Specifications
• Carry out any
pinpoint tests
DTC using the
manufacturer
Insufficient coolant
P012500 temperature for closed
loop fuel control
failure necessary.
Vehicles Without:
Supercharger
(26.45.07)
sensor as
necessary.
Engine Coolant
Temperature (ECT)
Sensor (18.30.10)
Coolant Thermostat • Drain and re-fill

• Low/contaminated
(Coolant Temperature cooling system to
coolant
P012800 Below Thermostat correct level and
• Thermostat
Regulating specification.
• Cooling fan
Temperature) Specifications
circuit(s)/module Cooling System
Draining, Filling
and Bleeding -
4.2L NA V8 -
AJV8
• Check and install a
new engine
thermostat as
necessary.
Thermostat -
Vehicles Without:
Supercharger
(26.45.07)
operation of
cooling fan, check
for DTCs and refer
to DTC Index
• Check for and

rectify any exhaust
leak between
cylinder head and
catalytic converter
(e.g. manifolds,
EGR system etc.)
• Exhaust gas leakage
• Carry out any
• H02S variable/constant
Heated Oxygen pinpoint tests
circuit - circuit fault,
P01311A Sensor (H02S) circuit associated with this
disconnected
- low voltage (bank 1) DTC using the
• H02S failure
manufacturer
approved
diagnostic system
as necessary.
Heated Oxygen
Sensor (HO2S)
• Check for and

rectify any exhaust
leak between
• Exhaust gas leakage
cylinder head and
• H02S variable/constant
Heated Oxygen catalytic converter
circuit - circuit fault,
P01321B Sensor (H02S) circuit (e.g. manifolds,
disconnected
- high voltage (bank 1) EGR system etc.)
• H02S failure
• Carry out any
pinpoint tests
DTC using the
manufacturer
approved
diagnostic system
as necessary.
Heated Oxygen
Sensor (HO2S)
• Carry out any

pinpoint tests
DTC using the
manufacturer
approved
diagnostic system
• Check for and
rectify any exhaust
• HO2S to ECM wiring leak between
shield high resistance cylinder head and
Heated Oxygen
• Exhaust leak catalytic converter
Sensor (H02S) circuit
P013300 • Fuel control system (e.g. manifolds,
- slow response (bank
fault EGR system etc.)
1)
• HO2 sensor failure • For fuel charging
and controls tests.
Fuel Charging and
Controls - 4.2L NA
V8 - AJV8/4.2L
SC V8 - AJV8
as necessary.
Heated Oxygen
Sensor (HO2S)
• Carry out any

pinpoint tests
Heated Oxygen associated with this
Sensor (H02S) circuit • HO2S slow activation DTC using the
P013400
- no activity detected manufacturer
(bank 1) approved
diagnostic system
• Catalyst monitor sensor • Carry out any

sensing circuit - short pinpoint tests
to ground, high associated with this
Catalyst monitor
resistance, DTC using the
P013700 sensor circuit - low
disconnected manufacturer
voltage (bank 1)
• Catalyst monitor sensor approved
failure diagnostic system
• Install new catalyst
monitor sensor as
necessary.
Catalyst Monitor
Sensor (18.30.66)
• Carry out any

pinpoint tests
• Catalyst monitor sensor associated with this
sensing circuit - short DTC using the
to power manufacturer
Catalyst monitor • Catalyst monitor sensor approved
P013800 sensor circuit - high ground braided shield - diagnostic system
voltage (bank 1) high resistance • Install new catalyst
• Catalyst monitor sensor monitor sensor as
failure necessary.
Catalyst Monitor
Sensor (18.30.66)
• Carry out any

pinpoint tests
Catalyst monitor • Catalyst monitor sensor
DTC using the
P013900 sensor circuit - slow slow response
manufacturer
response (bank 1)
approved
diagnostic system
• Carry out any

pinpoint tests
DTC using the
to ground, short to
manufacturer
power, high resistance,
disconnected
sensor circuit - no diagnostic system
P014000 • Catalyst monitor sensor
activity detected (bank • Install a new
ground braided shield -
1) catalyst monitor
high resistance
sensor as
necessary.
- mechanical damage
Catalyst Monitor
Sensor (18.30.66)
• Carry out any

• Catalyst monitor sensor pinpoint tests
heater control circuit - associated with this
Catalyst monitor high resistance DTC using the
P014100
heater circuit (bank 1) • Catalyst monitor sensor manufacturer
heater failure approved
diagnostic system
• Install a new
catalyst monitor
sensor as
necessary.
Catalyst Monitor
Sensor (18.30.66)
• Carry out any

pinpoint tests
• HO2S sensing circuit - DTC using the
Heated Oxygen
P01511A Sensor (H02S) circuit
resistance diagnostic system
- low voltage (bank 2)
• HO2S failure • Install a new HO2S
as necessary.
Heated Oxygen
Sensor (HO2S)
• Carry out any

pinpoint tests
• H02S sensing circuit - DTC using the
Heated Oxygen
P01521B Sensor (H02S) circuit
resistance diagnostic system
- high voltage (bank 2)
• H02S failure • Install a new HO2S
as necessary.
Heated Oxygen
Sensor (HO2S)
• Carry out any

pinpoint tests
DTC using the
manufacturer
approved
• HO2S to ECM wiring diagnostic system
shield high resistance • Check for and
Heated Oxygen
• Exhaust leak rectify any exhaust
Sensor (H02S) circuit
P015300 • Fuel control system leak between
- slow response (bank
fault cylinder head and
2)
• HO2 sensor failure catalytic converter
(e.g. manifolds,
EGR system etc.)
• For fuel system and
controls tests.
Fuel Charging and
Controls - 4.2L NA
V8 - AJV8/4.2L
SC V8 - AJV8
as necessary.
Heated Oxygen
Sensor (HO2S)
• Carry out any

pinpoint tests
Heated Oxygen associated with this
Sensor (H02S) circuit • H02S slow activation DTC using the
P015400
- no activity detected manufacturer
(bank 2) approved
diagnostic system
• Carry out any

pinpoint tests
• Catalyst monitor sensor DTC using the
sensing circuit - short manufacturer
to ground, high approved
Catalyst monitor
resistance, diagnostic system
P015700 sensor circuit - low
disconnected • Install a new
voltage (bank 2)
• Catalyst monitor sensor catalyst monitor
failure sensor as
necessary.
Catalyst Monitor
Sensor (18.30.66)
• Carry out any

pinpoint tests
DTC using the
manufacturer
to power
approved
diagnostic system
P015800 sensor circuit - high ground braided shield -
• Install a new
voltage (bank 2) high resistance
catalyst monitor
sensor as
failure
necessary.
Catalyst Monitor
Sensor (18.30.66)
• Carry out any

pinpoint tests
P015900 sensor circuit - slow slow response
DTC using the
response (bank 2)
manufacturer
approved
diagnostic system
• Carry out any

pinpoint tests
DTC using the
to ground, short to
manufacturer
power, high resistance,
disconnected
sensor circuit - no diagnostic system
P016000 • Catalyst monitor sensor
activity detected (bank • Install a new
ground braided shield -
2) catalyst monitor
high resistance
sensor as
necessary.
- mechanical damage
Catalyst Monitor
Sensor (18.30.66)
• Carry out any

pinpoint tests
• Catalyst monitor sensor associated with this
Catalyst monitor
heater control circuit DTC using the
P016100 sensor heater circuit
malfunction manufacturer
(bank 2)
approved
diagnostic system
• Check for leak

from air intake
system
P017100
any exhaust leak
prior to catalytic
converter
• Restricted air cleaner • Check air cleaner

• Leaking fuel injector(s) element is free
• Engine oil from restriction
System too rich (bank contaminated with fuel • Check for leaking
P017200
1) (too many cold starts injectors, install
with vehicle new injector(s) as
subsequently not necessary.
getting hot enough for Fuel Injector
long enough) (18.10.01)
• MAF sensor fault (high • Check for
intake air flow) contaminated
engine oil, drain
as necessary.
Engine Oil
Draining and
Filling
• Read DTCs and
refer to DTC Index
in this section for
MAF sensor tests
• Check for leak

from air intake
system
P017400
any exhaust leak
prior to catalytic
converter

element is free
from restriction
injectors, install
new injector(s) as
• Engine oil
necessary.
contaminated with fuel
Fuel Injector
(too many cold starts
(18.10.01)
System too rich (bank with vehicle
P017500 • Check for
2) subsequently not
contaminated
getting hot enough for
engine oil, drain
long enough)
as necessary.
intake air flow)
Engine Oil
Draining and
Filling
• Read DTCs and
refer to DTC Index
in this section for
MAF sensor tests
• Carry out any

pinpoint tests
DTC using the
circuit - short to
Engine Fuel manufacturer
ground, short to power,
Temperature (EFT) approved
high resistance
P018123 sensor circuit - diagnostic system
range/performance - • Install a new EFT
signal stuck low sensor as
necessary.
Fuel Temperature
Sensor (18.30.99)
• Carry out any

pinpoint tests
DTC using the
circuit - short to
high resistance
signal stuck high sensor as
necessary.
Fuel Temperature
Sensor (18.30.99)
• Carry out any

pinpoint tests
DTC using the
circuit - short to
high resistance
signal invalid sensor as
necessary.
Fuel Temperature
Sensor (18.30.99)
• EFT sensor sensing • Carry out any

Engine Fuel circuit - short to ground pinpoint tests
Temperature (EFT) • EFT sensor ground associated with this
P018200
sensor circuit - low circuit - short circuit DTC using the
input • EFT sensor failure manufacturer
approved
diagnostic system
• Install a new EFT
sensor as
necessary.
Fuel Temperature
Sensor (18.30.99)
• Carry out any

pinpoint tests
DTC using the
circuit - short to power,
manufacturer
Engine Fuel high resistance,
approved
Temperature (EFT) disconnected
sensor circuit - high • EFT sensor ground
• Install a new EFT
input circuit - high resistance
sensor as
necessary.
Fuel Temperature
Sensor (18.30.99)
• Carry out any

pinpoint tests
Fuel Rail Pressure • FRP sensor range and
DTC using the
P019100 (FRP) sensor circuit - performance
manufacturer
range/performance
approved
diagnostic system
• Carry out any

pinpoint tests
• FRP sensor sensing DTC using the
ground, high resistance, approved
Fuel Rail Pressure
disconnected diagnostic system
P019200 (FRP) sensor circuit -
• FRP sensor 5V supply • Install a new FRP
low input
circuit - high resistance sensor as
• FRP sensor failure necessary.
Fuel Rail Pressure
(FRP) Sensor
(18.30.98)
• FRP sensor • Carry out any

supply/sensing circuits pinpoint tests
Fuel Rail Pressure
- short circuit to each associated with this
P019300 (FRP) sensor circuit -
other DTC using the
high input
• FRP sensor sensing manufacturer
• FRP sensor ground diagnostic system
circuit - high resistance • Install a new FRP
• FRP sensor failure sensor as
necessary.
Fuel Rail Pressure
(FRP) Sensor
(18.30.98)
• Carry out any

pinpoint tests
DTC using the
Engine Oil • EOT sensor sensing manufacturer
Temperature (EOT) circuit - intermittent approved
P019623 sensor circuit - high resistance diagnostic system
range/performance - • EOT sensor failure • Install a new EOT
signal stuck low sensor as
necessary.
Oil Temperature
Sensor (18.31.01)
• Carry out any

pinpoint tests
DTC using the
signal stuck high sensor as
necessary.
Oil Temperature
Sensor (18.31.01)
• Carry out any

pinpoint tests
DTC using the
signal invalid sensor as
necessary.
Oil Temperature
Sensor (18.31.01)
P019700 Engine Oil • EOT sensor sensing • Carry out any

Temperature (EOT) circuit - short to ground pinpoint tests
sensor circuit - low • EOT sensor failure associated with this
input DTC using the
manufacturer
approved
diagnostic system
• Install a new EOT
sensor as
necessary.
Oil Temperature
Sensor (18.31.01)
• Carry out any

pinpoint tests
DTC using the
• EOT sensor sensing
manufacturer
Engine Oil circuit - short to power,
approved
Temperature (EOT) high resistance,
sensor circuit - high disconnected
• Install a new EOT
input • EOT sensor failure
sensor as
necessary.
Oil Temperature
Sensor (18.31.01)
• Carry out any

pinpoint tests
DTC using the
manufacturer
to ground, high
approved
Cylinder 1 injector resistance,
circuit - malfunction disconnected
• Install a new
injector as
necessary.
Fuel Injector
(18.10.01)
• Carry out any

pinpoint tests
DTC using the
to ground, high
manufacturer
P020200 approved
diagnostic system
• Install a new
injector as
necessary.
Fuel Injector
(18.10.01)
• Carry out any

pinpoint tests
DTC using the
manufacturer
to ground, high
approved
• Install a new
injector as
necessary.
Fuel Injector
(18.10.01)
• Carry out any

pinpoint tests
DTC using the
manufacturer
to ground, high
approved
• Install a new
injector as
necessary.
Fuel Injector
(18.10.01)
• Carry out any

pinpoint tests
DTC using the
manufacturer
to ground, high
approved
• Install a new
injector as
necessary.
Fuel Injector
(18.10.01)
• Carry out any

pinpoint tests
to ground, high
P020600 DTC using the
manufacturer
approved
diagnostic system
• Install a new
injector as
necessary.
Fuel Injector
(18.10.01)
• Carry out any

pinpoint tests
DTC using the
manufacturer
to ground, high
approved
• Install a new
injector as
necessary.
Fuel Injector
(18.10.01)
• Carry out any

pinpoint tests
DTC using the
manufacturer
to ground, high
approved
• Install a new
injector as
necessary.
Fuel Injector
(18.10.01)
• Carry out any

pinpoint tests
DTC using the
Throttle Position (TP) circuit TP 2 - short to approved
P022200 sensor circuit TP 2 - ground, high resistance diagnostic system
low input • TP sensor failure • Install a new
throttle body as
necessary.
Throttle Body
(19.70.04)
Throttle Position (TP) • TP sensor sensing • Carry out any

P022300 sensor circuit TP 2 - circuit TP 2- short to pinpoint tests
high input power associated with this
• TP sensor failure DTC using the
manufacturer
approved
diagnostic system
• Install a new
throttle body as
necessary.
Throttle Body
(19.70.04)
• Carry out any

pinpoint tests
Accelerator Pedal • APP sensor circuit APP associated with this
Position (APP) sensor 1 - short to ground, DTC using the
P022700
circuit APP 1 - low high resistance manufacturer
input approved
diagnostic system
• Carry out any

pinpoint tests
Accelerator pedal associated with this
• APP sensor circuit APP
position (APP) sensor DTC using the
P022800 1 - short to power
circuit APP 1 high manufacturer
input approved
diagnostic system
• ECM to ignition coil • If specific cylinder

primary circuit faults misfire or injector
(cylinder misfire DTCs are also
detected DTCs also logged refer to the
logged) tests associated to
• Fuel injector circuit those DTCs first
fault(s) (injector DTCs • For ignition coil
also logged) test.
• Ignition coil failure Engine Ignition
• Spark plug • Check and install
Random/multiple failure/fouled/incorrect new sparkplugs as
P030000 cylinder misfire gap necessary.
detected • Fuel delivery pressure Spark Plugs - 4.2L
(low/high) NA V8 - AJV8
• Fuel contamination (18.20.02)
• Fuel injectors • For fuel system
restricted, leaking, tests.
continuously open Fuel Tank and
• Cylinder compression Lines
low • For injector tests.
• Worn camshaft/broken Fuel Charging and
valve springs Controls - 4.2L NA
• Valve clearance V8 - AJV8/4.2L
adjustment SC V8 - AJV8
• Check cylinder
compressions.
Engine
• Check for
worn/broken
engine components
and valve clearance
adjustment.
Engine
Valve Clearance
Adjustment
(12.29.48)
Cylinder 1 misfire Refer to P030000 possible

P030100 Refer to P030000 actions
detected causes
detected causes
detected causes
detected causes
detected causes
detected causes
detected causes
detected causes
• Check for fuel
level sensor DTCs
and refer to DTC
• Misfire detected during
Misfire detected with Index
P031300 low fuel level condition
low fuel • Add fuel, clear the
DTC and test for
normal operation
• Check for specific

• Misfire detected on cylinder misfire
Engine misfire
P031600 first 1000 revs DTCs and refer to
detected on startup
the DTC Index
Knock sensor (KS) 1 • Poor sensor contact • Ensure a good

P032700 circuit - low input with the cylinder block electrical contact
(bank 1) • KS circuit - short to with the cylinder
ground block
• KS failure • Carry out any
pinpoint tests
DTC using the
manufacturer
approved
diagnostic system
• Install a new KS as
necessary.
Knock Sensor (KS)
(18.30.69)
• Ensure a good
electrical contact
with the cylinder
block
• Carry out any
• Poor sensor contact
pinpoint tests
with the cylinder block
Knock sensor (KS) 1 • KS circuit - high
DTC using the
P032800 circuit - high input resistance, short to
manufacturer
(bank 1) power
approved
• KS failure
diagnostic system
necessary.
Knock Sensor (KS)
(18.30.69)
• Ensure a good
electrical contact
with the cylinder
block
• Carry out any
• Poor sensor contact pinpoint tests
with the cylinder block associated with this
Knock sensor (KS) 2
• KS circuit - short to DTC using the
P033200 circuit - low input
ground manufacturer
(bank 2)
• KS failure approved
diagnostic system
necessary.
Knock Sensor (KS)
(18.30.69)
• Poor sensor contact • Ensure a good

Knock sensor (KS) 2
with the cylinder block electrical contact
P033300 circuit - high input
• KS circuit - high with the cylinder
(bank 2)
resistance, short to block
power • Carry out any
• KS failure pinpoint tests
DTC using the
manufacturer
approved
diagnostic system
necessary.
Knock Sensor (KS)
(18.30.69)
• Carry out any

pinpoint tests
DTC using the
manufacturer
• CKP sensor circuit - approved
short to ground, short diagnostic system
to power, high • Check CKP sensor
resistance, for damage and
Crankshaft Position
disconnected check air gap
(CKP) sensor circuit -
P033592 • CKP sensor gap (check at 90°
performance or
incorrect, foreign intervals, should be
incorrect operation
matter on sensor face, no greater than
damaged teeth on rotor 4.5mm)
• CKP sensor failure • Install a new CKP
sensor as
necessary.
Crankshaft Position
(CKP) Sensor
(18.30.12)
• Carry out any

pinpoint tests
• CKP sensor circuit -
DTC using the
manufacturer
to power, high
approved
resistance,
diagnostic system
Crankshaft Position disconnected
• Check CKP sensor
P033594 (CKP) sensor circuit - • CKP sensor gap
for damage and
unexpected operation incorrect, foreign
check air gap
(check at 90°
damaged teeth on rotor
intervals, should be
• CKP sensor failure
no greater than
4.5mm)
• Install a new CKP
sensor as
necessary.
Crankshaft Position
(CKP) Sensor
(18.30.12)
• Carry out any

pinpoint tests
DTC using the
manufacturer
• CKP sensor circuit - approved
short to ground, short diagnostic system
to power, high • Check CKP sensor
resistance, for damage and
Crankshaft Position disconnected check air gap
P033600 (CKP) sensor circuit - • CKP sensor gap (check at 90°
range/performance incorrect, foreign intervals, should be
matter on sensor face, no greater than
damaged teeth on rotor 4.5mm)
• CKP sensor failure • Install a new CKP
sensor as
necessary.
Crankshaft Position
(CKP) Sensor
(18.30.12)
• Carry out any

pinpoint tests
DTC using the
manufacturer
approved
to power, high
diagnostic system
Camshaft Position resistance,
• Check CMP sensor
(CMP) sensor circuit disconnected
for correct
P034092 (bank 1) - • CMP sensor gap
installation and
performance or incorrect, foreign
damage
incorrect operation matter on sensor face,
• Install a new CMP
damaged rotor
sensor as
necessary.
Camshaft Position
(CMP) Sensor RH
(18.31.11)
• CMP sensor circuit - • Carry out any

Camshaft Position
short to ground, short pinpoint tests
(CMP) sensor circuit
P034094 to power, high associated with this
(bank 1) - unexpected
resistance, DTC using the
operation
disconnected manufacturer
• CMP sensor gap approved
incorrect, foreign diagnostic system
matter on sensor face, • Check CMP sensor
damaged rotor for correct
• CMP sensor failure installation and
damage
sensor as
necessary.
Camshaft Position
(CMP) Sensor RH
(18.31.11)
• Carry out any

pinpoint tests
DTC using the
manufacturer
approved
to power, high
diagnostic system
resistance,
Camshaft Position • Check CMP sensor
disconnected
(CMP) sensor circuit for correct
(bank 1) - installation and
incorrect, foreign
range/performance damage
damaged rotor
sensor as
necessary.
Camshaft Position
(CMP) Sensor RH
(18.31.11)
• Carry out any

pinpoint tests
DTC using the
manufacturer
approved
to power, high
diagnostic system
Camshaft Position resistance,
• Check CMP sensor
(CMP) sensor circuit disconnected
for correct
P034592 (bank 2) - • CMP sensor gap
installation and
performance or incorrect, foreign
damage
incorrect operation matter on sensor face,
damaged rotor
sensor as
necessary.
Camshaft Position
(CMP) Sensor LH
(18.31.12)
• Carry out any
pinpoint tests
DTC using the
manufacturer
approved
to power, high
diagnostic system
resistance,
disconnected
(bank 2) - unexpected installation and
incorrect, foreign
operation damage
damaged rotor
sensor as
necessary.
Camshaft Position
(CMP) Sensor LH
(18.31.12)
• Carry out any

pinpoint tests
DTC using the
manufacturer
approved
to power, high
diagnostic system
resistance,
disconnected
(bank 2) - installation and
incorrect, foreign
range/performance damage
damaged rotor
sensor as
necessary.
Camshaft Position
(CMP) Sensor LH
(18.31.12)
• Carry out any

pinpoint tests
Ignition coil 1 circuits - short to
DTC using the
P035100 primary/secondary ground, power, high
manufacturer
circuit resistance
approved
diagnostic system
• Ignition module/coil • Carry out any

Ignition coil 2 circuits - short to pinpoint tests
P035200 primary/secondary ground, power, high associated with this
circuit resistance DTC using the
manufacturer
approved
diagnostic system
• Carry out any

pinpoint tests
DTC using the
manufacturer
circuit resistance
approved
diagnostic system
• Carry out any

pinpoint tests
DTC using the
manufacturer
circuit resistance
approved
diagnostic system
• Carry out any

pinpoint tests
DTC using the
manufacturer
circuit resistance
approved
diagnostic system
• Carry out any

pinpoint tests
DTC using the
manufacturer
circuit resistance
approved
diagnostic system
• Carry out any

pinpoint tests
DTC using the
manufacturer
circuit resistance
approved
diagnostic system
• Ignition module/coil • Carry out any

Ignition coil 8 circuits - short to pinpoint tests
P035800 primary/secondary ground, power, high associated with this
circuit resistance DTC using the
manufacturer
approved
diagnostic system
• EGR valve incorrectly

installed or loose • For EGR system
Exhaust Gas
• EGR pipe blocked tests.
Recirculation (EGR)
P040100 • EGR valve stuck Engine Emission
flow insufficient
closed, blocked Control
detected
• EGR valve failure
• Carry out any

pinpoint tests
Secondary Air associated with this
• AIR check valve
Injection (AIR) DTC using the
P041300 control circuit high
switching valve circuit manufacturer
open approved
diagnostic system
• Carry out any

pinpoint tests
Secondary Air associated with this
• AIR check valve
Injection (AIR) DTC using the
P041400 control circuit low
switching valve circuit manufacturer
shorted approved
diagnostic system
• Check for
misfire/lean
combustion DTCs
overheating damage
and refer to DTC
caused by misfire
Index in this
and/or lean combustion
Catalyst system section
P042000 efficiency below • Check the oil and
poisoning caused by
threshold (bank 1) fuel
excessive oil
condition/level.
consumption and/or
Check the catalytic
contaminated fuel
converter for
damage
• Check for
misfire/lean
overheating damage
combustion DTCs
caused by misfire
Catalyst system and refer to DTC
and/or lean combustion
P043000 efficiency below Index in this
threshold (bank 2) section
poisoning caused by
• Check the oil and
excessive oil
fuel
consumption and/or
condition/level.
contaminated fuel Check the catalytic
converter for
damage
• Carry out any

pinpoint tests
Evaporative Emission • Purge valve -
DTC using the
P044100 (EVAP) system range/performance
manufacturer
incorrect purge flow
approved
diagnostic system
• Carry out any

pinpoint tests
DTC using the
P044700 (EVAP) system vent short to ground
manufacturer
control circuit open
approved
diagnostic system
• Carry out any

pinpoint tests
DTC using the
P044800 (EVAP) system vent short to power
manufacturer
control circuit shorted
approved
diagnostic system
• For evaporative
• DMTL system has emissions tests.
(EVAP) system leak
P045600 detected a leak Evaporative
detected (very small
Emissions
leak)
• Carry out any

pinpoint tests
DTC using the
• EVAP canister purge manufacturer
valve control circuit - approved
Evaporative Emission short to ground, high diagnostic system
P045800 (EVAP) canister purge resistance • Install a new
valve circuit low • EVAP canister purge EVAP canister
valve failure purge valve as
necessary.
Evaporative
Emission Canister
Purge Valve - 4.2L
NA V8 - AJV8
(17.15.30)
• Carry out any

pinpoint tests
• EVAP canister purge associated with this
valve control circuit - DTC using the
P045900 (EVAP) canister purge
valve circuit high
approved
diagnostic system
• For fuel level

Fuel level sensor A sensor pinpoint
circuit - tests for this DTC.
P046129 failure
range/performance - Fuel Tank and
stuck Lines
• For fuel level

Fuel level sensor A sensor pinpoint
circuit - tests for this DTC.
P04612F failure
range/performance - Fuel Tank and
signal erratic Lines
• For fuel level

sensor pinpoint
Fuel level sensor A tests for this DTC.
P046200 failure
circuit - low input Fuel Tank and
Lines
• For fuel level

sensor pinpoint
Fuel level sensor A tests for this DTC.
P046300 failure
circuit - high input Fuel Tank and
Lines
• Carry out any

pinpoint tests
• Electric fan control associated with this
Fan 1 control circuit circuit - short to DTC using the
P048023
low ground, high resistance manufacturer
approved
diagnostic system
• Carry out any

• Electric fan control pinpoint tests
Fan 1 control circuit
P048024 circuit - short to power associated with this
high
DTC using the
manufacturer
approved
diagnostic system
• Carry out any

pinpoint tests
DTC using the
manufacturer
approved
diagnostic system
• Cooling fan difficult to
• CLEAR any
turn/obstructed
P048309 Fan rationality check obstruction and
• Fan/Motor damaged
INSTALL a new
fan as necessary.
Cooling Fan Motor
and Shroud -
Vehicles Without:
Supercharger
(26.25.25)
• Carry out any

pinpoint tests
DTC using the
manufacturer
approved
P048316 Fan rationality check diagnostic system
less than nine volts
• CHECK the battery
condition
• CHECK the
charging system
and fan circuits
• Carry out any

pinpoint tests
DTC using the
manufacturer
P048317 Fan rationality check approved
greater than 18 volts
diagnostic system
• CHECK the
charging system
and fan circuits
• Carry out any

• Cooling fan jammed pinpoint tests
DTC using the
manufacturer
approved
diagnostic system
• CLEAR any
obstruction and
INSTALL a new
fan as necessary.
Cooling Fan Motor
and Shroud -
Vehicles Without:
Supercharger
(26.25.25)
• Carry out any

pinpoint tests
• EGR valve power associated with this
Exhaust Gas
supply circuit - short to DTC using the
P048900 Recirculation (EGR)
ground, high resistance manufacturer
control circuit low
approved
diagnostic system
• Carry out any

pinpoint tests
Exhaust Gas • EGR valve control
DTC using the
P049000 Recirculation (EGR) circuit - short to power
manufacturer
approved
diagnostic system
• Check ABS for

• Vehicle speed - invalid DTCs and refer to
Vehicle speed sensor signal received over DTC Index.
P050082
malfunction CAN Anti-Lock Control
- Stability Assist
• Check ABS for

• Vehicle speed - invalid DTCs and refer to
Vehicle speed sensor signal received over DTC Index.
P050086
malfunction CAN Anti-Lock Control
- Stability Assist
• Check for
ABS/TCM DTCs
Vehicle speed sensor -
• Vehicle speed - range and refer to DTC
range/performance -
P050162 performance Index for speed
signal plausibility
sensor tests.
failure
Anti-Lock Control
- Stability Assist
Diagnostic
Strategy
• Carry out any

pinpoint tests
• The brake pressure
reading does not agree
Brake switch A/B DTC using the
P050400 with the brake light
switch value
approved
diagnostic system
• Brake switch high

fault: Brake lights stuck
• Carry out any
on Gearshift interlock
pinpoint tests
inoperative Speed
control inoperative
Brake switch A/B DTC using the
P050401 • Brake switch low fault:
Brake lights
approved
inoperative Gearshift
diagnostic system
stuck in Park Reduced
engine braking
• Ensure the air

intake system is
free from
(defective/seized
expected belt and
component)
components.
Accessory Drive
• Ensure the air

intake system is
free from
(defective/seized
expected belt and
component)
components.
Accessory Drive

and correct
installation of air
intake system
and correct
installation of
engine crankcase
breather system

and correct
installation of air
intake system
and correct
installation of
engine crankcase
breather system
• Check for any

• Cold start emission
engine ignition
reduction strategy
Cold start ignition related DTCs also
P050B84 engine spark timing too
timing performance logged and refer to
retarded
the DTC Index
• Check for any

• Cold start emission
engine ignition
reduction strategy
Cold start ignition related DTCs also
P050B85 engine spark timing too
timing performance logged and refer to
advanced
the DTC Index
• Carry out any

pinpoint tests
DTC using the
P05120C Starter request circuit high input
manufacturer
approved
diagnostic system
• Carry out any

pinpoint tests
DTC using the
P05120E Starter request circuit low input
manufacturer
approved
diagnostic system
Check for CAN network

Incorrect immobilizer • Security key invalid error. Re-synchronise ID
P051300
key by re-configuring the ECM
and instrument cluster as
new modules
P056013 System voltage • Battery back-up • Carry out any
malfunction pinpoint tests
DTC using the
manufacturer
approved
diagnostic system
• Check for sensor 5

volt supply related
• System voltage
System voltage DTCs and refer to
P056100 comparison
unstable DTC Index in this
section
• Carry out any

pinpoint tests
• Sensor 5 volt power associated with this
supply circuit - low DTC using the
P056200 System voltage low
input manufacturer
approved
diagnostic system
• Carry out any

pinpoint tests
• Sensor 5 volt power associated with this
supply circuit - high DTC using the
P056300 System voltage high
input manufacturer
approved
diagnostic system
• Check speed
• Speed control cancel control system for
Speed control cancel
P057501 button fault DTCs and refer to
button fault
DTC Index
• Check speed
Speed control multi- • Active speed limiter control system for
P059000 function input B fault DTCs and refer to
circuit stuck DTC Index
• Refer to new
Internal control
• CPU communication - module/component
module memory check
P060143 sub installation Note at
sum error - special
top of DTC Index
memory failure
Internal control • Refer to new

• CPU communication
P060145 module memory check module/component
sum error - program installation Note at
memory failure top of DTC Index

module Random module/component
• Initial RAM test
P060442 Access Memory installation Note at
(RAM) error - general top of DTC Index
memory failure
• Shut off RAM test
(RAM) error - special top of DTC Index
memory failure
• RAM check sum
(RAM) error - data top of DTC Index
memory failure
Internal control
• Refer to new
module Random
module/component
Access Memory • Initial RAM test
P060445 installation Note at
(RAM) error -
top of DTC Index
program memory
failure
• Configure the
Internal control • EEPROM/flash module using the
P060500 module Read Only checksum error Jaguar approved
Memory (ROM) error diagnostic system
• Refer to new
Internal control module/component
• ROM error
P060529 module Read Only installation Note at
Memory (ROM) error top of DTC Index

module Read Only module/component
• ROM check sum
P060542 Memory (ROM) error installation Note at
- general memory top of DTC Index
failure
• Shut off ROM test
- special memory top of DTC Index
failure
Internal control
• Refer to new
module Read Only • Initial ROM test
P060544 module/component
Memory (ROM) error
installation Note at
- data memory failure
top of DTC Index

• Continuous ROM test
- program memory top of DTC Index
failure
• Refer to new
• Continuous ROM test

• Shut off ROM test
- supervision software top of DTC Index
failure
• Refer to new
• ROM error - sub
• Refer to new
module/component
ECM/PCM processor • Watchdog error
fault
top of DTC Index
• Refer to new
ECM/PCM processor module/component
• Controller test - sub
P060601 fault - general installation Note at
electrical failure top of DTC Index
• Refer to new
module/component
ECM/PCM processor • System internal failures
fault
top of DTC Index
• Refer to new
• Throttle return spring
failure (throttle body
P060605 fault - system installation Note at
failure)
programming failures top of DTC Index
• Refer to new
ECM/PCM processor • Watch dog timer fault - module/component
P060641 fault - general sub installation Note at
checksum failure top of DTC Index
• Refer to new
ECM/PCM processor • Error capturing module/component
P060642 fault - general instructions installation Note at
• Refer to new
ECM/PCM processor • Duplication memory module/component
P060643 fault - special memory fault installation Note at
failure top of DTC Index
• Refer to new
ECM/PCM processor • Duplication memory module/component
P060644 fault - data memory fault - sub installation Note at
failure top of DTC Index
• Refer to new
ECM/PCM processor • Detection of write to module/component
P060645 fault - program internal ROM installation Note at
ECM/PCM processor
• Detection of write to Configure the module
fault -
P060646 internal ROM - sub using the Jaguar approved
calibration/parameter
diagnostic system
memory failure
Configure the module
ECM/PCM processor • Watch dog timer fault
P060647 using the Jaguar approved
fault
diagnostic system
ECM/PCM processor • Scheduling sequence Configure the module
P060648 fault - supervision check using the Jaguar approved
software failure diagnostic system
• Refer to new
• Controller test
P060649 fault - internal installation Note at
electronic failure top of DTC Index
• Refer to new
module/component
Control module • Sub - CPU watch dog
performance
top of DTC Index
• Carry out any

Internal control pinpoint tests
module accelerator • APS Communication associated with this
P060D00
pedal position DTC using the
performance manufacturer
approved
diagnostic system
• Throttle motor • Refer to new

Internal control
amplifier failure for module/component
module throttle
P060E62 valve sensor installation Note at
position performance -
malfunction top of DTC Index
signal compare failure

module throttle module/component
• TPS Communication
P060E64 position performance - installation Note at
signal plausibility top of DTC Index
failure
• Clear the DTC and
retest. If the DTC
• Internal control module
Internal control resets, refer to new
monitoring processor
P060A64 module monitoring module/component
performance
processor performance installation Note at
top of DTC Index
• Clear the DTC and

retest. If the DTC
• Internal control module
Internal control resets, refer to new
monitoring processor
P060A67 module monitoring module/component
performance
processor performance installation Note at
top of DTC Index
• Re-configure the
RJB using the
• Car configuration data
Control module manufacturer
P061000 mismatch
vehicle options error approved
diagnostic system
• Refer to new
• Pedal follower error
P061A00 module torque installation Note at
performance top of DTC Index
• Refer to new
Internal control • Absolute engine torque
module/component
module torque calculation failure -
P061A29 installation Note at
performance - signal sub-processor
top of DTC Index
invalid
• Refer to new
Internal control
• Absolute engine torque module/component
module torque
P061A64 calculation failure installation Note at
performance - signal
top of DTC Index
• Absolute and dynamic
module torque module/component
engine torque
P061B29 calculation installation Note at
calculation failure
performance - signal top of DTC Index
invalid
• Absolute and dynamic
module torque module/component
engine torque
P061B64 calculation installation Note at
calculation failure
performance - signal top of DTC Index
• Refer to the
electrical circuit
• Fuel pump control diagrams and check
Fuel pump A control circuit fault (FPDM to the FPDM to Fuel
P062700
circuit/open fuel pump) Pump circuit for
short to ground,
power, open circuit
• Refer to the
electrical circuit
diagrams and test
Fuel pump A control • Invalid fuel pump duty
the ECM to FPDM
P062A00 circuit requested by the ECM
monitor circuit for
range/performance
short to ground,
power, open circuit
• Configure the
module using the
Jaguar approved
diagnostic system,
clear DTC and re-
test, if DTC
VIN not programmed • CCF to CAN VIN
remains suspect the
P063000 or incompatible - mismatch
ECM. Refer to the
ECM/PCM
new
module/component
installation note at
the top of the DTC
Index
• Carry out any

pinpoint tests
• EMS control relay
EMS control relay DTC using the
P068773 malfunction
control circuit high manufacturer
approved
diagnostic system
• TCM Output shaft
Output speed sensor tests.
speed sensor error
P072186 circuit Diagnostic
received
range/performance Strategy
• Carry out any

pinpoint tests
Starter relay circuit DTC using the
P08170D (break wire)
(break wire) manufacturer
approved
diagnostic system
• Carry out any

pinpoint tests
Starter relay circuit • Starter relay circuit low DTC using the
P081A0B
low manufacturer
approved
diagnostic system
• Carry out any

pinpoint tests
Starter relay circuit DTC using the
P081B0C high
high manufacturer
approved
diagnostic system
• Carry out any

pinpoint tests
Park/Neutral switch DTC using the
P08510E input circuit - low
input circuit low manufacturer
approved
diagnostic system
• Carry out any

pinpoint tests
Park/Neutral switch DTC using the
P08520C input circuit - high
input circuit high manufacturer
approved
diagnostic system
• Incorrect ID received • Re-configure the

Immobilizer to ECM
P125900 from instrument cluster instrument cluster
signal error
using the
manufacturer
approved
diagnostic system
• ECM to ignition coil • Check for cylinder

primary circuit fault mis-fire, ignition
(cylinder misfire and injector DTCs
detected DTC also and refer to the
flagged) DTC Index
• Fuel injector circuit • For fuel system
fault(s) (injector DTCs tests.
also flagged) Fuel Tank and
• Fuel delivery pressure Lines
low • For spark plug
• Spark plug tests.
failure/fouled/incorrect Engine Ignition
gap • For cylinder
• Cylinder compression compression tests.
low Engine
• Check for
individual cylinder
• Misfire rate exceeds
Misfire rate exceeds misfire DTCs and
P131600 emissions thresholds
emissions thresholds refer to DTC Index
in this section
• Carry out any

• Ignition module/coil pinpoint tests
monitoring circuit - associated with this
Ignition amplifier short to ground, short DTC using the
P136700
group A to power, high manufacturer
resistance approved
diagnostic system
• Carry out any

• Ignition module/coil pinpoint tests
monitoring circuit - associated with this
Ignition amplifier short to ground, short DTC using the
P136800
group B to power, high manufacturer
resistance approved
diagnostic system
• Refer to new
module/component
• ECM fault
P160300 EEPROM error installation note at
top of DTC Index
P162600 ECM electronic • Dynamic torque • Suspect the ECM,

throttle monitoring error refer to new
monitoring/self test - module/component
torque monitoring installation note at
problem top of DTC Index
• Check integrity and

correct installation
of air intake system
• Heated Oxygen Sensor
• Check for any
Fuel trim too lean, (HO2S) fuel adaption -
P209600 HO2S codes also
bank 1 lean
logged and refer to
DTC Index in this
section

• Check for any
Fuel trim too rich, (HO2S) fuel adaption -
bank 1 rich
logged and refer to
DTC Index in this
section

• Check for any
Fuel trim too lean, (HO2S) fuel adaption -
bank 2 lean
logged and refer to
DTC Index in this
section

• Check for any
Fuel trim too rich, (HO2S) fuel adaption -
bank 2 rich
logged and refer to
DTC Index in this
section
• Carry out any

pinpoint tests
Throttle actuator • Jammed throttle blade, associated with this
P210129 control motor circuit gearing or motor DTC using the
range/performance manufacturer
approved
diagnostic system
• Install a new
throttle body. Refer
to the new
module/component
the top of the DTC
Index
• Refer to the
electrical circuit
diagrams and test
throttle actuator
control motor
circuit for short to
ground, power,
high resistance.
Throttle actuator • Jammed throttle blade,
Compare throttle
P210162 control motor circuit gearing or motor
position sensor 1
range/performance
and 2 datalogger
signals, if signals
are comparable
install a new
throttle body.
Throttle Body
(19.70.04)
• Carry out any

pinpoint tests
DTC using the
manufacturer
approved
Throttle actuator • Jammed throttle blade, diagnostic system
P210164 control motor circuit gearing or motor • Install a new
range/performance throttle body. Refer
to the new
module/component
the top of the DTC
Index
• Check for throttle

related DTCs and
• Throttle blade stuck
Throttle actuator refer to DTC Index
open
P210177 motor control circuit in this section
• Intake air system leak
range/performance • Check intake air
system for leaks
• Carry out any
pinpoint tests
DTC using the
• Throttle motor control manufacturer
Throttle actuator
P210329 motor control circuit
• ECM fault diagnostic system
high
• Refer to new
module/component
top of DTC Index
• Carry out any

pinpoint tests
DTC using the
Throttle actuator • Throttle motor control manufacturer
motor control circuit circuit - short to power approved
P210364
high - signal • ECM fault diagnostic system
plausibility failure • Refer to new
module/component
top of DTC Index
• Carry out any

pinpoint tests
Throttle actuator associated with this
• Throttle MIL request
control system - DTC using the
P210500 due to fuel cut
forced engine manufacturer
shutdown approved
diagnostic system
• Install a new
throttle body.
Throttle Body
Throttle actuator (19.70.04) Refer to
• Signal invalid
P210629 control system - new
forced limited power module/component
top of DTC Index
• Install a new
throttle body.
Throttle actuator • Signal plausibility Throttle Body
P210664 control system - failure (19.70.04) Refer to
forced limited power new
module/component
www.JagDocs.com
top of DTC Index
• Carry out any

pinpoint tests
Throttle actuator circuit - short to
DTC using the
P211800 motor control current ground, power, high
manufacturer
range/performance resistance
approved
diagnostic system
• Install a new
throttle body.
Throttle Body
Throttle actuator (19.70.04) Refer to
• Throttle spring faulty
P211900 control throttle body new
range/performance module/component
top of DTC Index
• Carry out any

pinpoint tests
Accelerator pedal • APP sensor circuit 2 -
DTC using the
P212200 position (APP) sensor low input
manufacturer
D circuit low input
approved
diagnostic system
• Carry out any

pinpoint tests
Accelerator pedal • APP sensor circuit 2 -
DTC using the
P212300 position (APP) sensor high input
manufacturer
D circuit high input
approved
diagnostic system
• Check APP sensor

circuits 1 and 2 for
short to ground,
• APP sensor circuit 1
Accelerator pedal power and high
and 2 range
position (APP) sensor resistance. Clear
P213528 performance - sub-
1 and 2 voltage the DTCs and
processor
correlation retest. If the code
remains, replace
the APP sensor
Accelerator pedal • APP sensor - excessive • Carry out any

P213529 position (APP) sensor difference between raw pinpoint tests
1 and 2 voltage values of circuit 1 and associated with this
correlation 2 - sub-processor DTC using the
manufacturer
approved
diagnostic system
• Check APP sensor

circuits 1 and 2 for
short to ground,
• APP sensor circuit 1
Accelerator pedal power and high
and 2 range
position (APP) sensor resistance. Clear
P213562 performance - sub-
1 and 2 voltage the DTCs and
processor
correlation retest. If the code
remains, replace
the APP sensor
• Carry out any

pinpoint tests
Accelerator pedal • APP sensor circuit 1 associated with this
position (APP) sensor and 2 range DTC using the
P213564
1 and 2 voltage performance manufacturer
correlation approved
diagnostic system
• Refer to new
• BARO sensor failure module/component
Barometric pressure
P222800 (internal ECM fault) installation note at
circuit low input
top of DTC Index
• Refer to new
• BARO sensor failure module/component
Barometric pressure
P222900 (internal ECM fault) installation note at
circuit high input
top of DTC Index
• Carry out any

pinpoint tests
Evaporative emission associated with this
(EVAP) system leak DTC using the
P240100 short to ground
detection pump manufacturer
control circuit low approved
diagnostic system
• Carry out any

(EVAP) system leak associated with this
P240200 short to power
detection pump DTC using the
control circuit high manufacturer
approved
diagnostic system

• For evaporative
Evaporative emission • DMTL pump circuit -
emissions system
(EVAP) system leak short to ground, power,
tests.
P240429 detection pump high resistance
Evaporative
sensing circuit • DMTL pipework
Emissions
range/performance blocked/leaking

Evaporative emission • For evaporative
(EVAP) system leak emissions system
short to ground, power,
detection pump tests.
P24042F high resistance
sensing circuit Evaporative
• DMTL pipework
range/performance - Emissions
blocked/leaking
signal erratic
• For evaporative
Evaporative emission • DMTL pump circuit - emissions system
(EVAP) system leak short to ground, power, tests.
P240500
detection pump high resistance Evaporative
sensing circuit low Emissions
• For evaporative
Evaporative emission • DMTL pump circuit - emissions system
(EVAP) system leak short to ground, power, tests.
P240600
detection pump high resistance Evaporative
sensing circuit high Emissions
• Carry out any

pinpoint tests
P240B00 circuit low
diagnostic system
• Carry out any

pinpoint tests
circuit high approved
diagnostic system
Secondary air • Secondary air injection • Check the

P243100 injection manifold system leaks secondary air
absolute pressure • Secondary air injection injection system for
sensor circuit pump leaks
range/performance • Secondary air injection • Carry out any
valve pinpoint tests
DTC using the
manufacturer
approved
diagnostic system
• Carry out any

• Secondary air injection pinpoint tests
Secondary air manifold absolute associated with this
injection manifold pressure sensor circuit - DTC using the
P243200
absolute pressure short to ground, high manufacturer
sensor circuit low resistance approved
diagnostic system
• Carry out any

pinpoint tests
• Secondary air injection
Secondary air associated with this
manifold pressure
injection manifold DTC using the
P243300 (MAP) sensor circuit -
absolute pressure manufacturer
short to power
sensor circuit high approved
diagnostic system
• Carry out any

pinpoint tests
• Secondary air injection associated with this
Secondary air
pump control circuit - DTC using the
P244400 injection system pump
short to ground manufacturer
stuck ON
approved
diagnostic system
• Carry out any

pinpoint tests
• Secondary air injection associated with this
Secondary air
pump control circuit - DTC using the
P244500 injection system pump
stuck OFF
approved
diagnostic system
Evaporative emission • Carry out any

(EVAP) system • DMTL system circuit - pinpoint tests
change-over valve short to ground, power, associated with this
P245000
(COV) high resistance DTC using the
performance/stuck manufacturer
open approved
diagnostic system
• Carry out any

(EVAP) system • DMTL system circuit - associated with this
change-over valve short to ground, power, DTC using the
P245100
(COV) high resistance manufacturer
performance/stuck approved
closed diagnostic system
• Check for DTCs

indicating a fault
with any of the
ECM/PCM Internal sensor fault
components listed,
P261064 engine off timer • Body processor module
and refer to
performance fault (time)
relevant DTC
• CAN error
Index
• Check for DTCs

indicating a fault
with any of the
ECM/PCM Internal sensor fault
components listed,
P261087 engine off timer • Body processor module
and refer to
performance fault (time)
relevant DTC
• CAN error
Index
• Carry out any

pinpoint tests
Control module • CAN Link circuit
DTC using the
U007300 communication bus malfunction
manufacturer
off
approved
diagnostic system
• Carry out any

pinpoint tests
• CAN Link ECM/TCM
Lost communication DTC using the
U010100 network malfunction
with TCM manufacturer
approved
diagnostic system
• Carry out any

• CAN Link ECM/gear pinpoint tests
Lost communication
shift network associated with this
U010300 with gear shift control
malfunction DTC using the
module
manufacturer
approved
diagnostic system
• Carry out any

pinpoint tests
• CAN Link ECM/speed associated with this
Lost communication
control module DTC using the
U010400 with speed control
network malfunction manufacturer
module
approved
diagnostic system
• Carry out any

pinpoint tests
Lost communication • CAN Link ECM/ABS associated with this
with anti-lock brake module network DTC using the
U012100
system (ABS) control malfunction manufacturer
module approved
diagnostic system
• Carry out any

• CAN Link pinpoint tests
Lost communication ECM/Electronic associated with this
with electronic parking brake signal DTC using the
U012800
parking brake control missing network manufacturer
module malfunction approved
diagnostic system
• Carry out any

pinpoint tests
Lost communication • Lost communication -
DTC using the
U015100 with restraints control CAN or hardwired
manufacturer
approved
diagnostic system
• Carry out any

pinpoint tests
DTC using the
U01511F with restraints control SRS fault
manufacturer
approved
diagnostic system
• Carry out any

pinpoint tests
U015157 with restraints control CAN fault
DTC using the
manufacturer
approved
diagnostic system
• Carry out any

pinpoint tests
• CAN Link
Lost communication ECM/instrument
DTC using the
U015500 with instrument cluster network
manufacturer
cluster malfunction
approved
diagnostic system
• Carry out any

pinpoint tests
Lost communication • Security challenge
DTC using the
U016700 with vehicle response timeout
manufacturer
immobilizer
approved
diagnostic system
• Check TCM for

Invalid data received DTCs and refer to
• TCM engine speed
from Transmission DTC Index.
U040208 control monitor
Control Module Diagnostic
(TCM) Strategy
• Check TCM for

• Actual gear position
U040264 status
(TCM) Strategy
• Check TCM for

• Selector lever position
U040267 status
(TCM) Strategy
• Check TCM for

• Output shaft speed
U040281 signal
(TCM) Strategy
Invalid Data Received • CAN Bus circuit fault Check the transmission
From Transmission • Circuit fault in supply control module for related
U040282 Control Module - voltage to transmission stored DTCs. Using the
TCM engine speed control module manufacturer approved
control monitor - diagnostic system,
plausibility (TCM complete a CAN network
alive counter) integrity test. Refer to the
electrical circuit diagrams
and check the CAN
network to the
module. Refer to the
electrical circuit diagrams
and check the power and
ground circuit to the
module
• Check TCM for
Invalid data received • TCM engine speed DTCs and refer to
from Transmission control monitor - DTC Index.
U040283
Control Module plausibility Diagnostic
(TCM) Strategy
• Check TCM for

Invalid data received • TCM engine speed DTCs and refer to
from Transmission control monitor - DTC Index.
U040286
Control Module rationality Diagnostic
(TCM) Strategy
• Check speed
• Invalid data received control module for
from speed control DTCs and refer to
U040581 from speed control
module DTC Index.
module
Speed Control
• Check speed
U040583 from speed control
module DTC Index.
module
Speed Control
• Check speed
U04058F from speed control
module DTC Index.
module
Speed Control
• Check anti-lock
Invalid data received control - stability
from Anti-lock Brake • Brake Position Switch assist module for
U041500
System (ABS) control DTCs and refer to
module DTC Index.
Anti-Lock Control
- Stability Assist
• Check anti-lock
control - stability
Invalid data received • Engine drag torque assist module for
from Anti-lock Brake control monitoring - DTCs and refer to
U041564
System (ABS) control plausibility DTC Index.
module Anti-Lock Control
- Stability Assist
• Check anti-lock
control - stability
Invalid data received • Engine drag torque assist module for
from Anti-lock Brake control monitoring - DTCs and refer to
U041567
System (ABS) control rationality DTC Index.
module Anti-Lock Control
- Stability Assist
cluster for DTCs
• Battery voltage level and refer to DTC
U042386 from instrument
Index.
cluster - signal invalid
Instrument Cluster
cluster for DTCs
Invalid data received • External ambient
and refer to DTC
U042481 from instrument temperature
Index.
cluster
Instrument Cluster
• Check CAN
network between
ECM and
instrument cluster.
Check power and
grounds to ECM
and instrument
Invalid data received • Security code mis- cluster. Check
U042600 from vehicle match correct ECM and
immobilizer instrument cluster
installed. Re-
synchronise ID by
re-configuring the
ECM and
instrument cluster
as new modules
• Set ignition to ON,
Warning indicator then OFF (wait 30
• Fuel Cut
U206400 requested by another seconds), then ON
control module (wait 4 seconds)
Camshaft Position (CMP) Sensor LH

(18.31.12)
Removal



Installation


Camshaft Position (CMP) Sensor RH
(18.31.11)
Removal


4 . Release the CMP sensor electrical connector.

Installation


Removal
2

4 . Remove the catalyst monitor sensor.
Installation
1
catalyst monitor sensor tip.
Install the catalyst monitor sensor and tighten to 45 Nm (33 lb.ft).


4 NOTE:

Cycle Self-Test
Crankshaft Position (CKP) Sensor
(18.30.12)
Removal
2
3 . NOTE:
Remove the crankshaft position (CKP) sensor.

Installation

Removal

Remove the 4 clips.

4 . Disconnect the engine harness electrical connector.

Loosen the bolt.
5 . Release the electrical connector.

6 . NOTE:
Remove the engine control module (ECM).

Remove the 3 bolts.
Release and disconnect the 2 engine harness electrical connectors.
Installation
Connect the ECM electrical connectors.
2 . Install the electrical connector.




7 . Using WDS, configure a new ECM.

Engine Coolant Temperature (ECT) Sensor
(18.30.10)
Removal
CAUTION: Engine coolant will damage the paint finished surfaces. If spilt,

2
steam or coolant, do not remove the filler cap from the coolant expansion tank
while the system is hot.

For additional information, refer to Cooling System Draining, Filling and Bleeding -
4.2L NA V8 - AJV8
3 Remove the thermostat housing.

. For additional information, refer to Thermostat Housing - Vehicles Without:
Supercharger
4 . Remove the ECT sensor.


Installation
1 . Install the O-ring seals.

3 Install the thermostat housing.

. For additional information, refer to Thermostat Housing - Vehicles Without:
Supercharger

. For additional information, refer to Cooling System Draining, Filling and Bleeding -
4.2L NA V8 - AJV8

Removal
personal injury.


4
Remove the FRP sensor.

Remove the 2 bolts.
Installation
1
Install the FRP sensor.



Removal
personal injury.


3

Installation
1
Install the fuel temperature sensor.


Removal
2
3 . Release and disconnect the heated oxygen sensor (HO2S) electrical connector.
4
. WARNING: Do not twist the HO2S wiring harness on removal. Failure to
Remove the HO2S.
Installation
1
HO2S tip.
Install the HO2S to the catalytic converter and tighten to 45 Nm (33 lb.ft).

4 NOTE:

Cycle Self-Test
Removal

3 . Remove the KS.

Remove the 2 nuts.
Installation
1 . Install the KS.


Manifold Absolute Pressure (MAP) Sensor
(18.30.86)
Removal


Remove the 2 bolts.

Installation



5 NOTE:

Cycle Self-Test
Removal
2
3 . Remove the air cleaner assembly.

Installation
1 . Install the air cleaner assembly.

3 NOTE:

Cycle Self-Test
Variable Camshaft Timing (VCT) Oil
Control Solenoid (18.30.90)
Removal
NOTE:
Removal of the RH is similar to this procedure.


3 . Remove the VCT oil control solenoid.

Remove the bolt.
Installation
1 . Install the VCT oil control solenoid.


4 NOTE:
.

Cycle Self-Test
Removal
2


Installation


Removal
2

4 . Remove the oil temperature sensor.

Installation
1 . Install the oil temperature sensor.


Removal
NOTE:
The brake pedal position switch also functions as the speed control deactivator switch.
1 . Remove the BPP switch.

For additional information, refer to Speed Control Deactivator Switch (19.75.20)
Installation
1 . Install the BPP switch.
For additional information, refer to Speed Control Deactivator Switch (19.75.20)
307 : Automatic Transmission/Transaxle
307-01 : Automatic Transmission/Transaxle
Specifications
Specifications
Specifications
High temperature grease Molecote FB180 / Jaguar 8309
Transmission fluid Shell M1375.4
Capacities
Liters
Transmission fluid 9.5
Transmission fluid (Supercharged models) 10.0
Service fill 6.0
Item Nm lb-ft lb-in

Crossmember to vehicle body - bolt 48 35 -
Fluid pan, gasket and filter - screw 8 6 71
Mass damper to crossmember - bolt 10 7 -
Output shaft flange - nut* 60 44 -
Selector lever to transmission - nut 12 9 -
Support insulator to crossmember - bolt 25 18 -
Support insulator to transmission - bolt 48 35 -
Flexplate to torque converter - screw 55 41 -
Torque converter housing to engine - bolt 48 35 -
Transmission control module (TCM) and Main control valve body - screw 8 6 71
Transmission fluid - drain plug 8 6 71
Transmission fluid - fill plug A -
Transmission heat shield 10 7 -
NOTE:
NOTE:
A = refer to the procedure for correct torque sequence.
General procedures
Transmission Fluid Drain and Refill

(44.24.02)
Adaptor
307-452
WARNING: Observe due care when draining, as the fluid can be very hot.
WARNING: Observe due care when working near a hot exhaust system.
1.
2. Remove the RH transmission heat shield.
• Remove the 2 bolts.

3. Clean the area around the transmission fluid drain and filler plugs.
4. Place a container under the transmission.
5.
Using the special tool, remove the transmission fluid filler/level plug.
6. Remove the transmission fluid drain plug.

• Allow the fluid to drain.
7. Install the transmission fluid drain plug and tighten to 8 Nm (6 lb.ft).
8. Add the correct transmission fluid, until a small thread of fluid runs from the filler/level hole.
9. Start and run the engine.
10. Add the correct transmission fluid, until a small thread of fluid runs from the filler/level hole.
11. Check and top-up the transmission fluid level.

Adaptor
307-452
CAUTION: The gearbox fluid level must only be checked when the temperature of the fluid
is between 30 degrees and 50 degrees. The fluid level obtained will be incorrect if the reading is
outside this temperature range.
1. The following steps must be observed before starting the transmission fluid level check and top-
up.
• The vehicle must be on a horizontal ramp.
• The parking brake must be applied.
• The wheels must be chocked.
2.
CAUTION: Make sure the transmission fluid temperature is below 30 degrees before
starting the fluid level check.
Connect WDS to the on-board diagnostic connector, to monitor the transmission fluid temperature.
3. Start the engine. Move the selector lever from 'P' through all gear positions, pausing in each gear
position for 2-3 seconds and return to the 'P' position.
4.
5. Remove the RH transmission heat shield.
• Remove the 2 bolts.
6. Place a container under the transmission.
7.
CAUTION: The gearbox fluid level must only be checked when the temperature of the fluid
is between 30 degrees and 50 degrees. The fluid level obtained will be incorrect if the reading is
outside this temperature range.
Using the special tool, remove the transmission fluid filler/level plug.
• Clean the area around the filler/level plug.
8. If no fluid loss is apparent when the filler/level plug is removed, with the engine at idle, continue
to fill the transmission until a small thread of oil runs from oil filler/level hole.
9.
WARNING: Make sure the transmission fluid filler plug is tightened to the correct
specification. The torque correction formula below must be followed to prevent damage to the
transmission case.
Install the transmission fluid filler/level plug and tighten to 35 Nm (26 lb.ft).
• 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 (2).
• 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.
10. Install the transmission heat shield.
• Tighten the bolts to 10 Nm (7 lb.ft).
11. Disconnect WDS from the vehicle.

COMPONENT LOCATION
INTRODUCTION
The ZF 6HP26 transmission is an electronically controlled, six speed unit. The transmission is
manufactured by ZF Transmissions GmbH in Saarbrücken, 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 are now
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. Further details of the ASIS function are contained
in the 'Driving Modes' section.
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 transmission is controlled by a Transmission Control Module (TCM) which contains

software to provide operation as a semi-automatic 'Jaguar Sequential Shift' transmission. The
TCM allows the transmission to be operated as a conventional automatic unit by selecting P,
R, N, D on the selector lever. Movement of the selector lever across the gate to the 'S' position
puts the transmission into electronic 'Sport' mode. Two steering wheel paddles, when
operated, puts the transmission into electronic manual 'Jaguar Sequential Shift' mode.
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 Engine Control Module (ECM) via the high speed Controller Area
Network (CAN) bus for communications
• Default mode if major faults occur
• Diagnostics available from the TCM via the CAN
ZF 6HP26 Automatic Transmission – Exploded View

NOTE:
The transmission shown is exploded to the extent of the serviceable items
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.
ZF 6HP26 Automatic Transmission – Sectional View

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 pan
20 Input shaft
21 Bell housing
TORQUE CONVERTER

1 Impeller
2 Turbine
3 Stator
4 Freewheel
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. With 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
NOTE:
Typical torque converter shown

1 Turbine
2 Stator
3 Impeller
When the engine is running the rotating impeller acts as a centrifugal pump, picking up fluid
at its centre 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 an anti-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.
Stator Functions
NOTE:
Typical stator shown
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.
When 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

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 signals from the TCM to give full, partial or
no lock-up of the torque converter.

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.
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. When 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
1 Position switch
2 Sliding block
3 Selector spool valve
4 Position switch assembly
5 Electronic Pressure Regulator Solenoid (EPRS) 6
6 Solenoid valve 1
7 EPRS 4
8 EPRS 5
9 EPRS 3
10 EPRS 2
11 EPRS 1
14 Valve housing
15 Valve plate
16 Torque converter retaining valve
17 Clutch return valve
18 Element seal
19 Pressure regulator dampers
20 Intermediate plate
ZF 6HP26 Automatic Transmission – Valve Housing

Components
1 Selector spool valve
2 Lubricating valve
3 Torque converter pressure valve
4 System pressure valve
5 Torque converter clutch valve
6 Retaining valve – Clutch E
7 Clutch valve E
8 Clutch valve A
9 Valve housing
10 Bolts
11 Retaining valve – Clutch A
12 Retaining valve – Clutch B
13 Pressure reducing valve
14 Shift valve 1
15 Retaining valve – Brake D
16 Shift valve 2
17 Damper
18 Electronic Pressure Regulator Solenoid (EPRS) 6
19 Solenoid valve 1
20 EPRS 4
21 EPRS 5
22 EPRS 2
23 EPRS 3
24 EPRS 1
ZF 6HP26 Automatic Transmission – Valve Plate

Components

1 Retaining valve – Brake D2
2 Clutch valve – Brake D2
3 Clutch valve B
4 Valve plate
5 Clutch valve – Brake D1
6 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 Pulse Width Modulation (PWM) 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 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 PWM 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 20°C (68°F).
Control Solenoid
A shift control Solenoid Valve (SV) is located in the valve block. The solenoid is controlled
by the TCM and converts electrical signals into hydraulic control signals to control clutch
application.
The shift control solenoid is an open/closed, on/off solenoid which is controlled by the TCM
switching the solenoid to earth. The TCM also supplies power to the solenoid. The TCM
energises the solenoid in a programmed sequence for clutch application for gear ratio changes
and shift control.
The resistance of the solenoid coil winding within the solenoid is between 26 to 30.4 ohms at
20°C (68°F).
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 twenty one 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
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. When 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

1 - Cylinder
2 - Baffle plate
3 - Ring gear
4 - Sun gear
5 - Planetary gear spider
6 - Torque converter input shaft
Double Web Planetary Gear Train

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
POWER FLOWS
Operation of the transmission is controlled by the TCM which electrically activates various
solenoids to control the transmission gear selection. The sequence of solenoid activation is
based on programmed information in the module memory and physical transmission operating
conditions such as vehicle speed, throttle position, engine load and selector lever position.
Powerflow Schematic
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.
Gear Selector Shift Control Electronic Pressure 1 2 3 4 5 6

Lever Position Solenoid Valve Regulator Solenoids
(EPRS)
P - - - - ON - -
ON-
R - - ON - ON - -
ON-
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.
Gear Selector Lever Shift Control Solenoid

Clutch Brake A B E WK C D
Position Valve
P - - - - - - X
R - - X - - - X
N - - - - - - X
D1 - X - - X- X
D2 - X - - XX-
D3 - X X - X- -
D4 ON X - XX- -
D5 ON - X XX- -
D6 ON - - XXX-
X = clutch applied
Shift Elements

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 gear selector lever and the manual 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 gear selector lever and the manual selector spool valve are in the 'D' position. Engine
of clutch 'B'.
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.
NOTE:
Power Flow 3rd Gear
of clutch 'B'.
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 transmit
drive to the locked double web planetary gear train carrier in the direction of engine rotation.
NOTE:
Power Flow 4th Gear
torque is transmitted from the torque converter turbine shaft to ring gear 1 of the single web
planetary gear train and the outer plate carrier of clutch 'E'.
of clutch 'B'.
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.
NOTE:
Power Flow 5th Gear

of clutch 'B'.
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.
NOTE:
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.
NOTE:
Power Flow Reverse Gear
The gear selector lever and the manual selector spool valve are in the 'R' position. Engine
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.
NOTE:
SELECTOR POSITION SWITCH

The Mechatronic valve block contains a position switch which is mechanically connected to
the selector spool valve. The selector spool valve is connected by a selector shaft to the
selector lever via a 'Bowden' selector cable.
The signals from the position switch are used by the TCM to determine the P, R, N or D
selection made by the driver.
INSTRUMENT CLUSTER
1 - Transmission selected gear status
2 - Malfunction Indicator Lamp (MIL)
3 - Message centre
The instrument cluster is connected to the TCM via the high speed CAN bus. Transmission
status is transmitted by the TCM and displayed to the driver in one of 2 displays in the
instrument cluster. For additional information, refer to Instrument Cluster (413-01 Instrument
Cluster)
Malfunction Indicator Lamp (MIL)

The MIL 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 on receipt of a relevant fault message from the TCM on
the high speed CAN. The nature of the fault can be diagnosed using the Integrated Diagnostic
System (IDS) which reads the fault codes stored in the TCM memory.
Transmission Status Display

The transmission status display is located in a Liquid Crystal Display (LCD) at the top of the
instrument cluster, between the speedometer and the tachometer. The LCD shows the selector
lever 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
DS 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 Centre Display

The message centre is located in the lower centre of the instrument cluster. The message
centre 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 centre 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 module
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 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 selector lever is connected to the automatic transmission and the position switch in the
transmission by a Bowden cable. Movement of the selector lever moves the position switch
via the cable and the switch position informs the TCM of the selected position. The sport
switch passes the sport selection to the TCM. 'Jaguar Sequential Shift' selections are sensed
when the driver operates the steering wheel paddle switches. An additional switch provides a
selector lever 'not in park' position signal. Once the selector lever position is confirmed, the
TCM outputs appropriate information which is received by the instrument cluster to display
the gear selection information in the message centre.
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.
A 'not in park' switch is located in the selector lever mechanism. The switch is connected to
the instrument cluster, Central Junction Box (CJB) and the ECM. The instrument cluster uses
the park switch status to display the selector position. The ECM uses the status to allow starter
motor operation only when the selector lever is in the Park or Neutral positions. The signal is
also passed from the CJB to the TCM.
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
• ABS control module
• Adaptive front lighting control module - if fitted
• Adaptive cruise 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
yellow/black (H) and yellow/brown (L) and are twisted together to minimise electromagnetic
interference (noise) produced by the CAN bus messages. For additional information, refer to
Communications Network (418-00 Module Communications Network)
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
• Gear position indication in instrument cluster message centre 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
• Sport mode
• Manual ('Jaguar Sequential Shift') mode
• Adaptive Shift Strategy (ASIS)
• 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 selector
lever is moved to the 'D' position, normal mode is automatically resumed.
Sport Mode
The sport mode provides enhanced acceleration and responsiveness. In sport mode the TCM
uses shift maps which allow the transmission to downshift more readily, hold gears for longer
at higher engine speeds, and limits the transmission to the first five gears (6th gear is not
used).
Sport mode is selected by moving the selector lever across the 'L' gate into the 'S' position.
When the sport mode is first selected, if 6th gear is currently engaged, the TCM downshifts to
5th.
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 at least 2 gears.
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
or continuous use of the brake pedal. The driver can prepare for the end of the descent by
moving the selector lever to D. 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)

The ASIS system is a new feature on automatic transmissions. 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 minimises 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 centre 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 selector lever will be locked in the 'N' or 'P' position by the shift interlock solenoid if
moved from the 'D' position.
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 125ºC (257ºF) or higher, the TCM employs
the cooling strategy. No message is displayed in the message centre 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 137ºC (278ºF) or higher, the transmission
will use the default (limp home mode). If the temperature exceeds 140ºC (284ºF), CAN bus
transmission is disabled.
The cooling strategy is cancelled when the transmission fluid temperature decreases to less
than 120ºC (248ºF) 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 engine control module signal on the 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 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 centre.
Some transmission faults may not illuminate the MIL or display a fault message, but the
driver may notice a reduction in shift quality. For additional information, refer to
Transmission Description (307-01 Automatic Transmission/Transaxle)
ENGINE SPEED AND TORQUE MONITORING

The ECM constantly supplies the TCM with information on engine speed and torque through
messages on the CAN bus. The TCM uses this information to calculate the correct and
appropriate timing of shift changes.
If the messages are not received by the ECM, the TCM will implement a back-up strategy to
protect the transmission from damage and allow the vehicle to be driven.
In the event of an engine speed or torque signal failure, the transmission will adopt the
electrical limp home mode with the transmission operating in a fixed gear.
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 automatic transmission selector lever to the neutral
position. If electrical power is not available, use the manual interlock release tab on
the selector lever to move the lever to the neutral (N) position.
• 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.
CONTROL DIAGRAM
NOTE:
A = Hardwired; D = High speed CAN Bus; N = Medium speed CAN Bus
1 Battery
2 Megafuse (175A)
3 CJB
5 TCM
6 Diagnostic socket
8 Transmission selector lever assembly
9 Automatic speed limiter switch
10 Stop/Start switch
11 ECM
Diagnostic Strategy
For a detailed description of the automatic transmission/transaxle, refer to the relevant Description
and Operation section n the workshop manual.
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 50°C (122°F) whilst checking
level. Should the temperature rise above this figure, abort the check and allow the transmission
fluid to cool to below 30°C (86°F).
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.
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.
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 General Specification chart in this section.
Specifications
Fluid Condition Check

1 . Check the fluid level.
2 . Observe the color and the odour of the fluid. The color under normal circumstances should be like
honey, not brown or black.
3 . Allow the fluid to drip onto a facial tissue and examine the stain.
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.

Mechanical Electrical Hydraulic
• Damaged shift
mechanism/linkages
• Fluid level too
• Damaged automatic transmission • Blown fuse(s)
high/low
casing • Damaged, loose or
• Poor condition
• Check the transmission selector corroded connectors
of fluid
lever cable for correct adjustment. • Wiring harness
• Fluid leak
Selector Lever Cable Adjustment
(44.15.07)
4 . If the cause is not visually evident check for diagnostic trouble codes (DTCs) and refer to the DTC
Index.
DTC Index
NOTE:
If the control module/transmission is suspect and the vehicle remains under manufacturer
module/transmission.
NOTE:
diagnostic system).
NOTE:
NOTE:
NOTE:
NOTE:
terminals.
P071100 Transmission Fluid • Transmission fluid

Install a new transmission control
temperature sensor
Temperature Sensor A pins short circuit or module and main control valve
Circuit fluid temperature rise body assembly, refer to the new
Range/Performance rate too low module/transmission installation
note at the top of the DTC Index.
Transmission Control Module
(TCM) and Main Control Valve
Body

module and main control valve
• Transmission fluid body assembly, refer to the new
Transmission fluid temperature
module/transmission installation
P093800 temperature sensor compared with
module temperature note at the top of the DTC Index.
range/performance
fault Transmission Control Module
Body

• Both transmission body assembly, refer to the new
Transmission fluid
fluid temperature module/transmission installation
P071300 temperature sensor sensor pins signal note at the top of the DTC Index.
circuit high input voltage too high Transmission Control Module
Body

• Both transmission body assembly, refer to the new
Transmission fluid
fluid temperature module/transmission installation
sensor pins signal note at the top of the DTC Index.
circuit low input voltage too low Transmission Control Module
Body

body assembly, refer to the new
Transmission fluid • Open circuit
P071000 temperature sensor transmission fluid
temperature sensor note at the top of the DTC Index.
circuit open
Body
Check for wheel speed related
DTCs and refer to DTC Index.
• No wheel speed
Transmission control body assembly, refer to the new
P070000 information on CAN
system (MIL Request) • TCM failure module/transmission installation
Body

Internal control module • EEPROM module/transmission installation
P062F00
EEPROM error communication error note at the top of the DTC Index.
Body
Re-configure the transmission

using the manufacturer approved
diagnostic system, clear DTC and
re-test. If DTC remains, Install a
new transmission control module
Internal control module • Software error and main control valve body
P060100
memory checksum error • TCM failure assembly, refer to the new
Body

• Transmission output
Output shaft speed module/transmission installation
P072000 shaft speed sensor
sensor circuit circuit short to power note at the top of the DTC Index.
Body

P072122 Output shaft speed • Transmission output
sensor circuit shaft speed sensor
range/performance signal out of range module/transmission installation
Body
• Engine speed signal Check engine management DTCs

Engine overspeed
P021900 received over CAN is and refer to DTC Index.
condition too high Electronic Engine Controls

Turbine/input shaft • Turbine/input shaft
P071700 speed sensor A circuit - speed sensor A circuit
- short to power note at the top of the DTC Index.
short to power
Body

Turbine/input shaft • Circuit short to body assembly, refer to the new
speed sensor A circuit ground, power, open module/transmission installation
P071600
failure or sensor out of circuit or signal out of note at the top of the DTC Index.
range range Transmission Control Module
Body
Transmission fluid Drain and re-fill transmission

requires replacement • Low transmission fluid fluid to correct level.
level
due to excessive Transmission Fluid Drain and
P089700 • Blocked or damaged
running time at transmission fluid Refill (44.24.02) Check for
maximum operating cooler blocked or damaged transmission
temperatures fluid cooler
Ensure the accelerator pedal is

free from restriction, check
'Accelerator Pedal Position
Throttle/pedal position • Pedal assembly faulty received on CAN' datalogger
P012100 sensor A circuit or does not have full signal (should be 100% when
range/performance range of movement pedal fully depressed). Check for
throttle/pedal position related
Transmission range
P070500 sensor A circuit (PRNDL • Signal out of range
input)
Body
Drain and re-fill transmission

• Low transmission fluid fluid to correct level.
level
Transmission over Transmission Fluid Drain and
P178300 • Blocked or damaged
temperature condition transmission fluid Refill (44.24.02) Check for
cooler blocked or damaged transmission
fluid cooler
Ensure battery is in a fully

charged and serviceable
care manual. Carry out any
pinpoint tests associated with
• Low battery charge
P056200 TCM supply voltage low this DTC using the manufacturer
• Harness fault
approved diagnostic system. Also
check for additional DTCs that
could be associated to loss of
power or ground feed and refer
to DTC Index

Actuator supply voltage
P065700 A - open circuit, • Signal out of range
range/performance
Body

• Actuator (pressure module and main control valve
Actuator supply voltage control valves etc) body assembly, refer to the new
P065900 supply voltage short module/transmission installation
A circuit high
to power note at the top of the DTC Index.
Body

• Actuator (pressure body assembly, refer to the new
Actuator supply voltage control valves etc) module/transmission installation
P065800
A circuit low supply voltage short note at the top of the DTC Index.
to ground Transmission Control Module
Body

• Microprocessor module/transmission installation
P061300 TCM processor
control failure note at the top of the DTC Index.
Body
Install a new torque converter,

Torque converter clutch
refer to the new
solenoid circuit
P074100 • Signal out of range module/transmission installation
range/performance or
stuck off

Pressure control • Pressure control
P096200 solenoid A control solenoid A short to
ground note at the top of the DTC Index.
circuit low
Body

P096014 solenoid A control solenoid A short to
ground, open circuit note at the top of the DTC Index.
circuit low
Body
Pressure control
P074800 solenoid A current out • Signal out of range
of range
Body

P096300 solenoid A control solenoid A control
circuit high circuit short to power note at the top of the DTC Index.
Body

• Pressure control
Pressure control module/transmission installation
P096013 solenoid A open
solenoid A open circuit circuit note at the top of the DTC Index.
Body

P096600 solenoid B control solenoid B short to
circuit low
Body

P096414 solenoid B control solenoid B short to
circuit low
Body
Pressure control
P077800 solenoid B current out • Signal out of range
of range
Body

P096700 solenoid B control solenoid B control
Body

Pressure control • Pressure control module/transmission installation
P096413
solenoid B open circuit solenoid B open circuit note at the top of the DTC Index.
Body

P097000 solenoid C control solenoid C short to
circuit low
Body

P096814 solenoid C control solenoid C short to
circuit low
Body
Pressure control
P079800 solenoid C current out • Signal out of range
of range
Body

P097100 solenoid C control solenoid C control
Body

Pressure control • Pressure control module/transmission installation
P096813
solenoid C open circuit solenoid C open circuit note at the top of the DTC Index.
Body

P272000 solenoid D control solenoid D short to
circuit low
Body

P271814 solenoid D control solenoid D short to
circuit low
Body
Pressure control
P271600 solenoid D current out • Signal out of range
of range
Body

P272100 solenoid D control solenoid D control
Body

P271813 solenoid D control solenoid D control
circuit open circuit note at the top of the DTC Index.
circuit open circuit
Body

P272900 solenoid E control solenoid E short to
circuit low
Body

P272714 solenoid E control solenoid E short to
circuit low
Body
Pressure control
P272500 solenoid E current out • Signal out of range
of range
Body

P273000 solenoid E control solenoid E control
Body

P272713 solenoid E control solenoid E control
Body

P276400 solenoid F control solenoid F short to
circuit low
Body

P276100 solenoid F control solenoid F short to
circuit low
Body
Pressure control
P275900 solenoid F current out • Signal out of range
of range (high)
Body

Pressure control
P276200 solenoid F current out • Signal out of range
of range (low)
Body

P276300 solenoid F control solenoid F control
Body

P074000 solenoid F control solenoid F control
Body

• Solenoid valve A
Solenoid valve A control module/transmission installation
P075200 control circuit short to
circuit low ground note at the top of the DTC Index.
Body
circuit low ground, open circuit note at the top of the DTC Index.
Body

circuit high power note at the top of the DTC Index.
Body

P075113 control circuit open
circuit open circuit circuit note at the top of the DTC Index.
Body
Check and set transmission fluid

to correct level.
Slip too high between • Low transmission fluid
Clear DTC and re-test. If DTC
P073000 input and output shaft level
• Worn clutches remains, install a new
speeds in any gear
transmission. Refer to the new
note at the top of the DTC Index

to correct level.
speeds in 1st gear
to correct level.
speeds in 2nd gear

to correct level.
speeds in 3rd gear

to correct level.
speeds in 4th gear

to correct level.
speeds in 5th gear

to correct level.
speeds in 6th gear
to correct level.
Shift monitoring fault - Transmission Fluid Level Check
input/output shaft • Low transmission fluid Ensure transmission fluid cooler
level
speed ratio out of range is free from restriction. Clear DTC
P078000 • Blocked transmission
during a shift (any gear). fluid cooler and re-test. If DTC remains,
Relevant clutch does • Worn clutches install a new transmission. Refer
not open or close to the new module/transmission
DTC Index

to correct level.
1-2 Shift - Comparison • Low transmission fluid Ensure transmission fluid cooler
of input and output level
is free from restriction. Clear DTC
P078162 speed during a shift 1 to • Blocked transmission
fluid cooler and re-test. If DTC remains,
2 (relevant clutch does
• Worn clutches install a new transmission. Refer
not open or close)
to the new module/transmission
DTC Index

to correct level.
not open or close)
DTC Index

to correct level.
not open or close)
DTC Index
to correct level.
not open or close)
DTC Index

to correct level.
not open or close)
DTC Index

to correct level.
not open or close)
DTC Index

to correct level.
not open or close)
DTC Index
to correct level.
not open or close)
DTC Index

to correct level.
not open or close)
DTC Index

to correct level.
not open or close)
DTC Index

to correct level.
P078123 speeds during gear shift • Blocked transmission
2 to 1. Clutch does not
open
DTC Index
to correct level.
open
DTC Index

to correct level.
open
DTC Index

to correct level.
open
DTC Index

to correct level.
open
DTC Index
to correct level.
Ensure transmission fluid cooler
• Low transmission fluid and re-test. If DTC remains,
Output speed against level
install a new Transmission
P072164 turbine speed and • Blocked transmission
fluid cooler Control Module. Refer to the
wheel speed fault
• Worn clutches new module/transmission
DTC Index
Body

to correct level.
open
DTC Index
Ensure battery is in a fully

charged and serviceable
Power supply voltage care manual. Check 'Battery
• Low battery charge
P056100 out of range when Voltage at TCM' datalogger
• Harness fault
engine running signal. Check for DTCs that could
be associated to loss of power or
ground feeds at TCM and refer to
DTC Index

• Park/neutral switch diagnostic system. After pinpoint
Starter inhibit signal
P085000 input circuit fault
fault test complete, re-test and if fault
• TCM failure
remains install a new
transmission control module and
main control valve body
assembly, refer to the new
Re-configure the TCM using the

diagnostic system, re-test. If DTC
remains, install a new
EPROM/FLASH • Software fault
P060500 transmission control module and
checksum error • TCM failure
main control valve body
assembly, refer to the new

TCM internal
P066900 • Signal out of range body assembly, refer to the new
temperature high

TCM internal
temperature low

Sensor supply voltage
fault high

Sensor supply voltage
fault low
Ensure battery is fully charged

• Battery discharged and in a serviceable condition,
• Transit relay installed refer to the battery care manual.
Loss of data in RAM
P060300 • Battery isolation
fault Remove transit relay or any
device installed
• Harness fault battery isolation device installed.
Clear DTCs and re-test, if DTC
remains check for additional
DTCs and refer to DTC Index
Check availability of speed

control. If speed control is also
inoperative, check instrument
• Shift paddles not cluster for related DTCs and refer
working. Instrument to DTC Index.
Manual shift CAN
P082600 cluster LIN/CAN Instrument Cluster If speed
request error gateway failure control is available, check the
• Shift paddle(s) failure shift paddle functionality using
the datalogger application on the
diagnostic system

Micro controller
component faults
Check anti-lock control - stability

assist module and ECM for wheel
Vehicle speed signal not • Wheel speed sensor speed sensor related DTCs and
P050000
detected fault refer to DTC Index.
Check anti-lock control - stability

assist module and ECM for wheel
Vehicle speed sensor A • Wheel speed sensor speed sensor related DTCs and
P050100
range/performance fault refer to DTC Index.
Check 'Battery Voltage at TCM'

datalogger signal. Check for
Battery voltage too high • High battery charge,
P056300 alternator/over charging related
when engine running alternator fault
DTCs and refer to relevant DTC
Index

Output shaft speed out
P072127 • Signal out of range module and main control valve
of range body assembly, refer to the new

to correct level.
• Low transmission fluid Ensure transmission fluid cooler
Slip too high between level
P073600 input and output shaft • Blocked transmission
speeds in reverse gear
DTC Index

TCM positive torque
P061B61 • Signal out of range body assembly, refer to the new
signal not valid

TCM positive torque
P061B65 • Signal out of range body assembly, refer to the new
signal not valid
Check ECM for DTCs and refer to

Invalid data received • Engine speed value
U040186 DTC Index.
from ECM invalid
Re-configure the TCM with the

• Mis-match between
Internal control module latest level software using the
U030055 vehicle and TCM
software incompatibility software levels manufacturer approved
diagnostic system

High speed CAN • Vehicle CAN Bus off associated with this DTC using
U000188 condition
communication Bus the manufacturer approved
diagnostic system
Check ECM for DTCs and refer to

Fault received from • Engine torque
U202386 DTC Index.
external node information
U010387 Lost communications Carry out any pinpoint tests

• Missing message from
with gear selector lever gear selector lever the manufacturer approved
diagnostic system

Lost communication • CAN timeout associated with this DTC using
U015587
with instrument cluster instrument cluster the manufacturer approved
diagnostic system

Lost communication
• CAN timeout parking associated with this DTC using
U012887 with parking brake
brake module the manufacturer approved
module
diagnostic system

Lost communication • Missing message from associated with this DTC using
U010087
with ECM ECM the manufacturer approved
diagnostic system
• CAN timeout stability

Lost communication
control module Check instrument cluster for
U012287 with stability control
(instrument cluster DTCs and refer to DTC Index
module Off Bus)
Check the anti-lock - stability

assist system for DTCs and refer
U041686 from Anti-lock control - • Brake information
to the DTC Index.
stability assist module
• Mis-match between Re-configure the TCM using the

U30004A Control module configuration data and manufacturer approved
calibrated data values diagnostic system
Invalid data received • Gear selector cable Check gear selector cable
from the gear selector out of adjustment. adjustment.
U040462
lever - implausible Gear selector lever Selector Lever Cable Adjustment
position assembly fault (44.15.07)
• Gear selector cable Check gear selector cable

out of adjustment. adjustment.
U040464 from the gear selector Gear selector lever Selector Lever Cable Adjustment
lever - implausible signal assembly fault (44.15.07)
• Gear selector cable Check gear selector cable

U040486 Invalid data received adjustment.
out of adjustment.
from the gear selector
Gear selector lever Selector Lever Cable Adjustment
lever - general failure assembly fault (44.15.07)
Removal
Torque converter seal installer

308-246
Torque converter handles

307-139
Removal
3

(47.15.01)
5 . NOTE:
Remove the 2 transmission heat shields.
Remove the 4 bolts.
6 . Release and disconnect the 2 LH HO2S electrical connectors.
Release the clip.
7 . Release and disconnect the 2 RH HO2S electrical connectors.
Release the clip.

8 . Remove the LH catalytic converter.
9 . Remove the RH catalytic converter.

10
moisture.
Remove the A/C pipe.
Remove the bolt.
Remove the nut.
11 .
NOTE:
Release the transmission fluid lines.
Remove the bolt.

Remove the 3 bolts.
13 . Using a transmission jack, support the transmission.
14 . Release the transmission support insulator.

Remove the 4 bolts.
15 . Release the engine ground cable.
Remove the bolt.
16
. WARNING: Secure the transmission to the transmission jack.
WARNING: 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, release the transmission.
18 . Release the selector cable.
Release the clip.
Remove the 2 bolts.

20 . NOTE:
Remove the transmission from the transmission jack.
21 . Remove the transmission support insulator.
Remove the 2 bolts.
23 . Using the special tools, remove the torque converter.

24
. CAUTION: Care must be taken to avoid damage to the seal register and running
surface.
Carefully remove and discard the torque converter fluid seal.
25 . Remove the selector lever.
Remove the nut.

26 . Remove the transmission breather line.

Installation
Torque converter seal installer

308-246
Torque converter handles

307-139
Installation
1 . Attach the transmission breather line.
2 . Attach the selector lever.
3 . Using the special tool, install a new torque converter fluid seal.
Clean the seal register.

4 . Install the torque converter.
Clean the seal contact area.
6 . Install the transmission support insulator.
7.
WARNING: Secure the transmission to the transmission jack.
Position the transmission to the transmission jack.
9.
With assistance, install the transmission.
10 . Install the ground cable.
11 . Secure the transmission support insulator.
13 . NOTE:
Connect the selector cable to the transmission.

Secure in the clip.
15 . Attach the transmission fluid lines.
16 . Install the 2 transmission heat shields.
17 . Install the RH catalytic converter.
Install and lightly tighten the nuts.
18 . Install the LH catalytic converter.
19 . Connect and secure the HO2S electrical connectors.

Secure the 2 clips.

(47.15.01)
21 . Tighten the catalytic converter to exhaust manifold clamps to 40 Nm (30 lb.ft).


24 . Fill the A/C system.

In vehicle repair
Extension Housing Seal (44.20.18)

Crankshaft damper remover

303-D121
Output shaft flange holding tool

205-053
Seal remover input and output

308-375
Slide hammer
100-012
Pinion seal replacer
204-264
Slide hammer adaptor

100-012-01
Transmission output flange socket

205-789
Removal
1


(47.15.01)
4 . Release the transmission support insulator.
5 . Using the special tool, to hold the output flange, remove the retaining nut.
Discard the nut.
6 . Using the special tool, remove the output flange.
7 . Using the special tools, remove the extension housing seal.
Installation
1 . Using the special tool, install a new extension housing seal.

2 . Using the special tools, install the output flange.

(47.15.01)


Transmission Fluid Pan, Gasket and Filter
(44.24.07)
Removal
2
3 . Drain the transmission.

For additional information, refer to Transmission Fluid Drain and Refill (44.24.02)
4 . Remove the fluid pan.
Remove and if necessary, discard the seal.

Installation
1 . Install the fluid pan.
Install the seal.

3 . Refill the transmision with fluid.

For additional information, refer to Transmission Fluid Drain and Refill (44.24.02)
Transmission Control Module (TCM) and
Main Control Valve Body
Removal
NOTE:
The transmission control module (TCM) is part of the main control valve body and cannot be
serviced separately.

2
3 . Remove the fluid pan.

For additional information, refer to Transmission Fluid Pan, Gasket and Filter (44.24.07)
5 . Remove and discard the electrical connector sleeve.

Release the retainer.
6 . Remove the TCM and valve body.
8 . Remove the seal block.

Installation
1.
CAUTION: Make sure that when fully fitted, all seals protrude by the same amount.
CAUTION: Engage the selector lever with the groove in the piston rod.
Install the valve body.
Install new seals.
Install a new seal block.

2 . Install a new electrical connector sleeve.
Secure with retainer.
3 . Connect the electrical connector.
4 . Install the fluid pan.

For additional information, refer to Transmission Fluid Pan, Gasket and Filter (44.24.07)

6 . Using WDS, calibrate a new TCM and valve body.

Transmission Support Insulator (12.45.04)
Removal
1

3
. CAUTION: During this procedure the transmission crossmember is removed, make
sure the transmission is correctly supported to avoid damaging associated components.
Using a transmission jack, support the transmission.
4 . Remove the transmission support crossmember damper.
Remove the 3 bolts.
5 . Remove the transmission support crossmember.
Remove the 6 bolts.

6 . NOTE:
Remove the transmission support insulator.
Remove the 2 bolts.
Installation
2 . Install the transmission support crossmember.

3 . Install the transmission support crossmember damper.

Selector Shaft Seal
Seal extractor
307-509-1(LRT-44-033/1)
Seal extractor
307-509-2(LRT-44-033/2)
Seal installer
307-509-3(LRT-44-033/3)
Removal
2

Release the clip.
6 . Remove the LH catalyst heat shield.
Remove the 2 bolts.
Remove the nut.
7 . Remove the transmission casing LH heat shield.

Remove the 2 bolts.
8 . Release the selector cable.
Release the clip.
Remove the 2 bolts.
9 . Remove the selector lever.
Remove the nut.

10
. 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.
Remove the selector shaft seal.
Install 307-509-1 to the seal.
Install 307-509-2 to 307-509-1 and extract the seal.
Installation
1 . Using 307-509-3, install the selector shaft seal.
2 . Install the selector lever.

3 . Install the selector cable.
4 . Install the transmission heat shield.
5 . Install the LH catalyst heat shield.
Install the nut and two bolts and tighten to 10 Nm (7 lb.ft).


307-02 : Transmission/Transaxle Cooling
Specifications
Specifications
Item Nm lb-ft lb-in

Fluid cooler tubes to radiator - union nuts 20 15 -
Fluid cooler tubes to transmission - bolt 23 17 -
Fluid cooler tubes support bracket - nut 10 7 88

1 Engine cooling radiator
2 Return pipe (to transmission)
3 Feed pipe (from transmission)
INTRODUCTION
The transmission cooler is integrated into the 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 louvred 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.
Fluid is supplied from the transmission fluid pump into the lower connection of the cooler.
After passing through the cooler, the fluid passes out of the upper connection and is returned
to transmission fluid pan.
For a detailed description of the automatic transmission cooling system, refer to the relevant

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
• Flush out the automatic transmission

fluid cooler with new automatic
Over heating of the transmission fluid
Obstruction in the automatic
automatic • If the flushing is unsuccessful, install a
transmission fluid cooler new radiator.
transmission
Radiator - Vehicles Without:
• Flush out the automatic transmission

fluid cooler tubes with new automatic
Over heating of the
Obstruction in the automatic transmission fluid
automatic
transmission fluid tubes • If the flushing is unsuccessful install
transmission new automatic transmission fluid
cooler tubes.
• Check the integrity of tubes,
Connections to the automatic
Loss of automatic connections and seals
transmission and the automatic
transmission fluid • Check the torque of the tube fixings.
transmission fluid cooler Specifications
• Check the integrity of tubes,

connections and seals
• Check the torque of the tube fixings.
Specifications
Loss of automatic • Check for automatic transmission
Leak at oil cooler
transmission fluid fluid contamination of the engine
coolant. INSTALL new radiator as
necessary.
Radiator - Vehicles Without:
307-05 : Automatic Transmission/Transaxle External
Controls
Specifications
Specifications
Item Nm lb-ft lb-in

Paddle switch to steering wheel - bolt 3 2 27
Selector lever to floor console bracket - screw 7 5 62
Selector lever, cable bracket to transmission - bolt 8 6 71
Selector cable to selector lever abutment bracket - adjustment nut 23 17 -
General procedures
Selector Lever Cable Adjustment (44.15.07)

1. Remove the rear seat armrest.
2. Remove the floor console veneer trim panel.

3. Remove the floor console rear panel.
• Carefully release the 2 clips.
4. Remove the floor console side panel trim.
• Remove the 2 Torx bolts.
• Carefully release 11 clips.
• Repeat the procedure and remove the opposite hand.

5. Carefully disconnect the selector cable ball joint.
• Apply gentle pressure.
6. NOTE:
Release the gear selector cable at the abutment.
• Loosen the 2 locknuts.
7. Fully extend the inner cable while supporting the outer, then retract the inner cable one detent.
8. Using the transmission selector lever, position to the REVERSE detent.
9. Install the gear selector cable to the floor console abutment.
• Position and lightly tighten the adjusting nuts.

10. Connect the selector cable ball joint.
• Adjust the cable, until the ball joint socket aligns with the ball, on the transmission selector
lever.
11. NOTE:
Check the operation of the transmission selector lever through the gate and detents.
• If the adjustment is correct, tighten the locknuts to 20 Nm (14 lb.ft).
12. Install the floor console side panel trim.
• Carefully align and secure the clips.
• Tighten the Torx screws to 6 Nm (4 lb.ft).
• Install the opposite hand.
13. Install the floor console rear panel.

• Align the lugs and secure the clips.
14. Install the floor console veneer trim panel.

15. Install the rear seat armrest.

External Controls
COMPONENT LOCATION

1 Right Hand (RH) + gear change upshift paddle switch
2 Left Hand (LH) - gear change downshift paddle switch
3 Selector lever and gear knob
4 'L' gate
5 Selector lever mechanism assembly
6 Selector cable
INTRODUCTION
The Transmission Control Module (TCM) contains software to provide operation as a semi-
automatic 'Jaguar Sequential Shift' transmission.
The TCM allows the transmission to be operated as a conventional automatic unit by selecting
P, R, N, D on the selector lever. In this mode, the selector lever is linked, via the selector
cable, to the transmission to provide a mechanical interface.
Movement of the selector lever across the 'L' gate to the 'S' position is sensed by a Hall effect
proximity sensor located within the selector mechanism assembly, and puts the transmission
into electronic 'Sport' mode.
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.
Selector Lever
2 Interlock solenoid
3 Module top housing
4 Cover
5 DSC/TRAC DSC button
6 Selector lever
7 Park switch
8 Disc
9 Sliding block
10 Selector cable
11 Rotation bracket
12 Housing
13 Rocker
14 'L' gate chrome finisher
15 Selector Printed Circuit Board (PCB)
16 Solenoid interlock lever
17 Selector interlock lever
The transmission selector assembly is located in a central position in the floor console. The
assembly is attached to a moulding in the floor console with four screws.
A park switch is located to the right of the lever and is operated when the lever is moved to
the 'P' Park position. The lever is located in a slot in a rotary disc. The disc rotates with
movement of the lever in the forward or back directions. The disk movement is detected by
Hall sensors located on the selector PCB which correspond with the different selector
positions.
Movement of the selector lever is passed to the transmission Mechatronic valve block via a
lever located on the side of the transmission casing. The lever, in turn, moves a manually
operated selector valve within the transmission valve block.
An interlock solenoid is located in the selector lever assembly. When energized, the solenoid
engages an interlock lever preventing the selector lever from being moved. When the
footbrake is applied, a signal from the brake switch de-energises the solenoid allowing the
selector lever to be moved from the 'P' or 'N' position. This prevents the selector from being
moved to the 'D' or 'R' position unintentionally and the application of the brakes also prevents
the vehicle 'creeping' when the gear is engaged.
If electrical power to the selector lever is lost, the selector lever will be locked in the 'N' or 'P'
position by the shift interlock solenoid if moved from the 'D' position. The selector lever will
remain locked until electrical power to the selector lever is restored. There is no emergency
interlock solenoid release mechanism on the selector lever.
Selections made using the selector lever are passed to the TCM in high speed Controller Area
Network (CAN) bus messages. The park switch is hardwired to the instrument cluster and the
Central Junction Box (CJB).
Paddle Switches
Each paddle switch has 3 connections; ground, illumination Pulse Width Modulation (PWM)
supply and switch signal.
Pulling the LH downshift paddle (-) provides down changes and pulling the RH 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. Movement of the
selector lever back to the 'D' position, returns the transmission to conventional automatic
operation. To reselect Sport mode from Manual mode, the selector lever must be first moved
to the 'D' position and then returned to the 'S' position.
Temporary operation of manual mode can also be operated with the selector lever in the 'D'
position. Operation of either the upshift or downshift paddles activates the manual mode
operation. The current selected gear will displayed in the instrument cluster message center. If
continued use of manual mode is required, move the selector lever to the 'S' position.
With the selector lever in the 'D' position, temporary manual mode will be maintained whilst
the driver is accelerating, decelerating, cornering or continuing to request shifts via the
paddles. The transmission will revert to automatic operation after a short period of driving at
steady speed. Alternatively the RH upshift (+) paddle may be held for approximately one
second to return directly to automatic operation in 'D'.
Selector Lever
The selector lever is located in a slot in the rotary disc which rotates with movement of the
lever in the forward or back directions. The disc movement positions magnets located on the
disc which are detected by Hall sensors located on the selector PCB which correspond with
the different selector positions. The Hall sensors produce a signal relative to the lever position
which is passed as a high speed CAN bus message to other system modules.
Paddle Switches
When the switch is operated, a ground for the switch contacts is completed via a resistor. The
completed ground signal is passed via a hardwired connection to the steering wheel module.
The module converts the switch signal into a Local Interconnect Network (LIN) bus message
which in turn is passed to the instrument cluster, via the steering wheel clockspring. The
instrument cluster converts the LIN message into a high speed CAN bus message which is
broadcast to the TCM and other system modules.
External Controls
For a detailed description of the automatic transmission controls, refer to the relevant Description
and Operation section in the workshop manual.
External Controls

• Check for correct gear selector lever cable

adjustment. • Fuse(s).
Selector Lever Cable Adjustment (44.15.07) • Loose or corroded electrical
• Visibly damaged or worn components. connector(s).
• Loose or missing fasteners.
4 . If the cause is not visually evident, verify the symptom and refer to the manufacturer approved
diagnostic system, or pinpoint tests below.
Pinpoint Tests
PINPOINT TEST G561950p1 : GEAR

SELECTOR LEVER ASSEMBLY
CIRCUIT CHECKS
G561950t1 : CHECK FOR IGNITION SUPPLY TO THE GEAR SELECTOR LEVER
ASSEMBLY
1. Disconnect the gear selector lever assembly electrical connector IP027. 2. Set the ignition status to
ON, engine OFF. 3. Measure the voltage at IP027 Pin 1.
• Is the voltage greater than 10 Volts?

-> Yes
-> No
Repair the electrical circuit between the gear selector lever assembly electrical connector IP027 Pin 1
and the Central Junction Box (CJB). For additional information, refer to the electrical circuit diagrams.
TEST the system for normal operation.
G561950t2 : CHECK THE GROUND SUPPLY TO THE GEAR SELECTOR LEVER

ASSEMBLY
1. Set the ignition status to OFF. 2. Measure the resistance between the gear selector lever assembly
electrical connector IP027 Pin 2 and GROUND.
-> Yes
-> No
Repair the circuit between the gear selector lever assembly electrical connector IP027 Pin 2 and
GROUND. For additional information, refer to the electrical circuit diagrams. TEST the system for
normal operation.
G561950t3 : CHECK FOR IGNITION SUPPLY TO THE PARK POSITION SWITCH

1. Set the ignition status to ON, engine OFF 2. Measure the voltage at IP027 Pin 4.
• Is the voltage greater than 10 Volts?
-> Yes
No fault has been identified with the gear selector lever assembly circuits. Check all connections for
damaged and corroded pins. Check CAN network using manufacturer approved diagnostic system.
-> No
Repair the electrical circuit between the gear selector lever assembly electrical connector IP027 Pin 4
and the Central Junction Box (CJB). For additional information, refer to the electrical circuit diagrams.
PINPOINT TEST G561950p2 : GEAR

SELECTOR PADDLE SWITCH TESTS
G561950t4 : GEAR SELECTOR PADDLE SWITCH TESTS
1. Check steering wheel speed control switches are functioning correctly.
• Are the steering wheel speed control switches functioning correctly?
-> Yes
Refer to the electrical circuit diagrams and test circuit between gear selector paddle switches and
steering wheel audio switch.
-> No
Check the TCM and Instrument Cluster for related DTCs and refer to relevant DTC Index. Check the
steering wheel speed and audio control switch circuits.
Speed Control
Audio System Refer to the electrical circuit diagrams and test the LIN circuit between the steering
wheel audio switch and the instrument cluster.
Downshift Paddle Switch

Removal
1 . Remove the paddle gear selector lever.
For additional information, refer to Upshift Paddle Switch
Installation
Selector Lever Assembly (44.15.04)
Removal


5 . Release the LH side floor console electrical harness connector blocks.
6 . Disconnect the gear selector assembly electrical connector.
7 . Remove the gear selector assembly.
Carefully disconnect the selector cable ball joint.

Installation
1 . Install the gear selector assembly.
Connect the selector cable ball joint.
2 . Connect the gear selector assembly electrical connector.
3 . Install the LH side floor console electrical harness connector blocks.



Selector Lever Cable and Bracket
(44.15.08)
Removal
2 . NOTE:
Connect a line to the transmission selector cable to aid installation.
Release the transmission selector lever cable.
Release the gaiter.
Pass the gear selector cable through the vehicle floor.
Tie the recovery line to the floor console ground nut.
4 . Release the exhaust heat shield for access.
Remove the 4 bolts.

5 . Position the LH side transmission casing heat shield aside.
Remove the 2 bolts.
6 . Remove the selector cable and bracket.
Remove the 2 bolts.
Withdraw the cable.
Disconnect the recovery line.

Installation
1 . Install the selector cable and bracket.
Connect the recovery line to the transmission selector cable.
2 . Install the LH side transmission casing heat shield.
3 . Install the exhaust heat shield.
4 . Install the transmission selector cable gaiter.
Disconnect the recovery line.

Selector Lever Knob (44.15.06)
Removal
Vehicles without supercharger
1
. CAUTION: Protect the surrounding trim from damage when changing the
component.
Remove the selector lever knob.
Carefully loosen the locking collar.
Unscrew the knob.
Remove the spacer.
Remove the locking collar.
Vehicles with supercharger

2 . Remove the selector lever knob.
Installation
1 . Install the selector lever knob.
Apply threadlock if the selector lever knob is to be reused.

2 . Install the selector lever knob.
Install the locking collar.
Install the spacer.
Align the knob and tighten the locking collar.

Upshift Paddle Switch
Removal
1 . Remove the paddle gear selector lever.
Installation
1 . Install the paddle gear selector lever.
309 : Exhaust System
309-00 : Exhaust System
Specifications
Specifications
Item Nm lb-ft lb-in

Catalytic converter to exhaust manifold - nut 40 30 -
Catalytic converter to exhaust manifold - stud 40 30 -
Catalytic converter to resonator pipe - clamp nut/bolt 50 37 -
Front muffler pipe to rear muffler pipe - clamp nut/bolt 50 37 -
Rear muffler front-hanger bracket to vehicle - bolt 25 18 -

COMPONENT LOCATION

1 Muffler
2 Mounting rubber
3 Semi Active Muffler (SAM) valve
4 Mounting rubber
5 Mounting rubber
6 LH front to rear section joint
7 LH catalyst
8 LH Down stream HO2S
9 LH Upstream HO2S
11 RH Upstream HO2S
12 RH exhaust manifold
13 RH catalyst
14 RH Downstream HO2S
15 RH front to rear section joint
INTRODUCTION
The 4.2L V8 exhaust system is fabricated from stainless steel and is supplied as four separate
assemblies:
• A LH front section incorporating a catalytic converter

• A RH front section incorporating a catalytic converter
• A center section incorporating a silencer
• A rear section Including the main silencer box.
Each section of the exhaust system is available as a service replacement.
The exhaust system is attached to the underside of the body with five mounting rubbers, two
on the center section and three on the rear muffler. The mounting rubbers attach to the exhaust
system via stainless steel hangers and brackets. The mounting rubbers locate on
corresponding hangers which are attached to the underside of the vehicle body. The system is
routed along the center of the chassis before splitting near the rear differential prior to
entering the main exhaust silencer at the rear of the vehicle.
To reduce the carbon monoxide and hydrocarbons content of the exhaust gases, a catalytic
converter is integrated into each of the front pipes of the exhaust system.
The rear muffler unit includes a Semi Active Muffler (SAM) valve. This valve is operated by
the pressure in the exhaust system. At low engine speed the valve is partially closed to
provide a more refined noise quality. At higher engine speed the increased pressure within the
exhaust system opens the valve to provide a more sporting noise. The SAM valve is non
serviceable and the rear muffler is replaced as a complete assembly.
Exhaust System - 4.2L SC V8 - AJV8
COMPONENT LOCATION

1 RH Post catalyst H02 sensor
2 LH Post catalyst H02 sensor
3 RH joint
4 RH rear hanger
5 RH muffler hanger bracket
6 RH active exhaust valve
7 Muffler
8 Vacuum control lines
9 Vacuum pump and reservoir
10 LH active exhaust valve
11 LH muffler hanger bracket
12 Muffler center hanger
13 LH rear hanger
14 Center silencer
15 Center silencer
16 LH joint
17 LH catalyst
18 LH pre catalyst H02 sensor
19 RH catalyst
20 RH Pre catalyst H02 sensor
OVERVIEW
The exhaust system is fabricated from stainless steel and is supplied as four separate
assemblies:
• A LH front section incorporating a catalytic converter

• A RH front section incorporating a catalytic converter
• A center section incorporating 2 silencers
• A rear section including the main silencer box.
Each section of the exhaust system is available as a service replacement.
The exhaust system is attached to the underside of the body with five mounting rubbers, two
on the center section and three on the rear muffler. The mounting rubbers attach to the exhaust
system via stainless steel hangers and brackets. The mounting rubbers locate on
corresponding hangers which are attached to the underside of the vehicle body. The system is
routed along the center of the chassis before splitting near the rear differential prior to
entering the main exhaust silencer at the rear of the vehicle.
To reduce the carbon monoxide and hydrocarbons content of the exhaust gases, a catalytic
converter is integrated into each of the front pipes of the exhaust system.
ACTIVE EXHAUST SYSTEM

The rear muffler unit incorporates an active exhaust system. The active exhaust system is
designed to give a more sporty sound and also reduces the back pressure in the exhaust
system by opening a valve in the second exhaust outlet pipe.
The active exhaust system is controlled by the ECM. The ECM controls a vacuum control
valve which in turn applies a vacuum to the active exhaust valves. The vacuum system
comprises:
• A vacuum reservoir
• A vacuum pump
• A control solenoid
• A Vacuum check/non return valve
• A vacuum restrictor valve located in the vacuum line just above the check valve
The vacuum restrictor valve allows air back into the vacuum lines to allow the active exhaust
valves to open more slowly than they close.
Exhaust System Vacuum Control System

1 Vacuum pump
2 Vacuum lines to RH active exhaust valve
3 Active exhaust valve
4 Vacuum lines to LH active exhaust valve
5 Vacuum check valve
6 Vacuum control valve
7 Vacuum reservoir
8 Mounting bracket
The active exhaust valves are opened in response to engine speed and throttle angle. At
startup the valve is always opened to give an enhanced sound. The following table details
when the valves are open and when they are closed.
Throttle Engine Speed

500 1000 1500 2000 2500 3000 3500 4000>
Angle% RPM
0 Open Closed Closed Closed Closed Closed Closed Open
50 Open Closed Closed Closed Closed Closed Open Open
90 Open Closed Closed Closed Closed Open Open Open
100 Open Closed Closed Closed Closed Open Open Open
NOTE:
At engine speeds above 4000 RPM the valves are open independent of throttle angle.
The active exhaust valves are normally open until a vacuum is applied to them. The active
exhaust valves are either open or closed they do not partially open.
Exhaust Gas Flow

1 RH Active exhaust valve
2 Muffler
3 LH Active exhaust valve
4 Vacuum control assembly
A Valve closed
B Exhaust gas out
C Valve open
D Exhaust gas in
Exhaust System
For a detailed description of the exhaust system, refer to the relevant Description and Operation

Mechanical
• Leaks
• Metal fatigue
• Pipes, mufflers and catalytic converters
• Joints
• Mountings
• Clearance around components
Symptom Chart
• Inspect exhaust system, refer to

Visual Inspection above
Excessively
• Exhaust • Rectify leaks or Install new
noisy/leaking
system/components components as necessary. Refer to
exhaust Removal and Installation instructions
in this section
• Exhaust sound • Install new muffler and tailpipe

Exhaust excessively
enhancement valve assembly.
noisy at low speed stuck open Muffler and Tailpipe (30.10.52)
• Install new exhaust components as
• Restricted exhaust
necessary. Refer to Removal and
system
Installation instructions in this section
• Exhaust sound
enhancement valve
Loss of power Fuel Tank and Lines
stuck closed
• For ignition system tests.
• Fuel system
Engine Ignition
• Ignition system
• For electronic engine control tests.
Catalytic Converter (17.50.05)

Removal

2

Release the clip.

Release the clip.
7 . Remove the RH catalytic converter.

8 . NOTE:
NOTE:
Remove the 4 HO2S from the catalytic converters.
Installation
1
. WARNING: Make sure the H02S wiring harness is not twisted more than 180
degrees and is not in contact with the exhaust.
CAUTION: Make sure the anti-seize compound does not contact the HO2S tip.
CAUTION: Make sure the anti-seize compound does not contact the catalyst
monitor sensor tip.
Install the HO2S to the catalytic converters and tighten to 45 Nm (33 lb.ft).
Apply anti-seize compound to the sensor threads.
2 . Install the RH catalytic converter.

Secure the 2 clips.

Exhaust System
Removal

2
3 . Remove the floor bracket.
4 . Release the LH catalytic converter-to-muffler clamp.
5 . Release the RH catalytic converter-to-muffler clamp.

6 . With assistance, remove the exhaust system.
Disconnect the 4 exhaust hangers.
Installation
1 . With assistance, install the exhaust system.
Attach the exhaust hangers.
2 . Tighten the catalyst-to-muffler clamps.
3 . Install the bracket.

Front Muffler (30.10.18)
Removal

2
3 . Remove the floor bracket.
4 . Remove the rear muffler.

For additional information, refer to Muffler and Tailpipe (30.10.52)
5 . Release the 2 clamps.

6 . With assistance, remove the front muffler.
Release the 2 exhaust hangers.
Installation
1 . Install the front muffler.
2 . Install the rear muffler.

For additional information, refer to Muffler and Tailpipe (30.10.52)
3 . Install the bracket.

Muffler and Tailpipe (30.10.52)
Removal

2
3 . With assistance, remove the rear muffler.
Release the 2 clamps.
Release the 2 exhaust hangers.
Installation
1 . Install the rear muffler.


Exhaust Sound Enhancement Vacuum
Pump
Removal
1

3 . Release the rear lower edge of the LH fender splash shield.

4 . Remove the exhaust sound enhancement vacuum pump assembly.
Remove the bolt.
Remove the 2 nuts.
5.
CAUTION: Note the fitted position of the component prior to removal.
NOTE:
Remove the exhaust sound enhancement vacuum pump.
Release from the 3 rubber mountings.

6 . Remove the exhaust sound enhancement vacuum reservoir.
Remove the 2 bolts.
7 . Remove the exhaust sound enhancement solenoid.
Remove the bolt.
Disconnect the 2 vacuum lines.

Installation
1 . Install the exhaust sound enhancement solenoid.
Tighten the bolt.
Connect the vacuum lines.
2 . Install the exhaust sound enhancement vacuum reservoir.
3 . Install the exhaust sound enhancement vacuum pump.
Secure with the rubber mountings.
4 . Install the exhaust sound enhancement vacuum pump assembly.


310 : Fuel System
310-00 : Fuel System – General Information
Specifications
Specifications
General procedures
Fuel System Pressure Release (19.50.02)

Fuel Pressure Gauge

310-012 (JD209)
1.
WARNING: Place the vehicle in a quarantined area and arrange "No Smoking/Petrol Fumes"
signs about the vehicle.
WARNING: 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.
WARNING: 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.
WARNING: The fuel system remains pressurized for a long time after the ignition is switched
off. The fuel pressure must be relieved before attempting any repairs. Failure to follow these
instructions may result in personal injury.
personal injury.
WARNING: If taken internally do not induce vomiting, seek immediate medical attention.
WARNING: If fuel contacts the eyes, flush the eyes with cold water or eyewash solution and
seek medical attention.
WARNING: Wash hands thoroughly after handling, as prolonged contact may cause
irritation. Should irritation develop, seek medical attention.
Disconnect the battery ground cable.
2. Remove the fuel system pressure relief valve cap.
3.
WARNING: Make sure the tap of the special tool is rotated fully clockwise before installing
the special tool to the fuel system pressure relief valve. Failure to follow these instructions may
Install the special tool to the fuel system pressure relief valve.
4. NOTE:
When relieving the fuel system pressure, catch any displaced fuel in a suitable container.
Relieve the fuel system pressure.
• Rotate the tap of the special tool fully counterclockwise.
5. Remove the special tool from the fuel system pressure relief valve.
6. Install the fuel system pressure relief valve cap.

7. Connect the battery ground cable.
Fuel Tank Draining
Fuel drain adaptor

310-154
WARNING: Place the vehicle in a well ventilated, quarantined area and arrange ' No
Smoking/Petrol Fumes' signs about the vehicle.
CAUTION: Before disconnecting or removing components, ensure the area around the joint
faces and connections are clean. Plug open connections to prevent contamination.

2. Remove the rear RH seat cushion cover.
• Release the 2 clips.
3. Position the underseat sound deadner, to gain access to the fuel tank grommet.
4. Remove the rubber grommet.
• Disconnect the electrical connector.
5. Cut the sealing plug from the top of the 2 drain ports.
• Disconnect the electrical connector.

6. Connect the fuel tank drain equipment ground cable to the vehicle.
7. Remove the fuel from the tank, via the 2 drain ports, to drain the left and right sides of the fuel
tank.
8. Remove the fuel drain equipment.
9.
WARNING: After the fuel tank drain is complete always fit the sealing covers over the drain
ports. Failure to do so will mean that fuel vapour can escape.
Install the drain port sealing covers.
10. Install the grommet.
• Connect and secure the electrical connector.
11. Position the sound deadner.
12. Install the RH rear seat cushion.
• Carefully secure the clips.
13. Refill the fuel tank.

Quick Release Coupling
Disconnect
1.
WARNING: Place the vehicle in a quarantined area and arrange "No

Smoking/Petrol Fumes" signs about the vehicle.
WARNING: 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.
WARNING: Do not carry or operate cellular phones when working on or near

any fuel related components. Highly flammable vapors are always present and may
WARNING: 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.
WARNING: After carrying out repairs, the fuel system must be checked visually
for leaks. Failure to follow these instructions may result in personal injury.
WARNING: This procedure involves fuel handling. Be prepared for fuel spillage
at all times and always observe fuel handling precautions. Failure to follow these
WARNING: If taken internally do not induce vomiting, seek immediate medical

attention. Failure to follow these instructions may result in personal injury.
WARNING: If fuel contacts the eyes, flush the eyes with cold water or eyewash
solution and seek medical attention.
WARNING: Wash hands thoroughly after handling, as prolonged contact may
cause irritation. Should irritation develop, seek medical attention.
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.
Quick Release Coupling - Push Connect
Disconnect
1.
WARNING: Place the vehicle in a quarantined area and arrange "No

Smoking/Petrol Fumes" signs about the vehicle.
WARNING: 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.
WARNING: Do not carry or operate cellular phones when working on or near

any fuel related components. Highly flammable vapors are always present and may
WARNING: 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.
WARNING: After carrying out repairs, the fuel system must be checked visually
for leaks. Failure to follow these instructions may result in personal injury.
WARNING: This procedure involves fuel handling. Be prepared for fuel spillage
at all times and always observe fuel handling precautions. Failure to follow these
WARNING: If taken internally do not induce vomiting, seek immediate medical

attention. Failure to follow these instructions may result in personal injury.
WARNING: If fuel contacts the eyes, flush the eyes with cold water or eyewash
solution and seek medical attention.
WARNING: Wash hands thoroughly after handling, as prolonged contact may
2. Disconnect the push connect fitting.

• Press the collar.
• 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.
Spring Lock Couplings
Fuel spring lock decoupling tool 310-D005
WARNING: Place the vehicle in a quarantined area and arrange "No Smoking/Petrol Fumes"
signs about the vehicle.
WARNING: 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
personal injury.
WARNING: If taken internally, do not induce vomiting, seek immediate medical attention.
WARNING: If fuel contacts the eyes, flush the eyes with cold water or eyewash solution and
seek immediate medical attention.
WARNING: Wash hands thoroughly after fuel handling, as prolonged contact may cause
irritation. Should irritation develop, seek medical attention.
WARNING: Make sure the garter spring snaps over the male end of the spring lock coupling.
CAUTION: Before disconnecting or removing components, ensure the area around the joint
faces and connections are clean. Plug open connections to prevent contamination.
1. Release the fuel line safety clip.
2. Install the special tool.

3. Close the special tool and push it into the female end of the spring lock coupling.
4. Disconnect the spring lock coupling.
• Position an absorbent cloth to collect fluid spillage.
5. Remove the special tool.
6. Connect the spring lock coupling.

• Install a new garter spring.
7. Check the spring lock coupling, to make sure it is correctly connected.
8. Attach the fuel line safety clip.

310-01 : Fuel Tank and Lines
Specifications
Specifications
Item
Fuel system type Electronic - returnless
Fuel tank construction Stainless steel pressings
Fuel filter Located in the fuel delivery line, forward of the fuel tank
Fuel tank sender unit Mounted on the body of the fuel pump
Fuel Pump:
Type/location Electric - submersible - located in the fuel tank
Operating pressure 3.8 bar - 55 lbf/in²
Maximum output at 11.5 volts 4.8 bar - 69 lbf/in²
Capacities
Liters
Fuel tank capacity 71.1 (total) / 70.6 (useable)
Item Nm lb-ft lb-in

Fuel filter to bracket - bolt 7 5 62
Fuel filter bracket to vehicle - nut 7 5 62
Fuel tank filler pipe bracket to vehicle 7 5 62
Fuel tank strap to vehicle - bolt 35 26 -
Fuel/vapor tube bracket to vehicle - bolt 9 7 80
Fuel Tank and Lines

COMPONENT LOCATION
1 Filler cap and lanyard
2 Charcoal cannister assembly
3 Fuel tank
4 Fuel pump module assembly

5 Pipe - Fuel pump to engine (feed)
6 Pipe - EVAP charcoal canister to purge valve
7 Fuel filter
8 DMTL Pump (NAS only)
9 Fuel filler pipe
10 FPDM
11 DMTL filter
INTRODUCTION
The major components of the 4.2L V8 fuel system comprise
• Stainless steel saddle type fuel tank

• Fuel pump
• Fuel filler pipes
• Fuel level sensors
• Fuel delivery pipes.
The fuel system uses an electronic returnless fuel system which comprises a pump module mounted
in the fuel tank to deliver fuel at variable flow and pressure to the fuel rails which supply fuel to all
fuel injectors. The fuel pump operation is regulated by a Fuel Pump Driver Module (FPDM) which is
controlled by the engine management system. The control module regulates the flow and pressure
supplied by controlling the operation of the fuel pump using a PWM output. For additional
information, refer to Fuel Charging and Controls (303-04 Fuel Charging and Controls - 4.2L)
For additional information, refer to Evaporative Emissions (303-13 Evaporative Emissions)
For additional information, refer to Electronic Engine Controls (303-14 Electronic Engine Controls -
4.2L)
FUEL TANK
1 Fuel supply to engine
2 Fuel pump flange
3 Fuel pump flange electrical connection
4 Liquid vapor separator vent hose
6 DMTL pump
7 EVAP hose
8 Purge valve hose
9 Liquid vapor separator (including Roll Over Valve)
10 LH fuel level sensor
11 Fuel filter
12 LH jet pump
13 LH fuel level sensor float
14 Internal fuel transfer pipes
15 RH jet pump
16 RH fuel level sensor float
17 Fuel pump module
The fuel tank is a saddle type tank made of stainless steel pressings. 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 via the pump module flange aperture on the top of the tank.
The flange assembly comprises a pump module flange which contains all external pipe and electrical
connections for the tank internal components, a collar and a clamp. The flange is fitted with a seal
which locates in the tank aperture. An arrow on the flange must be aligned between two molded
lines on the tank, adjacent to the pump module flange aperture, to obtain the correct orientation.
The collar is located over the flange and is secured with the clamp. The flange, seal, collar and clamp
arrangement meets the sealing requirements of LEV2 emissions.
The flange has a five pin external connector which provides for electrical connections for the level
sensors, a common ground for the sensors and the fuel pump. This connector is wired to three push
fit connectors on the underside of the flange. A quick release connector provides for the connection
of the fuel feed pipe and breather.
The fuel pump module is mounted on a bayonet fitting at the base of the fuel tank. The module locks
into position by rotating the module clockwise into the bayonet. The module comprises the fuel
pump, the RH jet pump, the pump inlet filter, a second fine mesh filter which mounts into the carrier
and an over pressure valve (PRV). The pump module, fuel filter and level sensors are available as
serviceable components, the individual assembly components are not available separately.
FUEL PUMP MODULE
1 Electrical connecter
2 Fuel pump module
3 Fuel level sensor
4 Level sensor float
The fuel pump module is attached to the base of the fuel tank by the bayonet fitting. The pump
module flange has three electrical connectors; one for the fuel pump motor and one for each of the
fuel level sensors. All are connected to the external electrical connector via the connectors on the
underside of the fuel pump module flange.
The pump module has a maximum rated flow of 180 liters/hour (47.55 US gallons/hour) and an
output pressure of 5.0 bar (72.5 lbf/in2).
The fuel pump is energized by the fuel pump relay which is located in the Battery Junction Box (BJB)
and the fuel pump control module which is located in the left hand side of the luggage compartment.
The relay and control module are controlled by the engine control module The relay is energized at
all times when the ignition switch is in ignition position II.
A 60 micron fine mesh, pump inlet filter is attached to the pump inlet port at the bottom of the
pump. The filter is located vertically at the side of the pump to ensure that a portion of the filter is
off the base of the swirl pot to prevent premature blocking of the filter.
A second, serviceable fine mesh filter is located in-line. This provides additional filtration to the fuel
before it is passed to the fuel rail. The filter has an electrical connection which is attached to ground
to prevent electrostatic build-up.
FUEL LEVEL SENSORS
Left Hand Fuel Level Sensor
1 Fuel transfer pipe
2 Fuel level sensor
3 Sensor mounting bracket
4 Jet pump
5 Filter
6 Fuel level sensor float
7 Fuel drain transfer pipe
8 Fuel transfer pipe

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 a separate bracket in the other side of the fuel tank. The
sensors are a Magnetic Passive Position Sensor (MAPPS) 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 front and rear fuel level sensors are
connected to the external electrical connector on the flange via the connectors 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.
Sensor Operating Principle
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 output 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.
A warning lamp is incorporated in the instrument cluster and illuminates when the fuel level is at or
below 10 liters (2.64 US gallons).
The fuel level sender signal is converted into a CAN 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 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.
The jet pump is connected via a pipe from a three-way connection in the fuel pump. The LH jet pump
collects fuel from the LH side of the tank and transfers it into the swirl pot, ensuring a constant
supply of fuel to the pump. The jet pump has a jet nozzle of 0.5 mm diameter.
The RH jet pump operates at pump output pressure and delivers some of the fuel at pump pressure
from the LH side of the tank. The jet pump has a jet nozzle of 0.5 mm diameter.
LIQUID VAPOR SEPARATOR (LVS)
1 Roll over valve
2 Fuel vapor vent hoses
3 Fuel Level Vent Valve (FLVV)

4 Liquid Vapor Separator (LVS)
The Liquid Vapor Separator (LVS) separates any liquid from the vapor and drains back into the tank
via the Fuel Level Vent Valve (FLVV) which is located on the underside of the LVS.
A single Roll Over Valve (ROV) is located in the liquid vapor separator. The separator is attached to
the upper half of the fuel tank and is connected via a pipe and T piece to the charcoal canister
breather outlet and the tank vent breather outlet. The ROV 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 (FLVV)

The main purpose of the FLVV is to control the fill volume of the tank. During filling, vapor is passed
via the FLVV to the LVS. The vapor then passes from the LVS to the vent connection via a corrugated
tube. The vent connection is connected to the charcoal canister which stores the fuel vapor. During
filling, when the tank reaches its full level, the FLVV closes and prevents fuel vapor passing through
to the LVS. This causes the pressure in the tank to rise which in turn causes the pump filling nozzle to
turn off.
FUEL FILTER
The fuel filter is located on a bracket on the LH side of the fuel tank. The bracket is secured by a
single bolt.
FUEL FILLER PIPE ASSEMBLY
1 Fuel filter
2 DMTL fresh air filter
4 DMTL pump
5 LVS breather hose
6 Fuel filler pipe
7 Fuel tank vent hose
8 Bracket
9 Fuel filler pipe
10 FLVV pipe
11 DMTL fresh air pipe
12 DMTL fresh air filter
13 Filler cap lanyard
14 Filler cap
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 a stainless steel fabrication which is secured to the vehicle body by a bracket.
Connections on the rear of the filler head allow for the connection of the fuel tank breather pipe
from the fuel tank flange, the fuel filler pipe to the tank and the charcoal canister breather pipe.
The fuel tank breather pipe has a quick release fitting and connects to the breather pipe from the
fuel tank flange.
The fuel filler pipe locates in a short flexible hose attached to the tank and is secured with worm
drive clamps. The canister breather pipe is routed alongside the fuel filler pipe and attaches to the
canister with a quick release coupling.
A fourth pipe is also routed alongside the fuel filler pipe and provides air ventilation for the charcoal
canister. On all petrol vehicles, except NAS vehicles, the pipe is connected to the air pump port on
the charcoal canister with a quick release coupling and connects to an insect trap at the fuel filler
head. On NAS vehicles fitted with a DMTL pump, the pipe connects to the pump vent port and is also
connected to a filter which is attached to the filler head.
FUEL LINES
The fuel lines are single piece construction from the fuel filter to the fuel rails in the engine
compartment.
Fuel Tank and Lines

For a detailed description of the fuel tank and lines, refer to the relevant Description and Operation
Fuel Tank and Lines

• 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 • Rear Junction Box (RJB)
• Damaged fuel tank filler pipe cap • Fuel pump relay
• Damaged fuel tank filler pipe • Engine Control Module (ECM)
3 . If an obvious cause for an observed or reported symptom is found, correct the cause (if possible)
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

system is free from
• Engine breather system restriction and is correctly
disconnected/restricted installed
Engine cranks, but does not • Ignition system • For ignition system tests.
fire • Fuel system Engine Ignition
• Electronic engine • For fuel system tests. Read
controls DTCs and refer to DTC
Index in this section
• For electronic engine
control tests.

purge valve • For fuel pump tests. Check
Engine cranks and fires, but
• Fuel pump for DTCs and refer to DTC
will not start • Spark plugs Index in this section
• Ignition coil failure(s) • For ignition system tests.
Engine Ignition
• Check the engine coolant

level and condition.
• Check engine coolant Specifications
level/anti-freeze • Ensure the battery is in a
content fully charged and
• Battery serviceable condition
• Electronic engine • For electronic engine
controls control tests.
Difficult cold start
• Exhaust gas Electronic Engine Controls
recirculation (EGR) valve • For EGR valve tests.
stuck open Engine Emission Control
• Fuel pump • For fuel system tests. Read
• Evaporative emissions DTCs and refer to DTC
purge valve Index in this section

tests, install new injectors
as necessary.
• Injector leak • For electronic engine
• Electronic engine control tests.
controls Electronic Engine Controls
• Evaporative emissions • For purge valve tests.
Difficult hot start
purge valve Evaporative Emissions
• Fuel pump • For fuel system tests. Read
• Ignition system DTCs and refer to DTC
• EGR valve stuck open Index in this section
Engine Ignition
Difficult to start after hot soak • Injector leak • Carry out injector leak
• Electronic engine tests, install new injectors
(vehicle standing, engine off,
controls as necessary.
after engine has reached • Evaporative emissions Fuel Injector (18.10.01)
operating temperature) purge valve • For electronic engine
• Fuel pump control tests.
• Ignition system Electronic Engine Controls
• EGR valve stuck open • For purge valve tests.
• For fuel system tests. Read
Engine Ignition

system is free from
restriction and is correctly
installed
• Breather system • For ECM relay tests.
disconnected/restricted Electronic Engine Controls
• ECM relay • For electronic engine
• Electronic engine control tests.
controls Electronic Engine Controls
Engine stalls soon after start
• Ignition system • For ignition system tests.
• Air intake system Engine Ignition
restricted • Check for blockage in air
• Air leakage cleaner element and air
• Fuel lines intake system
intake system
• For fuel line tests. GO to
• For fuel pressure tests. GO

to Pinpoint Test
G830073p8.
For fuel line tests. GO to
pump, fuel lines
For fuel pump tests. Read
• Injector leak
• Air leakage
• Carry out fuel injector leak
Engine hesitates/poor controls
tests, install new injectors
acceleration • Ignition system
as necessary.
• EGR valve stuck
• Transmission
• Check for leakage from air
malfunction
intake system
(carpet, etc)
control tests.
Engine Ignition
tests.
Diagnostic Strategy
• Ensure accelerator pedal is
• For fuel pump tests. Read

Index in this section. For
• Fuel pump, fuel lines fuel line tests. GO to
• Air leakage Pinpoint Test G830073p9.
• Electronic engine • Check for leakage from air
controls intake system
Engine backfires
• Ignition system • For electronic engine
• Sticking variable control tests.
camshaft timing (VCT) Electronic Engine Controls
hub • For ignition system tests.
Engine Ignition
• For VCT system tests.
• For fuel pump tests. Read

Index in this section. For
• Fuel pump, fuel lines fuel line tests. GO to
• Electronic engine Pinpoint Test G830073p9.
Engine surges controls • For electronic engine
• Ignition system control tests.
Engine Ignition

control tests.
• Electronic engine • For fuel pump tests. Read
controls DTCs and refer to DTC
• Fuel pump, fuel lines, Index in this section. For
Engine detonates/knocks fuel quality fuel line tests. GO to
• Air leakage Pinpoint Test G830073p9.
• Sticking VCT hub • Check for leakage from air
intake system
• For VCT system tests.
DTC Index
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.
NOTE:
system).
NOTE:
NOTE:
NOTE:
terminals.
• Fuel rail pressure (FRP) • Carry out any pinpoint

Fuel rail/system
P008700 sensor, sensing circuit - tests associated with
pressure - too low short to ground, open this DTC using the
circuit manufacturer
• FRP sensor supply circuit - approved diagnostic
high resistance system
• FRP sensor failure • Install a new FRP
• Fuel pump failure sensor as necessary.
• Fuel line leak, restriction Fuel Rail Pressure (FRP)
Sensor (18.30.98)
• Check for logged fuel
pump DTCs and refer
to DTC index
• Check for fuel line
leaks/restrictions and
rectify as necessary.
GO to Pinpoint Test
G830073p9.

this DTC using the
manufacturer
• FRP sensor
approved diagnostic
supply/sensing circuits -
system
short to each other
• Install a new FRP
• FRP sensor sensing circuit
- short to power
Fuel rail/system Fuel Rail Pressure (FRP)
P008800 • FRP sensor ground circuit
pressure - too high Sensor (18.30.98)
- high resistance
• Check for fuel
leaks/restrictions and
• Restricted fuel line
rectify as necessary.
• Fuel pump short circuit to
GO to Pinpoint Test
power
G830073p9.
pump DTCs and refer
to DTC index
• Check for leak from air

• Air intake leak between
intake system
MAF sensor and cylinder
• Check fuel system is
head
• Fuel filter, injector,
System too lean (bank • For MAF sensor tests.
P017100 system restriction
1) Electronic Engine
• MAF sensor fault (low
Controls
intake air flow)
• Check and rectify any
• Exhaust leak (forward of
exhaust leak prior to
catalytic converter)
catalytic converter
• Air intake leak between • Check for leak from air

System too lean (bank MAF sensor and cylinder intake system
P017400
2) head • Check fuel system is
• Fuel filter, injector, free from restriction
system restriction • For MAF sensor tests.
• MAF sensor fault (low Electronic Engine
intake air flow) Controls
• Exhaust leak (forward of • Check and rectify any
catalytic converter) exhaust leak prior to
catalytic converter
• If specific cylinder
misfire or injector DTCs
are also logged refer to
the tests associated to
those DTCs first.
Electronic Engine
Controls
• For ignition coil test.
• ECM to ignition coil
Electronic Engine
primary circuit faults
Controls
(cylinder misfire detected
• Check and install new
DTCs also logged)
spark plugs as
• Fuel injector circuit
necessary.
fault(s) (injector DTCs also
Spark Plugs - 4.2L NA
logged)
V8 - AJV8 (18.20.02)
• Ignition coil failure
• Spark plug
system DTCs and refer
failure/fouled/incorrect
Random/multiple to relevant DTC Index.
gap
P030000 cylinder misfire Fuel Charging and
• Fuel delivery pressure
detected Controls - 4.2L NA V8 -
(low/high)
• Fuel contamination
Electronic Engine
• Fuel injectors restricted,
Controls
leaking, continuously
Fuel Tank and Lines
open
• For injector tests.
• Cylinder compression low
Fuel Charging and
• Worn camshaft/broken
Controls - 4.2L NA V8 -
valve springs
• Valve clearance
• Check cylinder
adjustment
compressions.
Engine
• Check for worn/broken
engine components
and valve clearance
adjustment.
Valve Clearance Check
(12.29.47)
Fuel level sensor A • Fuel level sensor A

circuits - intermittent • For fuel level sensor
circuit -
P046129 short circuit, high tests. GO to Pinpoint
range/performance - resistance Test G830073p3.
signal invalid • Fuel level sensor failure
Fuel level sensor A • Fuel level sensor circuits -
• For fuel level sensor
circuit intermittent short circuit,
P04612F tests. GO to Pinpoint
range/performance - high resistance
Test G830073p3.
signal erratic • Fuel level sensor failure
• Fuel level sensor circuits -

Fuel level sensor A intermittent short to
P046200 tests. GO to Pinpoint
circuit - low input ground, high resistance
Test G830073p3.
• Fuel level sensor failure
• Fuel level sensor circuits -

Fuel level sensor A intermittent short to
P046300 tests. GO to Pinpoint
circuit - high input power
Test G830073p3.
• Fuel level sensor failure

Fuel pump A control • Fuel pump control circuit check the FPDM to
P062700 fault (FPDM to fuel pump) Fuel Pump circuit for
circuit/open
short to ground,
power, open circuit
• For ECM to FPDM

Fuel pump A control
• Invalid fuel pump duty circuit tests. GO to
P062A00 circuit
requested by the ECM Pinpoint Test
range/performance G830073p5.
Pinpoint Tests
PINPOINT TEST G830073p3 : FUEL

LEVEL SENDER(S) CIRCUIT
RANGE/PERFORMANCE
G830073t6 : CHECK THE SIGNAL CIRCUIT BETWEEN THE RJB AND FUEL
LEVEL SENDER 'A' FOR SHORT CIRCUIT TO GROUND
1. Disconnect the fuel pump module electrical connector, CA127. 2. Measure the resistance between:
Fuel pump module connector CA127, harness side Battery

-> Yes
REPAIR the short circuit. For additional information, refer to the wiring diagrams. CLEAR the DTC, test
the system for normal operation.
-> No
LEVEL SENDER 'A' FOR SHORT CIRCUIT TO POWER
-> Yes
-> No
LEVEL SENDER 'B' FOR SHORT CIRCUIT TO GROUND
-> Yes
-> No
LEVEL SENDER 'B' FOR SHORT CIRCUIT TO POWER
-> Yes
-> No
G830073t10 : CHECK THE SIGNAL RETURN CIRCUIT BETWEEN THE RJB AND
FUEL LEVEL SENDERS FOR SHORT CIRCUIT TO GROUND
-> Yes
-> No
FUEL LEVEL SENDERS FOR SHORT CIRCUIT TO POWER
-> Yes
-> No
G830073t12 : CHECK THE FUEL LEVEL SENDER 'B' RESISTANCE AT EMPTY

1. Drain the fuel tank.
Fuel Tank Draining 2. Measure the resistance between:
Fuel pump module connector CA127, component Fuel pump module connector CA127, component
side side
Pin 05 Pin 06
• Is the resistance 51±2 ohms?
-> Yes
-> No
INSTALL a new fuel tank.
Fuel Tank (19.55.01) CLEAR the DTC, test the system for normal operation.
G830073t13 : CHECK THE FUEL LEVEL SENDER 'B' RESISTANCE AT FULL

1. Remove the fuel tank. 2. Invert fuel tank to set sensor float to it's highest position. 3. Measure the
resistance between:
side side
Pin 05 Pin 06
-> Yes
-> No
INSTALL a new fuel tank.
Fuel Tank (19.55.01) CLEAR the DTC, test the system for normal operation.
G830073t14 : CHECK THE FUEL LEVEL SENDER 'A' RESISTANCE AT EMPTY

1. Correct fuel tank orientation. 2. Remove the fuel pump module.
Fuel Pump Module (19.45.08) 3. Move the sender float to it's lowest position. 4. Measure the
resistance between:
side side
Pin 01 Pin 02
-> Yes
-> No
INSTALL a new fuel level sender.
Fuel Level Sender CLEAR the DTC, test the system for normal operation.
G830073t15 : CHECK THE FUEL LEVEL SENDER 'A' RESISTANCE AT FULL

1. Move the sender float to it's highest position. 2. Measure the resistance between:
side side
Pin 01 Pin 02
-> Yes
-> No
INSTALL a new fuel level sender.
Fuel Level Sender CLEAR the DTC, test the system for normal operation.
LEVEL SENDER 'A' FOR HIGH RESISTANCE
1. Disconnect the RJB electrical connector, CA070. 2. Measure the resistance between:
RJB connector CA070, harness side Fuel pump module connector CA127, harness side
Pin 13 Pin 02
-> Yes
REPAIR the high resistance circuit. For additional information, refer to the wiring diagrams. CLEAR the
-> No
LEVEL SENDER 'B' FOR HIGH RESISTANCE
Pin 12 Pin 06
-> Yes
-> No
FUEL LEVEL SENDER 'A' FOR HIGH RESISTANCE
Pin 04 Pin 01
-> Yes
-> No
FUEL LEVEL SENDER 'B' FOR HIGH RESISTANCE
Pin 04 Pin 05
-> Yes
-> No
CHECK for DTCs indicating another cause of the complaint.
PINPOINT TEST G830073p5 : ECM TO
FPDM MONITOR AND CONTROL
CIRCUITS
G830073t22 : CHECK THE ECM TO FPDM MONITOR CIRCUIT FOR SHORT
CIRCUIT TO GROUND
1. Set ignition status to OFF. 2. Disconnect the FPDM electrical connector, CA125. 3. Measure the
resistance between:
FPDM connector CA125, harness side Battery
-> Yes
-> No
G830073t23 : CHECK THE ECM TO FPDM MONITOR CIRCUIT FOR SHORT

CIRCUIT TO POWER
-> Yes
-> No
G830073t24 : CHECK THE ECM TO FPDM CONTROL CIRCUIT FOR SHORT
CIRCUIT TO GROUND
-> Yes
-> No
G830073t25 : CHECK THE ECM TO FPDM CONTROL CIRCUIT FOR SHORT

CIRCUIT TO POWER
-> Yes
-> No
G830073t26 : CHECK THE ECM TO FPDM MONITOR CIRCUIT FOR HIGH

RESISTANCE
FPDM connector CA125, harness side ECM connector FL072, harness side
Pin 04 Pin 21
-> Yes
-> No
G830073t27 : CHECK THE ECM TO FPDM CONTROL CIRCUIT FOR HIGH

RESISTANCE
FPDM connector CA125, harness side ECM connector FL072, harness side
Pin 03 Pin 20
-> Yes
-> No
CHECK for DTCs indicating a module fault.

THE FUEL SYSTEM PRESSURE
G830073t39 : CHECK THE PUMP ACTIVITY
1. Remove the rear seat cushion.
Rear Seat Cushion (76.70.37) 2. Set ignition status to ON, engine OFF. 3. Listen for pump noise.
• Can the fuel pump be heard running?
-> Yes
-> No
CHECK for DTCs.
G830073t40 : CHECK THE FUEL SYSTEM PRESSURE

1.
personal injury.
Make sure the vehicle is in Park and apply the parking brake. 2. Set ignition status to OFF 3. NOTE:
Place suitable absorbent material around the Schraeder valve to absorb any spillage when
connecting the gauge set.
Connect adapter and gauge assembly 310-116 to the fuel Schraeder valve. Remove the absorbent
material and dispose of safely. 4.
Disconnect and plug the vacuum hose from the pressure regulator. 5. Open the valve on the fuel
pressure gauge 310-116. 6. Set ignition status to ON, engine OFF. 7. Record the fuel pressure reading.
• Is the fuel pressure 3.8 bar (55.11 lb/in²). A slow decay to approximately 3 bar should occur
over one minute.
-> Yes
-> No
CHECK for DTCs.
G830073t41 : CHECK THE FUEL SYSTEM PRESSURE WITH THE ENGINE

CRANKING
1. Apply footbrake and press start button. 2. Record the fuel pressure reading when engine cranking.
• Is the fuel pressure 3.8 bar (55.11 lb/in²) nominal.
-> Yes
-> No
CHECK for DTCs.
G830073t42 : CHECK THE FUEL SYSTEM PRESSURE WITH THE ENGINE

IDLING (WHERE POSSIBLE)
1. With engine running.
• Is the fuel pressure 3.8 bar (55.11 lb/in²)
-> Yes
CHECK for DTCs and symptoms indicating another cause of the problem.
-> No
CHECK the fuel pump module power and ground circuits.

THE FUEL LINES
G830073t43 : CHECK THE FUEL LINES FOR RESTRICTIONS
1.
personal injury.
Detach the fuel line from the fuel rail and from the fuel pump module. 2. Using an air line gently blow
through the line checking for blockages or restrictions.
• Is a blockage or restriction evident?
-> Yes
CLEAR/REPAIR the blocked or restricted fuel line and test the system for normal operation.
-> No
G830073t44 : CHECK THE FUEL TANK LINES FOR RESTRICTIONS

1. Remove the fuel pump module locking ring.
Fuel Pump Module (19.45.08) 2. Detach the fuel lines from the fuel pump module. 3. Using an air
line gently blow through the tank lines checking for blockages or restrictions.
• Is a blockage or restriction evident?
-> Yes
CLEAR/REPAIR the blocked or restricted fuel line and test the system for normal operation.
-> No
CHECK for DTCs and symptoms indicating another cause for the problem.
Fuel Filter (19.25.02)

Removal

2
3
. WARNING: The spilling of fuel is unavoidable during this operation. Ensure that all
CAUTION: Before disconnecting or removing components, ensure the area around

NOTE:
Remove the fuel filter.
Remove the nut.
Disconnect the 2 fuel lines.
4 . Remove the fuel filter bracket.
Remove the bolt.
Installation
1 . Attach the fuel filter support bracket.
2 . Install the fuel filter.
Connect the fuel lines.

Fuel Level Sender
Removal
2 . Remove the fuel pump module.

For additional information, refer to Fuel Pump Module (19.45.08)
3 . Remove the fuel level sender unit.
Installation
1 . Install the fuel level sender unit.
2 . Install the fuel pump module.

For additional information, refer to Fuel Pump Module (19.45.08)

Fuel Pump Module (19.45.08)

Removal

2
3 . With assistance, remove the fuel tank.

For additional information, refer to Fuel Tank (19.55.01)
4 . Remove the fuel pump and sender cover locking ring.

Remove the 6 nuts.
5 . Remove the fuel pump and sender cover.
6 . Remove and discard the seal.
7
. WARNING: The fuel tank is manufactured from stainless steel. Hand and arm
protection must be used when removing parts from the inside of the tank, to prevent any
injury.
WARNING: Wash hands thoroughly after fuel handling, as prolonged contact may
Remove the fuel pump module.
Rotate the pump module counter-clockwise.
8 . NOTE:
Remove the fuel level sender unit.

Installation
1 . Install the fuel level sender unit.
2
. WARNING: The fuel tank is manufactured from stainless steel. Hand and arm
protection must be used when removing parts from the inside of the tank, to prevent any
injury.
WARNING: Wash hands thoroughly after fuel handling, as prolonged contact may
Install the fuel pump module.
Connect the hoses.
3 . Install the new O-ring seals.
4 . Install the fuel pump and sender cover.

5 . Install the fuel pump and sender cover locking ring.
6 . With assistance, install the fuel tank.


Fuel Tank (19.55.01)
Removal

2 . Drain the fuel tank.

For additional information, refer to Fuel Tank Draining
3
4 . Remove the rear sub-frame assembly.

5 . Release the 2 electrical connectors.

6
Disconnect the fuel filter.
Release the fuel supply line.
7 . Release the fuel filler neck and the evaporative emissions breather hoses.
8 . Using a transmission jack, support the fuel tank.
Remove the 2 bolts.
Remove the 2 retaining pins.
9 . Remove the fuel tank.
10 . NOTE:

Remove the fuel line.
Disconnect the fuel line.
Installation
1 . Install the fuel line.
2 . Install the fuel tank.
Using a transmission jack, position and support the fuel tank.
3 . Install the fuel tank straps.
Install the retaining pins.
4 . Install the fuel filler neck and the evaporative emissions breather hoses.
5 . Secure the electrical connectors.
6 . Connect the fuel filter.
7 . Install the rear sub-frame.

8 . Refill the fuel tank.

For additional information, refer to Fuel Tank Draining

Fuel Tank Filler Pipe (19.55.33)
Removal

2 . Open the fuel filler door and remove the cap.
3

5 . Release the rear lower edge of the rear fender splash shield.
6 . Release the fuel tank filler pipe.
Release the clip.
7 . Release the breather hose.
Release the clip.
8 . NOTE:
Note the fitted position of the locating pegs.
Remove the fuel filler neck assembly.
Remove the 2 bolts.
Remove the 2 clips.
Installation
1 . NOTE:
Install the fuel filler neck assembly.
Install the clips.

2 . Install the breather pipes.
Release the clip.
3 . Install the fuel tank filler pipe.
Secure the clip.

6 . Install the fuel filler cap and close the fuel filler door.

310-02 : Acceleration Control
Specifications
Specifications
Item Nm lb-ft lb-in

Accelerator pedal to bracket - screw 10 7 -
COMPONENT LOCATION

1 Electric throttle
2 APP sensor
INTRODUCTION
Acceleration control for the 4.2 Liter engine is achieved via an electronic throttle drive by
wire system. The throttle is electronically connected to the ECM and the ECM then controls
the fueling for the relevant throttle demand signal from the APP sensor.
For a detailed description of the acceleration control systems, refer to the relevant Description and

• Fuses
• Wiring harness
• Accelerator pedal
• Throttle body
• Sensor(s)
4 . If the concern is not visually evident, check for Diagnostic Trouble Codes (DTCs) and refer to the
DTC Index.
DTC Index
NOTE:
NOTE:
fault (the last two digits give additional information read by the manufacturer-approved
diagnostic system).
NOTE:
NOTE:
NOTE:
terminals.
• Carry out any pinpoint tests

• TP sensor
Throttle Position (TP) associated with this DTC using
sensing circuits
sensor circuits TP 1 and TP 1 and TP 2 -
TP 2 - short to power,
• Install a new throttle body as
range/performance high resistance
necessary.

• TP sensor
sensing circuit TP
Throttle Position (TP) the manufacturer approved
1 - short to
P012200 sensor circuit TP 1 - low diagnostic system
ground, high
input • Install a new throttle body as
resistance
necessary.
Throttle Position (TP) • TP sensor • Carry out any pinpoint tests

P012300 sensor circuit TP 1 - high sensing circuit associated with this DTC using
input TP1 - short to the manufacturer approved
power diagnostic system
• TP sensor failure • Install a new throttle body as
necessary.

• TP sensor
sensing circuit TP
2 - short to
ground, high
resistance
necessary.

• TP sensor
sensing circuit TP
2- short to power
necessary.
• APP sensor • Carry out any pinpoint tests

Accelerator Pedal
circuit APP 1 - associated with this DTC using
P022700 Position (APP) sensor
short to ground, the manufacturer approved
circuit APP 1 - low input high resistance diagnostic system

Accelerator pedal • APP sensor
P022800 position (APP) sensor circuit APP 1 -
circuit APP 1 high input short to power
diagnostic system

Throttle actuator • Jammed throttle diagnostic system
P210129 control motor circuit blade, gearing or • Install a new throttle body.
range/performance motor Refer to the new
module/component
the DTC Index
• Refer to the electrical circuit

diagrams and test throttle
actuator control motor circuit
Throttle actuator • Jammed throttle
for short to ground, power,
P210162 control motor circuit blade, gearing or
high resistance. Compare
range/performance motor
throttle position sensor 1 and
2 datalogger signals, if signals
are comparable install a new
throttle body.

Throttle actuator • Jammed throttle diagnostic system
P210164 control motor circuit blade, gearing or • Install a new throttle body.
range/performance motor Refer to the new
module/component
the DTC Index
Throttle actuator motor • Check for throttle related DTCs

• Throttle blade
control circuit and refer to DTC Index in this
stuck open
P210177 range/performance section
• Intake air system
(commanded position • Check intake air system for
leak
not reachable) leaks

• Throttle motor
Throttle actuator motor control circuit -
control circuit high short to power
• Refer to new module
• ECM fault
installation Note at top of DTC
Index

• Throttle motor
Throttle actuator motor the manufacturer approved
control circuit -
P210364 control circuit high - diagnostic system
short to power
signal plausibility failure • Refer to new module
• ECM fault
installation Note at top of DTC
Index

Throttle actuator • Throttle MIL
P210500 control system - forced request due to
engine shutdown fuel cut
diagnostic system
• Install a new throttle body.

Throttle Body (19.70.04) Refer
Throttle actuator
to the new
P210629 control system - forced • Signal invalid
module/component
limited power installation note at the top of
the DTC Index
P210664 Throttle actuator • Install a new throttle body.

• Signal plausibility
control system - forced Throttle Body (19.70.04) Refer
limited power failure to the new
module/component
the DTC Index
• Throttle motor
Throttle actuator motor control circuit -
P211800 control current short to ground,
range/performance power, high
diagnostic system
resistance
• Install a new throttle body.

Throttle actuator Throttle Body (19.70.04) Refer
control throttle body • Throttle spring to the new
P211900
range/performance - faulty module/component
spring installation note at the top of
the DTC Index

P212200 position (APP) sensor D circuit 2 - low
circuit low input input
diagnostic system

P212300 position (APP) sensor D circuit 2 - high
circuit high input input
diagnostic system
• Check APP sensor circuits 1

and 2 for short to ground,
circuit 1 and 2
position (APP) sensor 1 power and high resistance.
P213528 range
and 2 voltage Clear the DTCs and retest. If
performance -
correlation the code remains, replace the
sub-processor
APP sensor
• APP sensor -
excessive
Accelerator pedal • Carry out any pinpoint tests
difference
position (APP) sensor 1 associated with this DTC using
P213529 between raw
and 2 voltage the manufacturer approved
values of circuit 1
correlation diagnostic system
and 2 - sub-
processor

• Check APP sensor circuits 1
circuit 1 and 2
position (APP) sensor 1 and 2 for short to ground,
P213562 range
and 2 voltage power and high resistance.
performance -
correlation Clear the DTCs and retest. If
sub-processor
the code remains, replace the
APP sensor
Accelerator pedal • APP sensor • Carry out any pinpoint tests

position (APP) sensor 1 circuit 1 and 2 associated with this DTC using
P213564
and 2 voltage range the manufacturer approved
correlation performance diagnostic system
Accelerator Pedal (19.20.01)

Removal
1
. CAUTION: Removal of the clips is a delicate procedure, damage will
occur if any force is used.

2 . Remove the throttle pedal assembly.

Installation
1 . Install the throttle pedal assembly.

310-03 : Speed Control
Specifications
Specifications
Speed control sensor - vertical alignment 90° ± 0.75°
Item Nm lb-ft lb-in

Speed control module - nut 5 4 44
Speed control sensor - bolt 5 4 44
Speed control sensor, adjustment - lock nut 5 4 44
Speed control switch. - - -
General Procedures

Inclinometer
501-F007
1.
2. Remove the front bumper cover.

3.
CAUTION: Drive the vehicle on to a flat, level surface.
Position the vehicle on a smooth level surface and settle the suspension.
4. Using the special tool, check the speed sensor is level, (+/- 0.5 degree).
5. NOTE:
The speed sensor has no mechanical horizontal adjustment.
NOTE:
Do not release the lock nut.
Using the special tool, set the speed control sensor.
• Rotate the vertical adjuster.
• Adjust using an internal Torx Bit.
6. Install the front bumper cover.

Control
COMPONENT LOCATION
NOTE:
RHD shown, LHD similar
1 Adaptive speed control sensor (Adaptive speed control only)
2 Brake switch
3 Instrument cluster warning lamps and icons
4 APP sensor
5 Forward alert switch (adaptive speed control system only)
6 Steering wheel mounted speed control switches
7 Adaptive speed control module (adaptive speed control system only)
8 ECM
INTRODUCTION
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. 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 sensor.
The adaptive system incorporates the following additional components:
• An adaptive speed control module

• An adaptive speed control sensor
• A forward alert switch
• A Time gap switch
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/Suspend switch
• '+' and '–' (set/accelerate and decelerate)
• 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 controls the electronic throttle to adjust the fuel supply as
required to maintain the set speed.
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 20 mph (32 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 120 mph (192 kph).
• If the accelerator pedal is used to accelerate beyond the set speed for too long.
SPEED CONTROL SWITCHES

1 Set speed adjustment
2 Cancel switch
3 Resume switch
There are three speed control switches:
• Speed adjustment
• Cancel
• Resume
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

The adaptive speed control system comprises the following components:
• Adaptive Speed Control Sensor

• Adaptive Speed Control module
• Steering wheel control switches
• ECM
• 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 32
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.
RADAR SENSING
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.
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
when 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.
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 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.

1 Follow mode warning indicator
2 Forward Alert warning indicator
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.
ADAPTIVE SPEED CONTROL SWITCHES

1 Set speed adjustment switch
2 Time gap switch
3 Cancel switch
4 Resume switch
The Adaptive Speed control system is controlled from the steering wheel switches. The
switches are the same as used for normal speed control with the addition of an extra time gap
setting switch. The time gap setting switch allows the driver to adjust the time gap to one of
four pre-set time gaps. The selected time gap is displayed in the vehicle message center.
The time gap will return to the default gap (the third setting) each time the ignition is cycled.
ADAPTIVE SPEED CONTROL MODULE

The Adaptive Speed Control module, located on the bottom of the RH (right-hand) A pillar.
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 mounted centrally behind the front bumper. 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 IDS. 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
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.

1 Forward alert switch
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.
CONTROL DIAGRAM
NOTE:
A = Hardwired connection; D = High speed CAN bus; O = LIN (local interconnect
network) bus; U = Private CAN
1 APP sensor
2 Brake switch
3 Electric throttle
4 ECM
5 TCM
7 Clock spring
9 ABS module
10 Transmission selector lever
11 Diagnostic socket
12 Adaptive speed control sensor (adaptive speed control system only)
13 Forward alert switch (adaptive speed control system only)
14 Adaptive speed control module (adaptive speed control system only)
Speed Control
Principles of Operation
There are two options of speed control available, adaptive speed control and non-adaptive speed
control. For a detailed description of the speed control systems, refer to the relevant Description and
Speed Control

• Fuses
• Wiring harness
• Speed control sensor • Electrical connector(s)
• Ensure the speed control sensor is free from • Steering wheel switches
obstructions • Brake switch
• Speed control module • Speed control sensor
• Speed control module
4 . If the cause is not visually evident, verify the symptom and refer to the Symptom Chart,
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 the
adjustment of the speed control sensor.
Symptom Chart
• Default mode • Check for Network related DTCs that

Speed control inhibited
enabled could be caused by power failure to
or disabled • Supply voltage to the module or sensor and refer to DTC
speed control Index.
module Communications Network
• Supply voltage to • For steering wheel speed control
speed control switch and circuit tests. GO to
sensor Pinpoint Test G831824p9.
• Steering wheel • For engine throttle position sensor
speed control tests.
switch(s) Electronic Engine Controls
• Steering wheel Electronic Engine Controls
speed control • For brake switch tests. GO to Pinpoint
switch circuit Test G831824p10.
• Throttle sensors
• Brake switch
Unable to
• Steering wheel • For speed control switch circuit tests.
regulate/adjust vehicle
switch malfunction GO to Pinpoint Test G831824p9.
speed
Unable to cancel speed

• Steering wheel • For speed control switch circuit tests.
control from steering
switch malfunction GO to Pinpoint Test G831824p9.
wheel
Unable to cancel speed

• Brake switch • For brake switch tests. GO to Pinpoint
control from brake
malfunction Test G831824p10.
pedal
DTC Index
NOTE:
NOTE:
system).
NOTE:
NOTE:
NOTE:
terminals.
• RJB reporting invalid Re-configure RJB using

B1A84-
Car configuration data car configuration manufacturer approved diagnostic
81 parameters system and re-test.
Speed control sensor Carry out speed control sensor

C1A67- • Speed control sensor
alignment angle - out adjustment procedure.
54 out of alignment
of range Speed Control Sensor Adjustment

C1A67- Speed control sensor - • Yaw rate voltage - out associated with this DTC using the
81 Yaw rate sensor of range manufacturer approved diagnostic
system

C1A67- Speed control sensor - Incorrect or missing data from associated with this DTC using the
87 Missing data speed control sensor manufacturer approved diagnostic
system
C1A67- Speed control sensor - • Internal hardware Install a new speed control sensor.
96 Internal sensor failure failure Speed Control Sensor
This DTC will be cleared
C1A67- Speed control sensor - • Sensor reduced
automatically when environmental
97 reduced visibility visibility
conditions allow
• Speed control sensor This DTC will be cleared

C1A67- Speed control sensor -
internal temperature automatically when environmental
98 temperature high exceeded threshold conditions allow
Using the manufacturer approved

ABS wheel speed • Follow speed is mis-
P174E- diagnostic system, clear the DTC
correlation - active calculated to too high
81 a value and re-test. If the DTC is logged
speed output error
contact Dealer Technical Support.

U0001- High speed CAN • Vehicle CAN Bus off associated with this DTC using the
88 communication Bus condition manufacturer approved diagnostic
system

U0100- Lost communications associated with this DTC using the
• ECM missing message
00 with ECM manufacturer approved diagnostic
system

U0101- Lost communications associated with this DTC using the
• TCM missing message
00 with TCM manufacturer approved diagnostic
system

U0121- Lost communication associated with this DTC using the
• ABS missing message
00 with ABS manufacturer approved diagnostic
system

Lost communications
U0128- • Parking brake missing associated with this DTC using the
with parking brake
00 message manufacturer approved diagnostic
module
system

U0155- Lost communications • Instrument cluster associated with this DTC using the
00 with instrument cluster missing message manufacturer approved diagnostic
system
Internal control Re-configure the RJB using the

U0300- • Invalid configuration
module software manufacturer approved diagnostic
00 incompatibility message is received system. Clear DTCs and re-test. If
DTC still logged, suspect speed
control module. Refer to new
module installation note at top of
DTC Index
Control module
• RJB - at least one of
software Re-configure the RJB using the
U0300- the car configuration
incompatibility - manufacturer approved diagnostic
55 parameters is not
module configuration configured system. Clear DTCs and re-test.
failure
• ECM did not respond Check ECM for DTCs and refer to
U0401- properly to speed DTC Index.
from ECM - ECM cancel
00 control cancel or auto Electronic Engine Controls
fault brake cancel request Electronic Engine Controls
• ECM did not respond Check ECM for DTCs and refer to
U0401- properly to speed DTC Index.
from ECM - ECM
67 control resume Electronic Engine Controls
resume fault request Electronic Engine Controls
Invalid data received Check ECM for DTCs and refer to

U0401- from ECM - speed • Speed control DTC Index.
81 control inhibited by inhibited by ECM Electronic Engine Controls
ECM Electronic Engine Controls
Check ABS module for DTCs and

U0415- Invalid data received
• Stability assist fault refer to DTC Index.
81 from ABS
Invalid data received • Parking brake module

Check parking brake module for
U0417- from parking brake did not respond
67 module - parking brake properly to apply
request Parking Brake
apply acknowledge
Invalid data received • Speed control Check parking brake module for
U0417-
from parking brake inhibited by parking DTCs and refer to DTC Index.
81 brake module
module Parking Brake
Check CJB for DTCs and refer to DTC

U0422- Invalid data received • CJB message not up-
Index.
00 from CJB dated
U0423- Invalid data received • Instrument cluster not Check instrument cluster for DTCs
81 from instrument enabled for adaptive and refer to DTC Index.
cluster speed control Instrument Cluster
Check RJB for DTCs and refer to DTC

U0443- Invalid data received • RJB message not up-
Index.
00 from RJB dated
Refer to wiring diagrams and test

U1A00- • Private CAN Bus off Private CAN Bus circuit between
Private CAN Bus circuit
88 condition speed control module and speed
control sensor for circuit faults
Install a new speed control module,

refer to the new module installation
U1A14- CAN initialisation • Internal electronic note at the top of the DTC Index.
49 failure failure Speed Control Module - Vehicles
Without: Adaptive Speed Control
(19.75.26)
Re-configure RJB using

Control module
U2101- • Data sent from RJB is tool, clear DTC and re-test. If DTC
configuration
00 invalid remains check RJB for DTCs and
incompatible
refer to DTC Index.
• Internal micro Install a new speed control module,

U3000-
Control module controller error refer to new module installation
41 • Checksum fault note at top of DTC Index

U3000- • Internal RAM test
Control module refer to new module installation
42 fault
note at top of DTC Index

U3000- • Internal control
Control module refer to the new module installation
49 module failure
Pinpoint Tests
PINPOINT TEST G831824p9 : SPEED

CONTROL SWITCH CIRCUIT TESTS
G831824t29 : CHECK THE STEERING WHEEL SPEED CONTROL SWITCH FOR
OPEN CIRCUIT
1. Disconnect the battery negative terminal.
Battery (86.15.01) 2. Wait two minutes for the system to become safe. 3. Disconnect the speed
control switch connector SW009. 4. Measure the resistance between:
speed control switch connector SW009, pin 02, component side
• Is the resistance 4310 ohms?
-> Yes
-> No
INSTALL a new speed control switch assembly.
Speed Control Switch (19.75.25) TEST the system for normal operation.
G831824t23 : CHECK THE STEERING WHEEL SPEED CONTROL RESUME

SWITCH CIRCUIT
speed control switch connector SW009, pin 03, component side 2. Operate the RESUME switch.
• Does the resistance switch between 4310 ohms and 2110 ohms when the switch is
operated?
-> Yes
-> No
G831824t24 : CHECK THE STEERING WHEEL SPEED CONTROL SET+ SWITCH

CIRCUIT

speed control switch connector SW009, pin 03, component side 2. Operate the SET+ switch.
operated?
-> Yes
-> No
G831824t25 : CHECK THE STEERING WHEEL SPEED CONTROL HEADWAY

REDUCTION SWITCH CIRCUIT
speed control switch connector SW009, pin 03, component side 2. Operate the HEADWAY
REDUCTION switch.
operated?
-> Yes
-> No
G831824t26 : CHECK THE STEERING WHEEL SPEED CONTROL HEADWAY

INCREASE SWITCH CIRCUIT
speed control switch connector SW009, pin 03, component side 2. Operate the HEADWAY INCREASE
switch.
operated?
-> Yes
-> No
G831824t27 : CHECK THE STEERING WHEEL SPEED CONTROL SET- SWITCH

CIRCUIT
speed control switch connector SW009, pin 03, component side 2. Operate the SET- switch.
operated?
-> Yes
-> No
G831824t28 : CHECK THE STEERING WHEEL SPEED CONTROL CANCEL

SWITCH CIRCUIT
speed control switch connector SW009, pin 03, component side 2. Operate the CANCEL switch.
• Does the resistance switch between 4310 ohms and zero ohms when the switch is
operated?
-> Yes
-> No
G831824t30 : CHECK THE STEERING WHEEL SPEED CONTROL SWITCH
CIRCUIT FOR OPEN CIRCUIT
speed control switch connector SW009, pin 02, harness side
steering wheel audio control switch connector SW004, pin 02, harness side
-> Yes
REPAIR the circuit speed control switch connector SW009, pin 02 to clockspring connector SW004,
pin 02. For additional information, refer to the wiring diagrams. TEST the system for normal
operation.
-> No
G831824t1 : CHECK THE STEERING WHEEL SPEED CONTROL SWITCH FOR

OPEN CIRCUIT
speed control switch connector SW009, pin 03, harness side
steering wheel audio control switch connector SW004, pin 03, harness side
-> Yes
REPAIR the circuit speed control switch connector SW009, pin 02 to clockspring connector SW004,
operation.
-> No
No fault has been identified with the speed control switch or circuit, check integrity of connections.
Refer to the electrical circuit diagrams and test the LIN circuit between the steering wheel audio
switch and the instrument cluster. Test the steering wheel audio switch.
Audio System
PINPOINT TEST G831824p10 : BRAKE

SWITCH CIRCUIT TEST
G831824t33 : CHECK THE BRAKE SWITCH FUNCTION, WITH THE BRAKE
PEDAL RELEASED
1. Set ignition status to OFF. 2. Disconnect the brake switch connector CA142. 3. Measure the
resistance between:
Brake switch connector CA142, pin 02 component side
-> Yes
INSTALL a new brake switch.
Speed Control Deactivator Switch (19.75.20) TEST the system for normal operation.
-> No
G831824t34 : CHECK THE BRAKE SWITCH FUNCTION, WITH THE BRAKE

PEDAL DEPRESSED
• Is the resistance greater than 10,000 ohms?
-> Yes
-> No
INSTALL a new brake switch.
Speed Control Deactivator Switch (19.75.20) TEST the system for normal operation.
G831824t35 : CHECK THE BRAKE SWITCH GROUND CIRCUIT FOR OPEN

CIRCUIT
Brake switch connector CA142, pin 03
GROUND
-> Yes
REPAIR the circuit between the brake switch connector CA142, pin 03 and GROUND. For additional
information, refer to the wiring diagrams. TEST the system for normal operation.
-> No
G831824t36 : CHECK THE ECM TO BRAKE SWITCH CIRCUIT FOR OPEN

CIRCUIT
1. Disconnect the ECM connector, FL072. 2. Measure the resistance between:
ECM connector FL072, pin 40
-> Yes
-> No
No fault is indicated with the brake switch or circuit. Check the integrity of all connections and TEST

CIRCUIT
1. Disconnect intermediate electrical connector FL002. 2. Measure the resistance between:
ECM connector FL072, pin 40
Intermediate electrical connector FL002, pin 13
-> Yes
REPAIR the circuit between the ECM connector FL072, pin 40 and intermediate electrical connector
FL002, pin 13. For additional information, refer to the wiring diagrams. TEST the system for normal
operation.
-> No
CIRCUIT
Intermediate electrical connector FL002, pin 13
-> Yes
REPAIR the circuit between the brake switch connector CA142, pin 02 and intermediate electrical
connector FL002, pin 13. For additional information, refer to the wiring diagrams. TEST the system
for normal operation.
-> No
No fault is indicated with the brake switch or circuit. Check the integrity of all connections and TEST
Speed Control Deactivator Switch

(19.75.20)
Removal
NOTE:
This component also functions as the brake pedal switch.
1


Installation
CAUTION: During installation of the brake switch, make sure the brake pedal is
not depressed at any time. Depressing the pedal may cause: poor operation of the brake
light switch and brake lights, diagnostic trouble codes to be logged and/or failure of the
vehicle to start.

Secure the clip.

Speed Control Module - Vehicles Without:
Adaptive Speed Control (19.75.26)
Removal
NOTE:
The speed control module is part of the ECM.
1 . Remove the ECM.

Installation
Speed Control Module - Vehicles With:
Adaptive Speed Control (19.75.26)
Removal
NOTE:
This component is mounted to the rear of the RH A-pillar.
1 . NOTE:
Remove the RH cowl side trim panel.
2 . Remove the adaptive speed control module.
Installation
Speed Control Sensor
Removal
1 . Connect WDS to the vehicle and up-load the relevant data.
2

4 . Remove the speed control sensor.
Remove the 2 bolts.
Remove the nut.
Installation
1 Install the speed control sensor.
.
Tighten the bolts to 5 Nm (4lb.ft).
Install the speed sensor level adjustment lock nut and tighten to 5 Nm
(4lb.ft).
2 . Check and adjust the speed sensor leveling.

For additional information, refer to Speed Control Sensor Adjustment
3 . With assistance, install the front bumper cover.

4 . Using WDS download the data previously up-loaded.

Speed Control Switch (19.75.25)
Removal
NOTE:
Removal and installation of the speed control switch is shown in the steering wheel procedure.
1 . Remove the steering wheel.

Installation
1 . Install the steering wheel.
4. ELECTRICAL
412 : Climate Control System
412-00 : Climate Control System – General Information
Specifications
Specifications
General Specification
Item Description
Automatic temperature control, heating, Dual zone with side to side temperature
ventilation and air conditioning unit control
Clutchless, belt driven from engine with
Compressor
electronically controlled outputs
General procedures

1.
WARNING: 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
WARNING: 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.
WARNING: 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 instruction may result in personal injury.
WARNING: Prior to using the A/C flushing equipment for the first time, follow
the operating instructions. Failure to follow this instruction may result in personal
injury.
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.
2. Remove the desiccant sack. <<412-03>>
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. <<412-03>>
6. Add the required amount of oil to the A/C system depending on the repair procedure.
7. Evacuate and charge the A/C system.
8. Carry out fluorescent dye leak detection test.

Fluorescent Dye Leak Detection
9. Check the A/C system for correct operation.

Air Conditioning (A/C) System Recovery,
Evacuation and Charging (82.30.30)
1.
WARNING: 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.
WARNING: 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.

Contaminated Refrigerant Handling
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.
• On completion of the recovery of the contaminated refrigerant, it will be necessary to
carry out the A/C system flushing procedure.
Electronic Leak Detection
1.
WARNING: Good ventilation is necessary in the area where A/C leak testing is to
be carried out. If the surrounding air is contaminated with refrigerant gas, the leak
detector will indicate this gas all the time. Odors from other chemicals such as
antifreeze, diesel fuel, disc brake cleaner, or other cleaning solvents can cause the same
problem. A fan, even in a well ventilated area, is very helpful in removing small traces of
contamination from the air that might affect the leak detector. Failure to follow this
instruction may result in personal injury.
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 24°C (75°F) with the engine
off.
• If little or no pressure is indicated, carry out the air conditioning (A/C) system recovery,
evacuation and charging procedure.
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.
Refrigerant Oil Adding
CAUTION: Make sure when disconnecting air conditioning (A/C) connections,
that the exposed ports are capped immediately. Make sure you do not leave the A/C
system open to the atmosphere. Failure to follow this instruction may result damage to
the vehicle.
NOTE:
A new replacement A/C compressor is pre-filled with ND8 oil.
1. Drain the oil from the old compressor and measure the quantity of oil drained.
2. Drain the oil from the new compressor into a clean container.
3.
CAUTION: If less than 30 cc of oil was drained from the old compressor, then 30
cc of oil must be refilled into the new compressor. Failure to follow this instruction may
NOTE:
Use the new compressor oil to refill to the required quantity.
Refill the new compressor with the same amount of oil which was measured from the old
compressor.
Refrigerant System Tests
1.
WARNING: Use extreme care and observe all safety precautions related to the
use of refrigerants. Failure to follow this instruction may result in personal injury.
WARNING: 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 instruction may result in personal
injury.
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.

NOTE:
All Air Conditioning (A/C) related tests should be run in an ambient temperature of at least 10°C
(50°F).
• Coolant level
• Refrigerant leaks (UV lamp)
• Fuse(s)
• Drive belt
• Circuit
• Compressor
• Blower motor
• Cooling fan
• Control flap(s)
• Compressor
• Duct(s)
• Cooling fan
• Register(s)
• Actuators
• Cabin air filter
• Climate control assembly
• Hose(s)
• Coolant pump
3 . Listen for any unusual noises during climate control system operation.
4 . Inspect the refrigerant system with an ultraviolet (UV) lamp for traces of UV sensitive leak trace
dye.
diagnostic system.
412-01 : Air Distribution and Filtering
Specifications
Specifications
Item Nm lb-ft lb-in


COMPONENT LOCATION
NOTE:
Right-Hand Drive (RHD) shown, Left-Hand Drive (LHD) similar
1 Windshield vents
2 Windshield and side window air duct

3 Driver side window vent
4 Driver instrument panel register
5 Driver instrument panel air duct
6 Driver footwell air duct
7 Center instrument panel register
8 Air deflector nozzle
9 Passenger footwell air duct
10 Passenger instrument panel air duct
11 Passenger instrument panel register
12 Passenger side window vent
13 Air intake
14 Water shield
15 Cabin air filter
INTRODUCTION
The air distribution and filtering system controls the distribution and quality of air supplied to the
vehicle interior. The system consists of:
• Air ducts
• Air registers and vents
• A cabin air filter
AIR DUCTS
The air ducts distribute air from the heater assembly to the various registers and vents in the
instrument panel. The windshield and side window air duct, the driver instrument panel air duct, and
the passenger instrument panel air duct all form part of the structure of the instrument panel.
AIR REGISTERS AND VENTS

The air registers allow occupants to control the flow and direction of air from the air ducts. The
instrument panel contains 4 air registers; 1 mounted at each end of the panel, and 2 mounted
centrally above the Touch Screen Display (TSD).
The air vents are fixed outlets. The instrument panel contains 4 air vents; 1 mounted at each end of
the panel, and 2 mounted along the top edge of the panel, below the windshield.
CABIN AIR FILTER
1 Filter housing
2 Cabin air filter
3 Water shield
The cabin air filter is located in a plastic housing on the passenger side of the engine compartment.
The filter removes odours and fine particles, including pollen, from air entering the blower assembly.
The filter housing also contains a shield to prevent water from contaminating the filter element and
entering the heating and ventilation system.

For additional information, refer to <<412-00.>>
Center Registers (82.20.38)

Removal
1 . Remove the information and entertainment module.
For additional information, refer to Information and Entertainment Module (86.53.48)
2 . NOTE:
The Torx screws may not be fitted.
Remove the center register.
Carefully release the component.
Installation
1 . NOTE:
Carefully install the center register.

2 . Install the information and entertainment module.
For additional information, refer to Information and Entertainment Module (86.53.48)
Driver Side Register (82.20.39)
Removal
1 . Remove the instument panel driver's side reinforcement trim panel.
2.
CAUTION: Care must be taken to avoid damage to the mating surfaces.
Remove the driver side register trim panel.
Installation
1 . Install the driver side register trim panel.

2 . Install the instument panel driver's side reinforcement trim panel.
Align the pegs and secure with the clips.

Passenger Side Register (82.20.40)
Removal
1 . Remove the instrument panel passenger side reinforcement trim panel.
2 . Remove the passenger side register.
Installation
1 . Install the passenger side register.

2 . Install the instrument panel passenger side reinforcement trim panel.

Pollen Filter (76.10.09)
Removal
1 . Open the hood.
Remove the 3 clips.
3 . Release the pollen filter housing cover.
4.
CAUTION: Remove any debris from the filter aperture.
Remove the pollen filter.

Installation
1 . Install the pollen filter.
2 . Secure the pollen filter housing cover.
4 . Close the hood.

412-02 : Heating and Ventilation
Specifications
Specifications
Item Nm lb-ft lb-in


COMPONENT LOCATION
NOTE:
RHD (right-hand drive) shown, LHD (left-hand drive) similar
1 Blower relay
2 Ventilation outlets (2 off)

3 Heater assembly
4 Blower motor control module
5 Blower
6 Air inlet
7 Heater coolant pump
INTRODUCTION
The heating and ventilation system controls the temperature and flow of air supplied to the vehicle
interior. The system is dual zone, and can provide different temperature settings for the Left Hand
(LH) and Right Hand (RH) side of the cabin. The system can be operated in 'Automatic' or 'Manual'
mode, with temperature settings being selected using the control switches located below the TSD.
For information on how to operate the heating and ventilation system, refer to the Owner's
Handbook.
AUTOMATIC TEMPERATURE CONTROL MODULE
Many of the features and operations of the heating and ventilation system are controlled by the
Automatic Temperature Control (ATC) module, which is located on the end of the air inlet duct
casing. For additional information, refer to Control Components (412-04)
AIR INLET DUCT
1 ATC module
2 Fresh/recirculated air door
3 Fresh/recirculated air door motor
5 Blower motor and fan assembly
The air inlet duct is installed behind the instrument panel on the passenger side. Inlet air passes
through the cabin filter and into the air inlet duct where it enters the blower. A servo motor
mounted on the air inlet duct allows fresh or recirculated air to be selected. Operation of the
fresh/recirculated door is controlled by the ATC module.
BLOWER
The blower is contained within the air inlet duct assembly and consists of an open hub, centrifugal
fan powered by an electric motor. Operation of the blower is controlled by the ATC module using a
relay located in the auxiliary junction box and the blower motor control module. The blower motor
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.
HEATER ASSEMBLY
1 A/C evaporator
2 Heater coolant pipes
3 Windshield distribution door motor
4 RH temperature blend motor
5 Heater core
6 LH temperature blend motor
7 Face and feet distribution door motor
The heater assembly controls the temperature of the air supplied to the air distribution ducts, as
directed by the ATC module. The heater assembly is installed on the vehicle center line, between the
instrument panel and the engine bulkhead.
The heater assembly consists of a casing which contains the Air Conditioning (A/C) evaporator, the
heater core, 2 air distribution control doors, and 2 temperature blend control doors.
The A/C evaporator is controlled as part of the A/C system. For additional information, refer to Air
Conditioning (412-03)
The heater core provides the heat source to warm the air being supplied to the cabin. The heater
core is an aluminium 2 pass, fin and tube heat exchanger, and is installed across the width of the
heater housing. Two aluminium tubes attached to the heater core extend through the engine
bulkhead and connect to the engine cooling system. When the engine is running, coolant is
constantly circulated through the heater core by the coolant pump. For additional information, refer
to Engine Cooling (303-03)
HEATER COOLANT PUMP
A heater coolant pump is mounted on the RH rear face of the radiator housing. The pump is
electrically driven and provides the necessary flow rate of engine coolant to the heater core.
Operation of the pump is controlled by the Central Junction Box (CJB) on receipt of medium speed
Controller Area Network (CAN) bus signals from the ATC module.
The pump will run when the engine is running and operates at a single speed. The CJB broadcasts
pump status over the medium speed CAN bus for use by other vehicle systems.
NOTE:
The pump can be forced to run when the engine is not running if required. For additional
information, refer to Engine Cooling (303-03)
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 tail 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 differential between cabin
and outside air pressures.
Operation of the heating and ventilation system is controlled by the ATC module. For additional
information, refer to Control Components (412-04)

<<412-00>>
Auxiliary Coolant Flow Pump - 4.2L NA V8

- AJV8 (82.25.59)
Removal
2

- AJV8


6 . Remove the auxiliary coolant flow pump.
Installation
1 . Install the auxiliary coolant flow pump.




- AJV8
Auxiliary Coolant Flow Pump - 4.2L SC V8
- AJV8 (82.25.59)
Removal
2

- AJV8


6 . Remove the auxiliary coolant flow pump.
Installation
1 . Install the auxiliary coolant flow pump.




- AJV8
Blower Motor (82.25.66)
Removal
1
force is used.
Remove the passenger side footwell trim panel.
Remove the 3 clips.
2 . Remove the blower motor.

Installation
1 . Install the blower motor.
2 . Install the passenger side footwell trim panel.

Heater Core (80.20.29)
Removal
1

3 . Remove the heater and evaporator core housing.

For additional information, refer to Heater Core and Evaporator Core Housing (82.25.21)
4 . Remove the RH side footwell heater duct.
5 . Remove the heater core.
Remove the coolant pipe clamp.
Remove the screw.
Remove the heater core retaining bracket.

Remove the screw.
Position the RH footwell duct mounting bracket aside for access.
Loosen the screw.
6 . NOTE:
NOTE:
Remove the heater core, inlet and outlet pipes.
Release the 2 clamps.

Installation
1 . NOTE:
Lubricate the seals with coolant.
Install the heater core, inlet and outlet pipes.
Install the clamps and tighten the screws.
2 . Install the heater core.
Secure the heater core retaining bracket.
Install the screw.
Install the coolant pipe clamp.
Install the screw.
Align the footwell duct mounting bracket and tighten the screw.
3 . Install the RH side footwell heater duct.
Install the screws.

4 . Install the heater and evaporator core housing.

Heater Core and Evaporator Core Housing
(82.25.21)
Removal
All vehicles
1



- AJV8

- AJV8
All vehicles
7.
Disconnect the heater supply and return hoses.
Carefully release the clips.
8
contamination.
Disconnect the A/C lines.
Remove the bolt.

Position the carpet aside for access.
Release both footwell lamp holders.
Remove the 5 nuts.
Remove the bolt.
Installation
All vehicles
2 . NOTE:
Lubricate the O-ring seals with clean refrigerant oil.
Connect the A/C lines.
3 . Connect the heater supply and return hoses.

Secure the clips.



- AJV8

- AJV8
All vehicles
412-03 : Air conditionning
Specifications
Specifications
General Specification
Item Specification
Compressor Clutchless, belt driven from engine with electronically controlled outputs
make Denso
type 7SEU17
Specifications
Refrigerant R134A
Compressor oil JLM 12260
Capacities
Item Specification
Refrigerant charge weight 700g ± 25g
Compressor oil capacity 130 ml
Item Nm lb-ft lb-in

Compressor to mounting bracket - bolt 25 18 -
Compressor mounting bracket to engine - bolt 25 18 -
Condenser core to bracket - bolt 10 7 88
Pressure cutoff switch to refrigerant pipe 10 7 88
Refrigerant pipes to compressor - bolt 9 7 80
Refrigerant pipes to condenser - nut 10 7 88
Thermostatic expansion valve to evaporator - bolt 6 4 53
Air Conditioning
COMPONENT LOCATION
1 Evaporator
2 Thermostatic expansion valve
3 High pressure line
4 Low pressure line

5 Air Conditioning (A/C) compressor
6 Receiver/Drier
7 Condenser
8 Refrigerant pressure sensor
9 High pressure servicing connection
10 Low pressure servicing connection
INTRODUCTION
The A/C system transfers heat from the vehicle interior to the outside atmosphere to provide the
heater assembly with dehumidified cool air. The A/C system 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.
Operation of the A/C system is controlled by the Automatic Temperature Control (ATC) module. For
additional information, refer to Control Components (412-04)
A/C COMPRESSOR

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 vapour from the evaporator and discharging the resultant high pressure, high
temperature vapour 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
1 Right Hand (RH) end tank

2 Condenser core
3 Left Hand (LH) end tank
4 Mounting brackets (4 off)
5 Low pressure line connector block
6 High pressure 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
vapour 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 2 end tanks. Divisions in the end tanks separate the heat exchanger into a 4
pass upper (condenser) section and a 2 pass lower (sub-cooler) section.
The LH end tank provides the connections to the high pressure line from the A/C compressor and the
low pressure line to the evaporator.
The RH end tank provides the connections to the receiver drier.
RECEIVER DRIER
The receiver drier is mounted on the condenser RH end tank and removes 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. For additional information, refer to Control
Components (412-04)
THERMOSTATIC EXPANSION VALVE
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. Low pressure, low temperature refrigerant changes
from liquid to vapour in the evaporator, absorbing large quantities of heat as it changes state.
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 2 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.
CONTROL DIAGRAM
NOTE:
A = Refrigerant liquid; B = Refrigerant vapour; C = Air flow
1 Evaporator
2 Thermostatic expansion valve
3 High pressure servicing connection

6 Condenser
7 Receiver/Drier
8 Variable displacement A/C compressor
9 Low pressure servicing connection
10 Blower
To accomplish the transfer of heat, the refrigerant is circulated around the system, where it passes
through 2 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 vapour 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
vapour to a liquid in the condenser.
Operation of the A/C system is controlled by the Automatic Temperature Control (ATC) module. For
additional information, refer to Control Components (412-04)
The A/C system works in conjunction with the heating and ventilation system, and the air distribution
and filtering system. For additional information, refer to Heating and Ventilation (412-02)
For additional information, refer to Air Distribution and Filtering (412-01)
Air Conditioning
For additional information refer to<<412-00>>
Air Conditioning (A/C) Compressor - 4.2L

NA V8 - AJV8 (82.10.20)

303-021

303-749
Removal
4 . Release the throttle body.


.
drive wrench.
6.
7 . Remove the LH heated oxygen sensor (HO2S).

For additional information, refer to Heated Oxygen Sensor (HO2S)

Remove the 6 bolts.

10 . Release the A/C compressor.
Remove the 3 bolts.
11
moisture.
Remove the 2 bolts.

Installation
2.


5 . Install the HO2S.



Air Conditioning (A/C) Compressor - 4.2L
SC V8 - AJV8 (82.10.20)

303-021

303-749
Removal

5.

6 . Remove the LH heated oxygen sensor (HO2S).

Remove the 6 bolts.
9 . Release the A/C compressor.
Remove the 3 bolts.

10
moisture.
Remove the 2 bolts.

Installation
2.

5 . Install the HO2S.



Blower Motor Resistor
Removal
1
force is used.
Remove the 3 clips.
2 . Remove the blower motor resistor.

Installation
1 . Install the blower motor resistor.
Install the screws.

Condenser Core - 4.2L NA V8 - AJV8
(82.15.07)
Removal
2

Remove the 7 clips.

6 . Disconnect the A/C pipes.
Remove the 2 nuts.
Install blanking caps to the exposed ports.
7 . Remove the condenser core.
Remove the 2 bolts.
Installation
1 . Install the condenser core.

2 . Connect the A/C pipes.
Remove the blanking caps from the ports.
Install the clips.
Secure the clips.


Condenser Core - 4.2L SC V8 - AJV8
(82.15.07)
Removal
1
2 . Remove the supercharger radiator.

For additional information, refer to Radiator
4 . Disconnect the A/C pipes.
Remove the 2 nuts.
Install blanking caps to the exposed ports.
5 . Remove the condenser core.

Installation
1 . Install the condenser core.
2 . Connect the A/C pipes.
Remove the blanking caps from the ports.
3 . Install the supercharger radiator.

For additional information, refer to Radiator

Evaporator Core (82.25.20)
Removal
2
3 . Remove the TXV assembly.

For additional information, refer to Thermostatic Expansion Valve (82.25.01)
4.
Remove the A/C pipes.
Release the clamp.
Release the clip.
Release the foam pad and the upper section of the clamp.
5 . Remove the coolant pipe clamp.
Remove the screw.
6 . Carefully separate the evaporator housing.
Release the blower motor harness clip.
Release the 2 evaporator housing clips.

7 . Remove the evaporator core.
Carefully remove the evaporator core temperature sensor.
Installation
1 . NOTE:

Install the evaporator core.
Carefully install the evaporator core temperature sensor.
2
. CAUTION: Make sure the evaporator temperature sensor harness does not become
trapped.
Install the evaporator housing cover.
Install the clips.
Install the screws.
3 . Install the coolant pipe clamp.
Install the screw.
4 . Install the A/C pipes.
Install the foam pad.
Install the clamp.
Install the screws.
5 . Install the TXV assembly.

For additional information, refer to Thermostatic Expansion Valve (82.25.01)

Pressure Cutoff Switch (82.10.32)
Removal

Remove the bolt.
5
Remove the pressure cutoff switch.

Installation
1 . NOTE:
Lubricate the O-ring seals with clean refrigerant oil.
Install the pressure cutoff switch.
Tighten the cutoff switch to 10 Nm (7 lb.ft).
Tighten the clips.

Thermostatic Expansion Valve (82.25.01)
Removal
2

4.
Remove the TXV assembly.
Carefully cut and release the insulation for access.

Installation
1.
NOTE:
Make sure all component mating faces are clean.
Install the TXV assembly.
Install and tighten the Allen bolts to 6 Nm (4 lb.ft).
Replace the TXV insulation.

412-04 : Control Componements
Specifications
Specifications
lb- lb-
Item Nm
ft in
Climate control module and audio/cd module assembly to instrument panel -
3 - 27
bolt
Climate control and audio/cd modules to assembly bracket - bolt 3 - 27
Climate control and audio/cd modules to assembly bracket - screw 2.5 - 22
Control Components
COMPONENT LOCATION
1 Pollution sensor (if fitted)

3 Sunload/Light sensor
4 Windshield distribution (defrost) stepper motor
5 Right-Hand (RH) temperature blend stepper motor
6 Cabin humidity and temperature sensor
7 Evaporator temperature sensor
8 Control switches
9 Left-Hand (LH) temperature blend stepper motor
10 Face/feet distribution stepper motor
12 Blower motor
13 Automatic Temperature Control (ATC) module
14 Ambient air temperature sensor
15 Air intake servo motor
16 Air Conditioning (A/C) compressor solenoid valve
INTRODUCTION
The ATC (automatic temperature control) module controls the A/C (air conditioning) system and the
heating and ventilation system to regulate the temperature, volume, and distribution of air into the
cabin.
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 cabin. Manual overrides for the
system include intake air source, blower speed and air distribution. These selections can be made
using either the Touch Screen Display (TSD) or the control switches located below the TSD.
For information on how to operate the A/C (air conditioning) system and the heating and ventilation
system, refer to the Owner's Handbook.
AUTOMATIC TEMPERATURE CONTROL MODULE
The ATC (automatic temperature control) module is mounted on the end of the blower motor casing,
behind the instrument panel. The ATC (automatic temperature control) module processes inputs
from the TSD, the control switches located below the TSD, and the system sensors. In response to
these inputs, the ATC (automatic temperature control) module outputs control signals to the A/C (air
conditioning) system and the heating and ventilation system.
In addition to controlling the A/C (air conditioning) system and the heating and ventilation system,
the ATC (automatic temperature control) module also controls the following:
• The seat heaters. For additional information, refer to Seats (501-10 Seating)
• The rear window heater. For additional information, refer to Glass, Frames and
Mechanisms (501-11 Glass, Frames and Mechanisms)
• The windshield heater. For additional information, refer to Glass, Frames and
Mechanisms (501-11 Glass, Frames and Mechanisms)
• The exterior mirror heaters. For additional information, refer to Rear View Mirrors (501-09
Rear View Mirrors)
• The steering wheel heater (if fitted). For additional information, refer to Steering Column
Switches (211-05 Steering Column Switches)
Two electrical connectors provide the interface between the ATC (automatic temperature control)
module, and the vehicle wiring. The ATC (automatic temperature control) module uses hardwired
inputs from the system sensors, the LIN (local interconnect network) bus to communicate with the
stepper motors and the medium speed CAN (controller area network) bus to communicate with
other control modules on the vehicle.
AIR CONDITIONING COMPRESSOR SOLENOID VALVE

The A/C (air conditioning) compressor solenoid valve is integral with the A/C (air conditioning)
compressor. Operation of the solenoid valve is controlled by the ATC (automatic temperature
control) 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 (air conditioning) system
pressure and the evaporator operating temperature.
REFRIGERANT PRESSURE SENSOR
The refrigerant pressure sensor provides the ATC (automatic temperature control) 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 (automatic temperature control) 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 (automatic temperature control) module uses the signal from the pressure sensor to protect
the refrigerant system from extremes of pressure. The ATC (automatic temperature control) module
transmits the A/C (air conditioning) pressure, along with the compressor drive current value, to the
instrument cluster on the medium speed CAN (controller area network) bus. These signals are
broadcast to the ECM (engine control module) on the high speed CAN (controller area network) 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 (automatic temperature control) module
sets the A/C (air conditioning) compressor to the minimum flow position if the pressure:
• Decreases to 2.1 ± 0.2 bar (31.5 ± 3 lbf/in²); the ATC (automatic temperature control) module
loads the A/C (air conditioning) compressor again when the pressure increases to 2.3 ± 0.2
bar (33.4 ± 3 lbf/in²)
• Increases to 31 ± 1 bar (450 ± 14.5 lbf/in²); the ATC (automatic temperature control) module
loads the A/C (air conditioning) compressor again when the pressure decreases to 26 ± 1 bar
(377 ± 14.5 lbf/in²)
EVAPORATOR TEMPERATURE SENSOR

The evaporator temperature sensor is a NTC (negative temperature coefficient) thermistor that
provides the ATC (automatic temperature control) 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 (automatic temperature control) module uses the input from the evaporator temperature
sensor to control the load of the A/C (air conditioning) compressor and thus the operating
temperature of the evaporator.
CABIN HUMIDITY AND TEMPERATURE SENSOR
The cabin humidity and temperature sensor is installed behind a grill on the drivers side of the
instrument panel. The temperature inside the cabin is measured by a NTC (negative temperature
coefficient) thermistor. A motor within the sensor assembly draws cabin air in through the grill and
over the thermistor. The motor is provided a battery voltage feed by a relay located within the CJB
(central junction box) .
Humidity inside the cabin is measured by a sensor element made up of film capacitors 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 cabin is controlled by raising and lowering the evaporator temperature. An
increase in evaporator temperature increases the moisture content in the air entering the cabin.
Lowering the evaporator temperature reduces the moisture content in the air entering the cabin.
AMBIENT AIR TEMPERATURE SENSOR
The ambient air temperature sensor is a NTC (negative temperature coefficient) thermistor that
provides the ATC (automatic temperature control) module with an input of external air temperature.
The sensor is hard wired to the ECM (engine control module) and its signal is transmitted to the
instrument cluster on the high speed CAN (controller area network) bus. The instrument cluster acts
as a gateway and transmits the ambient air temperature signal to the ATC (automatic temperature
control) module on the medium speed CAN (controller area network) bus. The sensor is mounted on
the vehicle center line behind the lower front grill, and can be accessed from underneath the vehicle.
SUNLOAD/LIGHT SENSOR
The sunload/light sensor consists of 2 photoelectric cells that provide the ATC (automatic
temperature control) 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 (automatic temperature control) module to adjust
blower speed, temperature and distribution to improve comfort.
NOTE:
The solar sensor is also used as part of the Autolamp feature and also contains the active anti-
theft alarm indicator LED (light emitting diode) . For additional information, refer to Exterior
Lighting (417-01 Exterior Lighting)
For additional information, refer to Anti-Theft - Active (419-01 Anti-Theft - Active)
The sensor is installed in the center of the instrument panel upper surface and is powered by a 5 V
feed from the instrument cluster.
POLLUTION SENSOR
Up to 2009 MY, a pollution sensor was installed only on Japanese specification vehicles. From 2009
MY, the pollution sensor is a standard fit in all markets.
The pollution sensor allows the ATC (automatic temperature control) module to monitor the ambient
air for the level of hydrocarbons and oxidised gases such as nitrous oxides, sulphur oxides and carbon
monoxide. The sensor is mounted in the RH (right-hand) front corner of the engine compartment.
The pollution sensor is powered by an ignition controlled voltage feed from the CJB (central junction
box) and provides the ATC (automatic temperature control) module with separate signals of
hydrocarbon and oxidised gases. With a pollution sensor fitted, the ATC (automatic temperature
control) module can control the air intake source to reduce the amount of contaminants entering the
cabin. This function is fully automatic, but can be overridden by manual selection of the air source
using the recirculation control switch below the TSD.
If there is a fault with the sensor, the ATC (automatic temperature control) module disables
automatic operation of the recirculation door.
CONTROL DIAGRAM
NOTE:
A = Hardwired; D = High speed CAN (controller area network) bus; N = Medium speed CAN
(controller area network) bus; O = LIN (local interconnect network) bus
1 Battery
2 Control switches
4 Ambient air temperature sensor

5 Pollution sensor
8 Cabin humidity and temperature sensor
9 A/C compressor solenoid
10 RH temperature blend stepper motor
11 Windshield distribution (defrost) stepper motor
12 Face/feet distribution stepper motor
13 LH temperature blend stepper motor
14 Air intake servo motor
15 Blower motor
17 Evaporator temperature sensor
18 ATC module
19 CJB
20 Sunload/Light sensor
21 Megafuse (175A)
Air Intake Control

The source of intake air is automatically controlled unless overridden by pressing the air recirculation
switch located below the TSD. Under automatic control, the ATC (automatic temperature control)
module determines the required position of the recirculation door from its 'comfort' algorithm and, if
fitted, the pollution sensor.
The recirculation door is operated by an electric motor. The ATC (automatic temperature control)
module provides analogue signals to the motor along a hardwired connection. A potentiometer in
the motor supplies the ATC (automatic temperature control) 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 2 temperature blend doors operate independently to enable individual temperature settings for
the left and right sides of the cabin. The temperature blend doors are operated by stepper motors,
which are controlled by the ATC (automatic temperature control) module using LIN (local
interconnect network) bus messages.
The ATC (automatic temperature control) 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 (automatic temperature control) 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 (automatic
temperature control) module adopts an appropriate strategy for air distribution, blower speed, and
air source.
Temperature control of one side of the cabin can be compromised by the other side of the cabin
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 from the driver's side temperature control button. If 'HI' or 'LO'
is selected from the driver's side, the passenger side temperature will be automatically set to match
the driver's side.
When economy mode is selected by pressing the 'Econ' TSD soft button, no cooling of the intake 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 intake path.
Blower Motor Control

Operation of the blower motor is controlled by the ATC (automatic temperature control) module.
The ATC (automatic temperature control) module monitors a feedback voltage from the blower
motor control module. In response to the feedback voltage, the ATC (automatic temperature control)
module provides a drive signal back to the blower motor control module which is used to regulate
the voltage flow across the blower motor and hence regulate blower speed. The blower motor is
provided with a battery voltage feed from the blower motor relay, which is located within the
auxiliary junction box.
When the A/C (air conditioning) system is in automatic mode, the ATC (automatic temperature
control) module determines the blower speed required from its 'comfort' algorithm. When the A/C
(air conditioning) system is in manual mode, the ATC (automatic temperature control) module
operates the blower at the speed selected using either the rotary control switch or the '+/-' soft
buttons on the TSD.
The ATC (automatic temperature control) module also controls blower motor speed to compensate
for the ram effect on intake air produced by forward movement of the vehicle. As vehicle speed, and
consequently the ram effect increases, blower motor speed is reduced.
Air Distribution Control

Two air distribution doors are used to direct air into the cabin. The doors are operated by stepper
motors, which are controlled by the ATC (automatic temperature control) module using LIN (local
interconnect network) bus messages.
When the A/C (air conditioning) system is in automatic mode, the ATC (automatic temperature
control) module automatically controls air distribution into the cabin 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 cabin will remain as selected until the 'Auto' switch is pressed or a different
manual selection is made.
Programmed Defrost
When the 'DEF' button is pressed, the ATC (automatic temperature control) module instigates the
programmed defrost function. When selected, the ATC (automatic temperature control) module
configures the system as follows:
• Automatic mode off

• Selected temperature unchanged
• Air inlet set to fresh air
• Air distribution set to windshield
• Blower speed set to level 6
• Windshield and rear screen heaters 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 below the TSD
• A second press of the 'DEF' button
• Switching the ignition OFF
NOTE:
The blower speed can be adjusted without terminating the programmed defrost function.
A/C Compressor Control

When A/C (air conditioning) is selected ('Econ' off) the ATC (automatic temperature control) module
maintains the evaporator at an operating temperature that varies with the cabin cooling
requirements. If the requirement for cooled air decreases, the ATC (automatic temperature control)
module raises the evaporator operating temperature by reducing the flow of refrigerant provided by
the A/C (air conditioning) compressor.
NOTE:
The ATC (automatic temperature control) module closely controls the rate of temperature
increase to avoid introducing moisture into the cabin.
If the requirement for cooled air increases, the ATC (automatic temperature control) module lowers
the evaporator operating temperature by increasing the flow of refrigerant provided by the A/C (air
conditioning) compressor.
When economy mode is selected by pressing the 'Econ' TSD soft button, the compressor current
signal supplied by the ATC (automatic temperature control) module holds the A/C (air conditioning)
compressor solenoid valve in the minimum flow position, effectively switching off the A/C (air
conditioning) function.
The ATC (automatic temperature control) module incorporates limits for the operating pressure of
the refrigerant system. When the system approaches the high pressure limit the compressor current
signal is progressively reduced until the system pressure decreases. When the system pressure falls
below the low pressure limit the compressor current signal is held at its lowest setting so that the
A/C (air conditioning) compressor is maintained at its minimum stroke. This avoids depletion of the
lubricant from the A/C (air conditioning) compressor.
A/C Compressor Torque

The ATC (automatic temperature control) module transmits refrigerant pressure and A/C (air
conditioning) compressor current values to the ECM (engine control module) over the medium speed
then high speed CAN (controller area network) bus, using the instrument cluster as a gateway. The
ECM (engine control module) uses these values to calculate the torque being used to drive the A/C
(air conditioning) compressor. The ECM (engine control module) compares the calculated value with
its allowable value and if necessary forces the ATC (automatic temperature control) module to inhibit
the A/C (air conditioning) compressor by transmitting the 'ACClutchInhibit' CAN (controller area
network) message. This forces the ATC (automatic temperature control) module to reduce the drive
current to the A/C (air conditioning) compressor solenoid valve, which reduces refrigerant flow. This
in turn reduces the torque required to drive the A/C (air conditioning) compressor.
By reducing the maximum A/C (air conditioning) compressor torque, the ECM (engine control
module) 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 (automatic temperature control) 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
(engine control module) on the medium speed CAN (controller area network) bus. The ECM (engine
control module) then controls the temperature of the condenser using the cooling fan. For additional
information, refer to Electronic Engine Controls (303-14 Electronic Engine Controls - Vehicles
Windshield Heater
The ATC (automatic temperature control) module controls operation of the windshield heater using 2
relays in the power distribution box. When a request is made for windshield heater operation, the
ATC (automatic temperature control) module broadcasts a message to the CJB (central junction box)
on the medium speed CAN (controller area network) bus. On receipt of this message, the CJB (central
junction box) energises the relays by providing a ground path for both relay coils. This allows a
battery feed to flow across the relays to power the left and right heater elements.
NOTE:
Windshield heater operation is only enabled when the engine is running.
There are 2 modes of windshield heater operation; manual and automatic.
Manual operation is activated by pressing the windshield heater control switch. When the switch is
pressed, the ATC (automatic temperature control) module illuminates a LED (light emitting diode) in
the switch and powers the heater elements for 6.5 minutes.
The switch LED (light emitting diode) remains illuminated until the windshield heater switch is
pressed a second time (to switch the system off), the heating phase is completed, or the engine
stops. If the engine is re-started within 30 seconds the windshield heater resumes the previous
heating phase.
There are 2 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) at the start of a journey. In this instance, the ATC (automatic temperature control) module will
automatically power the windshield heater elements and illuminate the switch LED (light emitting
diode) for 6.5 minutes. The windshield heater can be switched off during this period by pressing the
control switch or stopping the engine.
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 (light emitting diode) 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.
Rear Window Heater
The ATC (automatic temperature control) module controls operation of the rear window heater using
a relay in the auxiliary junction box. When a request is made for rear window heater operation, the
ATC (automatic temperature control) module broadcasts a message to the auxiliary junction box on
the medium speed CAN (controller area network) bus. On receipt of this message, the auxiliary
junction box energises 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.
NOTE:
Rear window heater operation is only enabled when the engine is running.
There are 2 modes of rear window heater operation; manual and automatic.
Manual operation is activated by pressing the rear window heater control switch. When the switch is
pressed, the ATC (automatic temperature control) module illuminates a LED (light emitting diode) in
the switch and powers the heater element for 21 minutes.
The switch LED (light emitting diode) remains illuminated until the rear window heater switch is
pressed a second time (to switch the system off), the heating phase is completed, or the engine
stops. If the engine is re-started within 30 seconds the rear window heater resumes the previous
heating phase.
There are 2 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) at the start of a journey. In this instance, the ATC (automatic temperature control) module will
automatically power the rear window heater element and illuminate the switch LED (light emitting
diode) for 21 minutes. The rear window heater can be switched off during this period by pressing the
control switch or stopping the engine.
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 (light emitting diode) 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

Exterior mirror heater operation is determined by ambient air temperature and windshield wiper
status. When ambient air temperature reaches a pre-determined level, the ATC (automatic
temperature control) module broadcasts an exterior mirror heating request to the door modules
over the medium speed CAN (controller area network) bus. On receipt of this message, the door
modules provide feed and ground connections to both exterior mirror heater elements.
NOTE:
Operation of the exterior mirror heaters is fully automatic and not controllable by the driver.
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
There are 4 seat heater settings available; Off, 1, 2 or 3, which can be set through 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 (automatic temperature control) module.
When the ATC (automatic temperature control) module receives a heating request from the TSD, it
broadcasts a message to the CJB (central junction box) over the medium speed CAN (controller area
network) bus. The CJB (central junction box) then provides a hardwired 12 V supply to the 3 heater
elements contained within each seat. The 3 heater elements, 2 in the seat cushion and 1 in the seat
squab, are wired in series.
The ATC (automatic temperature control) module monitors seat temperature using a temperature
sensor located in each seat cushion. The CJB (central junction box) provides the temperature sensors
with a 5 V supply. The level of the returned voltage back to the CJB (central junction box) is
proportional to the seat temperature. The value of the return signal is broadcast to the ATC
(automatic temperature control) module over the medium speed CAN (controller area network) bus
which it then converts into a temperature value to allow it to control seat temperature to the
required level.
The ATC (automatic temperature control) 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 1 heat setting and can be turned on and off by pressing the soft
button located on the seat heater TSD screen. 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 heater will
reset to off.
Power for the heater element is supplied by the CJB (central junction box) on receipt of a request
from the ATC (automatic temperature control) module over the medium speed CAN (controller area
network) 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.
Control Components
For a detailed description of the climate control system, refer to the relevant Description and

• Fuse(s)
• Refrigerant
• Harness
• Heater control flaps
• Electrical connectors
• Ducting
• Switch(s)
4 . If the cause is not visually evident, check for Diagnostic Trouble Codes (DTCs) and refer to the DTC
Index.
DTC Index
NOTE:
NOTE:
system).
NOTE:
NOTE:
NOTE:
terminals.

• Aspirator fan circuit - short to
B105A01 Aspirator fan fault ground, open circuit
• Aspirator fan component fault the manufacturer approved
diagnostic system
Recirculation servo Carry out any pinpoint tests

motor actuator - • Sensor 5 volt supply - short to associated with this DTC using
B1A5911
sensor 5 volt ground the manufacturer approved
supply diagnostic system
Air conditioning Refer to electrical circuit

• Air conditioning pressure
pressure sensor - diagrams and test air
B1A5913 sensor 5 volt supply - open
sensor 5 volt circuit conditioning pressure sensor
supply circuit for open circuit
In car temperature Carry out any pinpoint tests

• In car temperature sensor
B1A6111 sensor circuit - circuit - short to ground associated with this DTC using
short to ground the manufacturer approved
diagnostic system
In car temperature Carry out any pinpoint tests

• In car temperature sensor
sensor circuit - associated with this DTC using
B1A6115 circuit - short to power, open
short to power, circuit the manufacturer approved
open circuit diagnostic system

Air conditioning
• Air conditioning pressure associated with this DTC using
B1A6211 pressure sensor -
sensor circuit - short to ground the manufacturer approved
short to ground
diagnostic system
Air conditioning Carry out any pinpoint tests

• Air conditioning pressure
pressure sensor - associated with this DTC using
B1A6215 sensor circuit - short to power,
short to power, open circuit the manufacturer approved

Right hand sun
• Right hand sun load sensor associated with this DTC using
B1A6311 load sensor - short
circuit - short to ground the manufacturer approved
to ground
diagnostic system

Left hand sun load
• Left hand sun load sensor associated with this DTC using
B1A6411 sensor - short to
ground
diagnostic system
Refer to electrical circuit

Vehicle sensor
• Vehicle sensor ground - open diagrams and test vehicle
B1A6713 ground - open circuit sensor ground circuit for open
circuit
circuit

• Humidity sensor circuit - short
Humidity sensor associated with this DTC using
B1A6901 to power, ground, open circuit
fault • Sensor component fault the manufacturer approved
diagnostic system

B1A7001 Compressor fault • Over current detection
diagnostic system
Stepper motor Refer to electrical circuit

B1A9815 actuator LIN Bus • No response from ALL
diagrams and test stepper
steppers for 20 seconds - LIN
fault, or power motor actuator LIN Bus for
supply - open network fault open circuit
circuit
Recirculation servo
motor actuator - • Sensor 5 volt supply - open
B1B6013 diagrams and test sensor 5
sensor 5 volt circuit
volt supply for open circuit
supply

Pollution sensor HC
• Pollution sensor HC input - associated with this DTC using
B1B6111 input - short to
ground
diagnostic system

Pollution sensor
• Pollution sensor Nox input - associated with this DTC using
B1B6211 Nox input - short to
ground
diagnostic system

Recirculation servo diagrams and test
• Recirculation servo motor
B1B6313 motor actuator - recirculation servo motor
actuator ground - open circuit
ground circuit actuator ground for open
circuit

Recirculation servo • Recirculation servo
B1B6711 potentiometer - potentiometer circuit - short
to ground the manufacturer approved
short to ground
diagnostic system
Recirculation servo Carry out any pinpoint tests

• Recirculation servo
potentiometer - associated with this DTC using
B1B6715 potentiometer circuit - short
short to power, to power, open circuit the manufacturer approved
• Recirculation servo Carry out any pinpoint tests

potentiometer circuit - short
Recirculation servo associated with this DTC using
B1B6801 to power, ground, open circuit
motor fault • Recirculation door/linkage the manufacturer approved
broken diagnostic system
Evaporator Carry out any pinpoint tests

temperature • Evaporator temperature associated with this DTC using
B1B7111
sensor - short to sensor circuit - short to ground the manufacturer approved
ground diagnostic system
Evaporator Carry out any pinpoint tests
• Evaporator temperature
temperature associated with this DTC using
B1B7115 sensor circuit - short to power,
sensor - short to open circuit the manufacturer approved
power, open circuit diagnostic system
Stepper motor Refer to electrical circuit

• Stepper motor actuator LIN
actuator LIN Bus diagrams and test stepper
B1B7211 Bus power supply - short to
power supply - ground motor actuator LIN Bus power
short to ground supply for short to ground

Defrost stepper
• Internal or external fault - associated with this DTC using
B1B7400 motor actuator
under/over voltage the manufacturer approved
fault
diagnostic system

Defrost stepper
• Internal electronic fault - associated with this DTC using
motor over temperature the manufacturer approved
fault
diagnostic system

Panel/foot stepper
fault
diagnostic system

Panel/foot stepper
fault
diagnostic system

Front left air blend
B1B7600 stepper motor
actuator fault
diagnostic system

Front left air blend
B1B7649 stepper motor
actuator fault
diagnostic system
Front right air Carry out any pinpoint tests

blend stepper • Internal or external fault - associated with this DTC using
B1B7700
motor actuator under/over voltage the manufacturer approved
fault diagnostic system
Front right air Carry out any pinpoint tests
blend stepper • Internal electronic fault - associated with this DTC using
B1B7749
motor actuator motor over temperature the manufacturer approved
fault diagnostic system

• Signal below allowable range
Air conditioning the manufacturer approved
• System leak
B1B7884 system under diagnostic system. Check
• Incorrect refrigerant charge
pressure weight system for leaks. Charge
system with correct weight of
refrigerant

Air conditioning
B1B7885 system over • Signal above allowable range
pressure
diagnostic system

Medium speed
U001088 CAN • Bus off
communication
diagnostic system

Internal control DTC and retest. If the DTC is
• Invalid configuration message
U030000 module software still logged suspect the
is received
incompatibility climate control module, refer
to the new module
the DTC Index
Install a new climate control

Failed to initialise module, refer to the new
U1A1449 • Internal electronic failure
CAN module installation note at

Stored vehicle diagnostic system. Clear DTC
• Incorrect car configuration
U300055 configuration data and re-test. If the DTC
data received
does not match remains suspect the climate
control module, refer to the
new module installation note

climate control module for
U300087 Control Module • Missing message DTCs and refer to the DTC
integrity using the
diagnostic system
Vehicle match. Corrupt VIN data being Install original module, check
U300281 Identification transmitted, module for DTCs and refer to relevant
Number (VIN) previously installed to other DTC Index
vehicle
Ambient Air Temperature Sensor

(82.20.02)
Removal
1

3 . Remove the ambient air temperature sensor.
Installation
1 . Install the ambient air temperature sensor.
Secure the clip.

Removal

3 . NOTE:
Note the relationship between the servo motor drive and the vent flap.
Remove the servo motor assembly.
Installation
1 . Install the servo motor assembly.
Align the servo motor drive.
Install the screws.


Defrost Vent/Register Blend Door Actuator
RH
Removal

3 . NOTE:
Installation
Install the screws.



Footwell Vent/Duct Blend Door Actuator
LH
Removal

3 . Remove the LH side footwell heater duct.
Release the lampholder.
4 . Remove the support bracket.
Remove the screw.

5 . NOTE:
Installation
Install the screws.

2 . Install the support bracket.
Install the screw.
3 . Install the LH side footwell heater duct.
Install the screws.


In-Vehicle Temperature Sensor (82.20.03)
Removal
2 . Remove the in-vehicle temperature sensor.
Installation
1 . Install the in-vehicle temperature sensor.

Recirculation Blend Door Actuator
(82.20.67)
Removal

3 . NOTE:
Installation
Install the screws.



Sunload Sensor (82.20.70)
Removal
1
component.
Remove the center speaker grille.
2 . Remove the sunload sensor.

Installation
1 . Install the sunload sensor.
Install the screws.
2 . Install the center speaker grille.
Secure the clips.

Climate Control Module
Removal

3 . Remove the A/C control module.
Installation
1 . Install the A/C control module.


Climate Control Assembly (82.20.07)
Removal
NOTE:
Removal of this component is part of the audio removal procedure.
2 . Remove the audio unit.

For additional information, refer to Audio Unit (86.50.03)
Installation
1 . Install the audio unit.
For additional information, refer to Audio Unit (86.50.03)

413 : Instrumentation and Warning Systems
413-00 : Instrumentation Cluster and Panel

Illumination

COMPONENT LOCATION

1 Accessory power socket
2 Overhead console
4 Illumination switch
5 Right-Hand (RH) steering column multifunction switch
6 Left-Hand (LH) steering column multifunction switch
7 Start/stop switch
8 Gear shift module
INTRODUCTION
Instrument cluster and panel illumination is achieved through a series of Light Emitting Diodes (LED's)
located throughout the interior of the vehicle. The intensity of illumination can be controlled by the
driver through a rotary control located on the lower drivers side of the instrument panel. The rotary
control is integral with the auxiliary lighting switch.
The rotary control is a variable resistor which is used as a potential divider to provide a high or low
voltage according to its set position. The voltage returned to the instrument cluster is converted into
a dimmer control positional message and transmitted to the CJB over the medium speed Controller
Area Network (CAN) bus. The CJB converts the illumination intensity message into a Pulse Width
Modulation (PWM) signal which it supplies to the instrument panel and switch illumination LED.
CONTROL DIAGRAM
NOTE:
A = Hardwired; N = Medium speed CAN bus

1 Megafuse (175A)
2 CJB
3 Gear shift module

5 Start/stop switch
6 Accessory power socket
7 Steering column multifunction switches
8 Overhead console
10 Illumination switch

For a detailed description of the Instrument Cluster and Panel Illumination, refer to the relevant

2 . Visually inspect for obvious signs of mechanical or electrical damage.
• Bulbs(s)
• Fuse(s)
• Wiring harness
• Fluid level(s) • Engine compartment components
• Accessory installations • Underbody components
• Dimmer switch
• Headlamp switch
• Autolamp sensor
diagnostic system.
413-01 Instrumenation Cluster
Specifications
Specifications
Item Nm lb-ft lb-in

Instrument cluster surround - screw 1 - 9
Instrument cluster - screw 1.5 - 13
Instrument Cluster
COMPONENT LOCATION
1 Speedometer
2 Message center
3 Tachometer
INTRODUCTION
The instrument cluster is located in the instrument panel, above the steering column. The instrument
cluster comprises analogue gauges, an Liquid Crystal Display (LCD) message center to provide vehicle
operation details to the driver and a number of indicator lamps to display system status.
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.
The instrument cluster also functions as an intelligent controller for a number of other vehicle
systems, for example column adjust positions, steering column multifunction switch inputs, steering
Servotronic control.
The instrument cluster is the gateway for the high speed and medium speed Controller Area Network
(CAN) and is also connected to the Local Interconnect Network (LIN) bus to the start control unit and
the steering wheel module.
ANALOGUE GAGES
Speedometer
The speedometer is located on the Left Hand (LH) side of the cluster and is available in three market
variants:
• major scale Miles Per Hour (MPH), minor scale kilometers per hour (km/h)
• major scale km/h, minor scale MPH
• major scale km/h only.
The speedometer is driven by high speed CAN signals transmitted by the Anti-lock Brake System
(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 located on the Right Hand (RH) side of the instrument cluster and displays engine
speeds up to 8000 Revolutions Per Minute (RPM) on naturally aspirated models and 7000 RPM on
supercharged models.
The tachometer is driven by an engine speed signal transmitted on the high speed CAN from the
Engine Control Module (ECM). The signal is derived from the Crankshaft Position (CKP) sensor. The
signal is received by the instrument cluster microprocessor and the output from the microprocessor
drives the tachometer.
LCD 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 area above the
message center displays the transmission gear position information and speed control related
information.
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.
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.
The fuel gage is controlled by CAN messages from the Auxiliary Junction Box (AJB). The AJB 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 area which displays odometer and trip readouts. When a trip
computer function is selected, these are replaced by a trip computer display for the trip function
selected.
Transmission Gear Position Display

The gear position display shows selector lever 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 Transmission Control Module (TCM) transmits a high speed CAN message to the instrument
cluster with data containing the selected gear when in Jaguar Sequential Shift mode.
Message Center
The message center displays system status and warning messages to the driver. For additional
information, refer to Information and Message Center (413-08 Information and Message Center)
WARNING INDICATORS
1 Anti-lock Braking System (ABS) indicator (USA only)
2 ABS indicator - (Canada/Mexico)
3 ABS indicator - (Rest of World (ROW))
4 Adaptive speed control indicator
5 Adaptive Front lighting System (AFS) indicator
6 Malfunction Indicator Lamp (MIL)
7 Tire Pressure Monitoring System (TPMS) indicator
8 Airbag indicator
9 Front fog lamp indicator
10 RH turn signal indicator
11 Rear fog lamp indicator
12 Dynamic Stability Control (DSC) indicator
13 High beam indicator
14 Side lamp indicator
15 Seat belt indicator

16 Message center
17 Automatic speed limiter
18 Forward alert indicator
19 Brake indicator (USA only)
20 Brake indicator (ROW)
21 LH turn signal indicator
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 dependant on software logic within the
instrument cluster for activation. The cluster software controls the indicator illumination check at
ignition on.
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 is also controlled by the sub-
system module on these indicators.
CONTROL DIAGRAM
NOTE:
A = Hardwired; D = High speed CAN bus; N = Medium speed CAN bus; O = LIN bus
1 Battery
2 Megafuse (175 A)
4 Ignition relay
6 High speed CAN bus to other vehicle systems
7 Medium speed CAN bus to other vehicle systems
8 LIN bus to start control module and steering wheel module
9 Gear selector module
10 Column adjustment switch
11 Column reach and rake adjustment motors
12 Column position potentiometer
14 Steering gear Servotronic valve
15 Steering column RH multifunction switch
16 Steering column LH multifunction switch
17 Auxiliary lighting switch
19 Light sensor (with integral alarm Light Emitting Diode (LED))

Warning Indicator Functionality
1 LH turn signal
2 RH turn signal
3 Brake warning
4 Forward alert
5 Automatic speed limiter
6 Adaptive speed control
7 ABS warning
8 AFS warning
9 MIL
10 TPMS warning
11 Airbag warning
12 Front fog lamps
13 DSC warning
14 Seat belt warning

15 Side lamp warning
16 High beam
17 Rear fog lamps
The functionality for each of the above warning indicators is described in the following section.
1 and 2. Turn Signal Indicators

The turn signal indicators are controlled by the Central Junction Box (CJB) on receipt of medium
speed CAN signals from the instrument cluster.
The instrument cluster outputs a voltage to the turn signal indicator switch. The switch contains
resistors of different values. When 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. When 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 AJB 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 CJB transmits a message to the instrument cluster which
responds by flashing the warning indicator and operating the sounder at double speed to indicate a
bulb failure and also displays an appropriate message and vehicle graphic 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 USA which have the word 'BRAKE' in addition to 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 ABS module monitors the fluid level in the brake fluid reservoir using a 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 ABS module issues a CAN message which is received by the instrument
cluster which illuminates the warning indicator and displays the message 'BRAKE FLUID LOW' in the
message center. The warning indicator can also be illuminated by the ABS module if an Electronic
Brake Distribution (EBD) fault is detected.
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 illuminates or flashes (dependant on market)
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 'FORWARD ALERT OFF' will be displayed in the message center.
5. Automatic Speed Limiter (ASL) Indicator

The ASL is controlled by the ECM. 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 all vehicles except NAS, the ABS warning indicator is also used for parking brake faults. The
indicator in these markets illuminates in an amber color and displays a brake symbol without the text
'ABS' in the icon.
On NAS vehicles, the ABS warning indicator is only used for ABS. The warning indicator has 'ABS' on
the icon and will illuminate in a amber color for ABS faults only.
8. Adaptive Front light System (AFS) Warning Indicator
The AFS warning indicator is controlled by the AFS control module. The AFS warning indicator
illuminates in an amber color if a fault in the AFS system is detected by the control module. If a fault
in another system occurs which prevents AFS operation, the warning indicator will flash. The
indicator is illuminated by the instrument cluster on receipt of a high speed CAN message from the
AFS control module. The indicator is illuminated in an amber color for a 3 second indicator check
when the ignition is switched on.
9. 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 Engine Control Module (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 On-Board Diagnostic (OBD) fault which will cause excessive emissions
output. This may relate to either an engine management system fault or a transmission fault.
10. 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.
11. 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 Restraints Control Module (RCM).
12. 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.
13. 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.
14. 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 is not permanently illuminated.
In certain markets the belt minder function can be enabled and disabled using the driver safety belt
switch. For additional information, refer to Safety Belt System (501-20A Safety Belt System)
15. 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 AJB. The lighting switch on the Left
Hand (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
CAN message to the CJB and the AJB. The CJB and the AJB 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.
16. 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 Left Hand
(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.
17. Rear Fog Lamp Indicator

The amber colored rear fog lamp indicator is controlled by the AJB and illuminated by the instrument
cluster on receipt of a rear fog lamp on message on the medium speed CAN bus from the AJB. 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.
Instrument Cluster
For a detailed description of the instrument cluster, refer to the relevant Description and Operation
Instrument Cluster

• Fuse(s)
• Wiring harness
• Fluid level(s) • Instrument cluster
• Accessory installations • Central Junction Box (CJB)
• Engine Junction Box (EJB)
• Driver Door Module (DDM)
DTC Index
NOTE:
module/component.
NOTE:
system).
NOTE:
NOTE:
NOTE:
terminals.

Wiper mode associated with this DTC using
B100811 • Circuit short to ground
switch the manufacturer approved
diagnostic system

Wiper mode • Circuit short to battery or associated with this DTC using
B100815
switch open the manufacturer approved
diagnostic system

• Faulty instrument cluster ground supplies to CJB and
Ignition • Target SID re-synchronisation instrument cluster. Re-
B100951
authorisation error following programming
synchronize ID by re-configuring
• CAN fault
the instrument cluster as a new
module. Check CAN
communications between
instrument cluster and tester

• Low speed CAN fault between CJB and instrument
• CJB fault cluster. Check ignition, power
Ignition • Instrument cluster fault and ground supplies to CJB and
• Incorrect module installed
authorisation instrument cluster. Confirm
B100962 (CJB/Instrument cluster)
signal compare • Target SID synchronisation correct module is installed. Re-
failure error following re- synchronise ID by re-configuring
programming the instrument cluster as a new
• Noise/EMC related error module. Check CAN network for

supplies to CJB and instrument
• CJB fault cluster. Check CAN network
Ignition • Low speed CAN fault between CJB and instrument
B100987 • Instrument cluster fault
authorisation cluster. Check battery is fully
• Low battery voltage <9V charged and in serviceable
care manual

Front fog lamp associated with this DTC using
control switch the manufacturer approved
diagnostic system

Front fog lamp • Circuit short to battery or associated with this DTC using
B104615
control switch open the manufacturer approved
diagnostic system

Fuel pump • Instrument cluster fault ground supplies to RJB and
B100A62 (RJB/Instrument cluster)
signal compare • Write target SID correct module installed. Re-
failure synchronisation error synchronise ID by re-configuring
following re-programming the RJB as a new module. Check
• Noise/EMC related error CAN network for
Re-synchronise ID by re-
• Write target SID configuring the RJB as a new
synchronisation error module. Check ignition, power
Fuel Pump
B100A64 following re-programming and ground supplies to RJB and
authorisation • RJB fault instrument cluster. Check CAN
• Low speed CAN fault network between RJB and
instrument cluster

supplies to RJB and instrument
• RJB fault cluster. Check CAN network
Fuel pump • Low speed CAN fault between RJB and instrument
B100A87
authorisation • Instrument cluster fault cluster. Check battery is fully
• Low battery voltage < 9 volts charged and in serviceable
care manual

• RJB fault Check power and ground
• Vehicle speed present when supplies to RJB and instrument
attempting to power steering
Column lock cluster. Check CAN network
column lock
B100B67 ground between RJB and instrument
• Engine speed present when
authorisation attempting to power steering cluster. Check ABS, ECM and CJB
column lock for DTCs and refer to the
• Power mode status > four relevant DTC Index
when attempting to perform
lock action

Column lock • Instrument cluster fault supplies to RJB and instrument
B100B87 ground • Low speed CAN fault cluster. Check CAN network
authorisation • RJB fault between RJB and instrument
cluster

• Low speed CAN fault Check power and ground
• CJB fault supplies to CJB and instrument
• Vehicle speed present when
Column lock cluster. Check CAN network
attempting to power steering
B100C67 supply between CJB and instrument
column lock
authorisation • Engine speed present when cluster. Check ABS, ECM and CJB
attempting to power steering for DTCs and refer to the
column lock relevant DTC Index
when attempting to perform
lock action

Column lock • Instrument cluster fault supplies to CJB and instrument
B100C87 supply • Low speed CAN fault cluster. Check CAN network
authorisation • CJB fault between CJB and instrument
cluster

• Instrument cluster fault and ground supplies to steering
Column lock • Incorrect module installed
column lock and instrument
authorisation - (Steering column
B100D62 cluster. Confirm the correct
signal compare lock/Instrument cluster)
• Target ID synchronisation modules are installed. Re-
failure
error following re- synchronize ID by re-configuring
programming the steering column lock as
• Noise/EMC related error new. Check CAN network for
Check CAN network to steering

Column lock
• CAN fault column lock. Check power and
authorisation -
B100D64 • Steering column lock fault ground supplies to steering
signal plausibility • Instrument cluster fault column lock and instrument
failure
cluster

Column lock • Steering column lock fault
instrument cluster. Check power
B100D87 authorisation - • Instrument cluster fault
• Low voltage at steering and ground supplies to steering
missing message
column lock < 8V column lock and instrument
cluster

Column lock and ground supplies to steering
B100D96 • Low temperature < -30 °
authorisation • Low voltage at steering column lock and instrument
column lock < 8 volts cluster. Check there is no torque
• Restricted bolt movement applied to the steering
column/wheel
Wiper/washer Carry out any pinpoint tests

B10A011 • Circuit short to ground
switch associated with this DTC using
diagnostic system

Wiper/washer • Circuit short to battery or associated with this DTC using
B10A015
switch open the manufacturer approved
diagnostic system

B10A611 Main light switch • Circuit short to ground
diagnostic system

• Circuit short to battery or associated with this DTC using
B10A615 Main light switch
open the manufacturer approved
diagnostic system
Transfer fuel For fuel system tests.

B115C7A • Fluid leak or seal failure
pump Fuel Tank and Lines

Ambient light associated with this DTC using
B1A8511 • Circuit short to ground
sensor the manufacturer approved
diagnostic system

Ambient light • Circuit short to battery or associated with this DTC using
B1A8515
sensor open the manufacturer approved
diagnostic system
• Operator only cycles one key

during programming Ensure all keys to be
Key transponder - • Instrument cluster, start programmed are available.
control unit or key loses
number of keys Check power and ground
power or circuit failure during
B1B0100 stored below programming
supplies to all relevant modules.
minimum number • Faulty key Replace faulty key. Check CAN
required • Unable to programme key network for noise/EMC related
due to noise/EMC related issues
issues
Key transponder - • Error following start control Re-synchronize ID by re-

unit replacement configuring the start control
start control unit
B1B0105 • Start control unit fault
already unit as new module. Check
• LIN fault
programmed • Instrument cluster fault power and ground supplies to
instrument cluster. Check LIN
circuit between start control
unit and instrument cluster
Check LIN circuit between start

• LIN fault control unit and instrument
Key transponder - • Instrument cluster fault
cluster. Check power and
start control unit • Faulty key
B1B0151 ground supplies to start control
programming • Start control unit fault
• Attempted to programme a unit and instrument cluster.
error
non-default key Ensure new keys are from a
known good source
• Un-programmed key inserted

Key transponder -
in start control unit Confirm correct keys are being
B1B0155 transponder not
• Non-default key inserted used
programmed during key programming

• Start control unit fault diagnostic system. Check power
Key transponder - • Incorrect module installed and ground supplies to start
start control unit (instrument cluster/start control unit and instrument
B1B0162
challenge control unit) cluster. Check correct modules
response error • Error during or following the are installed. Re-synchronize ID
write target SID routine
by re-configuring the start
• Noise/EMC related issues
control unit as a new module.

• LIN fault diagnostic system. Check LIN
Key transponder - • Instrument cluster fault
circuit between start control
transponder • Key fault
B1B0164 unit and instrument cluster.
challenge • Start control unit fault
• Error occurred during key Check power and ground
response error
programming supplies to start control unit
and instrument cluster. Confirm
correct key operation. Re-run
key programming
• LIN fault Carry out any pinpoint tests

B1B0167 Key transponder - • Instrument cluster fault
start control unit • Key fault
• Start control unit fault
invalid response • Another key in close proximity diagnostic system. Check LIN
• Attempted to programme a circuit between start control
non default key unit and instrument cluster.
• IPK Cold initialisation whilst in
Ignition On state, without key
being present in the SCU ground supplies to start control
• Race condition caused by unit and instrument cluster.
closing driver door and Confirm correct key operation.
pressing start button within a Confirm single key operation.
small time window Ensure new keys are from a
• Passive Key search function known good source. Check for
from last door closed and key
intermittent power and ground
inserted in the SCU
at instrument cluster. Design
condition - advise customer of
correct starting sequence.
Design condition - determine
customer transponder key
usage

• LIN fault diagnostic system. Check LIN
Key transponder -
B1B0187 • Instrument cluster fault circuit between start control
timer expired • Start control unit fault unit and instrument cluster.
supplies to start control unit

• CAN fault ECM and instrument cluster.
Target I.D.
• ECM fault Check ignition, power and
transfer - system
B1B3305 • Instrument cluster fault grounds to ECM and instrument
programming • ECM or instrument cluster cluster. Re-synchronise ID by re-
failures incorrectly configured configuring the instrument
cluster as a new module

• CAN fault
ECM and instrument cluster.
• ECM fault
• Instrument cluster fault Check ignition, power and
Target I.D. grounds to ECM and instrument
B1B3362 transfer - signal (ECM/instrument cluster) cluster. Check correct ECM and
compare failure • Synchronisation error instrument cluster installed. Re-
following re-programming synchronise ID by re-configuring
• Noise/EMC related error the instrument cluster as a new
module. Check CAN network for
• CAN fault Check CAN network between

• ECM fault ECM and instrument cluster.
• Instrument cluster fault Check ignition, power and
Target I.D. • Steering column lock status
grounds to ECM and instrument
B1B3364 transfer - signal incomplete
• Race condition caused by cluster. Check steering column
closing driver door and lock operation. Design condition
pressing start button within a - advise customer of correct
small time window start sequence

ECM and instrument cluster.
• CAN fault Check ignition, power and
Target I.D.
• ECM fault grounds to ECM and instrument
B1B3387 transfer - missing
• Instrument cluster fault cluster. Check battery is in fully
message • Low battery voltage charged and serviceable
care manual

Steering column • Commanded position not associated with this DTC using
B1C3277
tilt solenoid reachable the manufacturer approved
diagnostic system

Steering column associated with this DTC using
B1C3294 • Unexpected operation
tilt solenoid the manufacturer approved
diagnostic system

Steering column
B1C3312 tilt feedback • Circuit shorted to battery
signal
diagnostic system

Steering column
• Circuit short to ground or associated with this DTC using
B1C3314 tilt feedback
signal
diagnostic system

Steering column
• Commanded position not associated with this DTC using
B1C3477 telescope reachable the manufacturer approved
solenoid
diagnostic system
Steering column
B1C3494 telescope • Unexpected operation
solenoid
diagnostic system

Steering column
B1C3512 telescope • Circuit shorted to battery
feedback signal
diagnostic system

Steering column
• Circuit short to ground or associated with this DTC using
B1C3514 telescope
feedback signal
diagnostic system

Steering column
B1C3611 tilt/telescope • Circuit short to ground
switch
diagnostic system

Flash to pass associated with this DTC using
B1C4811 • Circuit short to ground
diagnostic system

Flash to pass associated with this DTC using
B1C4815 • Circuit short to power or open
diagnostic system

Front wiper associated with this DTC using
intermittent data the manufacturer approved
diagnostic system

Front wiper associated with this DTC using
B1C5315 • Circuit short to power or open
intermittent data the manufacturer approved
diagnostic system

Turn indicator associated with this DTC using
B1D3611 • Circuit short to ground
diagnostic system
Turn indicator associated with this DTC using
B1D3615 • Circuit short to power or open
diagnostic system

Wiper switch associated with this DTC using
connection circuit the manufacturer approved
diagnostic system

Wiper switch associated with this DTC using
B1D3715 • Circuit short to power or open
connection circuit the manufacturer approved
diagnostic system

Power steering approved diagnostic system, re-
C111064 • Signal plausibility failure
calibration data configure the instrument cluster
as new

Power steering associated with this DTC using
P063511 • Circuit short to ground
control circuit the manufacturer approved
diagnostic system

P063512 • Circuit short to power
diagnostic system

P063513 • Circuit open
diagnostic system

Power steering • First received speed value associated with this DTC using
P063522
control circuit above threshold the manufacturer approved
diagnostic system
• Internal Fault - Wrong reply Carry out any pinpoint tests

Power steering from VAPS driver or NVM associated with this DTC using
P063544
control circuit checksum error (after the manufacturer approved
~500ms) diagnostic system
High speed CAN
• Bus off, break in connection associated with this DTC using
to bus the manufacturer approved
Bus
diagnostic system
Medium speed Carry out any pinpoint tests

CAN • Bus off, break in connection associated with this DTC using
U001088
communication to bus the manufacturer approved
Bus diagnostic system

Lost
U010000 communication • Missing message
with ECM
diagnostic system

Lost
with TCM
diagnostic system

Lost
with 'L' gate
diagnostic system
Lost Carry out any pinpoint tests

communication associated with this DTC using
U010400 • Missing message
with speed the manufacturer approved
Lost
communication Carry out any pinpoint tests
with Anti-lock associated with this DTC using
Brake System the manufacturer approved
(ABS) control diagnostic system
module
Lost
communication Check PSM for DTCs and refer to
U012600 with Passenger • Missing message DTC Index.
Seat Module Seats
(PSM)
U012700 Lost • Missing message Carry out any pinpoint tests

with Tire Pressure the manufacturer approved
Monitor System diagnostic system
(TPMS) module
Lost
communication
U012800 with Parking • Missing message
Brake control
diagnostic system
module
Lost
Check adaptive damping
communication
module for DTCs and refer to
U013900 with adaptive • Missing message
DTC Index.
damping control
module
Lost Check CJB for DTCs and refer to

U014000 communication • Missing message DTC Index.
with CJB Communications Network

Lost
with RJB
diagnostic system
Lost
communication Carry out any pinpoint tests
with associated with this DTC using
Supplemental the manufacturer approved
Restraints System diagnostic system
(SRS) module
Lost
communication
Check information and
with Information
U015600 • Missing message entertainment module for DTCs
and
and refer to DTC Index
Entertainment
Module
Lost
communication Check climate control module
with climate for DTCs and refer to DTC Index
control module
Lost
communication Check DDM for DTCs and refer
with Driver Door to DTC Index
Module (DDM)
Lost
communication
Check PDM for DTCs and refer
U020000 with Passengers • Missing message
to DTC Index
Door Module
(PDM)
Lost
communication
U020600 with Convertible • Missing message
Top control
diagnostic system
module
Lost
communication Check DSM for DTCs and refer
With Driver Seat to DTC Index
Module (DSM)
Lost
communication Check Remote Keyless Entry
U021400 with Remote • Missing message module for DTCs and refer to
Keyless Entry DTC Index
Module
Lost
communication Check lighting control module
with Active Front for DTCs and refer to DTC Index
Lighting system
Lost
communication Check Pedestrian Protection
U025000 with Pedestrian • Missing message system module for DTCs and
Protection system refer to DTC Index
module
Lost
communication Check Integrated Control Panel
with Integrated for DTCs and refer to DTC Index
Control Panel
diagnostic system. Clear DTCs
Internal control • RJB car configuration data is
and re-test. If DTC still logged,
U030000 module software not compatible with the
instrument cluster suspect the instrument cluster.
incompatibility
Refer to the new module
the DTC Index

Auxiliary switch associated with this DTC using
U200411 • Circuit short to ground
pack the manufacturer approved
diagnostic system

Auxiliary switch associated with this DTC using
U200415 • Circuit short to power or open
pack the manufacturer approved
diagnostic system
Install a new instrument cluster.

• Calibration/parameter Refer to the new module
U300046 Control module
memory failure installation note at the top of
the DTC Index
Install a new instrument cluster,

the DTC Index

configuration • Incorrect car configuration and re-test. If the DTC remains
U300055
data does not data received suspect the instrument cluster,
match refer to the new module
the DTC Index

instrument cluster for DTCs and
refer to the DTC Index. Check
CAN network integrity using the
diagnostic system
vehicle

• Circuit voltage below associated with this DTC using
threshold the manufacturer approved
diagnostic system

• Circuit voltage above associated with this DTC using
diagnostic system

U300362 Battery voltage • Signal compare failure
diagnostic system
Instrument Cluster (88.20.01)

Removal
1 NOTE:
.
Make sure all smart keys are available before a new instrument cluster is installed.
If a new instrument cluster is being installed, all smart keys must be cleared from the passive
anti-theft system (PATS), using the Jaguar approved diagnostic equipment prior to the
instrument cluster removal.
2 . Remove the instrument panel driver's side reinforcement trim panel.
3
component.
Remove the instrument cluster surround.

4 . Remove the instrument cluster.
Raise the steering column finisher for access to the lower screws.
Installation
1 . Install the instrument cluster.
Install the screws.
2 . Install the instrument cluster surround.
Install the screws.
3 . Install the instrument panel driver's side reinforcement trim panel.
4 NOTE:
.
Make sure all smart keys are available before the new instrument cluster is installed.
Using the Jaguar approved diagnostic equipment, programme the new instrument cluster and
reprogram all of the smart keys to the vehicle.
413-06 : Horn
Specifications
Specifications
Item Nm lb-ft lb-in

Horn - stud 25 18 -
Horn
COMPONENT LOCATION
1 Horns
2 Horn switch
3 Horn relay and fuse (15A)

INTRODUCTION
The vehicle horns are operated by pressing the center of the steering wheel. Two horns are fitted to
the vehicle; a high tone horn and a low tone horn. Voltage supply to the horns is controlled by the
horn relay, which is energised when the horn switch is pressed.
The horn relay is incorporated within the Battery Junction Box (BJB) and when energised provides a
supply to both horns simultaneously. Circuit protection is provided by fuse 10 (15A), which is located
in the BJB.
The horns are mounted on a bracket, which is secured to the center of the front bumper beam, and
form part of the anti-theft system. For additional information, refer to Anti-Theft - Active (419-01A
Anti-Theft - Active)
CONTROL DIAGRAM
NOTE:
A = Hardwired
1 Battery
2 Megafuse (175A)
4 Horn relay
5 Horns
6 Horn switch
7 Clock spring
Horn
2 . Visually inspect for obvious signs of electrical damage.

Electrical
• Fuse(s)
• Wiring Harness
• Horn(s)
• Relay
• Horn switch
• Clockspring
2 . If the cause is not visually evident, verify the symptom and refer to the Jaguar Approved
Diagnostic System.
Horn (86.30.02)
Removal
1 . Open the hood.

3


Remove the 2 scrivets.
All vehicles
6 . NOTE:
Remove the horn assembly.
Release the clip and position the wiring harness aside for access.
Remove the stud.
Installation
Tighten the stud to 25 Nm (18 lb.ft).

413-08 : Information and Message Center

COMPONENT LOCATION
1 Message center
INTRODUCTION
The message center is a Liquid Crystal Display (LCD) located in a central position in the instrument
cluster.
The message center displays system information, vehicle status and trip computer information to the
driver. The message center is controlled by the instrument cluster and displays system information
using CAN and hard wired signals received from other vehicle system control modules.
MESSAGE CENTER
The message center LCD display has a viewable area of 240 pixels horizontal and 315 pixels vertical. It
is divided into five information display zones as follows, starting from the top:
• Transmission position
• Set speed
• Warning /message display
• 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 is displayed at its full brightness when the ignition is on and the exterior
lights are off. If the exterior lights have been activated by the AUTO windshield wipers feature, the
illumination will remain at full brightness. If the exterior lights are on in any position other than
AUTO, then the LCD will be illuminated at a brightness controlled by the illumination dimmer which is
located in the auxiliary lighting switch.
If more than one message is active, each message is displayed in turn in the order of priority. Once all
messages have been displayed, they are again displayed in turn for 2 seconds each. Warning
messages can be displayed when the ignition is in convenience mode 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
Transmission Display
The transmission display is located in the upper section of the LCD. The transmission position
information is sent from the Transmission Control Module (TCM) in a high speed CAN message to the
instrument cluster.
The transmission has three modes of operation:
• Conventional automatic operation (selector in 'D' position)

• Sport automatic operation (selector lever in 'S' position)
• Manual gear operation - Jaguar Sequential Shift
The following table shows the selector lever position and the highlighted indication displayed in the
transmission display.
The following table shows the Jaguar Sequential Shift display. Selections are made using the steering
wheel mounted paddle switches.
Selector Lever Position Transmission Display
(P) Park P
(R) Reverse R
(N) Neutral N
(D) Drive D
(S) Sport DS
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.
Set Speed Display
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
LIMITER SET None Displays new speed setting None

XXX MPH for the ASL
(km/h)
LIMITER None Displayed when ASL is None

STANDBY activated and speed control
is selected
LIMITER None Displayed for 4 seconds None

CANCELLED when driver deselects ASL
OVERLIMIT • Amber ASL warning Displayed when vehicle Reduce vehicle speed to
XXX MPH indicator illuminated speed exceeds the ASL set ASL set limit
(km/h) at +4.8 km/h (+3 speed
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 NOT None Displayed when ECM has Use the Integrated
AVAILABLE detected a fault Diagnostic System to
diagnose fault
SETSPEED None Displays the new speed None

XXX MPH input for the speed control
(km/h)
DRIVER None Immediate action required • Apply brakes if
INTERVENE by the driver to apply the required.
brakes if required • May also be
displayed if speed
control system
loses CAN
messages when
active.
CRUISE NOT None Speed control cannot be A fault has occurred in

AVAILABLE engaged the speed control system.
Diagnose fault using IDS.
GAP None Displays the current set or If required, adjust

default adaptive speed distance using the
control distance. Displayed steering wheel switches.
along with a vehicle graphic
in the LCD.
RADAR None The adaptive speed control Remove obstruction or

SENSOR radar sensor has become clean the radar sensor.
BLOCKED dirty or obstructed.
FORWARD None Forward alert has been None

ALERT OFF switched off. No warning
will be given for objects in
the vehicles forward
direction.
FORWARD None Forward alert has been None

ALERT switched on or the gap
settings have changed.
CRUISE None Driver has pressed the WARNING: Adaptive

OVERRIDE accelerator pedal, cruise braking will be
overriding the speed control disabled when this
system. Message will go off message is displayed.
when accelerator pedal is
released and speed control
is active.
CRUISE None Driver has cancelled speed Re-activate the speed

CANCELLED control or the brake pedal control system or press
has been pressed. the 'Resume' switch on
the steering wheel.
CRUISE None Displayed when speed None
STANDBY control is activated and ASL
is selected
CRUISE None Displayed when speed None

ENGAGED control is active
TOO FAST TO None Displayed when 'Resume' Reduce vehicle speed to

RESUME switch is pressed but vehicle set speed then press
speed is 30 km/h (18 mph) 'Resume' switch.
above the set speed.
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.
Message Other Warnings Reason Action
FUEL LEVEL LOW Amber warning Fuel level has reached 1/16 Refuel vehicle at earliest
triangle illuminated in of tank capacity - Fuel opportunity.
LCD. range approximately 48 -64
km/h (30 to 40 miles).
FUEL PUMP Amber warning Fuel system fault detected A fault has occurred in the
SYSTEM FAULT triangle illuminated in by the instrument cluster fuel system. Check fuel pump
LCD. checking the signals from operation.
the auxiliary junction box.
Only detected if the left
hand fuel level sensor
shows nearly full and the
right hand fuel level sensor
shows nearly empty.
WASHER FLUID Amber warning Washer fluid level has Refill washer fluid reservoir.
LOW triangle illuminated in become low and activated
LCD. low level switch.
DOOR OPEN Red warning triangle Door(s) open. Close door(s).
illuminated in LCD.
Vehicle graphic
displayed showing
open door(s).
BOOT OPEN Red warning triangle Liftgate open. Close liftgate.

illuminated in LCD.
Vehicle graphic
displaying open
liftgate.
BONNET OPEN Red warning triangle Hood open. Close hood.

illuminated in LCD.
Vehicle graphic
showing open hood.
COLUMN None Column adjust switch has None

ADJUST been moved to the column
position.
COLUMN None Column is operating in auto None

ADJUST AUTO adjust memory mode.
MEMORY 1 None Memory 1 button pressed None

RECALLED or Smart Key assigned to
memory 1 sensed in vehicle
by Keyless Vehicle Module.


MEMORY 1 None New memory settings None

SETTINGS SAVED assigned to memory 1.

CHECK Red warning triangle A fault is present in the A fault has occurred in the
PEDESTRIAN illuminated in LCD. pedestrian protection pedestrian protection system.
SYSTEM system when no accident Interrogate pedestrian
or deployment has protection system control
occurred. module for faults and
diagnose fault using IDS.
INERTIA SWITCH Amber warning Vehicle may have been Check for fuel system leaks.
TRIPPED triangle illuminated in involved in an impact which Perform the inertia switch
LCD. has caused the Restraints reset procedure. For
Control Module to activate additional information, refer
the inertia switch. to Electronic Engine
Controls (303-14B Electronic
Engine Controls - Vehicles
VALET MODE None Valet Mode has been Use TSD to exit the valet
selected by the driver to mode.
secure the luggage
compartment and the
glovebox.
VEHICLE ARMED None Displayed when the vehicle None

is locked and is displayed
simultaneously with the
visual and audible locking
confirmation.
SMART KEY NOT None The Smart Key has not Insert Smart Key into the slot
FOUND. PLEASE been detected by the in the start control module.
INSERT IN SLOT Keyless Vehicle Module. This may caused by Smart Key
low battery voltage or local RF
interference.
CHECK SMART None Keyless Vehicle Module has Ensure that the Smart Key in
KEY not detected a Smart Key in range of the vehicle LF
the vehicle. antennae.
REMOVE SMART None Smart Key has been Remove Smart Key from slot.
KEY detected by the start
control module.
PRESS BRAKE None Driver has pressed the Press brake pedal to start
WHEN Start/Stop button for a engine.
STARTING second time without
pressing on the brake
pedal.
GEAR SELECTOR None Transmission selector lever Move transmission selector

NOT IN PARK is not the 'PARK' position lever to the 'PARK' position.
when a request to start or
stop the engine is made.
SMART KEY None The Keyless Vehicle Module Replace Smart Key battery.
BATTERY LOW has detected that the
Smart Key battery is low on
power.
STEERING None The Electric steering Turn off the ignition, move
COLUMN column lock has failed to the steering wheel gently
LOCKED unlock the steering and the from side to side and try again
engine is prevented from to start the engine. If this fails
starting. a fault has occurred which
must be rectified.
LIGHTS ON Chime from the The vehicle side lamps are Turn off side lamps or close
instrument cluster. switched on and the driver's door.
driver's door has been
opened.
TAIL LAMP Amber warning A LH or RH tail lamp bulb Replace defective bulb.
FAILURE triangle illuminated in has failed.
LCD. Vehicle graphic
displaying failed tail
lamp displayed.
BRAKE LAMP Amber warning A LH or RH brake lamp bulb Replace defective bulb.
FAILURE triangle illuminated in has failed.
LCD. Vehicle graphic
displaying failed brake
lamp displayed.
INDICATOR Amber warning A LH or RH, front or rear Replace defective bulb.

LAMP FAILURE triangle illuminated in turn signal indicator bulb
LCD. Vehicle graphic has failed.
displaying failed turn
signal indicator
displayed.
DSC ON DSC warning indicator Displayed for a short time None

flashes for a short when the DSC switch is
time. operated to activate the
DSC system.
DSC OFF DSC warning indicator Displayed for a short time None
illuminated. when the DSC switch is
operated to de-activate the
DSC system.
TRAC DSC DSC warning indicator Displayed for a short time None
illuminated. when TRAC DSC has been
selected by the driver using
the DSC switch.
DSC NOT DSC warning indicator A fault is present in the DSC A fault has occurred in the
AVAILABLE illuminated. system. DSC system. Interrogate ABS
module for faults and
diagnose fault using IDS.
BRAKE FLUID • Brake warning Brake fluid level has Investigate fluid loss and
LOW indicator become low and activated check brake system for leaks.
illuminated. low level switch. Repair system as required and
• Red warning
replenish brake fluid
triangle
illuminated in reservoir.
LCD.
ABS FAULT • ABS warning A fault is present in the ABS A fault has occurred in the
indicator system. Braking system will ABS system. Interrogate ABS
illuminated. operate but ABS will not be module for faults and
• Amber
available. diagnose fault using IDS.
warning
triangle
illuminated in
LCD.
BRAKE ASSIST Amber warning A fault is present in the A fault has occurred in the
FAULT triangle illuminated in braking system preventing brake assist system.
LCD. brake assist operation. Interrogate ABS module for
Braking system will operate faults and diagnose fault using
but brake assist will not be IDS.
available and increased
effort on the brake pedal
may be required.
CATS SYSTEM Amber warning A fault is present in the A fault has occurred in the
FAULT triangle illuminated in Computer Active CATS system. Interrogate the
LCD. Technology Suspension CATS module for faults and
(CATS). Suspension will diagnose using IDS.
default to the 'hard'
setting.
PARK BRAKE None Parking brake has been None

APPLIED applied when the vehicle
moving at a speed 5 km/h
(3 mph) or above.
PARK BRAKE • Brake warning A fault is present in the A fault has occurred in the
FAULT indicator parking brake system. parking brake system.
illuminated. Interrogate the parking brake
• Red warning
module for faults and
triangle
illuminated in diagnose using IDS.
LCD.
APPLY FOOT Amber warning The battery has been Apply foot brake and parking
AND PARK triangle illuminated in disconnected or power brake to reset the parking
BRAKE LCD. supply interrupted to the brake module.
parking brake module.
CANNOT APPLY • Brake warning A fault is present in the A fault has occurred in the
PARK BRAKE indicator parking brake system and parking brake system.
flashing. the parking brake cannot Interrogate the parking brake
• Red warning
be applied. module for faults and
triangle
illuminated in diagnose using IDS.
LCD.
• NOTE: In
certain
markets the
brake warning
indicator does
not flash.
CHECK TYRE • Tire Pressure A tire pressure has Check tires for punctures and
PRESSURE Monitoring decreased to below the re-inflate to correct pressures.
System (TPMS) warning threshold.
warning
indicator
illuminated.
• Vehicle
graphic
displaying tire
location.
CHECK ALL TYRE • Tire Pressure One or more tire pressures • Check tires for
PRESSURES Monitoring have decreased to below punctures and re-
System (TPMS) the warning threshold. inflate to correct
warning pressures.
indicator • Message may be
illuminated. displayed when TPMS
• Amber is learning position of
warning a new sensor.
triangle
illuminated in
LCD.
• Vehicle
graphic
displaying tire
location.
TYRE NOT • Tire Pressure • One or more tire • Check for local RF
MONITORED Monitoring pressure sensors interference.
System (TPMS) have developed a • A wheel has been
warning fault. fitted without a TPMS
indicator • A temporary spare sensor fitted (space
illuminated. wheel or a wheel saver spare wheel).
• Vehicle without a sensor • TPMS sensor has
graphic has been fitted at developed a fault or
displaying tire the displayed the battery voltage is
location. position. low.
• An unapproved • A fault has occurred
accessory may be in the TPMS.
interfering with the Interrogate the TPMS
TPMS. module for faults and
diagnose using IDS.
TYRE PRESSURE • Tire Pressure • Wheels and tires A fault has occurred in the
SYSTEM FAULT Monitoring without sensors TPMS. Interrogate the TPMS
System (TPMS) have been fitted to module for faults and
warning the vehicle.
diagnose using IDS.
indicator • TPMS sensors have
illuminated. become defective.
• Amber • An unapproved
warning accessory may be
triangle interfering with the
illuminated in TPMS.
LCD. • A fault is present in
the TPMS system
and the tire
pressures cannot
be monitored.
ENGINE Amber warning Engine coolant • Stop vehicle and allow

TEMPERATURE triangle illuminated in temperature has exceeded engine to idle for 5
HIGH LCD at temperatures threshold for normal minutes. Switch off
engine and allow to
of between 118.0°C operation.
stand for not less than
(244.4°F) and 119.3°C 10 minutes. Check
(246.8°F). coolant level.
• If message re-
appears, investigate
coolant system for
leakage.
ENGINE Red warning triangle Engine coolant • Stop vehicle and allow
OVERHEATING illuminated in LCD at temperature has exceeded engine to idle for 5
temperatures of threshold for normal minutes. Switch off
engine and allow to
119.4°C (247°F) or engine operation.
stand for not less than
above. 10 minutes. Check
coolant level.
• If message re-
appears, investigate
coolant system for
leakage.
ENGINE OIL Red warning triangle Engine oil pressure has Stop the engine immediately.
PRESSURE LOW illuminated in LCD. fallen below the threshold Check engine oil level. If oil
for normal operation. level correct, do not restart
engine until oil pressure loss
has been identified and
corrected.
RESTRICTED Red or Amber warning A fault has occurred which Investigate cause of engine
PERFORMANCE triangle illuminated in has reduced engine power power loss. Interrogate
LCD depending on output. control modules for faults and
nature of power loss. diagnose using IDS.
ENGINE • MIL • A fault has • Investigate cause of

SYSTEMS FAULT illuminated for occurred in the fault. Interrogate ECM
certain faults. engine and TCM for faults
• Red or Amber management and diagnose using
warning system or, if the IDS.
triangle MIL is illuminated, • Check start/stop
illuminated in an emissions switch for correct
LCD. related fault is operation or short
present which has circuits.
been detected by
the On-Board
Diagnostic systems
in the ECM and
TCM.
• A fault has
occurred with the
start/stop switch.
CHECK FUEL • (NAS Only) Diagnostic Monitoring of Check fuel filler cap to ensure
FILLER CAP • Red warning Tank Leakage (DMTL) is it correctly installed and
triangle system has detected fuel secure.
illuminated in
filler cap has not been
LCD.
correctly installed.
ENGINE Red warning triangle A fault has occurred in the Investigate cause of engine
TEMPERATURE illuminated LCD. engine management temperature failure.
INDICATION system and the engine Interrogate ECM for faults and
FAULT temperature signal is no diagnose using IDS.
longer being received.
GEARBOX FAULT Red warning triangle TCM has detected a fault in Investigate transmission fault.
illuminated in LCD. the transmission. Interrogate TCM and diagnose
Transmission may default fault using IDS.
to 'limp home' mode and
only allow operation of one
forward gear and reverse.
BATTERY NOT Red warning triangle Charge output from Investigate cause of generator
CHARGING illuminated in LCD. generator not detected by failure.
ECM.
OVER 120 km/h • (GULF States Vehicle has exceeded the Reduce vehicle speed.
Only) preset 120 km/h speed
• Amber value.
warning
triangle
illuminated in
LCD.
HOOD NOT Red warning triangle The convertible top is not Ensure convertible top is
LATCHED illuminated in LCD. correctly latched. correctly latched and secured.
HOOD OUT OF Amber warning The convertible top is Open or close the convertible
POSITION triangle illuminated in incorrectly positioned. top again and ensure it is
LCD. correctly positioned.
LUGGAGE Amber warning The luggage separator is Check the positioning of the
COVER OUT OF triangle illuminated in incorrectly positioned. luggage separator and it is
POSITION LCD. correctly engaged.
LISTENING None Telephone voice system is None.

active.
Odometer Display
The odometer displays the total distance which the vehicle has travelled. This is calculated by the
instrument cluster using wheel speed signals from the ABS module.
The odometer can show 6 characters and distances up to 999,999 miles or kilometers. The total
distance travelled is stored in a Electronically Erasable Programmable Read Only Memory (EEPROM)
and the Random Access Memory (RAM). This ensures that the total distance is not lost if the battery
is disconnected.
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
Diagnostic Trouble Codes (DTC).
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 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 auxiliary
junction box 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 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)
• Gear selector not in park
• Valet mode
• Lights on reminder
• Hood operation
• Passive Entry / Passive Start (PEPS)
• Memory set
• Turn signal indicators
• 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.


• Fuse(s)
• Wiring harness
• Engine compartment components
• Fluid level(s)
• Underbody components
• Accessory installations
• Door switches
• Electronic modules
• Boot/bonnet switch
2 . If the cause is not visually evident, verify the symptom and refer to the Jaguar approved diagnostic
system.
413-09 : Warning Devices
Warning Devices

• Door ajar switch(es) • Fuse(s)

• Safety belt buckle and pretensioner • Wiring harness
• Headlamp switch • Electrical connector(s)
• Fuel gauge • Switch(es)
• Inertia switch • Sensor(s)
2 . If the cause is not visually evident, verify the symptom and refer to the Jaguar approved diagnostic
system.
Low Washer Fluid Warning Indicator

Switch (84.10.17)
Removal
1
2 . Remove the RH fender splash shield.

3 . Drain the washer reservoir fluid.
4 . Remove the low washer fluid warning indicator switch.

Installation
1 . Install a new seal.
2 . Install the low washer fluid warning indicator switch.

4 . Refill the washer reservoir.

413-13 : Parking Aid
Specifications
Specifications
Item Nm lb-ft lb-in

Parking aid module - nut 2 - 18
Parking Aid
COMPONENT LOCATION
1 Audio head unit

2 Gateway module
3 Control switch
4 Control module
5 Front parking aid sensors (4 off)
6 Rear parking aid sensors (4 off)
INTRODUCTION
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 fitted) or reversing manouevre. The purpose of the
system is to assist the driver when parking or manoeuvring in 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 be fitted with
both front and rear sensors.
Audible warnings to the driver are given by the entertainment system speakers. A visual
representation is shown on the Touch Screen Display (TSD).
The control module controls operation of the speakers via the audio head unit. A gateway module is
incorporated into the system to convert medium speed Controller Area Network (CAN) bus messages
from the control module into Media Orientated System Transport (MOST) messages for use by the
audio head unit. For additional information, refer to Audio System (415-01 Audio Unit)
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 control module to
calculate the distance from an object.
The roof console mounted control switch allows the driver to deactivate the parking aid system if
operation is not required.
NOTE:
The control switch is only fitted to vehicles with front parking aid sensors.
CONTROL MODULE
The parking aid control module is located in the passenger footwell, behind a protective panel. The
control module uses a single microprocessor to perform the following tasks:
• Control of the ultrasonic sensors

• Monitoring of the sensors
• Evaluation of received echo signals from the sensors
• Noise and disturbance suppression
• Control of the audio system speakers
• Control and monitoring of the switch status Light Emitting Diode (LED) and associated wiring
• Evaluation and monitoring of the control inputs
• Management of diagnostic and test functions
• Monitoring of power supply
• Communication via diagnostic link.
The control module is connected to the vehicle electrical system by either 3 (vehicles fitted with front
and rear sensors) or 2 (vehicles fitted with rear sensors only) multiplug connectors.
Inputs and Outputs

The table below shows control module inputs and outputs
Component Description Input/Output
Transmission Control Medium speed CAN bus message - reverse gear selected Input
Module (TCM)
TCM Medium speed CAN bus message - forward gear selected Input
Control switch Status - On/Off Input
Parking brake module Medium speed CAN bus message via the gateway Input
module - parking brake applied
Auxiliary junction box Electrical power supply Input
Parking aid sensors Electrical power and ground Output
Parking aid sensors Digital transmit and receive signals Output
Audio system speakers Varying frequency outputs Output
Control switch LED illumination Output
Diagnostics
The control module has a diagnostic connection via the medium speed CAN bus to enable faults to be
retrieved using the Integrated Diagnostic System (IDS). Additionally an on-board diagnostic routine
within the control module constantly monitors the system and alerts the driver to a system fault by
emitting a 5 second continuous tone through the audio system speakers when the ignition is
switched on and a gear is selected. If front parking aid sensors are fitted, the control switch LED will
also illuminate.
PARKING AID SENSORS
Four sensors are positioned in the rear bumper and four in the front bumper (if fitted). The front
sensor housings are glued into position; the rear sensor housings are welded into position. The
sensor bodies are then clipped into the housings from the rear.
Each sensor has a 3 pin connector which connects into a common harness linking all 4 sensors. The 3
pins of each connector provide the sensor a negative feed, a positive feed and a signal line. The rear
parking aid harness connects to the main vehicle body harness. The front parking aid harness
connects to the Left-Hand (LH) engine compartment harness.
Each sensor comprises a plastic housing which contains a piezoelectric disc. The disc resonates at a
frequency of approximately 50 kHz, producing an ultrasonic signal output. The disc also receives the
reflected echo signal.
Each sensor has 2 modes of operation; combined transmitter and receiver mode or receiver mode
only. The control module controls the operating mode of each sensor by the output of a digital signal
on the signal line.
In the combined mode, the sensor emits a series of ultrasonic impulses and then switches to receiver
mode to receive the echo reflected by an obstacle in the detection range. These echo signals are
amplified and converted from an analogue signal to a digital signal by the sensor. The digital signal is
then transmitted to the control module and compared with preprogrammed data stored in an
Electrically Erasable Programmable Read Only Memory (EEPROM) within the module.
The module receives this data via the signal line from the sensor and calculates the distance to the
obstacle according to the elapses time between the transmitted and received impulse. The duration
of the impulse transmission is determined by the control module. The frequency of the impulse is
determined by the sensor.
In the receiver mode, the sensor will receive impulses that were emitted by adjacent sensors. The
control module uses this information to precisely determine position and distance of the obstacle.
CONTROL SWITCH
1 Control switch
The control switch is located in the roof console. The switch is non-latching with an integral LED. The
switch receives a 12 V output from the control module, and is also connected to ground. When the
switch is operated, a momentary ground is completed. This is interpreted by the control module as a
signal to enable or disable the parking aid system.
The switch also receives a 12 V output from the control module to drive the LED when the parking
aid system is on.
NOTE:
The control switch will only switch off the front parking aid sensors. The rear parking aid sensors
will remain operational.
CONTROL DIAGRAM
NOTE:
A = Hardwired; N = Medium Speed CAN bus; P = MOST

1 Battery
2 Megafuse (175A)
4 Control module
5 Right outer front sensor
6 Right inner front sensor
7 Left inner front sensor
8 Left outer front sensor
9 Right outer rear sensor
10 Right inner rear sensor
11 Left inner rear sensor
12 Left outer rear sensor
13 Audio head unit
14 To audio system speakers
15 Gateway module
16 Control switch
If a forward drive gear is selected when the vehicle ignition is first switched on, the front parking aid
sensors (if fitted) will not be operational. If reverse (R) is the first gear selected after the ignition is
switched on, both the front and rear parking aid sensors will become operational. If a forward drive
gear is subsequently selected, the rear parking aid sensors be switched off by the control module but
the front parking aid sensors will remain operational until vehicle speed increases above 16 km/h (10
mph).
Parking aid will only become active if the following conditions exist:
Front and rear sensors fitted
• Ignition on
• 'Park' is not selected
• Parking brake is released
• Vehicle speed drops below 7 km/h (4.5 mph) - rear sensors only
• Vehicle speed drops below 7 km/h (4.5 mph) and control switch pressed - front sensors only.
Rear sensors only
• Ignition on
• Reverse gear selected for more than 1 second.
Audible and Visual Warnings

The control module processes the distance readings from the ultrasonic parking aid sensors to
determine if there are any objects within the detection areas. If there are no objects no audible
warning is produced. If an object is detected, repeated audible warnings are produced via the audio
system speakers. The time delay between the audible warnings decreases as the distance between
the detected object and the vehicle decreases until eventually a continuous tone is emitted from the
speakers.
A visual interpretation of the detection areas is given in the TSD.
The detection ranges of the sensors are shown in the table below.
Sensors Maximum Detection Range Continuous Tone
Front 800 mm (31 inches) 250 mm (10 inches)
Rear 1600 mm (63 inches) 300 mm (12 inches)
After the initial detection of an object, if there is no decrease in the distance between an object and
the central sensors, the time delay between the audible warnings remains constant. If an object is
detected by one of the corner sensors only, the audible warnings stop after approximately 5 seconds
if there is no change in the distance between an object and the corner sensor.
Detection Calculation
When operating in the combined transmitter and receiver mode, the sensor outputs a number of
ultrasonic pulses and receives the reflected echo signal. The control module amplifies the received
echo signals and compares them with a preprogrammed threshold to calculate the distance to the
object. This is achieved by determining the elapsed time between the transmission and reception of
the ultrasonic signal.
When operating in receiver mode, the sensor receives echo signals transmitted by an adjacent
sensor. This mode is used to improve the accuracy of the system.
The detection cycle consists of the control module operating 1 sensor in the combined transmitter
and receiver mode and transmitting a number of pulses. The control module then switches the
transmitting sensor and the adjacent sensor(s) to receiver mode. After a short time delay this
sequence is repeated using a different sensor to transmit the ultrasonic signal. This sequence is
completed in 100 ms. The control module uses several measurements of the same sensors to remove
errors from the calculation.
If the detected object is directly behind a sensor, the distance is calculated using the time between
the transmission and reception of the ultrasonic signal. If the object is positioned between 2 sensors,
the control module uses both signals to determine the correct distance using triangulation.
To perform the triangulation calculation, the control module must know the distance between the
individual sensors in the bumper. This information is stored in the control module memory. From the
received distance signal from each sensor and using the known distance between adjacent sensors,
the control module can calculate the minimum distance from the vehicle to the detected object.
When approaching several objects, the control module recognises the distance from the vehicle to
the nearest object.
Parking Aid
For a detailed description of the parking aid system, refer to the relevant Description and Operation
Parking Aid
CAUTION: Diagnosis by substitution from a donor vehicle is NOT acceptable. Substitution of

control modules does not guarantee confirmation of a fault, and may also cause additional faults in
the vehicle being tested and/or the donor vehicle.
NOTE:
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
Electrical
• Fuse(s)
• Relay(s)
• Wiring Harness
• Front parking aid sensor(s) and holders
• Rear parking aid sensor(s) and holders
• Audio system
• Touch screen display unit
• Parking aid switch and LED
• Reversing lamp switch
• Parking aid module
Index.
DTC Index
NOTE:
NOTE:
diagnostic system).
NOTE:
three decimal places, and with an up-to-date calibration certificate. When testing resistance
NOTE:
NOTE:
NOTE:
terminals.
• Front right outer sensor signal Carry out any pinpoint tests
circuit - short to ground, high
Front right outer associated with this DTC using
B1B3601 resistance
sensor • Front right outer sensor power the manufacturer approved
supply circuit - high resistance diagnostic system

Front right outer • Front right outer sensor signal associated with this DTC using
B1B3612
sensor circuit - short to power the manufacturer approved
diagnostic system

• Front right outer sensor
Front right outer ground circuit - open circuit
B1B3696 diagnostic system. Install new
sensor • Front right outer sensor
internal failure sensor as necessary.
Front Outer Parking Aid Sensor
(86.54.22)
• Front right inner sensor signal Carry out any pinpoint tests
Front right inner associated with this DTC using
B1B3801 resistance
sensor • Front right inner sensor power the manufacturer approved

Front right inner • Front right inner sensor signal associated with this DTC using
B1B3812
diagnostic system
• Front right inner sensor Carry out any pinpoint tests

Front right inner ground circuit - open circuit associated with this DTC using
B1B3896 • Front right inner sensor the manufacturer approved
sensor
internal failure diagnostic system. Install new
Front Inner Parking Aid Sensor
(86.54.21)
• Front left outer sensor signal Carry out any pinpoint tests
Front left outer associated with this DTC using
B1B4001 resistance
sensor • Front left outer sensor power the manufacturer approved

Front left outer • Front left outer sensor signal associated with this DTC using
B1B4012
diagnostic system

• Front left outer sensor ground
Front left outer circuit - open circuit
sensor • Front left outer sensor internal
failure sensor as necessary.
Front Outer Parking Aid Sensor
(86.54.22)
• Front left inner sensor signal Carry out any pinpoint tests
Front left inner associated with this DTC using
B1B4201 resistance
sensor • Front left inner sensor power the manufacturer approved

Front left inner • Front left inner sensor signal associated with this DTC using
B1B4212
diagnostic system

• Front left inner sensor ground
Front left inner circuit - open circuit
sensor • Front left inner sensor internal
Front Inner Parking Aid Sensor
(86.54.21)

• Rear right outer sensor signal
Rear right outer associated with this DTC using
B1B4401 circuit - short to ground, high
sensor resistance the manufacturer approved
• Rear right outer sensor power diagnostic system
supply circuit - high resistance

Rear right outer • Rear right outer sensor signal associated with this DTC using
B1B4412
diagnostic system

• Rear right outer sensor ground
Rear right outer circuit - open circuit
sensor • Rear right outer sensor
Rear Parking Aid Sensor
(86.54.14)
• Rear right inner sensor signal Carry out any pinpoint tests
Rear right inner associated with this DTC using
B1B4601 resistance
sensor • Rear right inner sensor power the manufacturer approved

Rear right inner • Rear right inner sensor signal associated with this DTC using
B1B4612
diagnostic system

• Rear right inner sensor ground
Rear right inner circuit - open circuit
sensor • Rear right inner sensor
(86.54.14)
• Rear left outer sensor signal Carry out any pinpoint tests
Rear left outer associated with this DTC using
B1B4801 resistance
sensor • Rear left outer sensor power the manufacturer approved

Rear left outer • Rear left outer sensor signal associated with this DTC using
B1B4812
diagnostic system
• Rear left outer sensor ground Carry out any pinpoint tests
Rear left outer circuit - open circuit associated with this DTC using
B1B4896
sensor • Rear left outer sensor internal the manufacturer approved
failure diagnostic system
• Rear left inner sensor signal Carry out any pinpoint tests
Rear left inner associated with this DTC using
B1B5001 resistance
sensor • Rear left inner sensor power the manufacturer approved

Rear left inner • Rear left inner sensor signal associated with this DTC using
B1B5012
diagnostic system

• Rear left inner sensor ground
Rear left inner circuit - open circuit
sensor • Rear left inner sensor internal
(86.54.14)
• Parking aid status LED - short Refer to the electrical circuit

Parking aid status
B1B5411 to ground (detected if driven diagrams and test status LED
LED only) circuit for short to ground
• Parking aid status LED - short Refer to the electrical circuit

Parking aid status
B1B5412 to power (detected if not diagrams and test status LED
LED driven only) circuit for short to power

Front sensors
• Front sensors power supply diagrams and test front sensor
B1B5711 power supply
circuit - short to ground power supply circuit for short to
circuit
ground

Rear sensors
• Rear sensors power supply diagrams and test rear sensor
B1B5811 power supply
circuit - short to ground power supply circuit for short to
circuit
ground
• Disable switch stuck closed Carry out any pinpoint tests

B1C3073 Disable switch • Disable switch circuit - short to
ground
diagnostic system

CAN • Medium speed CAN associated with this DTC using
U001000
communication communication Bus the manufacturer approved

Control module
• Control module associated with this DTC using
communication Bus "A" Off the manufacturer approved
Bus "A" Off
diagnostic system

Lost
• Logged when subscribed CAN associated with this DTC using
message missing from CJB the manufacturer approved
with CJB
diagnostic system

Lost
message missing from RJB the manufacturer approved
with RJB
diagnostic system

• Logged when subscribed CAN
U015500 message missing from
with instrument instrument cluster the manufacturer approved

diagnostic system. Clear DTCs
Internal control • RJB car configuration data is
and re-test. If DTC still logged,
U030000 module software not compatible with the
parking aid module install a new parking aid
incompatibility
module. Refer to the new
module installation note at the
Check CJB for DTCs and refer to

Invalid data • Logged when subscribed CAN
U042200 DTC Index.
received from CJB message invalid data from CJB
Invalid data
• Logged when subscribed CAN Check instrument cluster for
received from
U042300 message invalid data from DTCs and refer to DTC Index.
instrument Instrument Cluster Instrument Cluster
cluster
Check RJB for DTCs and refer to
Invalid data • Logged when subscribed CAN
U044300 DTC Index.
received from RJB message invalid data from RJB

Initial
• No configuration has been diagnostic tool, clear DTC and
U210000 configuration not
previously set re-test. If DTC remains check
complete
CAN network.

Control module diagnostic tool, clear DTC and
U210100 configuration • Data sent from RJB is invalid re-test. If DTC remains check
incompatible Check RJB for DTCs and refer to
DTC Index.
Install a new parking aid control

U300049 Control module • Internal control module failure
Install original module, check

• Vehicle/component mis- for parking aid related DTCs and
Vehicle match. Corrupt VIN data being refer to DTC Index. If DTC
U300281 Identification transmitted, module remains suspect parking aid
Number (VIN) previously installed to other module, refer to new module
vehicle installation note at top of DTC
Index

diagnostic system

U300317 Battery voltage threshold the manufacturer approved
diagnostic system

U300362 Battery voltage • Mis-match of battery voltage,
of 2 volts or lower, between
parking aid module and RJB diagnostic system
Parking Aid Module (86.80.39)

Removal
NOTE:
The park control module is situated in the LH footwell and does not change position with the
hand of drive.

2 . LH side: Remove the cowl side trim panel.
Remove the hood release lever.
Release the forward edge of the scuff plate trim panel.
3
. CAUTION: Make sure the wiring harness and electrical connectors are not damaged
during the carpet release.
Carefully release the carpet for access.
Carefully release the forward edge of the floor console side trim panel.
4 . Release the subwoofer cover.
Remove the 4 bolts.
Position aside.
5 . Remove the parking aid module.
Position the acoustic pad aside.
Release 2 electrical harness clips from the body and position aside.
Remove the 2 nuts.

Installation
1 . Install the parking aid module.
Secure the electrical harness.
Align the acoustic pad.
2 . Install the subwoofer cover.
3
. CAUTION: Make sure the carpet is correctly installed and that no foul-condition
exists when the accelerator pedal is depressed.
Install the carpet.
Install the floor console side panel trim.
4 . Install the cowl side trim panel.
Secure the scuff plate trim panel.

Rear Parking Aid Sensor (86.54.14)
Removal
1
2 . Remove the rear bumper cover.

For additional information, refer to Rear Bumper Cover (76.22.74)
3 . Remove the parking aid sensor.
Repeat the above for the other 3 sensors.
Installation
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.
Install the parking aid sensor.

Repeat the above procedure for the remaining 3 sensors.
2 . Install the rear bumper cover.

Front Inner Parking Aid Sensor (86.54.21)
Removal
All vehicles
1
Vehicles with 4.2L engine


All vehicles

Installation
1

Front Outer Parking Aid Sensor (86.54.22)
Removal
1
2 . Remove the headlamp assembly.

Installation
1

414 : Battery and Charging System
414-00 : Charging System – General Information
General procedure
Battery Charging
1. Before charging a discharged battery inspect and repair the following conditions, if
necessary:
• Loose accessory drive belt.
• Pinched or grounded wiring harness to the generator or voltage regulator.
• Loose wiring harness connections at the generator or voltage regulator.
• Loose or corroded connections at battery, headlamp panel junction wire or engine
ground.
• Carry out generator charging checks.
• Excessive battery quiescent drain due to:
engine compartment, load space, glove compartment and courtesy lamps remaining on
(switch damaged or out of adjustment, glove compartment left open).
Battery Charging - Maintenance-Free

Batteries
WARNING: KEEP BATTERIES OUT OF REACH OF CHILDREN.
BATTERIES CONTAIN SULPHURIC ACID, AVOID CONTACT WITH SKIN, EYES
OR CLOTHING. SHIELD YOUR EYES WHEN WORKING NEAR THE BATTERY
TO PROTECT AGAINST POSSIBLE SPLASHING OF THE ACID SOLUTION. IN
CASE OF ACID CONTACT WITH SKIN OR EYES, FLUSH IMMEDIATELY WITH
WATER FOR A MINIMUM OF 15 MINUTES AND SEEK PROMPT MEDICAL
ATTENTION. IF ACID IS SWALLOWED, CALL A PHYSICIAN IMMEDIATELY.
FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL
INJURY.
WARNING: BATTERIES NORMALLY PRODUCE EXPLOSIVE GASES

WHICH CAN CAUSE PERSONAL INJURY, THEREFORE DO NOT ALLOW
FLAMES, SPARKS, OR LIGHTED SUBSTANCES TO COME NEAR THE
BATTERY. WHEN CHARGING OR WORKING NEAR A BATTERY ALWAYS
SHIELD YOUR FACE AND PROTECT YOUR EYES . ALWAYS PROVIDE
ADEQUATE VENTILATION. FAILURE TO FOLLOW THESE INSTRUCTIONS
MAY RESULT IN PERSONAL INJURY.
1. Cold batteries will not readily accept a charge. Therefore, batteries should be allowed to
warm up approximately to 15 degrees centigrade (59 degrees Fahrenheit) before charging.
This may require 12 hours at room temperature depending on the initial temperature and
battery size.
2. A battery which has been completely discharged may be slow to accept a charge initially,
and in some cases may not accept a charge at the normal charger setting. When batteries are
in this condition, charging can be started by use of the 'dead battery' switch which is fitted to
certain types of battery chargers. Follow the manufacturer's instructions when carrying out
this procedure.
3. To determine whether a battery is accepting a charge, follow the manufacturer's

instructions for the charger.
4. After releasing dead battery switch and with the charger still operating, measure battery
voltage. If the voltage is 12 volts or higher, the battery may be accepting a charge and may be
capable of being recharged. If the temperature of the battery is below 15 degrees centigrade
(59 degrees Fahrenheit) the battery may require charging for up to two hours before the
charge rate is high enough to show on the charger ammeter. It has been found that all un-
damaged batteries can be charged by this procedure. If a battery cannot be charged by this
procedure, it should be replaced.
5. A rapid recharge procedure has been developed for recharging batteries that have passed
the 'No-Load Test' and only need a recharge. This can be due to non start battery failures or
battery discharged in vehicle due to key-off loads.
6. The battery can be rapidly recharged by using either of the following methods:
• Perform a two hour charge using a constant current of 20 amps (manual setting on the
charger).
• Perform a two hour charge using a constant voltage (automatic setting on the charger).
Quiescent Current Measurement

1. NOTE:
The following quiescent current measurement does not apply to vehicles with the Tracker
system installed. If the vehicle is installed with the tracker system the quiescent current
may be up to 14 milliamps higher. If non-jaguar approved accessories are installed the
following measurements may not apply.
Disconnect the battery ground cable.
2. Check the vehicle off-load battery voltage. If below 12.5 volts, install a fully charged slave
battery for the tests and recharge the vehicle battery.
3. Connect a 'shorting' link lead between the negative battery terminal and the negative
battery lead, before connecting a suitable ammeter to the battery (with the negative test lead
clip to the negative battery terminal, and the positive test lead clip to the battery negative
lead).
4. NOTE:
Make sure that all electrical accessories are switched off.
Operate the key fob unlock button to disarm the vehicle security system.
• Select ignition mode (without starting the engine) for around 10 seconds.
• Deselect ignition mode, close doors, hood & luggage compartment lid latch.
• Lock vehicle.
• After 15 minutes on vehicles with TPMS installed or 4 minutes on vehicles without
TPMS installed, remove shorting link & note ammeter reading.
• The quiescent current should be less than 35mA.
• Replace Shorting link.
• Unlock the vehicle.
• Superlock the vehicle.
• After 15 minutes, on vehicles with TPMS installed, or 4 minutes, on vehicles without
TPMS installed, remove shorting link & note ammeter reading.
• The quiescent current should be less than 35mA.
5. NOTE:
In the unlocked state, the vehicle will take 30mins to shut down to its min quiescent
current.
If intermittent wake-ups are suspected, monitor battery current continuously
6. Disconnect the ammeter. Reconnect the battery ground cable.

Charging System
For a detailed description of the charging system, refer to the relevant Description and Operation
Battery and Cables
Generator

NOTE:
Check the vehicle battery condition and state of charge before condemning any of the charging
system components. For additional information, refer to the battery care manual.
• Generator
• Generator • Battery
• Drive belt • Fuse 5 Rear Junction Box (RJB)
• Drive belt tensioner • Engine/generator ground connection
• Generator pulley • Circuit(s)
• Check the security of the generator fixings • Electrical connector(s)
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
Battery Not Charging • Fuse 5 RJB Check Fuse 5 RJB. Check the battery condition
warning displayed • Front End and state of charge. Refer to the battery care
on message center Accessory Drive manual. Check the FEAD belt tension.
(FEAD) belt tension Accessory Drive Check ECM and instrument
• Generator fault cluster for DTCs and refer to relevant DTC Index.
• ECM
fault Instrument Cluster
• Controller Area Communications Network
Network (CAN)
fault
For ignition power circuit tests. GO to Pinpoint

Test G834532p1.
Check the quiescent drain. Check the battery
condition and state of charge, refer to the battery
• No ignition power
from CJB care manual.
Battery keeps • Battery quiescent Battery Charging Check the FEAD belt tension.
discharging, no drain Accessory Drive Check RJB for DTCs B2A9016,
warning message • Battery fault B2A9116, Note: if battery requires replacing and
displayed on • FEAD belt tension these DTCs were logged, complete and return the
• Generator pulley
message center battery report form listing the DTCs, see battery
fault
care manual. Check ECM for DTCs and refer to
• Generator failure
relevant DTC Index.
Electronic Engine Controls Check the generator
pulley does not turn independently of the
generator
• FEAD belt tension

• FEAD belt
• FEAD belt tensioner For noisy generator tests. GO to Pinpoint Test
Generator noisy
• FEAD belt idler G834532p7.
pulleys
• Generator failure
• Generator For radio interference tests. GO to Pinpoint Test

Radio interference • Wiring harness G834532p8.
DTC Index
NOTE:
module/component.
NOTE:
system).
NOTE:
NOTE:
NOTE:
terminals.
Generator faults • Charging system

P163200 fault GO to Pinpoint Test G834532p4.
sensor/circuit
Check battery is in fully charged and

serviceable condition (if battery requires
• Circuit voltage
B2A9016 Battery low replacing and this DTC is logged, complete and
below threshold
return battery report form listing this DTC),
refer to the battery care manual
B2A9116 Battery Check battery is in fully charged and

• Circuit voltage
serviceable condition (if battery requires
discharged below threshold replacing and this DTC is logged, complete and
return battery report form listing this DTC),
refer to the battery care manual
Pinpoint Tests
PINPOINT TEST G834532p4 : P163200

CHARGING SYSTEM FAULT
G834532t9 : CHECK THE BATTERY VOLTAGE WITH THE ENGINE RUNNING
1. Connect a suitable voltmeter across the battery terminals. 2. Start the engine and allow to idle
with no electrical loads applied. 3. Measure the maximum voltage achieved at the battery after start.
• Is the voltage greater than 13 volts?
-> Yes
-> No
INSTALL a fully charged battery. GO to Pinpoint Test G834532t13.
G834532t10 : CHECK THE GENERATOR 'S' TERMINAL FOR BATTERY

VOLTAGE
1. Set ignition status to OFF. 2. DISCONNECT generator electrical connector PI048. 3. MEASURE the
voltage at generator electrical connector PI048 pin 3.
-> Yes
-> No
G834532t11 : CHECK FUSE 5 IN REAR JUNCTION BOX (RJB)

1. Check fuse 5 in the RJB.
• Is the fuse OK?

-> Yes
REPAIR the circuit between the generator electrical connector PI048 pin 3 and fuse 5 in the RJB.
CLEAR the DTC, test the system for normal operation.
-> No
G834532t12 : CHECK THE GENERATOR 'S' TERMINAL FOR SHORT TO

GROUND
1. MEASURE the resistance between generator electrical connector PI048 pin 3 and ground.
-> Yes
REPAIR the circuit between the generator electrical connector PI048 pin 3 and fuse 5 of the RJB.
INSTALL a new fuse, CLEAR the DTC, test the system for normal operation.
-> No
INSTALL a new fuse, CLEAR the DTC, test the system for normal operation.
G834532t13 : CHECK FOR BATTERY VOLTAGE AT THE GENERATOR 'L'

TERMINAL
1. Set ignition status to OFF. 2. Disconnect generator electrical connector PI048. 3. Set ignition status
to ON. 4. Measure the voltage at generator electrical connector PI048 pin 1.
-> Yes
INSTALL a new generator.
Generator - 4.2L NA V8 - AJV8 (86.10.02) CLEAR the DTC, test the system for normal operation.
-> No
G834532t14 : CHECK THE GENERATOR 'L' LINE FOR SHORT TO GROUND

1. Set ignition status to OFF. 2. Disconnect battery. 3. MEASURE the resistance between the
generator electrical connector PI048 pin 1 and ground.
-> Yes
REPAIR the circuit between the generator electrical connector PI048 pin 1 and the Engine Control
Module (ECM). CLEAR the DTC, test the system for normal operation.
-> No
G834532t15 : CHECK THE GENERATOR 'L' LINE FOR SHORT TO POWER

1. MEASURE the resistance between the generator electrical connector PI048 pin 1 and battery
positive.
-> Yes
REPAIR the circuit between the generator electrical connector PI048 pin 1 and the Engine Control
Module (ECM). CLEAR the DTC, test the system for normal operation.
-> No
G834532t16 : CHECK THE GENERATOR 'L' LINE FOR OPEN CIRCUIT

1. Disconnect the ECM electrical connector PI300. 2. MEASURE the resistance between the generator
electrical connector PI048 pin 1and ECM electrical connector PI300 pin 16.
-> Yes
Install a new generator.
Generator - 4.2L NA V8 - AJV8 (86.10.02) CLEAR the DTC, test the system for normal operation.
-> No
REPAIR the circuit between the generator electrical connector PI048 pin 1 and the ECM electrical
connector PI300 pin 16. CLEAR the DTC, test the system for normal operation.
PINPOINT TEST G834532p1 : IGNITION

POWER CIRCUIT TESTS
G834532t1 : CHECK FOR IGNITION POWER AT GENERATOR
1. Set ignition status to OFF. 2. Disconnect generator electrical connector PI048. 3. Set ignition status
to ON. 4. Measure the voltage at generator electrical connector PI048 pin 2.
-> Yes
Check for quiescent current fault, check battery condition. Refer to the Battery Care Manual.
-> No
G834532t2 : CHECK THE IGNITION POWER CIRCUIT FOR SHORT TO

GROUND
1. Set the ignition status to OFF. 2. Disconnect the battery. 3. Check the resistance between
generator electrical connector PI048 pin 2 and GROUND.
-> Yes
REPAIR the circuit between the generator electrical connector PI048 pin 2 and the CJB. CLEAR the
-> No
G834532t3 : CHECK THE IGNITION POWER CIRCUIT FOR SHORT TO POWER

1. Check the resistance between generator electrical connector PI048 pin 2 and battery positive.
-> Yes
REPAIR the circuit between the generator electrical connector PI048 pin 2 and the CJB. CLEAR the
-> No
G834532t4 : CHECK THE IGNITION POWER CIRCUIT FOR OPEN CIRCUIT

1. Disconnect CJB electrical connector FL048. 2. Check the resistance between CJB electrical
connector FL048 pin 12 and generator electrical connector PI048 pin 2.
-> Yes
REPAIR the circuit between CJB electrical connector FL048 pin 12 and generator electrical connector
PI048 pin 2. CLEAR the DTC, test the system for normal operation.
-> No
G834532t5 : CHECK CJB IGNITION POWER OUTPUT DRIVE
1. Connect the battery. 2. Set ignition status to ON. 3. Check the voltage at CJB electrical connector
FL048, component side, pin 12.
-> Yes
Check no other modules connected to this circuit are pulling to GROUND. Clear the DTC, test the
system for normal operation.
-> No
Install a new generator.

GENERATOR NOISY
G834532t23 : CHECK THE GENERATOR FOR SECURITY
1. Inspect the generator fixings.
• Is the generator secure?
-> Yes
-> No
SECURE the generator. TEST the system for normal operation.
G834532t24 : CHECK THE FEAD BELT

1. Remove and inspect the FEAD belt.
• Is the FEAD belt in good condition?
-> Yes
-> No
INSTALL a new FEAD belt. TEST the system for normal operation.
G834532t25 : CHECK THE FEAD BELT TENSIONER
1. Remove and inspect the FEAD belt tensioner.
• Is the FEAD belt tensioner in good condition?
-> Yes
-> No
INSTALL a new FEAD belt tensioner. TEST the system for normal operation.
G834532t26 : CHECK THE GENERATOR FOR MECHANICAL NOISE

1. Rotate the generator pulley by hand.
• Does the generator rotor shaft rotate smoothly and quietly?
-> Yes
-> No
Generator - 4.2L NA V8 - AJV8 (86.10.02) TEST the system for normal operation.
G834532t27 : CHECK THE FEAD BELT IDLER PULLEYS

1. Rotate the FEAD belt idler pulleys by hand.
• Do the FEAD belt idler pulleys rotate smoothly and quietly?
-> Yes
-> No
INSTALL new FEAD belt idler pulleys as necessary.
Accessory Drive Belt Idler Pulley - 4.2L NA V8 - AJV8 (12.10.43) TEST the system for normal
operation.
G834532t28 : CHECK THE GENERATOR FOR ELECTRICAL NOISE

1. Install the FEAD belt pulleys and belt. 2. Start and run the engine at 1500 rpm. Apply a high
electrical load to the battery.
• Is the noise only heard with the high electrical load applied?
-> Yes
-> No
CHECK the air conditioning compressor.
Air Conditioning (A/C) Compressor - 4.2L NA V8 - AJV8 (82.10.20) CHECK the power steering pump.
Power Steering Pump - 4.2L NA V8 - AJV8 (57.20.14) TEST the system for normal operation.
G834532t29 : ELIMINATE THE GENERATOR AS THE CAUSE OF ELECTRICAL

NOISE
1. Disconnect generator electrical connector PI048. 2. Start and run the engine at 1500 rpm.
• Is the noise still present?
-> Yes
CHECK the air conditioning compressor.
Air Conditioning (A/C) Compressor - 4.2L NA V8 - AJV8 (82.10.20) CHECK the power steering pump.
Power Steering Pump - 4.2L NA V8 - AJV8 (57.20.14) TEST the system for normal operation.
-> No
Generator - 4.2L NA V8 - AJV8 (86.10.02) TEST the system for normal operation.
PINPOINT TEST G834532p8 : RADIO

INTERFERENCE
G834532t30 : CHECK IF THE GENERATOR IS THE CAUSE OF THE RADIO
INTERFERENCE
1. Start and run the engine at 1500 rpm. 2. Turn the radio to the ON position, and select the affected
station.
• Is the radio interference present?
-> Yes
-> No
G834532t31 : CHECK IF THE GENERATOR IS THE CAUSE OF THE RADIO
INTERFERENCE WITH A HIGH ELECTRICAL LOAD APPLIED TO THE
BATTERY
1. Start and run the engine at 1500 rpm. 2. Apply a high electrical load to the battery. 3. Turn the
radio to the ON position, and select the affected station.
-> Yes
-> No
DIAGNOSE the entertainment system.
Audio System
G834532t32 : ELIMINATE THE GENERATOR AS THE CAUSE OF RADIO

INTERFERENCE
1. Disconnect generator electrical connector PI048. 2. Start and run the engine at 1500 rpm. 3. Turn
the radio to the ON position, and select the affected station.
-> Yes
DIAGNOSE the entertainment system.
Audio System
-> No
CLEAN and tighten all mounting points, positive and negative cable connections (including the hood,
luggage compartment lid and engine GROUND straps). INSTALL fuse 5 to the RJB. TEST the system for
normal operation. If interference is still present, INSTALL a new generator.
414-01 : Battery, Mounting and Cables
Specifications
Specifications
Battery Specification
WARNING: Batteries produce explosive gases which may cause personal injury.
Do not expose the battery to a naked flame. When charging or working near a battery
wear protective clothing and eye protectors. Always provide adequate ventilation.
WARNING: Batteries contain sulphuric acid, avoid contact with skin, eyes and
clothing. Shield your eyes when working near the battery to protect against possible
contact of the acid solution. In case of contact with the skin or eyes, flush immediately
for a minimum of 15 minutes and seek prompt medical attention. if swallowed call a
physician immediately. Failure to follow these instructions may result in personal
injury.
CAUTION: Make sure all electrical systems are off before connecting the battery
ground cable. Failure to follow these instructions may result in damage to the electrical
system.
Battery
Engine Specification Battery Information
Battery type Specification
Vehicles fitted with 4.2L NA and SC engine Varta T8 90 Ah
Battery Cold Cranking Specification
Item Specification
90 Ah Battery Cold Cranking 800 Amps
Battery Disconnect/Connect Procedures

WARNING: The backup power supply energy must be depleted before any
supplementary restraint system repairs are carried out. To deplete the backup supply
energy, first disconnect the battery ground cable, then disconnect the battery positive
cable and wait ten minutes to avoid accidental deployment and personal injury. Failure
CAUTION: Disconnecting the battery cables will cause all of the electronic
control modules to lose all stored data/fault codes.
NOTE:
Following reconnecting of the battery, the engine should be allowed to idle as the stored
idle and drive values contained within the engine control module (ECM) will have been
lost. This may cause driveability concern if the following procedure is not carried out.
Battery disconnect procedure Battery connect procedure

1. If possible, apply parking brake or 1. Connect the battery cables and tighten to 5
alternatively, chock wheels. Nm. Ground cable must be connected last
2. If required, record any customer audio and
climate control settings. This also applies to 2. Install the battery cover and close the
all electronic control module stored luggage compartment lid.
information.
3. Start the engine and allow to idle until the
3. Switch off ignition.
engine reaches normal operating temperature.
4. Open the luggage compartment lid. 4. Switch the engine off.
5. Restart the engine and allow to idle for
5. Release the cover and disconnect the
approximately two minutes (this will allow the
battery ground cable.
ECM to learn the idle values).
6. Apply and hold the brake pedal, select drive
6. If required, disconnect the battery positive
and allow the engine to idle for a further two
cable.
minutes.
7. Drive the vehicle for approximately five
miles/eight kilometers of varied driving to
enable the ECM to complete it's learning
strategy.
8. Reset the audio unit and climate control
assembly to original customer settings.
9. Reset the door window motors.

Battery positive cable terminal retaining nut 5 4 -
Battery negative cable terminal retaining nut 5 4 -
Battery clamp nuts 9 7 -
Battery and Cables

COMPONENT LOCATION
2 Generator
3 Starter motor
6 Battery
7 Remote jump start terminal

INTRODUCTION
Electrical power from the battery and generator is distributed throughout the vehicle through a
series of junction boxes.
IGNITION MODES
The vehicle has a possible 4 ignition modes. The modes and systems that are active in each mode are
detailed in the following table.
Ignition Mode Off Accessory (convenience) On Crank
Exterior lamps Memory functions seat, Exterior lamps fog lamps Stability controls
headlamps – Dip column etc directional Indicators
only approach
lamps
Interior lighting Manual adjust seat column Convertible hood Heated/cooled

etc Seat
Preheat - timed in Interior lighting Wash/wipe Adaptive speed

control
Electric park Brake lights HVAC Adaptive

brake - On damping

cluster - stand by, headlamps, reversing lamps,
clock, odometer side lamps, tail lamps
Hazard warning Auto infotainment previous Instrument cluster – dials Pedestrian

lamps condition (preset volume), and warnings fuel gauge Protection
radio standby, phone temperature gauge lamp system
standby, steering wheel check
switches
Locking and Instrument cluster –message Windows Gearshift control

unlocking center, trip computer & TCM
Security Horn EPB – power to EPB – power to

disengage (foot on break) disengage
Cigar lighter/power socket Restraints check

BATTERY
The battery is located behind a cover at the front of the luggage compartment. The cover is held in
place by 4 retainers. The battery sits in a tray and is secured with a clamp plate and 2 nuts.
The positive and negative battery cables are fitted with Service loops. The Service loops add extra
length to the cables and allow the battery to be slid rearward in the luggage compartment without
disconnection.
Remote Jump Start Terminal

The positive battery cable is also connected to a remote jump start terminal. The remote jump start
terminal is located in the Left-Hand (LH) rear corner of the luggage compartment and can be
accessed by removing the air vent trim. Although also fitted to coupe vehicles, the terminal has been
specifically designed to allow a convertible vehicle to be jump started if a drained battery is
experienced when the top is in the stowed condition.
The starter motor power lead is also connected to the remote jump start terminal and is insulated
from the battery jump start cable and the vehicle body by a nylon washer.
The negative jump start connection is a stud located in the spare wheel well. For more information
on jump start procedure, refer to the Owners Handbook.
Transit Relay
The vehicle is also fitted with a transit relay. This is a disposable device and not for use by the
customer. This relay is fitted in series with the battery and ground. It disconnects the battery from
the vehicles ground and thus eliminates quiescent current drain during delivery. The relay must be
removed before delivery to the customer. For more information, refer to the Pre-Delivery Inspection
(PDI) manual.
BATTERY JUNCTION BOX (BJB)
Mounted on the LH side of the battery is the BJB. The BJB contains 3 megafuses delivering battery
power to; the starter motor (400A); the auxiliary junction box (175A) and the CJB (175A). For more
information, refer to the Electrical Guide.
AUXILIARY JUNCTION BOX
The auxiliary junction box is mounted on the passenger compartment rear bulkhead and secured by
2 nuts/studs. The junction box can be accessed by opening the center panel of the rear seat back.
The center panel is secured in position by a single stud at the top, and hinged at the bottom.
The auxiliary junction box receives electrical power from the BJB via a 175A megafuse. For more
information on the circuits and systems served by the auxiliary junction box, refer to the Electrical
Guide.
CENTRAL JUNCTION BOX (CJB)
The CJB is mounted at the base of the LH A pillar and secured by 2 nuts/studs. Access to the CJB can
be gained through a removable panel located below the LH side of the instrument panel.
The CJB receives electrical power from the BJB via a 175A megafuse. A second power supply lead
'daisy chains' off the CJB, providing electrical power to the power distribution box. For more
information on the circuits and systems served by the CJB, refer to the Electrical Guide.
The CJB also controls the functionality of a number of vehicle systems. These include:
• Electric steering column lock. For additional information, refer to Steering Column (211-04
Steering Column)
• Instrument cluster and panel illumination. For additional information, refer to Instrument
Cluster and Panel Illumination (413-00 Instrument Cluster and Panel Illumination)
• Exterior lighting systems. For additional information, refer to Exterior Lighting (417-01
Exterior Lighting)
For additional information, refer to Daytime Running Lamps (DRL) (417-04 Daytime Running
Lamps (DRL))
• Interior lighting systems. For additional information, refer to Interior Lighting (417-02
Interior Lighting)
• Active anti-theft alarm system. For additional information, refer to Anti-Theft - Active (419-
01 Anti-Theft - Active)
• Passive anti-theft alarm system. For additional information, refer to Anti-Theft -
Passive (419-01 Anti-Theft - Passive)
• Passive start. For additional information, refer to Handles, Locks, Latches and Entry
Systems (501-14 Handles, Locks, Latches and Entry Systems)
• Electric seats. For additional information, refer to Seats (501-10 Seating)
• Electric windows. For additional information, refer to Glass, Frames and Mechanisms (501-
11 Glass, Frames and Mechanisms)
• Wipers and washers. For additional information, refer to Wipers and Washers (501-16
Wipers and Washers)
POWER DISTRIBUTION BOX
The power distribution box is located in the LH rear of the engine compartment, beneath a closing
panel. The power distribution box is supplied electrical power from the BJB, via the CJB. For more
information on the circuits and systems served by the power distribution box, refer to the Electrical
Guide.
Battery
For additional information, <<414-00>>
Battery (86.15.01)
Removal
CAUTION: It is imperative that the battery ground cable is disconnected from the battery
terminal and not the body.
2 . Disconnect the battery positive cable.
Loosen the nut.
3 . Release the harness.
Release the electrical connector from the clip.
4 . Release the battery clamp.
Remove the 2 nuts.
5 . Remove the battery.

Disconnect the vent tube.
Installation
1 . Install the battery.
Connect the vent tube.
2 . Install the battery clamp.
3 . Secure the wiring harness.
Attach the electrical connector to the clip.
4 . Connect the battery positive cable.

414-02 : Generator and Regulator – 4.2L NA V8 –
Specifications
Specifications
Item Nm lb-ft lb-in

Electrical connector to generator - nut 12 9 -
Generator to mounting bracket - upper nut 25 18 -
Generator to mounting bracket - lower nut/bolt 40 30 -
Generator mounting bracket to engine - bolt 40 30 -
Generator
COMPONENT LOCATION
INTRODUCTION
The generator is located at the front Right-Hand (RH) side of the engine, on the cylinder block. The
generator has an output of 85/130 Amps and is manufactured by Denso. A six-ribbed polyvee belt
drives the generator pulley, which in turn is driven from the engine crankshaft pulley. The generator
comprises a stator, a rotor, a rectifier pack and a regulator.
The rotor comprises a field winding, wound around an iron core and mounted on a shaft. The iron
core has extensions at each end, which form North and South poles as current flows through the field
winding. The rotor is located inside the stator and is mounted on bearings for smooth running and to
support the rotor due to the high side loading applied by the drive belt tension.
The stator has three sets of coils made from copper wire. The three coil windings are connected in a
'dual star' connection, where one end of the winding is connected to the other two windings. The
output current is supplied from the opposite end of each winding. Rotation of the rotor causes ac
current to be produced in the coils.
The rectifier converts the ac current produced in the stator coils into dc (rectified) current required
by the vehicle electrical system. The rectifier comprises 12 semi-conductor diodes mounted on a
heatsink to dissipate heat. An equal number of the diodes are on the negative and positive side. An
additional diode in the regulator controls feedback through the battery voltage signal line. The
rectifier also prevents current flow from the battery to the generator when the output voltage is less
than the battery voltage.
Initially, the ignition supply provides an excitation current to the rotor at low generator speeds via
brushes, which contact slip rings at the end of the rotor shaft. As the generator speed increases the
generator becomes self-exciting.
The charge warning lamp function is transmitted to the engine management system and then on to
the high speed Controller Area Network (CAN) bus to the instrument cluster.
Generator
For additional information, refer to section<<414-00>>

Removal
All vehicles
2
4 . Remove the RH HO2S.

6 . Disconnect the steering gear electrical connector.
All vehicles
7 . Release the battery positive cable from the body.
8 . Disconnect the ground cable from the transmission.
Remove the bolt.
9 . Disconnect the generator electrical connectors.
Release the cover.
Remove the nut.
Remove the nut.

Rotate the generator.
Installation
All vehicles
2 . Connect the generator electrical connectors.
Secure the cover.
3 . Connect the ground cable.

4 . Secure the battery positive cable.
Attach the clips.

5 . Connect the steering gear electrical connector.
All vehicles
7 . Install the RH HO2S.

Generator - 4.2L SC V8 - AJV8 (86.10.02)
Removal
All vehicles
2

4 . Remove the RH HO2S.



6 . Disconnect the steering gear electrical connector.
All vehicles
7 . Release the battery positive cable from the body.
8 . Disconnect the ground cable from the transmission.
Remove the bolt.
Release the cover.
Remove the nut.
Remove the nut.

Rotate the generator.
Installation
All vehicles
Secure the cover.
3 . Connect the ground cable.

4 . Secure the battery positive cable.
Attach the clips.

5 . Connect the steering gear electrical connector.
All vehicles
7 . Install the RH HO2S.



415 : Information and Entertainement
Systems
415-00 : Information and Entertainement – General

Information
Audio System
For a detailed description of the Information and Entertainment System, refer to the relevant
Audio System
Antenna
Speakers

• Integrated audio module • Fuses

• Information and entertainment module • Loose or corroded connector(s)
• Audio amplifier • Integrated audio module
• Compact disc player jammed, not loading • Information and entertainment module
• Scratched/dirty compact discs • Audio amplifier
• Speakers • Speakers
Index.
DTC Index
Information and Entertainment Module
NOTE:
NOTE:
system).
NOTE:
NOTE:
NOTE:
terminals.
• Internal electronic failure Install a new information and

B1A59- Sensor 5 Volt supply
entertainment control module,
49 refer to the new module
the DTC Index
• Steering wheel audio switch For steering wheel audio

B1D21- Remote control
circuit - short to power, high control switch tests. GO to
15 switch resistance Pinpoint Test G834560p1.
Carry out the pinpoint test

U0010- Medium speed CAN • General failure No sub type associated with this DTC using
00 communication Bus information the manufacturer approved
diagnostic system
Lost communication Carry out the pinpoint test

U0127- with Tire Pressure • General failure No sub type associated with this DTC using
00 Monitor System information the manufacturer approved
(TPMS) module diagnostic system

U0140- Lost communication • General failure No sub type associated with this DTC using
00 with CJB information the manufacturer approved
diagnostic system

00 with RJB information the manufacturer approved
diagnostic system

Lost communication
U0155- • General failure No sub type associated with this DTC using
with instrument
00 information the manufacturer approved
cluster
diagnostic system

Lost communication
with parking aid
module
diagnostic system

Lost communication
with climate control
module
diagnostic system

U0184- Lost communication • General failure No sub type
00 with audio module information the manufacturer approved
diagnostic system

00 with audio amplifier information the manufacturer approved
diagnostic system

Lost communication
with satellite radio
tuner
diagnostic system

Lost communication
with telephone
module
diagnostic system

Lost communication
with driver door
module
diagnostic system

Lost communication
with passenger door
module
diagnostic system

Lost communication
with convertible top
module
diagnostic system

Lost communication
with remote
function actuation
diagnostic system

Lost communication
with integrated
control panel
diagnostic system
Lost communication Carry out the pinpoint test

U0245- • General failure No sub type
with multimedia associated with this DTC using
00 module information the manufacturer approved
diagnostic system

Lost communication
with touch screen
display
diagnostic system

diagnostic system, clear DTCs
• RJB car configuration data is
Internal control and re-test. If DTC still logged,
U0300- not compatible with the
module software suspect the information and
00 information and
incompatibility entertainment control module entertainment control module
and refer to the new module
Index
Re-configure the information

Internal control and entertainment control
U0300-
module software • System program failure module using the
51
incompatibility manufacturer approved
diagnostic system
Incomplete MOST
ring reported by
U1A15- associated with this DTC using
Information and • Missing message
87 the manufacturer approved
Entertainment
diagnostic system
control module

diagnostic system. Clear DTC
Stored vehicle and re-test. If the DTC remains
U3000- • Incorrect car configuration
configuration data suspect the information and
55 data received
does not match entertainment module, refer
to the new module installation
Index

U3000- manufacturer approved
Control module • Missing message
87 diagnostic system. Check
information and entertainment
module for DTCs and refer to
the DTC Index. Check CAN
network integrity using the
diagnostic system
U3002-
Identification transmitted, module for DTCs and refer to relevant
81 previously installed to other DTC Index
Number (VIN)
vehicle
• Mis-match of battery voltage, Carry out the pinpoint test

of 2 volts or lower, between
U3003- associated with this DTC using
Battery voltage information and
62 entertainment module and the manufacturer approved
RJB diagnostic system
Audio Amplifier (vehicles with premium audio)
NOTE:
NOTE:
system).
NOTE:
NOTE:
NOTE:
terminals.
• Front passenger Refer to the electrical circuit diagrams

B1A01- Speaker #1 - circuit
speaker circuits - and test front passenger speaker
13 open high resistance circuits for high resistance
• Front driver speaker Refer to the electrical circuit diagrams

circuits - high and test front driver speaker circuits for
13 open resistance high resistance
• Rear left speaker Refer to the electrical circuit diagrams

circuit - high and test rear left speaker circuit for high
13 open resistance resistance
• Rear right speaker Refer to the electrical circuit diagrams

circuit - high and test rear right speaker circuit for
• Front center speaker Refer to the electrical circuit diagrams

circuit - high and test front center speaker circuit for
• Sub-woofer speaker Refer to the electrical circuit diagrams

circuit - high and test sub-woofer speaker circuit for
Carry out the pinpoint test associated

B1A01- Speaker#1 - general • General electrical
with this DTC using the manufacturer
01 electrical failure failure

B1A02- Speaker #2 - general • General electrical
01 electrical failure failure approved diagnostic system




Short circuit of one

or both front
B1A09- Check for additional front speaker DTCs
speaker output - • Short to ground
11 and refer to DTC Index
circuit short to
ground
Short circuit of one

B1A10- or both rear speaker Check for additional rear speaker DTCs
• Short to ground
11 output - circuit short and refer to DTC Index
to ground
Refer to the electrical circuit diagrams

B1A11- Speaker#11 - circuit
• Short to power and check all speaker circuits for short
12 short to battery
to power
Fibre optic
communication Bus • Component or Check for additional DTCs and refer to
U2003-
- component or system over DTC Index. Clear DTC and re-
98 temperature
system over test/monitor condition
temperature
• Software
Control module - incompatibility Re-configure the audio amplifier as an
U3000- system • The version of the existing control module, using the
05 programming Local Configuration manufacturer approved diagnostic
failures file does not match system
that expected
Re-configure the audio amplifier as an
existing control module, using the
Control module - system. Clear DTC, cycle ignition and
U3000- • General memory
general memory read DTCs. If DTC returns, suspect audio
42 failure
failure amplifier module and install a new
module. Refer to the new module
installation note at the top of the DTC
Index
Re-configure the audio amplifier as an

existing control module, using the
system. Clear DTC, cycle ignition and
U3000- Control module -
• Data memory failure read DTCs. If DTC returns, suspect audio
44 data memory failure
amplifier module and install a new
module. Refer to the new module
Index

Stored vehicle
• Incorrect car system. Clear DTC and re-test. If the
U3000- configuration data
configuration data DTC remains suspect the audio
55 does not match - not received amplifier, refer to the new module
configured
Index

system. Check audio amplifier for DTCs
U3000- Control module -
• Missing message and refer to the DTC Index. Check CAN
87 missing message
network integrity using the
system
Control module -
• Component or Check for additional DTCs and refer to
U3000- component or
system over DTC Index. Clear DTC and re-
98 system over temperature test/monitor condition
temperature
Battery voltage - Carry out the pinpoint test associated

U3003- • Circuit voltage below
circuit voltage below with this DTC using the manufacturer
16 threshold
threshold approved diagnostic system
Battery voltage - Carry out the pinpoint test associated
U3003- • Circuit voltage above
circuit voltage above with this DTC using the manufacturer
17 threshold
threshold approved diagnostic system
Control module - Install a new audio amplifier module,

U3006-
circuit short to • Short to power refer to the new module installation
12
battery note at the top of the DTC Index
Control module - Install a new audio amplifier module,

U3006- • Circuit voltage below
circuit voltage below refer to the new module installation
16 threshold
threshold note at the top of the DTC Index
Integrated Audio Module
NOTE:
NOTE:
system).
NOTE:
NOTE:
NOTE:
terminals.

• Antenna power supply
B1B69- 12 Volt supply and test the antenna power supply
circuit - short to battery,
15 circuit high resistance circuit for short to battery and high
resistance

B1B69- 12 Volt supply • Antenna power supply
and test the antenna power supply
11 circuit circuit - short to ground
circuit for short to ground
Install a new integrated audio module,

B1D19- Compact disc • Circuit voltage below
16 unit threshold

B1D19- Compact disc • Commanded position not
77 unit reachable

B1D19- Compact disc
• No operation refer to the new module installation
93 unit

B1A01- • Front driver speaker
Speaker #1 and test front driver speaker circuits
11 circuits - short to ground
for short to ground

B1A01- • Front driver speaker
Speaker #1 and test front driver speaker circuits
12 circuits - short to power
for short to power
• Front driver speaker Carry out the pinpoint test associated

B1A01-
Speaker #1 circuits - resistance below with this DTC using the manufacturer
1A threshold approved diagnostic system

B1A01- Speaker #1
circuits - resistance above with this DTC using the manufacturer
1B threshold approved diagnostic system

B1A01-
Speaker #1 circuits - voltage out of with this DTC using the manufacturer
1C range approved diagnostic system

B1A02- • Front passenger speaker
Speaker #2 and test front passenger speaker
11 circuits - short to ground
circuits for short to ground

B1A02- • Front passenger speaker
Speaker #2 and test front passenger speaker
12 circuits - short to power
circuits for short to power
• Front passenger speaker Carry out the pinpoint test associated

B1A02-
Speaker #2 circuits - resistance below with this DTC using the manufacturer

B1A02-
Speaker #2 circuits - resistance above with this DTC using the manufacturer

B1A02-
Speaker #2 circuits - voltage out of with this DTC using the manufacturer
1C range approved diagnostic system

B1A03- • Rear left speaker circuits -
Speaker #3 and test rear left speaker circuits for
11 short to ground
short to ground

B1A03- • Rear left speaker circuits -
Speaker #3 and test rear left speaker circuits for
12 short to power
short to power
• Rear left speaker circuits - Carry out the pinpoint test associated
B1A03-
Speaker #3 resistance below with this DTC using the manufacturer
• Rear left speaker circuits - Carry out the pinpoint test associated
B1A03-
Speaker #3 resistance above with this DTC using the manufacturer
B1A03- • Rear left speaker circuits - Carry out the pinpoint test associated
Speaker #3 voltage out of range
1C with this DTC using the manufacturer

B1A04- • Rear right speaker circuits
Speaker #4 and test rear right speaker circuits for
11 - short to ground
short to ground

Speaker #4 and test rear right speaker circuits for
12 - short to power
short to power
• Rear right speaker circuits Carry out the pinpoint test associated
B1A04-
Speaker #4 - resistance below with this DTC using the manufacturer
• Rear right speaker circuits Carry out the pinpoint test associated
B1A04-
Speaker #4 - resistance above with this DTC using the manufacturer
13 threshold approved diagnostic system

Speaker #4 with this DTC using the manufacturer
1C - voltage out of range

B1D78- • Auxiliary input circuit -
Auxiliary input and test Auxiliary input circuits for
11 short to ground
short to ground

12 short to power
short to power

13 high resistance
high resistance

B1D79- Microphone • Microphone input circuit -
and test microphone input circuits for
11 input short to ground
short to ground

B1D79- Microphone • Microphone input circuit -
12 input short to power
short to power
B1D79- Microphone • Microphone input circuit - Refer to the electrical circuit diagrams
13 input high resistance
high resistance

B1134- • Phone input circuit - short
Phone input and test phone input circuits for short
11 to ground
to ground

B1134- • Phone input circuit - short
Phone input and test phone input circuits for short
12 to power
to power

B1134- • Phone input circuit - high
Phone input and test phone input circuits for high
13 resistance
resistance
Suspect the integrated audio module,

U3000-
Control module • Internal electronic failure refer to the new module installation
49

Stored vehicle
U3000- configuration
configuration data DTC remains suspect the integrated
55 data does not received audio module, refer to the new
match
module installation note at the top of
the DTC Index

system. Check integrated audio
U3000-
Control module • Missing message module for DTCs and refer to the DTC
87
Index. Check CAN network integrity
using the manufacturer approved
diagnostic system
Check for additional DTCs and refer to

U3000- • Component or system
Control module DTC Index. Clear DTC and re-
98 over temperature
test/monitor condition
• Mis-match of battery
voltage, of 2 volts or Carry out the pinpoint test associated
U3003-
Battery voltage lower, between with this DTC using the manufacturer
62 integrated audio module approved diagnostic system
and RJB
Pinpoint Tests

STEERING WHEEL AUDIO CONTROL
SWITCH CIRCUIT TESTS
G834560t1 : CHECK THE STEERING WHEEL AUDIO CONTROL SWITCH
CIRCUIT
1. Disconnect the battery negative terminal.
Battery (86.15.01) 2. Wait one minute for the supplemental restraints system back-up power to
dissipate. 3. Disconnect the information and entertainment module connector, IP087. 4. Measure the
resistance between:
Information and entertainment module connector, IP087 pin 07, harness side
GROUND
• Is the resistance 5036.71 ohms?
-> Yes
-> No
G834560t2 : CHECK THE STEERING WHEEL AUDIO CONTROL MUTE SWITCH

CIRCUIT
1. PRESS and HOLD the MUTE switch 2. Measure the resistance between:
GROUND
-> Yes
-> No
Install a new steering wheel audio control switch assembly.
G834560t3 : CHECK THE STEERING WHEEL AUDIO CONTROL SOURCE

SWITCH CIRCUIT
1. PRESS and HOLD the SOURCE switch 2. Measure the resistance between:
GROUND
-> Yes
-> No
G834560t4 : CHECK THE STEERING WHEEL AUDIO CONTROL SEEK DOWN

SWITCH CIRCUIT
1. OPERATE and HOLD the SEEK DOWN switch 2. Measure the resistance between:
GROUND
-> Yes
-> No
G834560t5 : CHECK THE STEERING WHEEL AUDIO CONTROL SEEK UP

SWITCH CIRCUIT
1. OPERATE and HOLD the SEEK UP switch 2. Measure the resistance between:
GROUND
-> Yes
-> No
G834560t6 : CHECK THE STEERING WHEEL AUDIO CONTROL VOLUME +

SWITCH CIRCUIT
1. OPERATE and HOLD the VOLUME + switch 2. Measure the resistance between:
GROUND
-> Yes
-> No
G834560t7 : CHECK THE STEERING WHEEL AUDIO CONTROL VOLUME -

SWITCH CIRCUIT
1. OPERATE and HOLD the VOLUME - switch 2. Measure the resistance between:
GROUND
-> Yes
No fault is indicated with the steering wheel audio control switches or circuit. Check the integrity of
all connections, TEST the system for normal operation.
-> No

CIRCUIT
1. Disconnect the clockspring connector IP042. 2. Measure the resistance between:
Clockspring connector IP042, pin 03, component side
Clockspring connector IP042, pin 06, component side
-> Yes
-> No

CIRCUIT
1. Disconnect the clockspring connector SW001. 2. Measure the resistance between:
Clockspring connector SW001, pin 04, harness side
-> Yes
INSTALL a new clockspring.
Clockspring TEST the system for normal operation.
-> No

CIRCUIT
1. Disconnect the steering wheel audio control switch connector SW003. 2. Measure the resistance
between:
Audio control switch connector SW003, pin 04, component side

Audio control switch connector SW003, pin 01, component side
-> Yes
-> No
Install a new steering wheel audio control switch.

CIRCUIT
Audio control switch connector SW003, pin 01, harness side
-> Yes
REPAIR the circuit - audio control switch connector SW003, pin 01 to clockspring connector SW001,
operation.
-> No

CIRCUIT
Audio control switch connector SW003, pin 04, harness side
-> Yes
REPAIR the circuit - audio control switch connector SW003, pin 04 to clockspring connector SW001,
operation.
-> No
No fault is indicated with the steering wheel audio control switches or circuit. Check integrity of all
connections and TEST system for normal operation.

CIRCUIT
Clockspring connector IP042, pin 03, harness side
Information and entertainment module connector IP087, pin 07, harness side
-> Yes
REPAIR the circuit - clockspring connector IP042, pin 03 to information and entertainment module
connector IP087, pin 07. For additional information, refer to the wiring diagrams. TEST the system for
normal operation.
-> No

CIRCUIT
Clockspring connector IP042, pin 06, harness side
GROUND point G40AR/1
-> Yes
REPAIR the circuit - clockspring connector IP042, pin 06 to GROUND point G40AR/1. For additional
information, refer to the wiring diagrams. TEST the system for normal operation.
-> No
No fault is indicated with the steering wheel audio control switches or circuit. Check integrity of all
connections and TEST system for normal operation.
PINPOINT TEST G834560p2 : MOST

NETWORK TESTS
G834560t15 : CHECK HLDF DISPLAY
1. Check HLDF display
• Is the HLDF showing a flashing Jaguar leaper, or a blank screen?
-> Yes
-> No
No ring break fault has occurred. Suspect invalid Car Configuration File parameter faults, check
modules on MOST Network for related DTCs and refer to the relevant DTC Index.
G834560t16 : CHECK INTEGRITY OF MOST RING TEST CONNECTOR OPTICAL

LOOP AND FUSE RL2
1. Check the MOST ring test connector optical loop IP090 is not disconnected or open circuit and free
from damage, and fuse RL2 in the RJB is not disconnected or open circuit.
• Is the MOST ring test connector optical loop IP090 disconnected, open circuit or damaged,
or fuse RL2 in the RJB disconnected or open circuit.
-> Yes
Rectify the fault condition and re-test.
-> No
G834560t17 : INITIATE RING BREAK DIAGNOSTIC (RBD) & READ DTCs

1. Ensure fuse RL2 is installed in RJB and is in serviceable condition. 2. Set ignition status from 'OFF'
to 'ON'. 3. Clear all DTCs. 4. Remove fuse RL2 from RJB and wait for at least 10 seconds, then replace
fuse RL2 in RJB and wait for at least 30 seconds for RBD to initiate and complete. 5. Read DTCs
• Is DTC U1A1587 logged?
-> Yes
-> No
Check HLDF for additional DTCs and refer to relevant DTC Index.
G834560t18 : CHECK FOR FAILURE AT INTERMEDIATE CONNECTOR TM071

PIN 1 FROM INFORMATION AND ENTERTAINMENT MODULE
1. Disconnect the MOST network intermediate connector TM071.
• Is the bright red light visible at the connector TM071, pin 1 female?
-> Yes
-> No
G834560t19 : CHECK FOR FAILURE AT FIRST HALF OF MOST NETWORK

1. Connect the Optical Bus Tester (OBT) to intermediate connector TM071, from information and
entertainment module. 2. Switch OBT 'ON' and set to 2+0 option. 3. Select the visible LED option.
• Is the Rx lamp/LED permanently 'ON' and the HLDF screen permanently displaying 'Home
menu screen' or Jaguar leaper?
-> Yes
On Low Line vehicles, check integrity of optical loop installed at intermediate connector TM071. On
High Line vehicles, fault is in second half of MOST Network. Disconnect OBT and re-connect
intermediate connector TM071. GO to Pinpoint Test G834560t21.
-> No
G834560t20 : CHECK FOR FAILURE OF OPTICAL FIBRE FROM INFORMATION

AND ENTERTAINMENT MODULE
1. Disconnect MOST connector IP088 from information and entertainment module.
• Is the bright red light visible at the connector IP088 pin 2, module side?
-> Yes
Fault is in optical fibre harness between intermediate connector TM071, pin 1 female and
information and entertainment module connector IP088, pin 2.
-> No
Install a new information and entertainment module and re-test.
G834560t21 : CHECK FOR FAILURE OF OPTICAL FIBRE BETWEEN

INTERMEDIATE CONNECTORS TM071 AND TM075
1. Disconnect intermediate connector TM075.
• Is the bright red light visible at the intermediate connector TM075, pin 2 female.
-> Yes
-> No
Fault is in optical fibre harness between intermediate connectors TM071 pin 1 and TM075 pin 2,
rectify the fault and re-test the vehicle.
G834560t22 : CHECK FOR FAILURE OF OPTICAL FIBRE BETWEEN

INTERMEDIATE CONNECTORS TM071 AND TM075
1. Connect the Optical Bus Tester (OBT) to intermediate connector TM075. 2. Switch OBT 'ON' and
set to 2+0 option. 3. Select the visible LED option.
-> Yes
Fault is in second half of MOST network. GO to Pinpoint Test G834560t48.
-> No
Fault is in optical fibre harness between intermediate connectors TM071 pin 2 and TM075 pin 1,
rectify the fault and re-test the vehicle.
G834560t23 : CHECK FOR FAILURE OF OPTICAL FIBRE TO HLDF

1. Disconnect MOST connector IP065 from HLDF.
• Is the bright red light visible at connector IP065 pin 1, harness side?
-> Yes
-> No
Fault is in optical fibre harness between intermediate connector TM071 pin 2 and HLDF connector
IP065 pin 1, rectify the fault and re-test the vehicle.
G834560t24 : CHECK FOR FAILURE AT HLDF

1. Connect the Optical Bus Tester (OBT) to HLDF connector IP065. 2. Switch OBT 'ON' and set to 2+0
option. 3. Select the visible LED option.
• Is the Rx lamp/LED permanently 'ON' and the HLDF screen permanently displaying blank
screen?
-> Yes
Check/repair power feed and ground lines to HLDF. If power feed and ground lines ok, install a new
HLDF.
-> No
G834560t25 : CHECK FOR INSTALLATION OF AUDIO AMPLIFIER

1. Check for installation of audio amplifier.
• Is there an audio amplifier installed to the vehicle?
-> Yes
-> No
G834560t26 : CHECK FOR FAILURE OF OPTICAL FIBRE TO AUDIO

AMPLIFIER
1. Disconnect MOST connector CA117 from audio amplifier.
• Is the bright red light visible at the connector CA117 pin 1, harness side?
-> Yes
-> No
G834560t27 : CHECK FOR FAILURE AT INTERMEDIATE CONNECTOR CA119

1. Disconnect intermediate connector CA119.
• Is the bright red light visible at the intermediate connector CA119, pin 1 female?
-> Yes
Fault is in optical fibre harness between intermediate connector CA119 pin 1 and audio amplifier
connector CA117 pin 1, rectify the fault and re-test the vehicle.
-> No
Fault is in optical fibre harness between intermediate connector CA119 pin 1 and HLDF connector
IP065 pin 2, rectify the fault and re-test vehicle.
G834560t28 : CHECK FOR FAILURE AT AUDIO AMPLIFIER
1. Connect the Optical Bus Tester (OBT) to audio amplifier connector CA117. 2. Switch OBT 'ON' and
set to 2+0 option. 3. Select the visible LED option.
-> Yes
Check/repair power feed and ground lines to audio amplifier. If power feed and ground lines ok,
install a new audio amplifier.
-> No
G834560t29 : CHECK FOR FAILURE OF OPTICAL FIBRE TO INTEGRATED

AUDIO MODULE
1. Disconnect MOST connector IP059 at integrated audio module.
• Is the bright red light visible at the connector IP059 pin 1 harness side?
-> Yes
-> No
If no audio amplifier is installed, the fault is in the optical fibre harness between HLDF connector
IP065 pin 2 and integrated audio module connector IP059 pin 1, rectify the fault and re-test the
vehicle. If audio module is installed. GO to Pinpoint Test G834560t30.
G834560t30 : CHECK FOR FAILURE AT INTERMEDIATE CONNECTOR CA119

PIN 2
1. Disconnect intermediate connector CA119.
• Is the bright red light visible at the intermediate connector CA119 pin 2 male?
-> Yes
Fault is in the optical fibre harness between intermediate connector CA119 pin 2 and integrated
audio module connector IP059 pin 1, rectify the fault and re-test the vehicle.
-> No
Fault is in the optical fibre harness between intermediate connector CA119 pin 2 and audio amplifier
connector CA117 pin 2, rectify the fault and re-test the vehicle.
G834560t31 : CHECK FOR FAILURE AT INTEGRATED AUDIO MODULE
1. Connect the Optical Bus Tester (OBT) to integrated audio module connector IP059. 2. Switch OBT
'ON' and set to 2+0 option. 3. Select the visible LED option.
-> Yes
Check/repair power feed and ground lines to integrated audio module. If power feed and ground
lines ok, install a new integrated audio module.
-> No
G834560t32 : CHECK FOR FAILURE OF OPTICAL FIBRE TO MOST TEST

CONNECTOR
1. Disconnect MOST test connector IP090.
• Is the bright red light visible at the connector IP090 pin 1 harness side?
-> Yes
-> No
Fault is in the optical fibre harness between integrated audio module connector IP059 pin 2 and
MOST test connector IP090 pin 1, rectify the fault and re-test the vehicle.
G834560t33 : CHECK FOR FAILURE AT MOST TEST CONNECTOR OPTICAL

LOOP
1. Connect the Optical Bus Tester (OBT) to MOST test connector IP090. 2. Switch OBT 'ON' and set to
2+0 option. 3. Select the visible LED option.
-> Yes
Install a new MOST test connector optical loop.
-> No
G834560t34 : CHECK FOR FAILURE OF OPTICAL FIBRE TO INFORMATION
AND ENTERTAINMENT CONTROL MODULE
1. Disconnect MOST connector IP088 from information and entertainment control module.
• Is the bright red light visible at connector IP088 pin 1, harness side?
-> Yes
No fault identified with the MOST network. Check integrity of all MOST network connections, and re-
test vehicle.
-> No
Fault is in the optical fibre harness between MOST test connector IP090 pin 2 and information and
entertainment module connector IP088 pin 1, rectify the fault and re-test the vehicle.
G834560t48 : CHECK FOR INSTALLATION OF NAVIGATION MODULE

1. Check for installation of navigation control module.
• Is a navigation control module installed to the vehicle?
-> Yes
-> No
G834560t35 : CHECK FOR FAILURE OF OPTICAL FIBRE TO NAVIGATION

MODULE
1. Disconnect MOST connector TM084 from navigation module.
• Is the bright red light visible at connector TM084 pin 1, harness side?
-> Yes
-> No
Fault is in the optical fibre harness between MOST intermediate connector TM075 pin 2 and
navigation module connector TM084 pin 1, rectify the fault and re-test the vehicle.
G834560t45 : CHECK FOR FAILURE AT NAVIGATION MODULE

1. Connect the Optical Bus Tester (OBT) to navigation module connector TM084. 2. Switch OBT 'ON'
and set to 2+0 option. 3. Select the visible LED option.
-> Yes
Check/repair power feed and ground lines to navigation module. If power feed and ground lines ok,
install a new navigation module.
-> No
G834560t36 : CHECK FOR INSTALLATION OF SATELLITE RADIO MODULE

1. Check for installation of satellite radio module.
• Is a satellite radio module installed to the vehicle?
-> Yes
-> No
G834560t37 : CHECK FOR FAILURE OF OPTICAL FIBRE TO SATELLITE RADIO

MODULE
1. Disconnect MOST connector TM100 from satellite radio module.
• Is the bright red light visible at connector TM100 pin 1 , harness side?
-> Yes
-> No
If navigation module is installed to the vehicle - the fault is in the optical fibre harness between
navigation module connector TM084 pin 2 and satellite radio module connector TM100 pin 1. If
navigation module is not installed to the vehicle - the fault is in the optical fibre harness between
intermediate connector TM075 pin 2 and satellite radio module connector TM100 pin 1.
G834560t38 : CHECK FOR FAILURE AT SATELLITE RADIO MODULE

1. Connect the Optical Bus Tester (OBT) to satellite radio module connector TM100. 2. Switch OBT
'ON' and set to 2+0 option. 3. Select the visible LED option.
-> Yes
Check/repair power feed and ground lines to satellite radio module. If power feed and ground lines
ok, install a new satellite radio module.
-> No
G834560t39 : CHECK FOR INSTALLATION OF BLUETOOTH MODULE

1. Check for installation of bluetooth module.
• Is a bluetooth module installed to the vehicle?
-> Yes
-> No
If satellite radio module is not installed. GO to Pinpoint Test G834560t43.
If satellite radio module is installed. GO to Pinpoint Test G834560t44.
G834560t40 : CHECK FOR FAILURE OF OPTICAL FIBRE TO BLUETOOTH

MODULE
1. Disconnect MOST connector TM023 from bluetooth module.
• Is the bright red light visible at connector TM023 pin 1, harness side?
-> Yes
-> No
If satellite radio module is installed to vehicle - fault is in optical fibre harness between bluetooth
module connector TM023 pin 1 and satellite radio module connector TM100 pin 2, rectify the fault
and re-test the vehicle. If satellite radio module is not installed - fault is in optical fibre harness
between bluetooth module connector TM023 pin 1 and navigation module TM084 pin 2, rectify the
fault and re-test vehicle.
G834560t41 : CHECK FOR FAILURE AT BLUETOOTH MODULE

1. Connect the Optical Bus Tester (OBT) to satellite bluetooth module connector TM023. 2. Switch
OBT 'ON' and set to 2+0 option. 3. Select the visible LED option.
-> Yes
Check/repair power feed and ground lines to bluetooth module. If power feed and ground lines ok,
install a new bluetooth module.
-> No
G834560t42 : CHECK FOR FAILURE OF OPTICAL FIBRE FROM BLUETOOTH

MODULE
1. Disconnect MOST intermediate connector TM075.
• Is the bright red light visible at connector TM075 pin 1 male?
-> Yes
No fault is identified with the MOST network. Check integrity of all MOST connectors and re-test the
vehicle.
-> No
Fault is in the optical fibre harness between bluetooth module connector TM023 pin 2 and
intermediate connector TM075 pin 1, rectify the fault and re-test the vehicle.
G834560t43 : CHECK FOR FAILURE OF OPTICAL FIBRE FROM NAVIGATION

MODULE
• Is the bright red light visible at the intermediate connector TM075 pin 1 male?
-> Yes
vehicle.
-> No
Fault is in optical fibre harness between intermediate connector TM075 pin 1 and navigation module
connector TM084 pin 2, rectify the fault and re-test the vehicle.
G834560t44 : CHECK FOR FAILURE OF OPTICAL FIBRE FROM SATELLITE

RADIO MODULE
• Is the bright red light visible at the intermediate connector TM075 pin 1 male?
-> Yes
vehicle.
-> No
Fault is in optical fibre harness between intermediate connector TM075 pin 1 and satellite radio
module connector TM100 pin 2, rectify the fault and re-test the vehicle.
Cellular Phone
For a detailed description of the telephone system, refer to the relevant Description and Operation
Cellular Phone

NOTE:
Prior to starting any diagnostics, ensure that the customer handset is on the Jaguar Approved
Phone List (as found in the vehicle technology information on the external Jaguar website). If the
customer handset is not on the approved phone list it should NOT be used when carrying out
these diagnostics, the technician should test using an approved handset only.
1 . Verify the customer concern by operating the telephone.
• Microphone
• Wiring harness for damage or corrosion
• Bluetooth antenna
• Fuses
Index.
System/Carrier Concerns - All Systems

Dropped calls, bad connections, noisy audio and other intermittent symptoms usually indicate a
system or cellular carrier concern, and are not the fault of the phone itself. Such symptoms may
occur in situations such as the following:
• In certain geographic areas (for example: areas of excessive foliage or hills) or at the edge of
coverage areas
• At the same place each day
• At the same time each day
• Under bridges, tunnels, in lower freeways, or in congested downtown areas
If the customer phone exhibits any of the above symptoms or symptoms occur under the above
conditions, the customer or the dealer should contact customer assistance at their particular cellular
provider/carrier.
Symptom Chart
Symptom Action
Unable to pair • GO to Pinpoint Test G1296535p1.
Not Auto Connecting • GO to Pinpoint Test G1296535p2.
Poor Quality Audio • GO to Pinpoint Test G1296535p3.
No Audio to 3rd Party • GO to Pinpoint Test G1296535p4.
No Audio from 3rd Party • GO to Pinpoint Test G1296535p5.
No Audio • GO to Pinpoint Test G1296535p6.
DTC Index
NOTE:
NOTE:
diagnostic system).
NOTE:
NOTE:
NOTE:
NOTE:
terminals.

Bluetooth
B1A5613 • Open circuit diagrams and test blue tooth
antenna
antenna circuit for open circuit

diagrams and test microphone input
Microphone • Signal amplitude <
B1D7984 circuit for short/open circuit. Check
input minimum
integrated audio module for DTCs
and refer to DTC Index
Install a new telephone module,

Private Bus • BT chipset
U1A0088 refer to the new module installation
circuit communications failure

• Initial configuration not manufacturer approved diagnostic
U210000 Control module complete system. If DTC remains, carry out
CAN network tests

• Configuration
U210100 Control module manufacturer approved diagnostic
incompatible
system. If DTC remains, suspect the
telephone module, refer to the new
module installation note at the top
of the DTC Index
Re-configure the telephone module.

If the DTC remains install a new
U300044 Control module • Data memory failure telephone module, refer to the new
of the DTC Index
Re-configure the telephone module.

If the DTC remains install a new
U300045 Control module • Program memory failure telephone module, refer to the new
of the DTC Index

Stored vehicle
configuration
U300055 configuration data DTC remains suspect the telephone
data does not received module, refer to the new module
match
DTC Index

system. Check telephone module for
U300087 Control module • Missing message DTCs and refer to the DTC Index.
Check CAN network integrity using
diagnostic system
Check for additional DTCs and refer

• Component or system to DTC Index. Clear DTC and re-
over temperature test/monitor condition for re-
occurrence

voltage, of 2 volts or
associated with this DTC using the
U300362 Battery voltage lower, between
telephone module and manufacturer approved diagnostic
RJB system
Pinpoint Tests
PINPOINT TEST G1296535p1 : Unable to

Pair
G1296535t1 : 'No Phone Fitted' Display
1. Carry out checks to determine if 'No Phone Fitted' is shown on vehicle display.
• Is 'No Phone Fitted' displayed?
-> Yes
-> No
Locate the connected telephone and if not Customer telephone, disconnect from the system.
G1296535t2 : 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 Pinpoint Test G1296535t3.
-> 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.
G1296535t3 : Telephone Handset Error

1. Check for any error shown on the telephone handset when 'Jaguar' is selected from the Bluetooth
device list.
• Was an error immediately shown on the telephone handset?
-> Yes
Wait 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 Pinpoint Test G1296535t4.
G1296535t4 : PIN Entry Status

1. Check for successful PIN entry.
• Was PIN entry successful?
-> Yes
-> No
Wait 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.
G1296535t5 : '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 G1296535p2 : Not

Automatically Connecting
G1296535t6 : Bluetooth Module Paired Device List
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
-> No
Carry out Unable to Pair Pinpoint Test. GO to Pinpoint Test G1296535p1.
G1296535t7 : 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
-> No
Carry out Unable to Pair Pinpoint Test. GO to Pinpoint Test G1296535p1.
G1296535t8 : 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
-> 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.
G1296535t9 : 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
G1296535t10 : 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
-> No
G1296535t11 : 'Land Rover' Authorisation

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
-> 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.
G1296535t12 : 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
G1296535t13 : 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
G1296535t14 : 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 G1296535p3 : Poor

Quality Audio
G1296535t15 : Microphone Installation
1. Check that the microphone is installed in the correct location/orientation.
• Is the microphone installed in the correct location/orientation?
-> Yes
-> No
Install microphone to correct location/orientation.
G1296535t16 : Signal Strength

1. Check the signal strength displayed on the telephone handset.
• Are at least two signal strength bars shown on the telephone handset display?
-> Yes
-> No
Suspect GSM Network issue. This can explain intermittent audio and dropped calls, and the inability
to initiate calls.
G1296535t17 : Poor Audio From Third Party Only

1. Establish from Customer feedback/symptom if there is poor audio from the Third Party only.
• Is the poor audio from the Third Party only?
-> Yes
Suspect GSM Network issue. This can explain intermittent audio and dropped calls, and the inability
to initiate calls.
-> No
G1296535t18 : Poor Audio To Third Party Only

1. Establish from Customer feedback/symptom if there is poor audio to the Third Party only.
• Is the poor audio to the Third Party only?
-> Yes
Check and install a new microphone as necessary.
-> No
G1296535t19 : Poor Audio with Vehicle Stationary

1. Establish from Customer feedback/symptom if there is poor audio when the vehicle is stationary
only.
• Is the poor audio when the vehicle is stationary only?
-> Yes
Check and install a new microphone as necessary.
-> No
G1296535t20 : Third Party Moving Vehicle

1. Establish from Customer feedback/symptom if the Third Party is in a moving vehicle.
• Is the Third Party in a moving vehicle?

-> Yes
There are limitations to the way the system can improve audio, and in this situation it is not possible
to determine the source of the audio degradation.
-> No
G1296535t21 : Customer Hearing Echo

1. Establish from Customer feedback/symptom if the Customer is hearing an echo.
• Is the Customer hearing an echo?
-> Yes
Echo from the Third Party is not vehicle failure, it is the Third Party set-up. No further action is
required for this symptom.
-> No
PINPOINT TEST G1296535p4 : No Audio

To Third Party
G1296535t22 : Microphone Diagnostic Trouble Codes (DTCs)
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

From Third Party
G1296535t23 : '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.

G1296535t24 : 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
-> No
Refer to the 'No Audio From Third Party' Pinpoint test. GO to Pinpoint Test G1296535p5.
G1296535t25 : 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
-> No
Refer to the 'No Audio To Third Party' Pinpoint test. GO to Pinpoint Test G1296535p4.
G1296535t26 : 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
-> No
Suspect MOST ring fault, refer to electrical circuit diagrams and check/rectify MOST ring as
necessary.
G1296535t27 : 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.
415-01 : Audio Unit
Specifications
Specifications
lb- lb-
Item Nm
ft in
Amplifier to bracket - screw 2.5 - 22
Audio/CD module and climate control module assembly to instrument panel -
3 - 27
bolt
Audio/CD and climate control modules to assembly bracket - bolt 3 - 27
Audio/CD and climate control modules to assembly bracket - screw 2.5 - 22
Radio frequency interference suppressor to engine cover bracket - bolt 10 7 88
Steering wheel audio controls - bolt 3.5 2.5 31
Audio System
COMPONENT LOCATION
2 Touch Screen Display (TSD)
3 Remote audio switches
4 Auxiliary Universal Serial Bus (USB) unit (from 2009 Model Year (MY))
5 Auxiliary input panel (from 2009 MY)
6 Integrated audio module
7 Information and entertainment Module
INTRODUCTION
The audio system contains the following functions:
• Six disc CD autochanger.

• AM/FM tuner.
• Interface Protocol Option Devices (iPod) and USB connectivity (from 2009 MY).
The audio system is available in two versions, standard and premium. The standard audio system
uses an internal amplifier to drive the system speakers. The premium system uses an external
amplifier and subwoofer assembly to drive the speakers. For additional information, refer to
Speakers (415-03 Speakers)
Control of the audio system is via the integrated control panel and the TSD, located in the center of
the instrument panel, and the remote audio switches on the steering wheel.
Control signals from the integrated control panel are relayed on the medium speed CAN (controller
area network) bus to the information and entertainment module. The information and
entertainment module relays the control signals to the rest of the audio system on the Media
Orientated System Transport (MOST) ring. The information and entertainment module is the timing
master for the MOST ring and also hosts a gateway function between the medium speed CAN
(controller area network) bus and the MOST ring. On premium audio systems the audio signals are
sent on the MOST ring from the integrated audio module to the amplifier. The control signal from the
remote audio switches to the information and entertainment module consists of an analogue voltage
from a resistive ladder.
The iPod and USB connectivity allows audio files on portable media players and mass storage devices
(i.e. portable audio devices) to be played through the speakers of the audio system. The audio
system supports portable audio devices with a storage capacity up to 256 GB (approximately 65,000
music tracks).
The iPod and USB connectivity is provided by:
• • An auxiliary input panel, installed in the cubby box of the floor console.
• • An auxiliary USB unit, attached to the RH rear quarter panel, behind the trim of the luggage
compartment.
The auxiliary input panel provides the interface between the portable audio device and the vehicle’s
audio system. An iPod port and a USB port are located in the top of the auxiliary input panel,
underneath a protective rubber cover. An iPod connector lead is supplied with the vehicle. Portable
audio devices can be connected to both ports at the same time.
The iPod and USB ports both incorporate a charging function. The maximum charging current
supplied is 500 ma.
Auxiliary Input Panel
1 USB port
2 iPod port
iPod Connector Lead
The auxiliary USB unit translates the electronic signals from the auxiliary input panel into optical
signals and transmits them on the MOST ring.
Operation of the portable audio device is controlled from the TSD via the integrated audio module.
For road safety reasons, the normal control interface of the portable device is disabled when it is
plugged into the auxiliary input panel, and it can only be controlled from the TSD.
Portable Audio Device Selection on TSD
Some MP3 players have a file system that is not supported by the audio system. To use one of these
MP3 players with the audio system, the MP3 player must be set to USB Removable Device mode or
Mass Storage Device mode (see the MP3 player manufacturer’s information for further details). Only
files that have been added to the MP3 player in these modes can be played on the audio system.
A number of other vehicle systems are operated from the TSD and the integrated control panel, or
have inputs into the audio system. These include:
• Air conditioning system. For additional information, refer to Air Conditioning (412-03 Air
Conditioning)
• Navigation. For additional information, refer to Navigation System (419-07 Navigation
System)
• Parking aid. For additional information, refer to Parking Aid (413-13 Parking Aid)
• Telephone. For additional information, refer to Cellular Phone (419-08 Cellular Phone)
Software in the information and entertainment module generates the graphics for the TSD.
CONTROL DIAGRAM - STANDARD AUDIO SYSTEM (UP TO 2009 MY)

NOTE:
A = Hardwired; N = Medium speed CAN (controller area network) bus; P = MOST ring
1 Auxiliary Junction Box (AJB)
2 TSD
4 To speakers
5 Clock spring

CONTROL DIAGRAM - STANDARD AUDIO SYSTEM (FROM 2009 MY)

NOTE:
1 AJB
2 TSD
3 Auxiliary USB unit

5 To speakers
6 Auxiliary input panel
7 Clock spring
CONTROL DIAGRAM - PREMIUM AUDIO SYSTEM (UP TO 2009 MY)

NOTE:
1 AJB
2 TSD
3 Audio amplifier
4 To speakers
7 Clock spring
CONTROL DIAGRAM - PREMIUM AUDIO SYSTEM (FROM 2009 MY)

NOTE:
1 AJB
2 TSD
3 To speakers
4 Audio amplifier
7 Auxiliary input panel
8 Clock spring

Audio System
For additional information, refer to<<415-00>>
Amplifier (86.50.10)
Removal
NOTE:
The component is situated in the passenger footwell. LHD is illustrated the procedure to remove
the component on a RHD vehicle is similar.
1 . Remove the instrument panel assembly.

2 . Remove the heater duct.
3

4 . Remove the subwoofer cover.
Remove the 4 bolts.
5
. CAUTION: Cover fibre optic cable connectors to minimise dust ingress and avoid
bending the cables in a radius of less than 30 mm.
Carefully disconnect the MOST connector.
6 . Remove the amplifier.

Installation
1 . Install the amplifier.
Connect the MOST connector.
4
Install the carpet.
5 . Install the heater duct.
Install the lampholder.
6 . Install the instrument panel assembly.

Audio Unit (86.50.03)
Removal
NOTE:
This component is easily recognised as a CD multichanger, it is however an audio module and

links to the MOST.

2 . Remove the navigation screen module.

For additional information, refer to Navigation System Display Module (86.62.07)
3 . Release the audio/CD module and climatic control assembly.
Remove the 4 module bracket Torx bolts.
4
. CAUTION: Care must be taken to avoid damage to the mating surfaces.
Separate the climatic control and audio/CD module from the module bracket.
Remove 2 Torx screws securing the navigation screen to the climatic
control assembly.
5 . Remove the CD unit.
Installation
1 NOTE:
.
Carefully check the CD access slot in the climatic control assembly is aligned to the CD
unit after tightening the screws. This is a visual check only, do not attempt to probe the
CD unit with a sharp object or load a CD .
Carefully install the audio/CD module to the climatic control assembly.
2 . Install the climatic control assembly and audio/CD module to the module bracket.
Install and tighten the navigation screen Torx screws.
Install the CD module bracket Torx bolts and tighten to 6 Nm (4 lb.ft).
Install the climatic control assembly Torx bolts and tighten to 6 Nm (4

lb.ft).
3 . Install the navigation screen module.



Removal
NOTE:
This procedure is identical to the removal of the steering wheel speed control switch.
1 . Remove the steering wheel switch assembly.

For additional information, refer to Speed Control Switch (19.75.25)
Installation
For additional information, refer to Speed Control Switch (19.75.25)
415-02 : Antenna
Specifications
Specifications
Item Nm lb-ft lb-in

Body earth point - nut 9 7 80
Electric AM/FM antenna 9 7 80
FM ariel splitter module - nut 7 5 62
Antenna
COMPONENT LOCATION
1 VICS beacon antenna (Japan only)
2 Amplitude Modulation (AM)/Frequency Modulation (FM) electric antenna
3 FM antenna signal splitter
4 GPS antenna
5 Bluetooth antenna
INTRODUCTION
The antenna systems on the vehicle cover the following functions:
• AM/FM radio reception

• Bluetooth connection with the Telephone Control Module
• FM reception for the VICS/TMC function of the navigation system
• Global Positioning System (GPS) signals.
GPS ANTENNA
The GPS antenna is located in the rear liftgate spoiler.
BLUETOOTH ANTENNA
The Bluetooth Antenna is located centrally behind the rear seat. The antenna is used to connect the
telephone control module to a Bluetooth compatible phone. The vehicle audio system can then be
used for making and recieving telephone calls hands free. For additional information, refer to
Cellular Phone (419-08 Cellular Phone)
ELECTRIC AM/FM ANTENNA

The electric AM/FM antenna is located on the rear RH quarter of the vehicle. The antenna is
controlled by the Integrated Audio Module, which supplies power to the antenna motor. The
antenna is extended when the radio is switched on and retracted when the system is switched off or
the ignition is switched off.
AM/FM ANTENNA AND AMPLIFIER - 08 MODEL YEAR ONWARDS
1 Antenna
2 FM amplifier
On all vehicles from 08MY, the AM/FM antenna is located in the rear spoiler. The antenna has a
hardwire connection to the amplifier which is mounted on the inner Left-Hand (LH) side of the lift
gate, behind the trim panel. The amplifier is held in place by a steel strap. The amplifier is connected
to the integrated audio module, via the FM antenna signal splitter, by a coaxial cable.
On coupe models, ground for the antenna amplifier is provided by a strap connected to the lift gate
hinge. On convertible models a block connected directly to the amplifier provides the ground
through the vehicle body.
FM ANTENNA SIGNAL SPLITTER

The FM antenna signal splitter is located in the luggage compartment just below the RH rear lamp
cluster. The splitter divides the recieved FM signal between the Intergrated Audio Module and the
navigation computer. The navigation computer uses the FM signal for TMC information For
additional information, refer to Navigation System (419-07 Navigation System)
.
VICS BEACON ANTENNA (Japan only)
The VICS beacon antenna is located on the passenger side of the instrument panel adjacent to the
windshield. The antenna receives infra red and microwave data transmissions from roadside
transmitters.
SDARS ANTENNA
Where fitted the SDARS antenna is located in the center of the liftgate just in front of the spoiler. The
antenna recieves satellite radio transmissions.
CONTROL DIAGRAM
Upto 08 Model Year

NOTE:
A=Hardwired; P=MOST; T=Coaxial

1 SDARS Antenna (where fitted)
2 VICS beacon antenna (Japan)
3 GPS antenna

5 AM/FM electric antenna
7 Navigation computer
8 Telephone control module
9 Bluetooth antenna
10 SDARS module
From 08 Model Year

NOTE:
A=Hardwired; P=MOST; T=Coaxial

1 SDARS Antenna (where fitted)
2 VICS beacon antenna (Japan)
3 GPS antenna

5 AM/FM antenna amplifier
9 Bluetooth antenna
10 AM/FM antenna
11 SDARS module
Antenna
For diagnosis and testing information.
Audio System
Antenna (86.51.17.60)
Removal
1 . Remove the RH rear quarter trim panel.
2 . Raise the vehicle on the lift.
3 . Release the antenna.
Remove the 2 nuts.
5 . Remove the antenna.
Disconnect the antenna cable.
Disconnect the antenna earth strap.

Installation
1 . Install the antenna.
Connect the antenna cable.
Connect the antenna earth strap.
2 . Raise the vehicle on the lift.
3 . Secure the antenna.

5 . Install the RH rear quarter trim panel.
415-03 : Speakers
Specifications
Specifications
Item Nm lb-ft lb-in

Front door speaker - screw 2 - 18
Subwoofer speaker - screw 5 4 44
Subwoofer speaker cover - bolt 5 4 44
Subwoofer speaker housing - bolt 5 4 44
Subwoofer speaker housing - nut 5 4 44
Subwoofer speaker housing - screw 5 4 44
Quarter panel speaker - screw 2 - 18
Speakers
COMPONENT LOCATION-STANDARD AUDIO SYSTEM
1 Front RH high range speaker
2 Front RH mid/low range speaker
3 Rear RH mid/low range speaker
4 Rear LH mid/low range speaker
5 Front LH mid/low range speaker
6 Front LH high range speaker
INTRODUCTION
The standard speaker system comprises 6 speakers that are driven by the Integrated Audio Modules
internal amplifier.
CONTROL DIAGRAM-STANDARD AUDIO SYSTEM
NOTE:
A=Hardwired

7 Integrated Audio Module
COMPONENT LOCATION-PREMIUM AUDIO SYSTEM
6 Subwoofer and power amplifier assembly
8 Center speaker
INTRODUCTION
Premium audio system is a 7 speaker system which is driven by a Dolby Prologic II Audio amplifier.
The subwoofer is located in the passenger footwell behind a false panel inside its own enclosure. The
Dolby Prologic II amplifier is attached to the front of the subwoofer enclosure.
CONTROL DIAGRAM-PREMIUM AUDIO SYSTEM

NOTE:
A=Hardwired
2 Center speaker
6 Subwoofer
9 Power amplifier
Speakers
For diagnosis and testing information.
Audio System
Front Door Speaker (86.50.13)

Removal
1 . Remove the front door trim panel.
For additional information, refer to Front Door Trim Panel (76.34.01)
2 . Remove the front door speaker.
Installation
1 . Install the front door speaker.
2 . Install the front door trim panel.

Front Door Tweeter Speaker (86.50.63)
Removal
1 . Remove the exterior mirror trim panel.
2 . Release the speaker tweeter.
Release from the clips.

Installation
1 . Install the speaker tweeter.
Release from the clips.
2 . Install the exterior mirror trim panel.

Subwoofer Speaker (86.51.05)
Removal
1 . Remove the instrument panel assembly.
3
Remove the 4 bolts.

5 . NOTE:
Remove the subwoofer.
6 . Remove the amplifier.

7 . Release the subwoofer speaker housing
Remove the 2 nuts.
Remove the 2 bolts.
Remove both speaker housing support brackets.
8
. CAUTION: Cover fibre optic cable connectors to minimise dust ingress and avoid
bending the cables in a radius of less than 30 mm.
Remove the subwoofer speaker housing.
Carefully disconnect the MOST connector.
Installation
1 . Install the subwoofer speaker housing.
Install the brackets.
Install the screws.
2 . Connect the subwoofer speaker housing electrical connectors.
Connect the MOST connector.
3 . Install the amplifier.
4 . Install the subwoofer.
Install the screws.

6
Install the carpet.
Install the lampholder.
8 . Install the instrument panel assembly.

Quarter Panel Speaker - 2-Door (86.50.12)
Removal
1 . Remove the rear quarter trim panel.
For additional information, refer to Rear Quarter Trim Panel - 2-Door (76.13.73)
2 . Remove the quarter panel speaker.
Installation
1 . Install the quarter panel speaker.
Install and tighten the Torx screws.
2 . Install the rear quarter trim panel.

Quarter Panel Speaker - Convertible
(86.50.12)
Removal
For additional information, refer to Rear Quarter Trim Panel - Convertible (76.13.73)
Installation
1 . Install the quarter panel speaker.

417 : Lighting
417-01 : Exterior Lightning
Specifications
Specifications
Bulbs
Lamp Bulb Type

Number plate lamp W5WL
Reverse lamp LED (non-serviceable)
Side repeater indicator WY5W
Headlamp unit:
Cornering lamp H8
Dip and main beam projector unit D1S35W
Direction indicator PY21W
Side lamp W5W
Side marker WY5W
Rear lamp unit:
Direction indicator PY21W Silver Vision
Side marker W5W
Stop and tail P21/5W
Tail lamp W5W
Fog lamps:
Front fog lamp H11 55W
Rear fog lamp LED (non-serviceable)
Adjustment
Item Adjustment Setting

Headlamp aim (ROW) -1% +/- 0.1%
Headlamp aim (NAS) -0.7%
Fog lamp aim -2% +/- 0.5%
Item Nm lb-ft lb-in

Headlamp assembly - bolt 6 4 53
Headlamp leveling, front sensor - bolt 20 15 -
Headlamp leveling module - bolt 4 3 35
Headlamp leveling, rear sensor - bolt 20 15 -
High-mounted stop lamp - screw 2 - 18
Rear lamp assembly to gate/lid - nut 2.5 - 22
Rear lamp assembly to fender - nut 2 - 18
General procedures
Front Fog Lamp Adjustment

1. Align the beam setting equipment to one fog lamp.
2. NOTE:
The fog lamp beam should be set at 1.2% below the horizontal and parallel.
Check the fog lamp beam alignment.
3. Turn the steering on to full lock for access.
4. NOTE:
Wheel shown removed for clarity.
Release the front of the fender splash shield.

• Tie the splash shield aside.
5. Adjust the fog lamp using the thumb wheel.

6. Install the fender splash shield.
• Tighten the Torx bolts.
7. To adjust the second fog lamp, repeat the above procedure.

Headlamp Adjustment (86.40.18)
1. Align the headlamp beam setting equipment to one headlamp.
2. NOTE:
The headlamp setting is 1.2 % below horizontal and parallel.
Check the headlamp beam alignment.
3. Open the hood.
4. Adjust the headlamps with an Allen Key.
5. To adjust the second headlamp, repeat the above procedure.

Exterior Lighting
COMPONENT LOCATION
1 Headlamp leveling/AFS control module

2 Light sensor
3 Rear height sensor
4 Turn signal indicator repeater lamp (2 off)
5 Cornering lamp
6 Headlamp power washer
7 Front side lamp
8 Xenon headlamp module
9 Front turn signal indicator
10 Side marker lamp
12 Front fog lamp switch
13 Rear fog lamp switch
14 License plate lamps
15 Reverse or rear fog lamp
16 Side lamp
17 Rear turn signal indicator
18 Side lamp/Stop lamp
19 Rear side marker lamp
21 Lighting switch
22 Front height sensor
23 Front fog lamp (2 off)

INTRODUCTION
The lighting systems are controlled by the Auxiliary Junction Box (AJB) 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 (central junction box) via the instrument cluster.
The lighting system has an 'auto' lights function which is controlled by the CJB (central junction box)
on receipt of signals from the light sensor. The exterior lights are turned on or off in response to
ambient light signals from the light sensor via the instrument cluster.
Two levels of headlamp are available; Bi-xenon or Bi-xenon with Adaptive Front lighting System
(AFS). The AFS headlamp has a swiveling projector module which moves the headlamp beam in the
direction of travel. The AFS headlamp also features a cornering/static bending lamp which
illuminates the area at the side of the vehicle when turning into driveways for example.
The tail lamp is in two parts. The turn signal indicator, side and stop lamps are located in each rear
fender. The reverse and rear fog lamps are located in separate units attached to the liftgate. The
locations of the fog and reverse lamps changes depending if the vehicle is LHD (left-hand drive) or
RHD (right-hand drive) . The turn signal indicator, side and stop lamps use conventional glass filament
bulbs. The rear fog and reverse lamp use colored LED (light emitting diode) .
EXTERIOR BULB TYPE/RATING

The following table shows the bulbs used for the exterior lighting system and their type and
specification.
Bulb Type Rating
Xenon Headlamps - Low/High beam Xenon D1S 35W
Front fog lamps - Naturally aspirated Halogen H11 55W
Front fog lamps - Supercharged Halogen H3 55W
Rear fog lamp LED (light emitting diode) Not

applicable
Turn signal indicator lamps - Front - Rest of World (ROW) Bayonet PY21W 21W
Turn signal indicator lamps - Front - North American Wedge S8W 3457K 27/7W
Specification (NAS)
Turn signal indicator repeater lamps Capless W5W 5W

Turn signal indicator lamps - Rear Bayonet PY21W 21W
Side lamps - Front Wedge W5W 5W
Stop / Side lamps Bayonet - Twin filament - 21W/5W

P21/5
High mounted stop lamp LED (light emitting diode) Not

applicable
Licence plate lamps Capless W5W 5W
Reverse lamp LED (light emitting diode) Not

applicable
Cornering lamp Halogen H8 35W
Side marker lamps (front/rear) Capless W3W 3W
CENTRAL JUNCTION BOX AND AUXILIARY JUNCTION BOX

The CJB (central junction box) is an integrated unit located in the passenger compartment LH (left-
hand) side on the 'A' pillar.
The Auxiliary Junction Box (AJB) is located in a central position, behind the rear seat.
CJB (central junction box) Control

The CJB (central junction box) receives inputs from the following switches via the instrument cluster
and the medium speed CAN (controller area network) bus:
• LH (left-hand) steering column multifunction switch Side lamp position Headlamp position
Automatic (AUTO) position Timer delay positions Turn signal indicators Headlamp flash and
high beam
• Stop lamp switch
• Hazard flasher switch
• Sunload/Light sensor.
The following lamps are controlled by the CJB (central junction box) :
• Front side lamps

• Front side marker lamps
• Headlamps
• Cornering lamps
• Front fog lamps.
AJB Control
The following lamps are controlled by the AJB:
• Rear fog lamp

• Reverse lamp
• Stop lamps
• High mounted stop lamp
• Rear side lamps
• Rear side marker lamps
• Licence plate lamps
• Front and rear turn signal indicators and side repeaters
The AJB is also connected via a hardwired connection to the hazard flasher switch.
Circuit Protection
The AJB and the CJB (central junction box) provide circuit protection for all exterior lighting circuits.
The exterior lighting circuits are protected by Field Effect Transistors (FETs). Operation of the exterior
lighting circuits is protected by the FETs which can detect overloads and short circuits. The FETs
respond to heat generated by increased current flow caused by a short circuit.
On a normal circuit this would cause the fuse to blow. The FETs 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 (central junction box) and the AJB 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
which will assist with fault detection.
Alarm Indications
The exterior lighting system is used for alarm arm and disarm requests.
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 (200ms off and 200ms on) to confirm the superlock request.
When the driver unlocks the vehicle, a visual indication of a successful lock and disarm request is
displayed to the driver by the hazard flashers operating twice (200ms off and 200ms on).
If the alarm is triggered, the hazard flashers are operated for ten 30 second cycles of 200ms on and
200ms off with a 10 second delay between each cycle.
NOTE:
On NAS vehicles the delay between cycle when the alarm is triggered is 60 seconds. The alarm
triggered hazard flasher operation varies depending on market.
Lights on Warning Chime
When the ignition is in the off mode or accessory mode conditions and the lighting 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 or accessory mode signal via a medium speed CAN (controller
area network) bus signal from the CJB (central junction box) .
Crash Signal Activation

When a crash signal is transmitted from the restraints control module, the AJB activates the hazard
flashers. The hazard flashers continue to operate until the ignition is in the off or accessory modes
and then returned to the ignition on mode. Once this condition has occurred, the restraints control
module will cease transmission of the crash signal.
Headlamp Timer
The AJB controls a 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 select this feature, the lighting control switch on the steering column multifunction switch must
be in one of the three headlamp timer positions when the ignition mode is changed from ignition on
mode to off mode. 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 mode is changed to off.
The timer period can be adjusted using one of the 3 positions on the lighting control switch on the LH
(left-hand) steering column multifunction switch. The 3 switch positions correspond to timer values
of 30, 60 and 120 seconds.
LIGHTING CONTROL SWITCH
1 Off position
2 Side lamp position
3 High beam position
4 RH (right-hand) turn signal indicator position
5 Headlamp flash/high beam off position
6 LH (left-hand) turn signal indicator position
7 Headlamp position
8 AUTO headlamp position
9 Headlamp timer 120 second delay position
10 Headlamp timer 60 second position
11 Headlamp timer 30 second position
The lighting control switch is located on the LH (left-hand) steering column multifunction switch. The
switch is a rotary control with positions for the following lighting selections:
• Off
• Side lamps
• Headlamps
• AUTO headlamps
• Headlamp timer (3 time period selections).
The steering column multifunction switch also provides for the selection of low and high beam
headlamps and also the headlamp flash function.
The steering column multifunction switch is connected to the instrument cluster by 3 wires. Two
wires supply a signal voltage to the lighting switch and the headlamp timer positions. The third wire
is a common ground. Each switch position is connected to the ground return via resistors which vary
the return voltage to the instrument cluster. The instrument cluster senses the voltage returning and
determines the switch position selected. The instrument cluster then generates an applicable
message which is sent to the AJB and the CJB (central junction box) on the medium speed CAN bus
for activation of the selected exterior lamps.
The steering column multifunction switch also provides the control for the turn signal indicators. The
switch can be pushed down to select the LH (left-hand) turn signal indicators or pushed up to select
the RH (right-hand) turn signal indicators. The switch has 2 positions. If the switch is pushed up or
down gently and held, the turn signal indicators will operate until the switch is released, if the switch
is pushed past a detent, the switch can be released and the selected position will automatically be
cancelled when the manoeuvre is completed. If a turn signal indicator bulb fails, the green turn signal
indicator warning indicator in the instrument cluster will flash at twice the normal rate and the
audible ticking will also be at twice the normal rate.
The steering column multifunction switch also has a lane change function. If the switch is gently
pushed to either turn signal indicator direction and then released, the turn signal indicators will flash
3 times and then automatically cancel.
AUXILIARY LIGHTING SWITCH
1 Front fog lamp switch
2 Rear fog lamp switch
The auxiliary lighting switch is located in the instrument panel, adjacent to the steering column. The
switch has 2 buttons which select the front and rear fog lamps. The buttons are non-latching
momentary switches.
The auxiliary lighting switch is connected to the instrument cluster by 3 wires. Two wires supply a
signal voltage to the each fog lamp switch. The third wire is a common ground. Each switch position
is connected to the ground return via a series of resistors which vary the supply voltage from the
instrument cluster. The instrument cluster senses the voltage and determines the switch position
selected. The instrument cluster then generates an applicable message which is sent to the AJB and
the CJB (central junction box) on the medium speed CAN bus for activation of the selected fog lamps.
The front fog lamps can only be activated when the ignition is in the ignition power mode and side
lamps or headlamps are active. The rear fog lamps can only be activated if the low beam headlamps
are on or if the sidelamps and front fog lamps are on. A second press of each fog lamp button will
switch of the selected fog lamps. If the lighting control switch or the ignition is changed to the off
mode, then both fog lamps will be switched off and will need to be re-selected if required.
HEADLAMP ASSEMBLY
Two types of headlamp are available; Bi-Xenon and Adaptive Front lighting System (AFS). The
headlamps are located with a locating dowel through the upper front bumper bracket and secured
with 3 bolts to the front body structure. Bulb replacement requires the removal of the complete
headlamp assembly.
The rear of the headlamp unit has removable access panels which allow access to the bulbs for
replacement. A large cover, which is rotated anti-clockwise to remove allows access to the Xenon
D1S bulb. Another removable cover provides access to the corning lamp bulb and the side lamp bulb,
which is retained with a spring clip. A smaller cover can be rotated anti-clockwise to provide access
to the turn signal indicator bulb and the side marker lamp bulb.
The headlamps have two 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
have to 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.
The low beam headlamps are switched on when the ignition is in the ignition mode and:
• the lighting control switch is in the headlamp position

• the lighting control switch is in the AUTO position and a 'lights on' signal is received by the
CJB (central junction box) from a 'lights on' message generated by the AJB.
The low beam headlamps can also be operated by the headlamp timer function.
The high beam headlamps are switched on when the ignition is in the ignition mode and:
• The low beam headlamps are selected on or activated via the AUTO feature and the LH (left-
hand) steering column multifunction switch is pushed forward, away from the driver
The high beam lamps will be switched off when:
• The LH (left-hand) steering column multifunction switch is moved rearwards, towards the
driver.
• The low beam headlamps are switched off
• The ignition mode is changed to accessory or off mode.
1 Headlamp power washer jet

2 Side lamp bulb
3 Cornering lamp (if fitted)
4 Xenon projector module
5 Turn signal indicator bulb
6 Side marker lamp bulb
7 Cover - Side lamp and cornering lamp
8 Powerwash hose connection
9 AFS power module (if fitted)
10 Xenon control module
11 Cover - Xenon bulb
13 Side marker lamp bulb and holder
14 Turn signal indicator bulb and holder
15 Igniter electrical connector
16 Igniter unit and bulb
17 Mounting collar
WARNING: The Xenon system generates up to 28000 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 followed when working on the Xenon 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 lamp in a mounted condition in the reflector.
The Xenon headlamp is known as Bi-Xenon because it operates as both a low and high beam unit.
The Xenon lamp or High Intensity Discharge (HID) lamp as they are sometimes called, comprise 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, the Xenon lamps operate when the high
beam 'flash' function is operated.
The Xenon headlamp system is controlled by the CJB (central junction box) 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 Xenon bulbs through their start-up phases of operation.
Xenon Headlamp Construction
Xenon Bulb Replacement
A Locking Ring Removal
B Locking Ring Replacement
1 Mounting ring
2 Xenon bulb
3 Igniter
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 is an assembly known as the projector module.
The reflector is curved and provides the mounting for the Xenon bulb. The bulb locates in a keyway
to ensure correct alignment in the reflector and is secured by a plastic mounting ring. The bulb is an
integral part 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 visa 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 theat
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 (central
junction box) 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.
Turn Signal Indicator Lamp

The turn signal indicator lamp is incorporated into the outer part of the headlamp assembly,
outboard of the projector module. The turn signal indicator lamp uses a PY21W bayonet orange
colored bulb in Rest Of World (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 is rotated to lock in position. Access to the turn
signal indicator bulb requires removal of the headlamp assembly.
The turn signal indicator lamps are operated by the LH (left-hand) steering column multifunction
switch or by the hazard flasher switch. The steering column multifunction switch is only active when
the ignition is the ignition mode. The hazard flasher switch is active at all times. When active, the
turn signal indicator lamps flash at a frequency cycle of 400 ms on and 400 ms off.
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
failure to the driver.
Side Lamp
The side lamp is incorporated into the outer part of the headlamp assembly, above the cornering
lamp. The side lamp shares the same housing and reflector as the cornering lamp.
The side lamp uses a W5W wedge fitting, orange colored bulb which is fitted in a holder and
connected by wires to the main headlamp connector. The holder is a push fit into a receptacle in the
headlamp housing. The bulb is accessible by removal of the cover on the side of the headlamp.
Access to the bulb and the cover requires removal of the headlamp assembly.
The side lamps are operated by selecting side lamps or headlamps on the lighting control switch. The
side lamps are operational at all times and are not dependant on the ignition mode. 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 (central junction box) from a 'lights on' message generated by the AJB.
Side Marker Lamp

The side marker lamp is located on the outer part of the headlamp, adjacent to the turn signal
indicator bulb. The side marker lamp uses an orange colored W3W wedge fitting bulb, which is fitted
in a holder which connects with contacts in the headlamp housing. The holder is fitted into an
aperture in the headlamp housing and is rotated to lock in position. Access to the side marker bulb
requires removal of the headlamp assembly.
The side marker lamp is active at all times when the side lamps are selected on using the lighting
control switch. The side marker 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 (central junction box) from a 'lights
on' message generated by the AJB.
Cornering Lamp - Vehicles without AFS

The cornering lamp functionality differs between vehicles with or without the AFS system. The
cornering lamps are 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 inner part of the headlamp assembly, below the side
lamp. The cornering lamp uses a 35W Halogen H8 bulb which is permanently fitted in an integral
holder which is located in the headlamp housing. The holder is connected by a removable harness
connector and the holder can be removed from the housing by rotating to unlock. The bulb is
accessible by removal of a cover on the side of the headlamp. Access to the bulb anc over requires
removal of the headlamp assembly.
The cornering lamps are controlled by the LH (left-hand) steering column multifunction switch, when
the lighting control switch is in the headlamps position and the ignition is in the ignition on mode.
The cornering lamps are controlled by the CJB (central junction box) which uses turn signal indicator
active and vehicle speed to operate the cornering lamps. The cornering lamps are deactivated if the
vehicle speed exceeds 25 mph (40 km/h) with the turn signal indicators selected on or if the
headlamp high beam is active.
Only one cornering lamp will illuminate at any one time. If the LH (left-hand) turn signal indicators
are active, the LH (left-hand) cornering lamp will be illuminated and visa versa, providing the vehicle
speed and the lighting control switch positions are correct.
Cornering Lamp - Vehicles with AFS

The cornering lamps fitted to vehicles with the AFS system functions differently to those fitted to
vehicle with non AFS headlamps. The construction and light distribution of the cornering lamp with
AFS is as described previously for cornering lamp without AFS.
The cornering lamps operate using high speed CAN (controller area network) signals from the
steering angle sensor which are received by the CJB (central junction box) and the AFS control
module. The AFS control module transmits a cornering lamp on request to the CJB (central junction
box) which, if all operating conditions are correct, activates the cornering lamp.
When the operating parameters of the cornering lamp is achieved, the CJB (central junction box)
fades the cornering lamp on using a PWM (pulse width modulation) voltage over a period of
approximately 2 seconds. When the lamp is switched off, the CJB (central junction box) fades the
bulb off by decreasing the PWM (pulse width modulation) voltage in a linear manner depending on
vehicle speed and steering angle.
ADAPTIVE FRONT LIGHTING SYSTEM (AFS)

The AFS headlamp is similar in its construction to the Xenon, non-AFS headlamp. The projector
module is constructed and functions as described for the Xenon headlamp but with the addition of
the AFS system which allows the projector module to be moved vertically and horizontally. The AFS
system is controlled by a AFS control module which is integral with the headlamp levelling module.
The AFS headlamp assembly contains an additional carrier frame which provides location for the AFS
actuators. The remaining lamps are as described previously. The carrier frame is attached to the AFS
vertical actuator. The projector module has a central pivot point which allows the module to move
horizontally in response to operation of the AFS horizontal actuator.
The AFS actuators are bi-polar (2 phase) dc stepper motors which are driven by a power output from
the AFS power module located on the rear of the headlamp assembly. Each stepper motor receives
its position information from the AFS control module via the applicable AFS power module. When
the actuators are powered to their requested positions, a holding current is applied to maintain the
actuator position.
The actuators do not supply a positional feedback signal to the AFS control module. Each stepper
motor requires referencing each time the AFS system becomes active. When the AFS system is
active, each vertical actuator is driven to the low beam position and each horizontal actuator is
driven to an inboard position until a mechanical stop in the actuator is reached. Once the stop is
reached a step counter in the AFS control module is set to zero and the actuator is then powered to
the operating position as determined by the AFS control module software.
The AFS control module receives front and rear vehicle height data from the height sensors to
provide headlamp levelling adjustment via the vertical actuator motor. The AFS control module also
receives vehicle speed signals from the ABS module to adjust the projector module vertically to
increase the beam range as the vehicle speed increases.
A Conventional headlamp beam distribution
B AFS swivel headlamp beam distribution
AFS Control Module

The AFS control module is located on the bulkhead, at the bottom of the RH (right-hand) 'A' pillar.
The AFS control module is a dual functionality unit which also incorporates software to control the
headlamp leveling. The AFS control module is connected to the high speed CAN (controller area
network) bus and receives inputs from other vehicle systems on the status of the following
parameters:
• Steering angle
• Vehicle speed
• Headlamp status
• Engine running
• Reverse gear selected
• AUTO lights on.
The AFS will only operate when the AFS control module receives an engine running signal on the high
speed CAN (controller area network) bus from the ECM (engine control module) . When the engine
running signal is received the AFS control module performs its initialisation routine.
The AFS will also function when the lighting control switch is in the AUTO position and the AFS
control module receives a lights on signal from the light sensor and an engine running signal.
The AFS control module then monitors the inputs from the other vehicle systems to control the AFS
functionality according to cornering angles and vehicle speed.
The AFS control module is connected to each AFS power module on a private Local Interconnect
Network (LIN) bus. The power modules read operating values supplied from the AFS control module
and control the output drivers for the stepper motor actuators inside the headlamp assembly.
AFS Operation
The AFS controls the swiveling angle of each projector module using speed and steering angle signals.
The angles of each projector module differ to give the correct spread of light, for example, when
turning left, the LH (left-hand) projector module will have a greater swiveling angle than the RH
(right-hand) projector module.
Initialisation Procedure
When the AFS control module receives an ignition mode on signal, the control module performs the
initialisation procedure which ensures that the headlamps are correctly aligned on both their vertical
and horizontal axes.
The headlamp leveling motors are powered from their current position, which can be either the
upper or lower limit or somewhere in between, to their lower position and then back to the 0
degrees position.
The AFS swivel initialisation starts less than 1 second after the headlamp leveling initialisation is
activated to ensure that the headlamps are at or below the 0 degree position in the vertical axis, thus
preventing glare to oncoming vehicles. The AFS swivel initialisation is completed in less than 2.5
seconds. The LH (left-hand) and RH (right-hand) AFS actuator motors are powered from the 0 degree
position to their fully inboard position, then to their fully outboard position and then back to the 0
degree position.
Failure Mode
In the event of a failure of the AFS system, a warning indicator in the instrument cluster is illuminated
to warn the driver. The AFS warning indicator illuminates when the ignition is in the ignition on mode
and will flash continuously until the fault is rectified. The AFS warning indicator will also be
illuminated if a failure of the steering angle sensor or the vehicle speed signal is detected.
Illumination of the warning indicator does not necessarily mean that there is a fault with the AFS
system. The fault may be caused by a failure of another system preventing the AFS system from
operating correctly.
The AFS control module performs a diagnostic routine every time AFS is requested. If any fault is
found, the AFS control module will suspend the operation of the AFS function.
If the AFS leveling system has failed with the projector module in a position other than the correct
straight ahead position, the AFS control module will attempt to drive the projector module to a
position a small amount lower than the standard position. If the swivel function has failed, the AFS
control module will lower the projector module using the leveling actuator to a position much lower
than standard to prevent excess glare to oncoming vehicles.
The AFS control module software can detect an internal failure of the control module control circuits.
The control module will power the projector modules to the zero position and prevent further
operation.
Faults can be investigated by interrogating the AFS control module using an approved Jaguar
diagnostic system to check for fault codes.
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 AJB, which is
connected to the instrument cluster, via the medium speed CAN (controller area network) bus, to
control 'AUTO' headlamp functionality.
The light sensor is located in the centre of the instrument panel upper surface. The sensor has three
functions; houses the alarm system LED (light emitting diode) , auto lamp function for AUTO
headlamps and sun load sensor for the A/C (air conditioning) system.
The sensor is hardwired to the instrument cluster which supplies a 5V current via a pull-up resistor to
2 photodiode light sensors within the sensor housing. The ambient light signals are returned to the
instrument cluster by the light sensor varying the current drawn from the 5V output, hence varying
the voltage at the 'pull-up' resistor. The instrument cluster then outputs a message relating to the
ambient light level on the medium speed CAN (controller area network) bus. The AJB receives the
message and determines if AUTO lamps are required to be activated.
Operation of the 'AUTO' headlamps requires the ignition to be in the ignition mode and the lighting
control switch must be in the AUTO position. The AJB will only activate the AUTO headlamps on
receipt of a valid ambient light signal on the medium speed CAN (controller area network) bus from
the instrument cluster.
HEADLAMP LEVELING
Headlamp leveling provides for the automatic adjustment of the vertical aim of the headlamps. The
leveling system is required to minimise glare to other road users when the vehicle attitude changes
due to braking or acceleration.
Headlamp leveling is controlled by a headlamp leveling module which is located on the bulkhead, at
the bottom of the RH (right-hand) 'A' pillar.
NOTE:
On vehicles with the AFS system, the headlamp leveling software is incorporated into the AFS
control module and the module is known as the AFS control module.
The headlamp leveling system comprises the following components and information from other
vehicle systems:
• Front and rear vehicle height sensors

• Two headlamp leveling, vertical adjustment motors
• Headlamp leveling module (or AFS control module if vehicle is fitted with AFS)
• Ignition in on mode
• Vehicle speed information form ABS (anti-lock brake system) module.
When the ignition is in the ignition power mode, power is supplied via the ignition relay in the
battery junction box to the headlamp leveling module (or AFS control module if vehicle is fitted with
AFS).
NOTE:
When the headlamp leveling module receives a power supply from the ignition relay, the
module performs an initialization procedure to correctly align the vertical aim of the headlamps
and to determine if the leveling motors are functioning correctly.
The headlamp leveling module receives information relating to vehicle attitude from the front and
rear height sensors. The headlamp leveling module processes these signal and provides an output to
the headlamp leveling motors to adjust the headlamp vertical aim according to vehicle speed and
attitude.
DAYTIME RUNNING LAMPS

Refer to the DRL (daytime running lamps) section for details. For additional information, refer to
Daytime Running Lamps (DRL) (417-04 )
FRONT FOG LAMP
1 Fog lamp - Naturally aspirated vehicles
2 Bulb H11
3 Bulb H3
4 Fog lamp - Supercharged vehicles
Two front fog lamps are located in apertures in the front bumper. The fog lamps are different in
design between the naturally aspirated and supercharged vehicles.
Front Fog Lamp - Naturally Aspirated Vehicles

The front fog lamp is a conventional design with a clear lens and smooth surface reflector. An H11
55W halogen bulb is located at the rear of the fog lamp. The bulb has an integral holder and can be
removed by rotating counter clockwise to remove from the lamp housing.
Fog lamp beam adjustment is provided by a rotary adjuster located on the underside of the lamp and
is accessible from the rear of the bumper.
The front fog lamps are controlled by the auxiliary lighting switch and the CJB (central junction box) .
Refer to the Auxiliary Lighting Switch section for switch operation.
Front Fog Lamp - Supercharged Vehicles

The front fog lamp is projector module, similar in design to the projector module used in the Xenon
headlamp. A halogen H3 bulb is located in the rear of the lamp and secured with a spring clip. The
bulb has a power lead which is secured to the rear of the lamp connector socket.
Fog lamp beam adjustment is provided by a screw at the top of the lamp. The screw is accessible
from the front of the lamp.
Front fog lamp control and operation is as described for 'Front Fog Lamp - Naturally Aspirated
Vehicles.
Front Fog Lamp Functionality (NAS and Canadian Markets Only)

The front fog lamps operate as described previously but with the following differences which cover
local laws governing lamp usage.
If the low beam headlamps and the front fog lamps are on at the same time, when the high beam
headlamps are switched on, the front fog lamps will be automatically switched off. When the high
beam headlamps are subsequently switched off, the front fog lamps will be switched on
automatically.
NOTE:
The front fog lamps will also be switched off if the high beam 'flash' function is operated.
REAR LAMP ASSEMBLY

The rear lamp assembly is a 2 piece unit, with one part being located in the rear quarter panel and
the second part being attached to the liftgate. The outer rear lamp assembly is located in a recess in
the vehicle body and is secured with 2 nuts which screw onto studs in the lamp assembly. The inner
rear lamp assembly is located in a recess in the liftgate and is secured with 3 nuts.
1 Inner rear lamp assembly
2 Outer rear lamp assembly
3 Rear fog lamp or reverse lamp LED (light emitting diode) (market dependant)
4 Turn signal indicator bulb and holder
5 Stop lamp and Tail lamp bulb and holder
6 Side marker bulb and holder
7 Turn signal indicator
8 Rear fog lamp or reverse lamp (market dependant)
9 Stop lamp and tail lamp
10 Side marker lamp
Rear Stop and Side Lamp

The stop and side lamp are located in the lower section of the outer rear lamp assembly. A
combined, twin filament 21W/5W bayonet fitting bulb is used. The stop lamp uses the 21W bulb
filament and the side lamp uses the 5W bulb filament. The bulb is located in a holder which connects
with contacts in the rear lamp housing. The holder can be released by rotating and pulling from the
aperture.
The stop lamps are active when the ignition is in the ignition mode and the stop lamp switch is
activated by pressing the brake pedal. The high mounted stop lamp will also be activated when the
brake pedal is pressed. Operation of the stop lamp switch is sensed by the CJB (central junction box)
which sends a message on the high speed CAN (controller area network) bus to the AJB which
activates the stop lamps.
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 (controller area network) bus to the
AJB which activates the stop lamps until an off message is received.
The side lamps are operated by selecting side lamps or headlamps on the lighting control switch. The
side lamps are operational at all times and are not dependant on the ignition mode. 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 (central junction box) from the light sensor.
Turn Signal Indicator Lamp
The turn signal indicator lamp is located in the upper section of the outer rear lamp assembly and
uses a PY21W bayonet fitting bulb. The bulb is located in a holder which connects with contacts in
the rear lamp housing. The holder can be released by rotating and pulling from the aperture.
The turn signal indicator lamps are operated by the LH (left-hand) steering column multifunction
switch or by the hazard flasher switch. The steering column multifunction switch is only active when
the ignition is the ignition mode. The hazard flasher switch is active at all times. When active, the
turn signal indicator lamps flash at a frequency cycle of 400 ms on and 400 ms off.
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
failure to the driver.
Reversing Lamp
The reversing lamp is located in the inner rear lamp assembly. The reversing lamp uses 3 LED (light
emitting diode) . Only one reversing lamp is fitted and is located in the LH (left-hand) inner lamp
assembly on RHD (right-hand drive) vehicles and in the RH (right-hand) inner lamp assembly on LHD
(left-hand drive) vehicles.
The reversing lamp is activated on receipt of reverse selected message sent on the medium speed
CAN signal from the TCM (transmission control module) to the AJB.
Rear Fog Lamp

The rear fog lamp is located in the inner rear lamp assembly. The fog lamp uses 3 LED (light emitting
diode) 's. Only one fog lamp is fitted and is located in the RH (right-hand) inner lamp assembly on
RHD (right-hand drive) vehicles and in the LH (left-hand) inner lamp assembly on LHD (left-hand
drive) vehicles.
The rear fog lamp is controlled by the auxiliary lighting switch and the CJB (central junction box) . The
rear fog lamp switch receives a power supply from the instrument cluster. When the rear fog lamp
switch is pressed, a ground path is completed through a resistor. The current flow is monitored by
the instrument cluster which determines that the switch has been pressed. The instrument cluster
transmits a rear fog lamp on request message on the medium speed CAN (controller area network)
bus to the AJB which activates the power supplies to the fog lamp provided the lighting switch is in
the correct position and the ignition mode is correct.
When the ignition is in ignition on mode and the lighting control switch is in the side lamp or
headlamp position and the front fog lamps are on, pressing the rear fog lamp switch on the auxiliary
lighting switch will activate the rear fog lamp. Pressing the rear fog lamp switch for a second time will
switch the rear fog lamp off. The rear fog lamp will also be deactivated if the lighting control switch is
moved to the off position or the ignition mode is changed to off mode.
LICENCE PLATE LAMPS
Two licence plate lamps are located in the underside of the liftgate (hardtop) or luggage
compartment lid (convertible) exterior trim finisher. Each lamp uses a W5W capless bulb which is
located in a holder at the rear of the lamp.
The lamp can be removed from the finisher by using a wide flat blade screwdriver or similar tool,
inserting it in the slot between the lamp lens and the finisher and gently levering the lamp from the
surround. The bulb is pushed into a holder which in turn is a press fit in the lamp housing.
The licence plate lamps are illuminated at all times when the side lamps are active.
HIGH MOUNTED STOP LAMP

The high mounted stop lamp is located in the rear spoiler on the upper edge of the liftgate or luggage
compartment lid. The lamp comprises 24 separate LED (light emitting diode) 's which illuminate
through a red colored lens. The high mounted stop lamp functionality is the same as that described
for the stop lamps.
TURN SIGNAL INDICATOR REPEATER LAMP

The turn signal indicator repeater lamps are located in each front fender and can be removed by
sliding the lamp assembly rearwards and releasing the front edge from the fender. The lamps use a
5W capless bulb which is located in a holder in the rear of the lamp housing.
The repeater lamps have the same functionality as described for the turn signal indicators and the
hazard flashers.
HAZARD FLASHERS
The hazard flashers are controlled by a non-latching switch located in the centre of the instrument
panel. The hazard flashers operate at all times when selected and are not dependant on an ignition
mode to be selected.
When the hazard flashers are selected on by the driver, a ground path is momentarily completed to
the AJB which activates the front and rear and side repeater turn signal indicators. A second press of
the switch is again sensed by the AJB and the hazard flasher will be deactivated. When the hazard
flasher 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 (restraints control module) .
The signal is received on the medium speed CAN (controller area network) bus from the instrument
cluster by the AJB which activates the hazard flashers. The hazard flasher can be cancelled by
changing the ignition mode to accessory or off mode and then changing it to ignition on mode on or
the crash mode signal is removed by the RCM (restraints control module) .
CONTROL DIAGRAM
NOTE:
1 Battery
2 Megafuse (175A)
3 Megafuse (175A)
4 Auxiliary Junction Box (AJB)
5 CJB (central junction box)
6 High speed CAN (controller area network) bus to other vehicle systems
8 LH (left-hand) steering column multifunction switch
9 Stop lamp switch
11 LH (left-hand) headlamp
13 RH (right-hand) headlamp
14 Rear height sensor
15 Front height sensor
16 Headlamp leveling/AFS control module
17 LH (left-hand) side repeater
18 RH (right-hand) side repeater
19 A/C (air conditioning) control module
20 Hazard warning switch
21 Light sensor
22 LH (left-hand) license plate lamp
23 RH (right-hand) license plate lamp
24 LH (left-hand) front fog lamp
25 RH (right-hand) front fog lamp

27 RH (right-hand) tail lamp assembly
28 LH (left-hand) tail lamp assembly

Headlamps
For a detailed description of the exterior lighting system, refer to the Description and Operation
section 417-00 - Exterior Lighting of the workshop manual.
Safety Information
WARNING: 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.
WARNING: 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 Workshop Practices of the workshop manual.


Electrical
• Headlamp Leveling Module (HLM)

• Bulb(s)
• Photocell(s)
• Ballast
• Wiring harness/electrical connectors
• Fuse(s)
Index.
Symptom Chart
Low beam • Bulb failure Check the bulb and fuse condition (see visual
lamp(s) • Fuse(s) blown inspection). Check the headlamp circuits. Check
inoperative • Circuit fault
the lighting control switch function. Check the
• Lighting control switch
left-hand steering column multifunction switch
fault
High beam • Left-hand steering operation. Refer to the electrical guides. Check for
lamp(s) column multifunction DTCs indicating a headlamp or related circuit
inoperative switch fault fault.
Low beam • Incorrect bulb rating

lamp(s) dim • Tourist lever set in the Check the bulb condition and rating. Check the
wrong position tourist lever is set correctly. Check the headlamp
• Circuit fault
circuits. Check the lighting control switch
• Lighting control switch
fault function. Check the left-hand steering column
High beam
• Left-hand steering multifunction switch function. Refer to the
lamp(s) dim
column multifunction electrical guides.
switch fault
Low beam • Circuit fault

• Lighting control switch Check the headlamp circuits. Check the lighting
lamp(s) stuck on
fault control switch function. Check the left-hand
• Left-hand steering steering column multifunction switch operation.
High beam column multifunction Check the headlamp timer function. Refer to the
lamp(s) stuck on switch fault electrical guides. Check for DTCs indicating a
• Headlamp timer
function fault headlamp circuit fault
Headlamp • Circuit fault Check the headlamp circuits. Check the left-hand
• Left-hand steering
low/high beam steering column multifunction switch operation.
column multifunction
switching Check the xenon lamp shutter mechanism
switch fault
function • Xenon lamp shutter operation. Refer to the electrical guides. Check for
inoperative mechanism fault DTCs indicating a headlamp circuit fault
• Fuse(s) blown
• Lighting control switch Check the fuse(s) (see visual inspection). Check
fault the lighting control switch function. Check the
Warning lamp(s) • Left-hand steering left-hand steering column multifunction switch
inoperative column multifunction function. Check the warning lamp circuits. Refer
switch inoperative to the electrical guides. Check for DTCs indicating
• Circuit fault
an instrument cluster or CAN system fault.
Check for outstanding Technical Service Bulletins

(TSBs) relating to 'Headlamp Internal
Headlamp Wet - • Condensation
Condensation'. Carry out the instructions in the
Internal • Water Ingress
service bulletin to determine if the fault is related
to condensation or water ingress.
DTC Index
NOTE:
If the Control Module or a component is suspect and the vehicle remains under manufacturer
module/component.
NOTE:
system).
NOTE:
NOTE:
NOTE:
terminals.
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.
Refer to the electrical circuit diagrams,

Front or Rear Height • Front or Rear Height
B1A59- and check Front and Rear Height
Sensors - Circuit Sensors 5 volt supply
11 short to ground Sensors 5 volt supply circuit for short
short to ground
to ground
Front or Rear Height • Front or Rear Height Refer to the electrical circuit diagrams,
B1A59-
Sensors - Circuit Sensors 5 volt supply
12 and check Front and Rear Height
short to power short to power
Sensor 5 volt supply circuit for short to
power
Front Right Height • Front Right Height Refer to the electrical circuit diagrams,
C1A04-
Sensor - Circuit Sensor signal circuit and check Front Right Height Sensor
11 short to ground
short to ground signal circuit for short to ground
Front Right Height • Front Right Height Refer to the electrical circuit diagrams,
C1A04- Sensor - Circuit Sensor signal circuit and check Front Right Height Sensor
15 short to power or short to power or open signal circuit for short to power or
open circuit circuit open circuit
NOTE:
This DTC may be logged if the

vehicles wheels have been raised
from the floor
Front Right Height
C1A04- • Sensor (PWM) Signal
Sensor - Signal
64 out of range
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
Rear Right Height • Rear right Height Refer to the electrical circuit diagrams,
C1A06-
Sensor - Circuit Sensor signal circuit and check Rear Right Height Sensor
11 short to ground
short to ground signal circuit for short to ground
Rear Right Height • Rear right Height Refer to the electrical circuit diagrams,
C1A06- Sensor - Circuit Sensor signal circuit and check Rear Right Height Sensor
15 short to power or short to power or open signal circuit for short to power or
open circuit circuit open circuit
NOTE:
This DTC may be logged if the

vehicles wheels have been raised
from the floor
Rear Right Height
Sensor - Signal
64 out of range
mechanical operation of the Height
Sensor. Refer to the electrical circuit
diagrams, and check Rear Right Height
Sensor signal circuit for fault
Turn the Headlamp Switch on, cycle
the ignition state to start the engine,
look for any errors in the Headlamp
Beam movement (compare with other
headlamp) and visually inspect the
lamp for internal damage or
dislocation (ball joints out). If no faults
Left Headlamp • Internal Headlamp
are evident refer to the electrical
B1A57- Leveling Motor - Motor Fault
circuit diagrams and check for circuit
01 General Electrical • Internal Headlamp
Circuit Fault fault between the Headlamp Power
Failure
Module and the swiveling feedback
sensor. If no mechanical or circuit
faults are evident, suspect headlamp
internal fault, replace as required.
Refer to the new module/component
Index
Turn the Headlamp Switch on, cycle

the ignition state to start the engine,
look for any errors in the Headlamp
Beam movement (compare with other
headlamp) and visually inspect the
lamp for internal damage or
dislocation (ball joints out). If no faults
Right Headlamp • Internal Headlamp
are evident refer to the electrical
B1A58- Leveling Motor - Motor Fault
circuit diagrams and check for circuit
01 General Electrical • Internal Headlamp
Circuit Fault fault between the Headlamp Power
Failure
Module and the swiveling feedback
sensor. If no mechanical or circuit
faults are evident, suspect headlamp
internal fault, replace as required.
Refer to the new module/component
Index
Check the Anti-lock Brake System

Lost communication Module for stored DTCs. Using the
with Anti-lock Brake • Lost communication manufacturer approved diagnostic
U0121- System (ABS) with the Anti-lock system, complete the CAN Network
00 Control Module - Brake System Module
Integrity test. Refer to the electrical
No sub type • CAN network fault
circuit diagrams and check the CAN
information network between the Headlamp
Leveling Module and the Anti-lock
Brake System Module
Check the Anti-lock Brake System

Module for stored DTCs. Using the
Lost communication manufacturer approved diagnostic
• Invalid signal from the
with Anti-lock Brake system, complete the CAN Network
U0121- Anti-lock Brake System
System (ABS) Integrity test. Refer to the electrical
86 Module
Control Module - • CAN network fault circuit diagrams and check the CAN
Signal invalid network between the Headlamp
Leveling Module and the Anti-lock
Brake System Module
Check the Engine Control Module for

stored DTCs. Using the manufacturer
• Lost communication approved diagnostic system, complete
Lost communication
U0100- with the Engine the CAN Network Integrity test. Refer
with ECM - No sub
00 Control Module to the electrical circuit diagrams and
type information • CAN network fault check the CAN network between the
Headlamp Leveling Module and the
Engine Control Module
Check the Transmission Control

Module for stored DTCs. Using the
• Lost communication
Lost communication system, complete the CAN Network
U0101- with the Transmission
with TCM - No sub Integrity test. Refer to the electrical
00 Control Module
type information • CAN network fault circuit diagrams and check the CAN
network between the Headlamp
Leveling Module and the Transmission
Control Module
Check the Auxiliary Junction Box for

stored DTCs. Using the manufacturer
Invalid data from • Invalid signal from the approved diagnostic system, complete
U0443- Body Control Auxiliary Junction Box the CAN Network Integrity test. Refer
00 Module B - No sub • Auxiliary Junction Box to the electrical circuit diagrams and
type information fault check the CAN network between the
Headlamp Leveling Module and the
Auxiliary Junction Box
High speed CAN • Adaptive Front Lighting Using the manufacturer approved
U0001- communication Bus System (AFS) Control diagnostic system, complete the CAN
49 - Internal electronic Module internal Network Integrity test. Refer to the
failure electronic failure electrical circuit diagrams and check
the CAN network to the Headlamp
Leveling Module. If no CAN Bus circuit
faults are evident suspect Headlamp
Leveling Module internal fault. Refer
to the new module/component
Index
Check the correct Headlamp Leveling

Internal Control • Configuration data Module is installed to vehicle
Module software received over the CAN
U0300- specification. Refit original or replace
incompatibility - BUS is different from
62 the stored the module as required. Refer to the
Signal Compare
configuration data new module/component installation
Failure.
Check other modules for stored DTCs.

High Speed CAN
U0001- • CAN Bus Off Carry out the CAN Network Integrity
Communication Bus
88 • CAN Bus Circuit fault test using the manufacturer approved
- Bus off
diagnostic system
• The stored Vehicle

Identification Number
is not the same as the Check the correct Headlamp Leveling
Vehicle
Central Broadcast Module is installed to vehicle
Identification
U3002- Vehicle Identification specification. Refit original or replace
Number (VIN) -
81 Number the module as required. Refer to the
Invalid Serial Data • The Headlamp Leveling new module/component installation
received Module has previously
been installed to
another vehicle
NOTE:
Sensor calibration routine must

be carried out with the vehicle
unladen
U3000- Control Module - • Height Sensors not

54 Missing Calibration calibrated to vehicle Calibrate the Headlamp Leveling
sensors using the manufacturer
approved diagnostic system, carry the
out routine 'Headlamp and Axle
Sensor Calibration' from the 'Module
programming and configuration -
Setup and Configuration - Lighting'
U3000- Control Module - • Internal electronic Install a new Headlamp Leveling

49 Internal electronic failure Module, refer to the new module
failure installation note at the top of the DTC
Index
NOTE:
The Car Configuration File (CCF)

parameters required are (Vehicle
type)(Headlamp type)(Gearbox
type) and (Dayrunning light)
• Incorrect Car
U3000- Control Module -
Configuration File
55 Not Configured Re-configure the Car Configuration File
(CCF) data received
(CCF) File (CCF) as required using the
system. Clear DTC and re-test. If the
DTC remains suspect the Headlamp
Leveling Module, refer to the new
module installation note at the top of
the DTC Index
• The power supply to Suspect Charging fault. Check the

the Module has been battery condition and state of charge.
U3003-
Battery voltage above 16 Volts for Check the vehicle charging system.
17 more than 1000 Refer to the relevant workshop
milliseconds manual section
Suspect Battery or Charging fault.

Check the battery condition and state
of charge. Check the vehicle charging
• The power supply to system. Refer to the relevant
U3003- the Module has been workshop manual section. Clear the
Battery voltage
16 below 9 Volts for more DTC, cycle ignition state to off then on,
than 1000 milliseconds if DTC returns refer to the electrical
circuit diagrams and check power and
ground circuit to the Headlamp
Leveling Module
DTC Index
NOTE:
If the Control Module or a component is suspect and the vehicle remains under manufacturer
module/component.
NOTE:
system).
NOTE:
NOTE:
NOTE:
terminals.
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
NOTE:
The Headlamp Power Module is referenced as the AFS ECU + Motors in the circuit diagrams.

B1A59- diagrams, and check Front and
Sensors - Circuit short to Sensors 5 volt supply
11 short to ground Rear Height Sensors 5 volt
ground
supply circuit for short to ground

B1A59- diagrams, and check Front and
Sensors - Circuit short to Sensors 5 volt supply
12 short to power Rear Height Sensor 5 volt supply
power

Front Right Height • Front Right Height
C1A04- diagrams, and check Front Right
Sensor - Circuit short to Sensor signal circuit
11 short to ground Height Sensor signal circuit for
ground
short to ground
• Front Right Height Refer to the electrical circuit

Front Right Height
C1A04- Sensor signal circuit diagrams, and check Front Right
Sensor - Circuit short to
15 short to power or open Height Sensor signal circuit for
power or open circuit circuit short to power or open circuit
NOTE:
This DTC may be logged if

the vehicles wheels have
been raised from the floor
Front Right Height
Sensor - Signal
64 out of range
mechanical operation of the
Height Sensor. Refer to the
electrical circuit diagrams, and
check Front Right Height Sensor
signal circuit for fault
• Rear Right Height
C1A06- Rear Right Height Sensor diagrams, and check Rear Right
Sensor signal circuit
11 - Circuit short to ground short to ground Height Sensor signal circuit for
short to ground
• Rear Right Height Refer to the electrical circuit

Rear Right Height Sensor
C1A06- Sensor signal circuit diagrams, and check Rear Right
- Circuit short to power
15 short to power or open Height Sensor signal circuit for
or open circuit circuit short to power or open circuit
NOTE:
This DTC may be logged if

the vehicles wheels have
been raised from the floor
Rear Right Height Sensor
- Signal plausibility
64 out of range
failure Check the location, security and
mechanical operation of the
Height Sensor. Refer to the
electrical circuit diagrams, and
check Rear Right Height Sensor
signal circuit for fault
NOTE:
The power module is a

service item
This DTC is logged if the

Headlamp Power Module supply
voltage is above 16 volts / below
• Headlamp Power
Left Headlamp Power 9.5 volts or the module suffers
B1D66- Module internal fault
Module - No sub type an internal failure. Record then
00 • Headlamp Power
information Module circuit fault clear the stored DTC, cycle the
ignition state and check
headlamp operation, if the DTC
returns refer to the electrical
circuit diagrams and check the
power, ground and signal circuit
of the Power Module for circuit
fault. If no circuit faults are
evident suspect the Headlamp
Power Module has an internal
fault, replace as required. Refer
the DTC Index
NOTE:

service item
This DTC is logged if the

Headlamp Power Module supply
voltage is above 16 volts / below
9.5 volts or the module suffers
an internal failure. Record then
• Headlamp Power clear the stored DTC, cycle the
Right Headlamp Power
B1D67- Module internal fault ignition state and check
Module - No sub type
00 • Headlamp Power
information headlamp operation, if the DTC
Module circuit fault
returns refer to the electrical
circuit diagrams and check the
power, ground and signal circuit
of the Power Module for circuit
fault. If no circuit faults are
evident suspect the Headlamp
the DTC Index
NOTE:

service item
• The parameter set of
Left Headlamp Power the power module does
B1D66- Module - not match the Adaptive Clear the DTC. Turn the
46 Calibration/parameter Front Lighting System Headlamp Switch on, cycle the
memory failure (AFS) Control Module
ignition state to start the engine,
parameter set
check for stored DTCs, if DTC
returns suspect the Headlamp
the DTC Index
NOTE:

service item
• The parameter set of

Right Headlamp Power the power module does Clear the DTC. Turn the
B1D67- Module - not match the Adaptive Headlamp Switch on, cycle the
46 Calibration/parameter Front Lighting System ignition state to start the engine,
memory failure (AFS) Control Module check for stored DTCs, if DTC
parameter set returns suspect the Headlamp
the DTC Index
Turn the Headlamp Switch on,

cycle the ignition state to start
the engine, look for any errors in
the Headlamp Beam movement
(compare with other headlamp)
and visually inspect the lamp for
internal damage or dislocation
(ball joints out). If no faults are
• Internal Headlamp evident refer to the electrical
Left Headlamp Swiveling
B1D68- Sensor Fault circuit diagrams and check for
Feedback Sensor circuit -
01 • Internal Headlamp circuit fault between the
General Electrical Failure Circuit Fault Headlamp Power Module and
the Headlamp Swiveling
Feedback Sensor. If no
mechanical or circuit faults are
evident suspect headlamp
internal fault, replace as
required. Refer to the new
module/component installation
• Internal Headlamp Turn the Headlamp Switch on,

B1D69- Right Headlamp Sensor Fault cycle the ignition state to start
01 Swiveling Feedback • Internal Headlamp
Sensor circuit - General Circuit Fault
Electrical Failure (compare with other headlamp)
evident refer to the electrical
circuit diagrams and check for
circuit fault between the
Headlamp Power Module and
the Headlamp Swiveling
Feedback Sensor. If no

• Internal Headlamp
Left Headlamp Swiveling evident refer to the electrical
B1D64- Motor Fault
Motor circuit - General circuit diagrams and check for
01 • Internal Headlamp
Electrical Failure Circuit Fault circuit fault between the
the Headlamp Swiveling Motor.
If no mechanical or circuit faults
are evident suspect headlamp

• Internal Headlamp the engine, and check headlamp
Right Headlamp
B1D65- Motor Fault operation, look for any errors in
Swiveling Motor circuit -
General Electrical Failure the Headlamp Beam movement
Circuit Fault
the Headlamp Swiveling Motor.
If no mechanical or circuit faults
are evident suspect headlamp

B10A3- Left Headlamp Swivel Actuator Fault
71 Actuator - Actuator stuck • Internal Headlamp
Circuit Fault circuit fault between the
the Swiveling Feedback
Actuator. If no mechanical or
circuit faults are evident suspect
headlamp internal fault, replace
as required. Refer to the new

• Internal Headlamp (compare with other headlamp)
B10A4- Right Headlamp Swivel Actuator Fault and visually inspect the lamp for
71 Actuator - Actuator stuck • Internal Headlamp
Circuit Fault
the Swiveling Feedback
Actuator. If no mechanical or
circuit faults are evident suspect
headlamp internal fault, replace
as required. Refer to the new

Left Headlamp Leveling evident refer to the electrical
B1A57- Motor Fault
motor - General circuit diagrams and check for
Electrical Failure Circuit Fault circuit fault between the
the Leveling motor. If no

• Internal Headlamp internal damage or dislocation
Right Headlamp Leveling (ball joints out). If no faults are
B1A58- Motor Fault
motor - General
01 • Internal Headlamp evident refer to the electrical
Electrical Failure Circuit Fault circuit diagrams and check for
the Leveling motor. If no
NOTE:
On Adaptive Front Lighting

System (AFS) equipped
vehicles the power feed to
Left Corner Lamp circuit the Corner Lamp is
B1C98- • Left Corner Lamp circuit
defect - Circuit short to supplied via the Headlamp
11 short to ground
ground Power Module

diagrams, and check Left Corner
Lamp circuit for short to ground
NOTE:

the Corner Lamp is
B1C98- Left Corner Lamp circuit • Left Corner Lamp circuit
supplied via the Headlamp
13 defect - Circuit open open
Power Module

diagrams, and check Left corner
lamp circuit for open circuit
NOTE:

the Corner Lamp is
Right Corner Lamp circuit
B1C99- • Right Corner Lamp supplied via the Headlamp
defect - Circuit short to
11 circuit short to ground Power Module
ground

diagrams, and check Right
corner lamp circuit for short to
ground
NOTE:

the Corner Lamp is
B1C99- Right Corner Lamp circuit • Right Corner Lamp supplied via the Headlamp
13 defect - Circuit open circuit open Power Module

diagrams, and check Right
corner lamp circuit for open
circuit
NOTE:
This circuit uses shielded

cable
NOTE:

service item

• Communication Circuit
fault diagrams, and check the
• Headlamp Power power/ground supply and
U1A39- Right Headlamp Power
Module internal fault Communication circuit to the
00 Module - No sub type • Headlamp Power Headlamp Power Module. Using
information Module Power or the manufacturer approved
Ground supply fault
diagnostic system, clear stored
DTCs in the Adaptive Front
Lighting System (AFS) Control
Module. Cycle the ignition state
to off, then return to on and
check for stored DTCs. If DTCs
U1A39-00 and U1A38-00 return
suspect Adaptive Front Lighting
System (AFS) Control Module
internal fault, If only DTC U1A39-
00 returns suspect Headlamp
Power Module internal fault.
Replace as required. Refer to the
new module/component
the DTC Index
NOTE:
This circuit uses shielded

cable
NOTE:

service item

diagrams, and check the
• Communication Circuit power/ground supply and
fault Communication circuit to the
• Headlamp Power Headlamp Power Module. Using
U1A38- Left Headlamp Power
Module internal fault the manufacturer approved
00 Module - No sub type • Headlamp Power diagnostic system, clear stored
information Module Power or
DTCs in the Adaptive Front
Ground supply fault
Module. Cycle the ignition state
to off, then return to on and
check for stored DTCs. If DTCs
U1A39-00 and U1A38-00 return
suspect Adaptive Front Lighting
internal fault, If only DTC U1A38-
00 returns suspect Headlamp
Power Module internal fault.
Replace as required. Refer to the
the DTC Index
Check the Steering Angle Sensor

Lost communication with • Lost communication Module for stored DTCs. Using
U0126- Steering Angle Sensor with the Steering Angle the manufacturer approved
00 Module - No sub type Sensor Module
diagnostic system, complete the
information • CAN network fault
CAN Network Integrity test.
diagrams and check the CAN
network between the Adaptive
Front Lighting System (AFS)
Control Module and the Steering
Angle Sensor Module
Check the Steering Angle Sensor

Module for stored DTCs. Using
Lost communication with CAN Network Integrity test.
U0126- Steering Angle Sensor
Steering Angle Sensor Refer to the electrical circuit
86 Module
Module - Invalid signal • CAN network fault diagrams and check the CAN
Control Module and the Steering
Angle Sensor Module
Check the Anti-lock Brake

System Module for stored DTCs.
approved diagnostic system,
Lost communication with • Lost communication complete the CAN Network
U0121- Anti-lock Brake System with the Anti-lock Brake Integrity test. Refer to the
00 (ABS) Control Module - System Module electrical circuit diagrams and
No sub type information • CAN network fault check the CAN network between
the Adaptive Front Lighting
and the Anti-lock Brake System
Module
Check the Anti-lock Brake

System Module for stored DTCs.
Lost communication with • Invalid signal from the complete the CAN Network
U0121- Anti-lock Brake System Anti-lock Brake System Integrity test. Refer to the
86 (ABS) Control Module - Module electrical circuit diagrams and
Signal invalid • CAN network fault check the CAN network between
and the Anti-lock Brake System
Module
U0100- Lost communication with • Lost communication Check the Engine Control
00 ECM - No sub type with the Engine Control Module for stored DTCs. Using
information Module the manufacturer approved
• CAN network fault diagnostic system, complete the
CAN Network Integrity test.
diagrams and check the CAN
Control Module and the Engine
Control Module
Check the Transmission Control

Module for stored DTCs. Using
Lost communication with CAN Network Integrity test.
U0101- with the Transmission
TCM - No sub type Refer to the electrical circuit
00 Control Module
information • CAN network fault diagrams and check the CAN
Control Module and the
Check the Auxiliary Junction Box

for stored DTCs. Using the
Invalid data from Body CAN Network Integrity test.
U0443- Auxiliary Junction Box
Control Module B - no Refer to the electrical circuit
00 • Auxiliary Junction Box
sub type information fault diagrams and check the CAN
Control Module and the
Auxiliary Junction Box

complete the CAN Network
• CAN network fault
High speed CAN • Adaptive Front Lighting Integrity test. Refer to the
U0001- electrical circuit diagrams and
communication Bus - System (AFS) Control
49 Module internal check the CAN network to the
Internal electronic failure
electronic failure Headlamp Leveling Module. If no
CAN Bus circuit faults are
evident suspect Adaptive Front
Module internal fault, replace as
• Configuration data Check the correct Adaptive Front

received over the CAN Lighting System (AFS) Control
BUS is different from Module is installed to vehicle
Internal Control Module the stored
U0300- specification. Refit original or
software incompatibility configuration data
62 • The Headlamp Leveling replace the module as required.
- Signal Compare Failure.
Module has previously Refer to the new
been installed to module/component installation
another vehicle note at the top of the DTC Index
Carry out the CAN Network

High Speed CAN
U0001- • CAN Bus Off Integrity test using the
Communication Bus -
88 • CAN Bus Circuit fault manufacturer approved
Bus off
diagnostic system
• The stored Vehicle

Identification Number is
Check the correct Adaptive Front
not the same as the
Central Broadcast Lighting System (AFS) Control
Vehicle Identification Module is installed to vehicle
Vehicle Identification
U3002- Number specification. Refit original or
Number (VIN) - Invalid
81 • The Adaptive Front replace the module as required.
Serial Data received Lighting System (AFS) Refer to the new
Control Module has
previously been
installed to another note at the top of the DTC Index
vehicle
NOTE:
Sensor calibration routine

must be carried out with
the vehicle unladen
U3000- Control Module - Missing • Height sensors not

54 Calibration calibrated to vehicle Calibrate the Headlamp Leveling
sensors using the manufacturer
carry the out routine 'Headlamp
and Axle Sensor Calibration'
from the 'Module programming
and configuration - Setup and
Configuration - Lighting'
Suspect an internal fault, replace

U3000- Control Module - • Internal electronic System (AFS) Control Module as
49 Internal electronic failure failure required, refer to the new
NOTE:
The Car Configuration File

(CCF) parameters required
are (Vehicle
type)(Headlamp
type)(Gearbox type) and
(Dayrunning light)
• Incorrect Car
U3000- Control Module - Not
Configuration File (CCF) Re-configure the Car
55 Configured data received Configuration File (CCF) as
required using the manufacturer
Clear DTC and re-test. If the DTC
remains suspect the Adaptive
Control Module, replace as
Suspect Charging fault. Check

• The power supply to the battery condition and state
U3003- the Module has been of charge. Check the vehicle
Battery voltage above 16 Volts for more charging system. Refer to the
17
than 1000 milliseconds relevant workshop manual
section
Suspect Battery or Charging

• The power supply to fault. Check the battery
U3003- the Module has been condition and state of charge.
Battery voltage
16 below 9 Volts for more Check the vehicle charging
than 1000 milliseconds system. Refer to the relevant
workshop manual section. 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 Adaptive Front
Module
Front Fog Lamp (86.40.96)

Removal
NOTE:

2


5 . Remove the front fog lamp.
Installation
1 . Install the front fog lamp.



5 . NOTE:
The fog lamp beam should be set at 1.2% below the horizontal and parallel.
Check the fog lamp beam alignment.

Headlamp Assembly (86.41.33)
Removal
WARNING: Vehicles fitted with Xenon headlamps, the following precautions must be
observed. Failure to comply may result in exposure to ultra violet rays, severe electric shock, burns
or the risk of explosion. Ensure the headlamps are switched off at all times. Eye and hand
protection must be worn. Never switch on the lamps or test the bulbs with the lamp holder
released from the headlamp.
2 . Open the hood.
3
. CAUTION: Always protect paintwork and glass when removing exterior
components.
Release the headlamp assembly.
Remove the 3 bolts.
Release the locating pegs.
4 . Disconnect the washer jet hose.

5 . Remove the LH headlamp assembly.
6 . Remove the headlamp bulb.
Remove the cover.
Release the clip.

7 . Remove the headlamp inner bulb.
Remove the cover.
Release the clip.
8 . Remove the turn signal indicator bulb.
Release the bulb holder.

9 . Remove the side marker bulb.
Release the bulb holder.

10 . Remove the gas discharge modules.
11 . Remove the headlamp washer jet.
Installation
1 . Install the headlamp washer jet.
2 . Install the gas discharge modules.

3 . Install the side marker bulb.
Install the bulb holder.
4 . Install the turn signal indicator bulb.
Install the bulb holder.
5 . Install the headlamp inner bulb.
Install the cover.
6 . Install the headlamp bulb.
Install the cover.
7 . Install the headlamp assembly.
Position the locating pegs.
8 . Connect the washer jet hose.
9 . Secure the headlamp assembly.
Tighten the bolts.

10 . Close the hood.

Headlamp Bulb - Vehicles With: High
Intensity Discharge Headlamps (86.42.14)
Removal
WARNING: Vehicles fitted with Xenon headlamps, the following precautions must be
observed. Failure to comply may result in exposure to ultra violet rays, severe electric shock, burns
or the risk of explosion. Ensure the headlamps are switched off at all times. Eye and hand
protection must be worn. Never switch on the lamps or test the bulbs with the lamp holder
released from the headlamp.
2 . Remove the headlamp assembly.

3 . Remove the headlamp bulb.
Remove the cover.
Release the clip.

4 . Remove the headlamp bulb retainer.
Release the clip.

Installation
1 . Attach the headlamp bulb retainer.
2 . Install the headlamp bulb.
Install the cover.


Headlamp Leveling Module
Removal
2 . Remove the blower motor.

For additional information, refer to Blower Motor (82.25.66)
3 . NOTE:
Remove the RH cowl side trim panel.
Reposition the carpet for access.
Remove the 4 bolts.

5 . Remove the headlamp leveling module.
Remove the 2 bolts.
Installation
2 . Install the headlamp leveling module.

Headlamp Leveling Front Sensor
Removal
1

3 . Remove the headlamp levelling sensor.
Disconnect the height sensor link.
Remove the 2 bolts.
4 . NOTE:
Remove the height sensor link.

5 . NOTE:
Remove the bracket.
Installation
1 . NOTE:
Install the bracket.
Tighten the Allen bolts to 5 Nm (4 lb.ft).
2 . Install the height sensor link.
3 . Install the headlamp levelling sensor.
Connect the height sensor link.

Headlamp Leveling Rear Sensor
Removal
1
2 . Remove the headlamp levelling sensor.
Disconnect the height sensor link.
Remove the 2 bolts.
3 . NOTE:
NOTE:
Remove the bracket.

Installation
1 . NOTE:
Install the bracket.
Tighten the Allen bolts to 5 Nm (4 lb.ft).
2 . Install the headlamp levelling sensor.
Install the height sensor link.

High Mounted Stoplamp (86.41.01)
Removal
1 . Remove the liftgate lower trim panel.
For additional information, refer to Liftgate Lower Trim Panel
2 . Disconnect the high mounted stoplamp electrical connector.
3 . Remove the high mounted stoplamp.
Carefully release the Torx bolt covers.
Installation
1 . Install the high mounted stoplamp.

Install the Torx bolt covers.
2 . Connect the high mounted stoplamp electrical connector.
3 . Install the liftgate lower trim panel.

Rear Lamp Assembly (86.40.70)
Removal
NOTE:
Take great care when removing the rear lamp assembly as the forward point of the lens can be
easily damaged.
1 . Remove the luggage compartment grille.
Release the clip.
2 . If installed, remove the loadspace lamp.
3.
CAUTION: Note the fitted position of the component prior to removal.
Remove the rear lamp assembly trim panel.

4
. CAUTION: Take great care when removing the rear lamp assembly as the forward
point of the lens can be easily damaged.
Remove the rear lamp assembly.
Remove the 2 nuts.

5 . NOTE:
Remove the wiring harness.
Release the 4 bulb holders.
Installation
1 . Install the wiring harness
Install the bulb holders.
2 . NOTE:
Install the rear lamp assembly.
3 NOTE:
.
Position the rear lamp assembly trim panel upper edge behind the rear quarter panel
lip.
Install the rear lamp assembly trim panel.
4 . Install the loadspace lamp.
5 . Install the grille.

Fog Lamp Bulb
Removal
NOTE:

4 . Remove the front fog lamp bulb.

Installation
1 . Install the fog lamp bulb.

Rear Fog and Reversing Lamp - 2-Door
Removal
2 . Remove the fog and reversing lamp.
Remove the 3 plastic nuts.
Installation
1 . Install the fog and reversing lamp.
Install the plastic nuts.

Rear Fog and Reversing Lamp -
Convertible
Removal
1 . Remove the luggage compartment lid trim panel.
For additional information, refer to Luggage Compartment Lid Trim Panel (76.19.05)
2 . Remove the reverse/fog lamp.
Remove the 3 plastic nuts.
Installation
1 . Install the reverse/fog lamp.
Install the plastic nuts.

2 . Install the luggage compartment lid trim panel.
For additional information, refer to Luggage Compartment Lid Trim Panel (76.19.05)
417-02 : Interior Lighting
Interior Lighting
COMPONENT LOCATION
1 Left Hand (LH) vanity mirror
2 Overhead console (Coupe version shown)
3 LH map reading lamp switch
4 Interior lamp switch
5 Right Hand (RH) map reading lamp switch
6 Map and interior lamps
7 RH vanity mirror
8 LH and RH door puddle lamps
9 LH and RH footwell lamps
10 LH and RH luggage compartment lamps
11 Glovebox lamp
INTRODUCTION
The interior lamps are controlled by the Central Junction Box (CJB) and have two modes of operation:
manual and automatic. In the manual mode the interior lamps can be switched on and off using the
momentary switches adjacent to each lamp or disabled completely using the same switches. In the
automatic mode the interior lamp functionality is controlled by the CJB on receipt of various input
signals.
The CJB receives the following inputs which affect the operation of the interior lamps:
• Ignition switch
• Door latch switches
• Liftgate latch switch
• Glovebox lamp switch
• Unlock signal
• Main interior lamp switch
• Map reading lamp switches
• Delayed power off relay
• Vanity mirror lamp switches.
The driver's and passenger door puddle lamps are controlled by the driver's door module and the
passenger door module respectively on receipt of Controller Area Network (CAN) signals from the
CJB.
CONTROL DIAGRAM
NOTE:
A = Hardwired; N = Medium speed CAN bus

1 Battery
2 Megafuse (175A)
3 Megafuse (175A)
4 CJB
6 Liftgate latch switch
7 Luggage compartment lamp
8 Luggage compartment lamp
9 Passenger door module
10 Passenger door puddle lamp
11 Driver's door module
12 Driver's door puddle lamp
13 Glovebox lamp switch
14 Glovebox lamp
15 Driver's vanity mirror
16 Passenger vanity mirror
17 Driver's footwell lamp
18 Passenger footwell lamp
19 Driver's map reading lamp
20 Interior lamp
21 Passenger map reading lamp

Interior Lighting
For a detailed description of the interior lighting system, refer to the relevant Description and
Interior Lighting

2 . Visually inspect for obvious signs of electrical damage and system integrity.
Electrical
• Fuse(s)
• Bulb(s)
• Wiring harness
• Loose or corroded connector(s)
• Accessories
• Switch(es)
diagnostic system.
417-04 : Daytime Running Lamps (DRL)

INTRODUCTION
Daytime Running Lamps (DRL) use the full intensity low beam headlamps which are permanently
illuminated when the vehicle is being driven. DRL are used in a number of markets and there are two
systems to cover these markets.
For additional information, refer to Exterior Lighting (417-01 Exterior Lighting)
DRL CANADIAN MARKET

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 automatic transmission selector lever

• Power mode 6 (ignition on) detected by the auxiliary junction box
• The Central Junction Box (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:
Adaptive Front lighting System (AFS) (where fitted) is non-functional when the DRL are active.
NOTE:
When DRL are active, the headlamp flash function using the left hand steering column
multifunction switch will operate normally.
The high beam headlamp function using the left hand steering column stalk switch will be
deactivated. When the selector lever is in the PARK position on automatic transmission vehicles, DRL
are turned off. This is to reduce battery discharge during long periods of engine idling in cold climate
conditions. When the selector lever is moved from the PARK position, normal DRL functionality is
restored.
DRL DENMARK, HOLLAND, NORWAY, SWEDEN, FINLAND AND POLAND

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 auxiliary junction box

• 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.

For a detailed description of the daytime running lamps, refer to the relevant Description and

Electrical
• Fuse(s)
• Bulb(s)
• Switch(es)
• Wiring Harness
diagnostic system.
418 : Electrical Distribution
418-00 : Module Communications Network
Specifications
Specifications
Item Nm lb-ft lb-in

Junction box - nut/screw 4 3 35
INTRODUCTION
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.
The communication networks available on the vehicle are:
• Medium speed Controller Area Network (CAN) bus

• High speed CAN bus
• Media Orientated System Transport (MOST) ring
• Local Interconnect Network (LIN) bus
• Private CAN bus
Bus Baud Rate
Medium speed CAN bus 125 kbits/s
High speed CAN bus 500 kbits/s
MOST ring 24 mbits/s
LIN bus 9.6 kbits/s
CONTROLLER AREA NETWORK (CAN) BUS

The CAN bus is a high speed broadcast network where control modules automatically transmit
information every few microseconds. Information is broadcast down a pair of twisted wires, known
as 'CAN high' and 'CAN low'. Information is transmitted on the CAN bus as a voltage difference
between the two wires.
Two CAN bus networks are used on the vehicle; medium speed and high speed, with the instrument
cluster acting as a gateway between the two networks. The table below shows the wire colours used
on both networks.
Network High Low
Medium Speed White (W) Blue (U)

High Speed Yellow (Y) Green (G)
Private CAN bus

The private CAN bus networks used on the vehicle can be either medium or high speed depending on
which vehicle system they are being used. All private CAN bus networks are proprietary systems and
cannot be interrogated using the Integrated Diagnostic System (IDS).
Diagnostic Socket
The diagnostic socket allows the transfer of information between the vehicle electronic control
modules and the IDS. The diagnostic socket is connected directly to both the medium speed CAN bus
and the high speed CAN bus and is located below the drivers side of the instrument panel.
MEDIA ORIENTATED SYSTEM TRANSPORT (MOST) RING

The MOST ring uses a fibre optic cable to transport data and audio around the information and
entertainment system. The fibre optic cable is arranged in a ring, with each unit on the ring having a
'MOST in' and 'MOST out' connection.
MOST is a synchronous network. A timing master supplies the clock and all other components on the
ring synchronize their operation to this clock. The timing master for the MOST ring is the Information
and Entertainment control module.
When handling MOST fibre optic cables the following precautions should be observed.
• After disconnection of any cables, carefully install appropriate dust caps to protect the
mating faces of the connectors from damage or contamination.
• Avoid introducing bends of less than 25 mm (0.98 inches) radius or kinks into the fibre optic
cable during service or repair. Tight bends or kinks could impair operation, cause immediate
system failure, or future system failure.
• Avoid excessive force, strain or stress on the fibers and connectors, especially permanent
stress after reinstallation.
Software Download Socket

The MOST software download socket is located below the drivers side of the instrument panel. A
service loop is fitted to the end of the socket to complete the MOST ring. If the service loop is
removed the MOST ring will be broken and all components on the ring will stop operating.
NOTE:
The software download socket is used for engineering purposes only and must not be used in
service.
Ring Break Diagnostics
Incorporated into the Auxiliary Junction Box (AJB) is a Ring Break Diagnostics (RBD) link. The RBD link
houses a copper link which when removed initiates the ring break diagnostics mode. The ring break
diagnostics mode allows the technician to locate an optical fiber break in the MOST ring. To initiate
the ring break diagnostics mode, carry out the following process:
• Connect the Jaguar approved diagnostic system.

• Ensure the vehicle is in power mode 4 or greater.
• Remove the RBD link for the length of time specified by the Jaguar approved diagnostic
system.
• Replace the RBD link.
After approximately 30 seconds a Diagnostic Trouble Code (DTC) will be logged in the Information
and Entertainment Control Module, identifying the location of the fault. The DTC can be read and
interrogated using the Jaguar approved diagnostic system.
LOCAL INTERCONNECT NETWORK (LIN) BUS

The LIN bus is a low speed broadcast network that employs master and slave components. The
master component transmits a message to the slave components identifying which slave is to
respond. This message has a header (slave identifier) and an empty data field. The identified slave
component fills the data field with the relevant information and returns the message to the master
component.
Unlike the CAN bus networks, the LIN bus utilizes a single wire network.
CONTROL DIAGRAM - MEDIUM SPEED CAN BUS

NOTE:
N = Medium speed CAN bus

2 Information and Entertainment control module
3 Convertible top control module
4 Tire pressure monitoring control module

5 Parking aid module
8 Diagnostic socket
9 Passenger door control module
10 Drivers door control module
11 Passenger seat module
12 Drivers seat module
13 Automatic Temperature Control (ATC) module
NOTE:
Only the buttons of the Integrated control panel are connected to the medium speed CAN bus.
The Touch Screen Display (TSD) is connected to the MOST ring.
CONTROL DIAGRAM - HIGH SPEED CAN BUS

NOTE:
D = High speed CAN bus

1 Diagnostic socket
2 Electric steering column lock
3 Park brake module

7 Anti-lock Brake System (ABS) module
8 Restraints control module
CONTROL DIAGRAM - MOST RING (UP TO 2009 MY)

NOTE:
P = MOST ring
1 Software download socket
3 Multi-media module
4 DAB/SDARS receiver
5 Bluetooth© phone module
6 TSD
7 Audio system amplifier
CONTROL DIAGRAM - MOST RING (FROM 2009 MY)

NOTE:
P = MOST ring

1 Software download socket
4 Multi-media module
5 DAB/SDARS receiver
7 TSD
8 Audio system amplifier
CONTROL DIAGRAM - LIN BUS AND PRIVATE CAN BUS

NOTE:
O = LIN bus; U = Private CAN bus

1 CJB
2 Active anti-theft sounder
4 Engine start control module
5 Steering wheel module
7 Passenger seat switch module
9 Drivers seat switch module
11 Adaptive speed control radar
12 ABS module
13 Yaw rate/acceleration sensor
16 Drivers door switch module

For a detailed description of the communications network, refer to the relevant Description and

CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these
charges, damage may result.
Electrical
• Fuses (refer to electrical guide)

• Wiring 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)
4 . If the cause is not visually evident check for diagnostic trouble codes (DTCs) and refer to the DTC
Index.
DTC Index
NOTE:
NOTE:
diagnostic system).
NOTE:
NOTE:
NOTE:
NOTE:
terminals.
Rear Junction Box (RJB)

supplies to RJB. Check CAN
Fuel pump • RJB fault
communications between RJB
B100A51 authorisation • Low speed CAN fault
• Instrument cluster fault and instrument cluster. Check
target ID not stored
instrument cluster

• Instrument cluster fault ground supplies to RJB and
Fuel pump • Incorrect module installed
instrument cluster. Confirm
B100A62 authorisation signal (RJB/Instrument cluster)
• Write target SID correct module installed. Re-
compare failure
synchronisation error synchronise ID by re-configuring
following re-programming the RJB as a new module. Check
• Noise/EMC related error CAN network for

supplies to RJB and instrument
• RJB fault cluster. Check CAN
Fuel Pump
• Low speed CAN fault communications between RJB
B100A63 Authorisation Time
Out • Low battery voltage <9V battery is in fully charged and
serviceable condition, refer to
the battery care manual

Steering column
• Steering column lock ground diagrams and test steering
B102612 lock ground circuit
circuit - short to power column lock ground circuit for
short to power
short to power

Blower fan relay • Blower fan relay circuit -
B10AF12 diagrams and test blower fan
relay circuit for short to power

Blower fan relay • Blower fan relay circuit -
B10AF14 open load or short short to ground, high
resistance the manufacturer approved
to ground
diagnostic system
Air bag deployed
• Air bag deployed circuit - diagrams and test air bag
B10DD12 circuit short to
short to ground deployed circuit for short to
ground
ground
Air bag deployed Carry out any pinpoint tests

• Air bag deployed circuit -
circuit open circuit, associated with this DTC using
B10DD15 short to power, high
short to power or resistance the manufacturer approved
no signal diagnostic system

Air bag deployed diagrams and test air bag
B10DD38 circuit signal out of • Signal frequency incorrect deployed circuit between RCM,
specification ECM and RJB for short to
power, ground and open circuit
Parking aid ignition Carry out any pinpoint tests

supply short to • Parking aid ignition supply associated with this DTC using
B111211
ground or over circuit - short to ground the manufacturer approved
temperature diagnostic system

Parking aid ignition • Parking aid ignition supply diagrams and test parking aid
B111213
supply open load circuit - high resistance ignition supply circuit for high
resistance
Left front comfort Carry out any pinpoint tests

solenoid short to • Left front comfort solenoid associated with this DTC using
B111311

Left front comfort • Left front comfort solenoid diagrams and test left front
B111313 circuit - high resistance
solenoid open load comfort solenoid circuit for high
resistance
Right front comfort Carry out any pinpoint tests

solenoid short to • Right front comfort solenoid associated with this DTC using
B111411
Right front comfort • Right front comfort solenoid Refer to the electrical circuit
B111413 circuit - high resistance diagrams and test right front
solenoid open load
comfort solenoid circuit for high
resistance
High mounted stop Carry out any pinpoint tests

• High mounted stop lamp
lamp control short associated with this DTC using
B111511 control circuit - short to
to ground or over ground the manufacturer approved

High mounted stop • High mounted stop lamp
diagrams and test high
B111513 lamp control open control circuit - high
resistance mounted stop lamp control
load
circuit for high resistance
Left rear lamp

assembly control • Left rear lamp assembly
B111611 circuit short to control circuit - short to
ground the manufacturer approved
ground or over
diagnostic system
temperature

Left rear lamp • Left rear lamp assembly
diagrams and test left rear lamp
B111613 assembly control control circuit - high
resistance assembly control circuit for high
circuit open load
resistance
Right rear lamp

assembly control • Right rear lamp assembly
ground or over
diagnostic system
temperature

Right rear lamp • Right rear lamp assembly
diagrams and test right rear
B111713 assembly control control circuit - high
resistance lamp assembly control circuit
circuit open load
for high resistance
Left rear side

marker control
• Left rear side marker control associated with this DTC using
ground or over
diagnostic system
temperature

Left rear side
• Left rear side marker control diagrams and test left rear side
B111813 marker control
circuit - high resistance marker control circuit for high
circuit open load
resistance
Right rear side
marker control • Right rear side marker
ground or over
diagnostic system
temperature

Right rear side • Right rear side marker
diagrams and test right rear
B111913 marker control control circuit - high
resistance side marker control circuit for
circuit open load
high resistance
License plate lamps Carry out any pinpoint tests

control circuit short • License plate lamps control associated with this DTC using
B111A11
to ground or over circuit - short to ground the manufacturer approved

License plate lamps
• License plate lamps control diagrams and test license plate
B111A13 control circuit open circuit - high resistance lamps control circuit for high
load
resistance
Luggage
compartment lid Carry out any pinpoint tests
• Luggage compartment lid
open motor control associated with this DTC using
B111D11 open motor control circuit -
circuit short to short to ground the manufacturer approved
ground or over diagnostic system
temperature
Luggage Carry out any pinpoint tests

compartment lid associated with this DTC using
B111D13 open motor control circuit -
open motor control high resistance the manufacturer approved
circuit open load diagnostic system
Luggage
compartment lid Carry out any pinpoint tests
lamps power associated with this DTC using
B111E11 lamps power supply circuit -
supply circuit short short to ground the manufacturer approved
to ground or over diagnostic system
temperature
Luggage Refer to the electrical circuit

diagrams and test luggage
B111E13 compartment lid lamps power supply circuit -
lamps power high resistance compartment lid lamps power
supply circuit open supply circuit for high resistance
load

Restraints ignition
• Restraints ignition relay diagrams and test restraints
B112311 relay short to
circuit - short to ground ignition supply relay circuit for
ground
short to ground

Restraints ignition
• Restraints ignition relay diagrams and test restraints
B112312 relay short to
circuit - short to power ignition supply relay circuit for
power
short to power
External luggage Carry out any pinpoint tests

compartment lid associated with this DTC using
B113E23 • Signal stuck low
release switch the manufacturer approved
stuck diagnostic system

Fuel sender No.1 • Fuel sender No.1 circuit - associated with this DTC using
B1A751C voltage out of range
fault the manufacturer approved
diagnostic system

Fuel sender No.2 • Fuel sender No.2 circuit - associated with this DTC using
B1A761C
fault voltage out of range the manufacturer approved
diagnostic system
Right fog lamp Carry out any pinpoint tests

control circuit short • Right fog lamp control associated with this DTC using
B1A7911
to ground or over circuit - short to ground the manufacturer approved

Rear fog lamp
• Rear fog lamp control circuit diagrams and test rear fog lamp
B1A7913 control circuit open
- high resistance control circuit for high
load
resistance

Horn relay short to • Horn relay circuit - short to
B1C5512 diagrams and test horn control
power power
Horn relay open Carry out any pinpoint tests

• Horn relay circuit - short to
B1C5514 load or short to associated with this DTC using
ground, high resistance
diagnostic system

Heated rear
• Heated rear window relay diagrams and test heated rear
B1C8312 window relay coil
circuit - short to power window relay circuit for short to
short to power
power
Heated rear Carry out any pinpoint tests

• Heated rear window relay
window relay coil associated with this DTC using
B1C8314 circuit - short to ground,
open load or short high resistance the manufacturer approved
to ground diagnostic system
Fuel filler door lock

motor control • Fuel filler door lock motor
B1C9111 circuit short to control circuit - short to
ground or over
diagnostic system
temperature

Fuel filler door lock • Fuel filler door lock motor
B1C9113 motor control control circuit - high
resistance the manufacturer approved
circuit open load
diagnostic system
Left turn signal Carry out any pinpoint tests

lamp control circuit • Left turn signal lamp control associated with this DTC using
B1D0611
short to ground or circuit - short to ground the manufacturer approved
over temperature diagnostic system

Left turn signal
• Left turn signal lamp control diagrams and test left turn
B1D0613 lamp control circuit
circuit - high resistance signal lamp control circuit for
open load
high resistance
Right turn signal Carry out any pinpoint tests

• Right turn signal lamp
lamp control circuit associated with this DTC using
B1D0711 control circuit - short to
short to ground or ground the manufacturer approved
over temperature diagnostic system

Right turn signal • Right turn signal lamp
diagrams and test right turn
B1D0713 lamp control circuit control circuit - high
resistance signal lamp control circuit for
open load
high resistance
B1D3523 Hazard switch stuck • Signal stuck low Carry out any pinpoint tests
diagnostic system
Check battery is in fully charged

• Circuit voltage below
B2A9016 Battery low and serviceable condition, refer
threshold
to the battery care manual
Check battery is in fully charged

B2A9116 Battery discharged and serviceable condition, refer
threshold
to the battery care manual

Right stoplamp
• Right stoplamp control associated with this DTC using
C111A11 short to ground or
over temperature
diagnostic system

Right stoplamp
• Right stoplamp control diagrams and test right
C111A13 control circuit open
circuit - high resistance stoplamp control circuit for high
load
resistance
Left stoplamp Carry out any pinpoint tests

control circuit short • Left stoplamp control circuit associated with this DTC using
C111B11
to ground or over - short to ground the manufacturer approved

Left stoplamp
• Left stoplamp control circuit diagrams and test left stoplamp
C111B13 control circuit open
- high resistance control circuit for high
load
resistance
Reversing lamp Carry out any pinpoint tests

control circuit short • Reversing lamp control associated with this DTC using
C112011 circuit - short to ground
to ground or over the manufacturer approved

Reversing lamp
• Reversing lamp control diagrams and test reversing
C112013 control circuit open
circuit - high resistance lamp control circuit for high
load
resistance

Fuel pump relay • Fuel pump relay circuit -
P123011 diagrams and test fuel pump
short to ground short to ground
relay circuit for short to ground
Fuel pump relay • Fuel pump relay circuit -
P123012 diagrams and test fuel pump
Medium Speed Carry out any pinpoint tests

CAN associated with this DTC using
U001088 • bus off
Communication the manufacturer approved

Lost associated with this DTC using
U014000 • Lost communication CJB
communication CJB the manufacturer approved
diagnostic system

communication • Lost communication with associated with this DTC using
U015500

U016400
with climate climate control module the manufacturer approved

communication • Lost Communication with associated with this DTC using
U020600
with convertible HDM the manufacturer approved
top module diagnostic system
Lost
U021400 with remote remote keyless entry
module the manufacturer approved
keyless entry
diagnostic system
module

Internal control diagnostic system. Clear DTC
• Calibration parameter
U030046 module software and re-test, if DTC remains,
failure
incompatibility suspect the RJB, refer to the
new module installation note at
U1A1449 CAN initialisation • Internal electronic failure Install a new RJB, refer to the
failure the top of the DTC Index
Install a new RJB, refer to the

U300049 Control module • Internal electronic failure new module installation note at

U300055 configuration data and re-test. If the DTC remains
data received
does not match suspect the RJB, refer to the
Vehicle match. Corrupt VIN data Install original module, check
U300281 Identification being transmitted, module for DTCs and refer to relevant
vehicle
Central Junction Box (CJB)


ground supplies to CJB and
• Faulty instrument cluster instrument cluster. Re-
• Target SID re-
Ignition synchronize ID by re-configuring
B100951 synchronisation error
authorisation following programming the instrument cluster as a new
• CAN fault module. Check CAN
communications between
instrument cluster and tester

• Low speed CAN fault between CJB and instrument
• CJB fault cluster. Check ignition, power
Ignition • Instrument cluster fault and ground supplies to CJB and
B100962 (CJB/Instrument cluster)
signal compare • Target SID synchronisation correct module is installed. Re-
failure error following re- synchronise ID by re-configuring
programming the instrument cluster as a new
• Noise/EMC related error module. Check CAN network for
Check Power and Ground
supplies to CJB and instrument
• CJB fault cluster. Check CAN
Ignition
• Low speed CAN fault communications between CJB
B100963 authorisation time-
out • Low battery voltage <9V battery is in fully charged and
serviceable condition, refer to
the battery care manual

Ignition
• CJB fault supplies to CJB and instrument
authorisation
B100964 • Low speed CAN fault cluster. Check CAN
signal plausibility • Instrument cluster fault communications between CJB
failure
Steering column Refer to the electrical circuit

lock power circuit diagrams and test steering
short to ground or column lock power circuit for
over temperature short to ground

Steering column
diagrams and test steering
B102613 lock power circuit • Circuit open
column lock power circuit for
open load
high resistance

• Low speed CAN fault supplies to CJB and RKE module.
Passive key
• Remote Keyless Entry (RKE) Check CAN communications
authorisation
B102B67 module fault between CJB and RKE module.
signal incorrect • Write target SID Re-synchronise ID by re-
after event synchronisation error configuring the RKE module as a
new module

• Low speed CAN fault supplies to CJB, RKE module and
• RKE module fault receiver. Check CAN
• Key fob battery low/battery
communications between CJB
contact issue
Passive key • Interference from other RF and instrument cluster. Check
B102B87 authorisation signal key fob battery. Confirm vehicle
missing message • EMC/noise surroundings, move vehicle.
• Receiver fault Check CAN network for
• Receiver not programmed interference/EMC related issues.
correctly
Disconnect battery, then re-
• Serial communications fault
(between receiver and RKE connect - confirm operation by
module) re-programming keys. Check
• Key fault serial circuit between receiver
• Passive antenna fault and RKE module. Confirm spare
• Confirm placement of key key works. Refer to the electrical
within vehicle
circuit diagrams and test circuits
to all 3 antennas. Check
whereabouts of key

B108A23 Start button stuck • Signal stuck low
diagnostic system

B108A29 Start button fault • Signal invalid
diagnostic system

Wiper On Off relay
diagrams and test wiper On Off
B109511 control circuit • Circuit short to ground
relay control circuit for short to
short to ground
ground

Wiper On Off relay
diagrams and test wiper On Off
B109512 control circuit • Circuit short to power
short to power
power

Wiper speed relay
diagrams and test wiper speed
B109612 control circuit • Circuit short to power
short to power
power
Wiper speed relay Refer to the electrical circuit

control circuit • Circuit short to ground or diagrams and test wiper speed
B109614
open load or short open relay control circuit for high
to ground resistance or short to ground
Heated front Refer to the electrical circuit

windshield relay diagrams and test heated front
B109712 • Circuit short to power
control circuit windshield relay control circuit
short to power for short to power
Heated front • Circuit short to ground or Refer to the electrical circuit

B109714 windshield relay diagrams and test heated front
open
control circuit windshield relay control circuit
open load or short for high resistance or short to
to ground ground
Intrusion sensor Refer to the electrical circuit

module power diagrams and test intrusion
B109F11 • Circuit short to ground
circuit short to sensor module power circuit for
ground short to ground
Rain sensor power

circuit short to
B10AD11 • Circuit short to ground diagrams and test rain sensor
ground or over
power circuit for short to ground
temperature

Rain sensor power
B10AD13 • Circuit open diagrams and test rain sensor
circuit open load
power circuit for high resistance
Rain sensor Install a new rain sensor.

B10AD49 • Internal electronic failure
internal fault Rain Sensor (84.12.10)

Front left global diagrams and test Front left
B10DB23 • Signal stuck low
close global close circuit for short to
ground

Front right global diagrams and test Front right
B10DC23 • Signal stuck low
close global close circuit for short to
ground
ECM wake-up Refer to the electrical circuit

B10E511 signal short to • Circuit short to ground diagrams and test ECM wake-up
ground signal for short to ground
Key In switch Refer to the electrical circuit

B10F111 circuit short to • Circuit short to ground diagrams and test Key In switch
ground circuit for short to ground
Front left side lamp Refer to the electrical circuit

control circuit diagrams and test front left side
short to ground or lamp control circuit for short to
over temperature ground
B10F313 Front left side lamp • Circuit open Refer to the electrical circuit
control circuit diagrams and test front left side
open load lamp control circuit for high
resistance
Front right side Refer to the electrical circuit

lamp control circuit diagrams and test front right side

Front right side
diagrams and test front right side
B10F413 lamp control circuit • Circuit open
lamp control circuit for high
open load
resistance

Cigar lighter relay
diagrams and test cigar lighter
B10F812 control circuit • Circuit short to power
short to power
power
Cigar lighter relay Refer to the electrical circuit

control circuit • Circuit short to ground or diagrams and test cigar lighter
B10F814

Accessory socket
diagrams and test Accessory
B10F912 'B' relay short to • Circuit short to power
socket 'B' relay for short to
power
power

Accessory socket
• Circuit short to ground or diagrams and test Accessory
B10F914 'B' relay open load
open socket 'B' relay for high
or short to ground
resistance or short to ground
Delayed power off Refer to the electrical circuit

relay power output diagrams and test delayed power
B10FA12 • Circuit short to power
circuits short to off relay power output circuits
power for short to power

Delayed power off
diagrams and test delayed power
relay power output • Circuit short to ground or
B10FA14 off relay power output circuits
circuits open load open
for high resistance or short to
or short to ground
ground
Engine Junction
Box (EJB) and ECM Refer to the electrical circuit
ignition relay diagrams and test EJB and ECM
B10FF11 • Circuit short to ground
control circuit ignition relay control circuits for
short to ground or short to ground
over temperature
Engine Junction
Box (EJB) and ECM
diagrams and test EJB and ECM
B10FF13 ignition relay • Circuit open
ignition relay control circuits for
control circuit
high resistance
open load
O2 sensor heater Refer to the electrical circuit

relay control circuit diagrams and test O2 sensor
short to ground or heater relay control circuit for

O2 sensor heater
diagrams and test O2 sensor
B110013 relay control circuit • Circuit open
heater relay control circuit for
open load
high resistance
Intruder detection Carry out any pinpoint tests

arm/disarm control associated with this DTC using
B113F12 • Circuit short to power
circuit short to the manufacturer approved
power diagnostic system
Engine crank
authorisation
• Engine crank authorisation associated with this DTC using
circuit short to ground the manufacturer approved
ground or over
diagnostic system
temperature

Engine crank
• Engine crank authorisation associated with this DTC using
B114013 authorisation circuit high resistance the manufacturer approved
circuit open load
diagnostic system
Ignition supply Refer to the electrical circuit

status circuits 1 diagrams and test ignition supply
short to ground or status circuits 1 for short to
Ignition supply
diagrams and test ignition supply
B114213 status circuits 1 • Circuit open
status circuits 1 for high
open load
resistance
Ignition supply Refer to the electrical circuit

status circuits 2 diagrams and test ignition supply
short to ground or status circuits 2 for short to

Ignition supply
diagrams and test ignition supply
B114313 status circuits 2 • Circuit open
status circuits 2 for high
open load
resistance
Steering wheel
heater supply
diagrams and test steering wheel
B114411 circuit short to • Circuit short to ground
heater supply circuit for short to
ground or over
ground
temperature

Steering wheel
diagrams and test steering wheel
B114413 heater supply • Circuit open
heater supply circuit for high
circuit open load
resistance
Passive sounder Refer to the electrical circuit

supply circuit short diagrams and test passive
to ground or over sounder supply circuit for short
temperature to ground

Passive sounder
diagrams and test passive
B114613 supply circuit open • Circuit open
sounder supply circuit for high
load
resistance
Front left fog lamp Refer to the electrical circuit

control circuit diagrams and test front left fog
Front left fog lamp Refer to the electrical circuit

B114713 control circuit • Circuit open
diagrams and test front left fog
open load lamp control circuit for high
resistance
Front right fog Refer to the electrical circuit

lamp control circuit diagrams and test front right fog

Front right fog
diagrams and test front right fog
B114813 lamp control circuit • Circuit open
lamp control circuit for high
open load
resistance
Front passenger
seat heater supply
diagrams and test front
B115A11 circuit short to • Circuit short to ground
passenger seat heater supply
ground or over
temperature

Front passenger
B115A13 seat heater supply • Circuit open
passenger seat heater supply
circuit open load
circuit for high resistance
Front driver seat

heater supply
diagrams and test front driver
B115B11 circuit short to • Circuit short to ground
seat heater supply circuit for
ground or over
short to ground
temperature

Front driver seat
diagrams and test front driver
B115B13 heater supply • Circuit open
seat heater supply circuit for
circuit open load
high resistance

LIN Bus short to
B1A9801 • General electrical failure diagrams and test LIN Bus for
ground or power
short to ground or power

diagrams and test LIN circuit to
LIN Bus header
B1A9881 • Invalid serial data received battery backed sounder for short
error
to ground, power, high
resistance
Install a new CJB, refer to the
LIN Bus checksum • Value of signal protection
B1A9883 new module installation note at
error calculation incorrect

Front left seat
diagrams and test front left seat
heater
B1B651C • Circuit voltage out of range heater temperature sensor
temperature
sensor fault
power, high resistance

Front right seat
diagrams and test front left seat
heater
B1B661C • Circuit voltage out of range heater temperature sensor
temperature
sensor fault

Master light switch
B1C4323 • Signal stuck low diagrams and test master light
stuck
switch circuit for short to ground

Front wiper park diagrams and test wiper park
B1C4523 • Signal stuck low
position stuck position switch circuit for short
to ground

Powerwash relay
diagrams and test powerwash
B1C7812 control circuit • Circuit short to power
short to power
power
Powerwash relay Refer to the electrical circuit

control circuit • Circuit short to ground or diagrams and test powerwash
B1C7814
Windshield washer
pump control
diagrams and test windshield
B1C7911 circuit short to • Circuit short to ground
washer pump control circuit for
ground or over
short to ground
temperature
Windshield washer Refer to the electrical circuit

B1C7913 pump control • Circuit open
diagrams and test windshield
circuit open load washer pump control circuit for
high resistance
Front left cornering Refer to the electrical circuit

lamp control circuit diagrams and test front left
short to ground or cornering lamp control circuit for

Front left cornering
diagrams and test front left
B1C9813 lamp control circuit • Circuit open
cornering lamp control circuit for
open load
high resistance
Front right
cornering lamp
diagrams and test front right
B1C9911 control circuit • Circuit short to ground
cornering lamp control circuit for
short to ground or
short to ground
over temperature
Front right Refer to the electrical circuit

cornering lamp diagrams and test front right
B1C9913 • Circuit open
control circuit cornering lamp control circuit for
open load high resistance
Front left low

beam control
diagrams and test front left low
B1D0011 circuit short to • Circuit short to ground
beam control circuit for short to
ground or over
ground
temperature

Front left low
diagrams and test front left low
B1D0013 beam control • Circuit open
beam control circuit for high
circuit open load
resistance
Front right low

beam control
diagrams and test front right low
ground or over
ground
temperature

Front right low
diagrams and test front right low
circuit open load
resistance
Front left high
beam control
diagrams and test front left high
ground or over
ground
temperature

Front left high
diagrams and test front left high
circuit open load
resistance
Front right high

beam control
high beam control circuit for
ground or over
short to ground
temperature

Front right high
high beam control circuit for high
circuit open load
resistance
Battery backed Refer to the electrical circuit

sounder power diagrams and test battery backed
circuit short to sounder power circuit for short
ground to ground

Battery backed
diagrams and test LIN Bus for
B1D1787 sounder reply • Missing message
short to ground, power or high
failure
resistance
Heater coolant
pump control
diagrams and test heater coolant
pump control circuit for short to
ground or over
ground
temperature

Heater coolant
diagrams and test heater coolant
B1D2713 pump control • Circuit open
pump control circuit for high
circuit open load
resistance
P080111 Reverse inhibit to • Circuit short to ground Refer to the electrical circuit
rear view mirror diagrams and test reverse inhibit
circuit short to to rear view mirror circuit for
ground or over short to ground
temperature

Reverse inhibit to
diagrams and test reverse inhibit
P080113 rear view mirror • Circuit open
to rear view mirror circuit for
circuit open load
open load

CAN associated with this DTC using
U001088 • Bus Off
communication the manufacturer approved

Lost
• Lost communication with associated with this DTC using
RJB the manufacturer approved
with RJB
diagnostic system

U015500
Lost
communication • Lost Communication with
U015600 with Information Information and
Entertainment module the manufacturer approved
and Entertainment
diagnostic system
module

U016400
with climate climate control module the manufacturer approved

U019900
with Driver Door DDM the manufacturer approved
Module (DDM) diagnostic system

• Lost communication with associated with this DTC using
PDM the manufacturer approved
with Passenger
Door Module diagnostic system
(PDM)

U020600
with convertible convertible top module the manufacturer approved
top module diagnostic system
Lost
U021400 with remote remote keyless entry
module the manufacturer approved
keyless entry
diagnostic system
module

diagnostic system. Clear the DTC
Internal control
• Invalid configuration and retest. If the DTC is still
U030000 module software
message is received logged suspect the CJB module,
incompatibility
DTC Index
Internal control Re-calibrate the CJB using the

• Calibration parameter
U030046 module software manufacturer approved
failure
incompatibility diagnostic system

CAN initialisation
U1A1449 • Internal electronic failure new module installation note at
failure
Switch illumination Refer to the electrical circuit

supply circuit short diagrams and test switch
U201011 • Circuit short to ground
to ground or over illumination supply circuit for
temperature short to ground

Switch illumination
diagrams and test switch
U201013 supply circuit open • Circuit open
illumination supply circuit for
load
high resistance

U300049 Control module • Internal electronic failure new module installation note at
Stored vehicle diagnostic system. Clear DTC and
U300055 configuration data re-test. If the DTC remains
data received
does not match suspect the CJB, refer to the new

diagnostic system. Check CJB for
U300087 Control Module • Missing message DTCs and refer to the DTC Index.
Check CAN network integrity
vehicle

diagnostic system

diagnostic system
Auxiliary Junction Box (AJB) (86.70.55)

Removal
2 . Release the auxiliary junction box access cover.
3 . Release the auxiliary junction box.
Disconnect the battery positive cable.
4 . Remove the auxiliary junction box.
Remove the 2 nuts.

Installation
1 . Install the auxiliary junction box.
2 . Secure the auxiliary junction box.
Tighten the battery positive lead nut to 10 Nm (7 lb.ft).
3 . Secure the auxiliary junction box access cover.
Secure in the clip.

Central Junction Box (CJB) (86.70.72)
Removal
2
force is used.
Remove the 3 clips.
3 . Remove the cowl side trim panel.
Remove the hood release lever.
Release the forward edge of the scuff plate trim panel.

4 . Release the CJB.
Release the battery positive cables.
5 . Remove the CJB.
Remove the 2 nuts.
Installation
1 . Install the CJB.

2 . Secure the CJB.
Attach the battery positive cables.
3 . Install the cowl side trim panel.
Align the pegs and secure the clip.
Install the scuff plate trim panel.
Install the hood release lever and secure with the screw.

6 . Using WDS, configure a new CJB.

418-01 : Module Configuration
There are two modes of configuration data. The first type requires configuration information so that
the module can interact with the vehicle correctly. This information will be transferred to the new
module using the manufacturer approved diagnostic system, so that it will contain the same settings
as the old module.
New modules which require configuration after installation are:
• Anti-lock control - stability assist module

• Speed control module
• Climate control module
• Adaptive damping module
• Headlamp levelling module
• Driver door module (DDM)
• Driver seat module (DSM)
• Engine control module (ECM)
• Parking brake module
• Central Junction Box (CJB)
• Navigation system display module
• Integrated audio module (CD player)
• Information and entertainment module
• Integrated control panel
• Audio amplifier
• Remote keyless entry (RKE) module
• Multimedia (navigation) module
• Parking aid module
• Passenger door module (PDM)
• Pedestrian protection system module
• Passenger seat module (PSM)
• Restraints control module (RCM)
• Rear Junction Box (RJB)
• Transmission control module (TCM)
• Telephone control module
• Tire pressure monitoring system
Customer Driven Preferences
The second type of configuration data is customer preference driven. These are items that the
customer may or may not want to have enabled. Typically, customer preference items can be toggled
on or off by the use of a compatible scan tool. You may need to ask the customer which preferences
they had enabled prior to installation of a new module, although after installation they will
automatically learn the settings by receiving information from existing modules.
To carry out the customer preference configuration process, use the manufacturer approved
diagnostic system. Refer to the configuration menu and select 'Vehicle Configuration'. Customer
options can be selected or de-selected by modifying the 'Car Configuration File'.
418-02 : Wiring Harnesses
Engine Wiring Harness - 4.2L NA V8 -

AJV8
Removal
2



Remove the nut.
10 . Remove the engine cover RH bracket.
Remove the 2 nuts.
11 . Remove the engine cover LH bracket.
Remove the 2 nuts.

12 . Release the engine wiring harness from the rear of the engine.
Remove the 2 bolts.
13 . Release the engine wiring harness from the intake manifold.



21 . NOTE:
Release the engine wiring harness from the LH valve cover.
Repeat the above procedure for the RH side.
22 . NOTE:
Disconnect the LH variable camshaft timing ( VCT) oil solenoid electrical connector.
23 . NOTE:
Remove the LH ignition coil-on-plug cover.
24 . NOTE:
Disconnect the ignition coil-on-plug electrical connector.
Repeat the above procedure for the remaining 7 coil-on- plugs.
25 . Disconnect the LH camshaft position CMP sensor electrical connector.

26 . Disconnect the RH CMP sensor electrical connector.
27 . Release the RH CMP sensor electrical connector.
28 . Disconnect the engine front cover ground cable.

Remove the bolt.

Remove the 4 bolts.

32 . LH side: Release the engine wiring harness.
Release the clip.

Release the clip.
36 . NOTE:
Disconnect the crankshaft position (CKP) sensor electrical connector.
37 . Disconnect the starter motor battery positive and generator cables.

Release the cover.
Remove the nut.

Release the cover.
Remove the nut.
43 . Release the generator.
Remove the nut.
Position the generator aside to access the engine wiring harness clips.
45 . Remove the engine wiring harness.
Installation
Secure the clips.
Secure the cover.
Tighten the screws.
9 . Connect the starter motor battery positive and generator cables.
Secure the cover.

10 . Connect the CKP sensor electrical connector.
Secure the 2 clips.
12 . Connect the A/C compressor electrical connector.
Secure the clips.

16 . Connect and secure the ECT sensor electrical connector.
17 . Connect the engine front cover ground cable.
18 . Connect and secure the CMP sensor electrical connectors.
19 . Connect the ignition coil-on-plug electrical connectors.

20 . Install the ignition coil-on-plug covers.
21 . Connect the VCT solenoid electrical connectors.
22 . Attach the engine wiring harness to the valve covers.
30 . Attach the engine wiring harness to the intake manifold.

31 . Attach the engine wiring harness to the rear of the engine.
32 . Install the engine cover LH bracket.
lb.ft).
33 . Install the engine cover RH bracket.

www.JagDocs.com



Engine Wiring Harness - 4.2L SC V8 -
AJV8
Removal
2



Remove the nut.
10 . Remove the engine cover RH bracket.
Remove the 3 nuts.
Release the hose.
11 . Disconnect the LH variable camshaft timing (VCT) oil control solenoid electrical connector.
12 . Remove the engine cover LH bracket.
Remove the 3 nuts.

Remove the 2 bolts.


19 . Disconnect the purge control valve (PCV) electrical connector.
20 . NOTE:
Remove the ignition coil-on-plug cover.
21 . NOTE:

Disconnect the ignition coil-on-plug electrical connector.
Repeat the above procedure for the remaining 7 coil-on- plugs.
22 . NOTE:
Release the coil-on-plug wiring harness.
23 . NOTE:
Release the engine wiring harness from the valve cover.

24 . Disconnect the LH camshaft position CMP sensor electrical connector.
25 . Disconnect the RH CMP sensor electrical connector.

26 . Disconnect the LH fuel injector wiring harness electrical connector.
27 . Disconnect the RH fuel injector wiring harness electrical connector.
31 . Disconnect the RH mass air flow (MAF) sensor electrical connector.

32 . Disconnect the engine front cover ground cable.
Remove the bolt.
33 . Disconnect the secondary air injection switching valve electrical connector.

35 . Release the engine wiring harness from the coolant manifold.
Remove the 2 bolts.

Remove the 4 bolts.
38 . LH side: Release the engine wiring harness.

Release the clip.
Release the clip.

42 . NOTE:
Disconnect the crankshaft position (CKP) sensor electrical connector.
43 . Disconnect the starter motor battery positive and generator cables.
Release the cover.
Remove the nut.


Release the cover.
Remove the nut.
49 . Release the generator.
Remove the nut.
Position the generator aside to access the engine wiring harness clips.
51 . Remove the engine wiring harness.
Installation
Secure the clips.
Secure the cover.
Tighten the screws.
9 . Connect the starter motor battery positive and generator cables.
Secure the cover.

10 . Connect the CKP sensor electrical connector.
Secure the 2 clips.
12 . Connect the A/C compressor electrical connector.
Secure the clips.

16 . Attach the engine wiring harness to the coolant manifold.
17 . Connect and secure the ECT sensor electrical connector.
18 . Connect the secondary air injection switching valve electrical connector.
19 . Connect the engine front cover ground cable.

23 . Connect and secure the fuel injector wiring harness electrical connectors.
24 . Connect and secure the CMP sensor electrical connectors.
25 . Connect the ignition coil-on-plug electrical connectors.
27 . Attach the engine wiring harness to the valve covers.
28 . Connect the PCV electrical connector.
29 . Install the ignition coil-on-plug covers.

30 . Connect the VCT solenoid electrical connectors.
37 . Attach the engine wiring harness to the rear of the engine.
38 . Install the engine cover LH bracket.
39 . Install the engine cover RH bracket.

Secure the hose.



419 : Electronic Feature Group
419-01A : Anti-theft - Active
Specifications
Specifications
Item Nm lb-ft lb-in

Antenna - bolt 5 - 44
Anti-theft alarm horn - nut 8 - 71
Battery backed sounder to bracket - nut 6 - 53
Battery backed sounder bracket to body - nut 8 - 71
Intrusion sensors - nut/screw 2 - 18
Keyless vehicle module - nut 5 - 44
Anti-Theft - Active
Authoring Template
COMPONENT LOCATION
Part
Item Description
Number
2 Left Hand (LH) and Right Hand (RH) door latch micro switches
3 Central Door Locking (CDL) RF receiver
4 Liftgate latch micro switch
5 Slave intrusion detection module
6 Intrusion detection module
7 Hood ajar switch
8 Passive anti-theft alarm horn (if fitted)
Battery backed sounder (if fitted) or battery backed sounder with tilt sensor (if
9
fitted)
10 Vehicle horns
INTRODUCTION
The active anti-theft system monitors the hinged panels for unauthorized opening. In some markets
the anti-theft system also incorporates monitoring of the vehicle interior and vehicle tilt sensing.
The active anti-theft alarm system is controlled by the following body system control modules:
• Central Junction Box (CJB)

• LH door module
• RH door module
• Auxiliary junction box
• Keyless vehicle module
• Instrument cluster.
The CJB is the main controller in the system. The CJB controls the following security functions, in
addition to other vehicle functions:
• Locking, double locking and unlocking

• Monitoring of hinged panel microswitches and panel ajar states
• Microwave intrusion detection modules
• Anti-theft horns or battery backed sounder
• Passive arming and disarming
• Panic alarm function
• Transceiver coil and transponder reading
• Valet function (via Touch Screen Display (TSD))
• Interior lighting.
Two levels of vehicle locking are available; perimeter mode locks all opening panels and volumetric
mode (if fitted) monitors the vehicle interior for intrusion and incorporates a tilt sensor to monitor if
the vehicle is being moved.
Door Modules
The door modules provide the interface between the door latch motors, the door and latch
microswitches and the CJB. The door modules provide door microswitch switch status information
and enable the door motors on request from the CJB or the keyless vehicle module. Additionally, the
door modules also control the exterior mirror functions. For additional information, refer to Rear
View Mirrors (501-09)
Auxiliary Junction Box and Central Junction Box (CJB)

The auxiliary junction box controls, in conjunction with the CJB:
• the horns
• the liftgate latch motors and microswitches (including the liftgate external release switch)
• the liftgate ajar switch
• the turn signal indicators
• the fuel filler flap operation
The auxiliary junction box is also has a connection to the Restraints Control Module (RCM) for
automatic operation of the interior lights and the turn signal indicators in the event of an accident.
The CJB and auxiliary junction box are both fitted with an anti-theft sense line. If the auxiliary
junction box is disconnected when the alarm system is active, the full alarm will be activated by the
CJB. If the CJB is disconnected when the alarm system is active, the auxiliary junction box takes
control of the security system and sounds the full alarm. The alarm will also be activated if the
instrument cluster is disconnected when the active anti-theft alarm system is active.
NOTE:
If the CJB is replaced, the new module will require configuring to the master car configuration
using the Integrated Diagnostic System (IDS).
The CJB automatically arms and disarms the active anti-theft system when the vehicle is locked and
unlocked after successful confirmation that a valid remote handset/smart key has been used.
Keyless Vehicle Module

The keyless vehicle module interfaces with the CDL 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 Controller Area Network (CAN) bus to the CJB, auxiliary junction box,
the door modules and the instrument cluster.
The keyless vehicle module also monitors the liftgate external release switch, 2 interior antennae, 1
luggage compartment antenna and an additional rear bumper antenna and 2 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 which is incorporated into the sunload/light
sensor mounted on the instrument panel.
The instrument cluster also controls, in conjunction with the Engine Control Module (ECM), 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 Light Emitting Diode (LED) located in the body of the sunload/light sensor.
When the ignition is off the indicator gives a visual indication of the active anti-theft system to show
if the alarm system set or unset.
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. For
additional information, refer to Anti-Theft - Active (419-01A)
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.
Passive Anti-Theft Horn (if fitted)
The passive anti-theft horn is located in the RH rear corner of the engine compartment and attached
to the bulkhead. The anti-theft horn is connected directly to the CJB which activates the anti-theft
horn when the alarm is triggered.
Battery Backed Sounder (if fitted)
The battery backed sounder is located in the RH rear corner of the engine compartment and
attached to the bulkhead.
On vehicles with a battery backed sounder, a tilt sensor can be incorporated which monitors the
vehicle attitude. The CJB monitors the tilt sensor and can detect if the vehicle is being moved, towed
or raised and activate the alarm system. The type of battery backed sounder can be identified by a
suffix change to the part number; sounders without a tilt sensor have the suffix AA and sounders
incorporating a tilt sensor have the suffix BA.
Operation of the sounder is controlled by the CJB on a Local Interconnect Network (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.
Intrusion Detection Modules
The intrusion detection modules are an optional fitment in some markets and are not available in
other markets. Two intrusion detection modules are fitted. One module is located on the front of the
floor console and monitors the front seat area, the second module is fitted at the rear of the floor
console and monitors the rear seat area. The modules are wired together in parallel with the forward
module being the master and the rearward module being the slave module.
Each intrusion detection module comprises two microwave sensors which allow the interior of the
vehicle to be monitored. The intrusion detection modules also monitor the vehicle interior on soft
top models when the soft top is down.
The intrusion detection modules are activated with the 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 'Intrusion/Tilt' option in
the 'Vehicle Settings' screen on the Touch Screen Display (TSD).
NOTE:
The TSD method of de-activation of the intrusion detection modules is only for one arm cycle.
They will revert to active once the vehicle is subsequently unlocked and then locked.
When the volumetric mode is active, if the vehicle battery voltage falls to below 9 volts, the CJB will
ignore any inputs from the modules to prevent false alarm activation.
CONTROL DIAGRAM
NOTE:
A = Hardwired; D = High speed CAN bus; N = Medium speed CAN bus; O = LIN Bus
Item Part Description

Number
1 Battery
2 Megafuse (175A)
3 Megafuse (175A)
5 CJB
7 Vehicle horns
8 Liftgate latch ajar switch
9 Intrusion detection module
10 Slave intrusion detection module
12 Hood ajar switch
13 CDL RF receiver
15 Light sensor (security LED)
16 RH door module
17 LH door module
18 LH door latch ajar switch
19 RH door latch ajar switch
Battery backed sounder (if fitted) or battery backed sounder with tilt sensor (if
20
fitted)
21 Passive anti-theft alarm horn (if fitted)

The CJB automatically arms and disarms the active anti-theft system when it operates the Central
Locking System (CLS).
On vehicles without intrusion detection modules, only the perimeter mode is available to monitor
the hinged panels and the validity of the Smart key.
When perimeter mode is active, the CJB monitors panel ajar micro switches located in the latch
mechanisms of the driver and passenger doors and the liftgate. A separate hood ajar micro switch,
located in the engine compartment, monitors the hood status.
When volumetric mode is active, the CJB monitors the interior of the vehicle for movement using 2
microwave intrusion detection modules located within the center console.
Arming
On vehicles without intrusion detection modules and a tilt sensor, the active anti-theft system is
armed in the perimeter mode when the vehicle is either locked or double locked.
On vehicles fitted with intrusion detection modules, the system has 2 modes of operation; perimeter
mode and volumetric mode.
Perimeter Mode
• Perimeter mode only monitors the hinged panels and validity of the remote handset/smart
key in the start control module. Perimeter mode is activated by a single press of the lock
button on either the Smart key or the door handle lock button on vehicles with the Passive
Entry system.
Volumetric Mode
• Volumetric mode monitors the vehicle interior for intrusion. If the vehicle is fitted with a
battery backed sounder, which incorporates a tilt sensor, the vehicle attitude is also
monitored when volumetric mode is active. Volumetric mode is activated by a second press
of the lock button on either the Smart Key or the door handle lock button on vehicles with
the Passive Entry system. The second press of either lock button must occur within 3 seconds
of the first press. The second press of the lock button also activates the perimeter mode
double locking feature.
The CJB arms the active anti-theft system when it locks or double locks the vehicle providing the
following conditions are met:
• All doors, liftgate and hood are closed

• The Smart key is not sensed inside the vehicle
• With no valid Smart Key outside of the vehicle
• The CJB is not in transit mode.
When the vehicle has successfully completed its locking routine, confirmation will be given by a long
single flash of the turn signal indicators to indicate the locked condition. If double locking is activated
then confirmation will be given by a double flash of the turn signal indicators, one flash for locked
and one long flash for double locked. In certain markets an audible warning is emitted to confirm
arming or double locking.
Mislock
If any doors, liftgate or hood is open when a lock or double lock request is received, the anti-theft
alarm system remains disarmed and the CJB generates a short mislock sound on the vehicle horns,
battery backed sounder or passive anti-theft horn and the turn signal indicators will not flash. Each
attempt to lock will be confirmed by two audible chimes being emitted.
When the CJB arms the active anti-theft alarm system, it first enables perimeter mode and monitors
the status of the hinged panels. If the vehicle is double locked and the vehicle is fitted with a battery
backed sounder, an arming signal is sent from the CJB to enable the sounder. If the vehicle is fitted
with intrusion detection modules, the CJB then sends an arming signal to the modules and the tilt
sensor when double locked. The CJB ignores the signals from the intrusion detection modules for the
first 30 seconds to allow time for the vehicle interior to settle and prevent false alarm activation.
If the liftgate is opened via the Smart Key or external mechanical lock the intrusion detection
modules and the tilt sensor are inhibited until the liftgate is closed.
Disarming
The CJB will disarm the active anti-theft system when it receives an unlock request from the Smart
Key or, on vehicles with Passive Entry, when the Smart Key is sensed and the driver's or passenger
door handles are pulled.
The CJB can selectively disarm parts of the active anti-theft system to prevent false alarm activation
under certain conditions as follows:
• When the vehicle active anti-theft alarm system is armed in volumetric mode, if the vehicle
battery voltage decreases to less than 9 V, the CJB will disable the volumetric mode and
remain in the perimeter mode only. This prevents false alarm activation because the
intrusion detection modules do not operate below 9 volts.
• On vehicles fitted with a battery backed sounder, if the vehicle battery voltage decreases
from 9.5 to 9 V in more than a 30 minute period, the CJB de-activates the battery backed
sounder and if required, will use the vehicle horns to sound an audible alarm trigger warning.
This prevents false alarm activation. At voltages below 9 volts, the CJB will not generate the
'heartbeat' signal to the battery backed sounder. If the sounder fails to receive the
'heartbeat' signal, it interprets this as the CJB has been tampered with and self activates its
sounder. If the battery voltage subsequently rises above 9.5 V, the CJB will re-arm the
battery backed sounder.
• If the vehicle is unlocked using the unlock button on the smart key and within 45 seconds a
hinged panel is not opened, the CJB automatically re-locks the vehicle and re-arms the active
anti-theft system (if 'auto re-lock' feature is enabled). This prevents leaving the vehicle
unlocked and disarmed by accidental operation of the Smart Key unlock button.
Alarm
When the alarm is triggered, the CJB activates audible and visual warnings. The audible warnings are
produced by the vehicles horns, the passive anti-theft horn or the battery backed sounder or a
combination of the audible devices. Visible indications are produced using the turn signal indicator.
The CJB activates the vehicle horns, passive anti-theft horn or battery backed sounder for 30 seconds
or a combination of the audible devices. The activation is stopped for 5 second and, if the alarm
trigger is still present, the CJB will cycle again for 30 seconds. This will be repeated for up to a
maximum of 10 cycles (3 cycles in some markets) of 30 seconds for any one arming period. The CJB
will deactivate the alarm if the 10 cycles (3 cycles in some markets) have been completed and the
alarm trigger is still present or until it receives a disarm signal.
NOTE:
If the battery backed sounder is triggered due tamper detection, the visual indication using the
turn signal indicators is not activated.
The alarm can be triggered by any of the hinged panels being opened, an intrusion detection module
detects a movement inside the vehicle, the tilt sensor detects vehicle movement, the CJB is
disconnected or an ignition tamper is detected (invalid Smart Key).
Battery Backed Sounder

When the CJB arms the active anti-theft system, in either the perimeter mode or the volumetric
mode, the CJB sends an arming signal to the sounder on the LIN bus. When the system is armed in
the volumetric mode, the CJB also sends an arming signal to the tilt sensor (if fitted).
On receipt of the arming signals, the sounder and the tilt sensor respond with a status message. If
the CJB does not receive the status signals within 12 seconds, the CJB assumes there is a fault and
responds with a disarm signal to either the sounder and/or the tilt sensor and stores a related fault
code. If the sounder is disarmed when the active anti-theft system is armed and the system is
subsequently triggered, the CJB instructs the auxiliary junction box to energize the horn relay and use
the vehicle horns to sound the audio warning in place of the sounder.
When the sounder is armed, the CJB sends a periodic (heartbeat) signal to the sounder which
prompts the sounder to monitor the vehicle battery supply and the LIN bus link with the CJB. The
sounder will operate if:
• it receives an alarm signal from the CJB or the tilt sensor

• the power supply or the LIN bus link from the CJB is disrupted.
The tilt sensor measures the longitudinal and lateral angle of the vehicle over a range of ±16° from
the horizontal. When the active anti-theft system is armed in volumetric mode, the tilt sensor stores
the current vehicle angles in its memory and monitors the tilt sensor readings. If the vehicle angle
changes in either direction by more than the alarm limit, the tilt sensor activates the sounder.
If the alarm system is active and the battery or battery backed sounder is disconnected, the battery
backed sounder will operate without the visual indication of the turn signal indicators flashing.
Customer Programmable Security Features

A number of security features can be programmed to the customers requirements by use of the
Touch Screen Display (TSD).
Global Open/Close
The global open/ close feature allows the driver to fully raise/lower the driver and passenger
windows with a single press of a Smart Key button. The button must be pressed and held for more
than 2 seconds. Either or both of the open/close functions can be disabled from the TSD.
NOTE:
Remote global close is not available in some markets, i.e. NAS market.
From the 'Home' screen, select the 'Vehicle' screen and select 'Veh. Settings'. The 'Security button
will be highlighted as the default selection. Scroll the screen until the 'Global Open' and 'Global Close'
selections are displayed. Global open and/or global close can be switched on or off by touching the
applicable button on the TSD.
Valet Mode
Valet mode allows the liftgate to be inhibited when in valet mode. When in valet mode, if either the
switch pack or exterior luggage compartment release button is pressed, an audible warning chime is
emitted to warn that the liftgate is inhibited.
Enabling Valet Mode

Using the emergency key from the Smart Key, lock the glovebox. From the 'Home' screen, select the
'Valet' button'. The valet mode screen is displayed and requires a four digit Personal Identification
Number (PIN) for access. Enter the PIN using the digits on the TSD and press 'OK'. When the PIN is
accepted the screen displays 'Valet On'. The glovebox and the liftgate are now locked in valet mode.
On leaving the vehicle, only give the attendant the Smart Key without the emergency key installed.
Disabling Valet Mode

After entering the vehicle, access the valet mode screen and enter the four digit PIN number and
touch the 'OK' button. When the PIN is accepted, the screen displays 'Valet Off'. Unlock the glovebox
using the emergency key and replace the emergency key in it stowage slot in the Smart Key.
Single Point Entry

The single point entry feature only unlocks one door, all other panels remain locked.
On vehicles with the remote Central Locking system (CLS), a single press of the unlock button on the
Smart key unlocks only the driver's door and the liftgate. A second press will unlock the passenger
door.
On vehicles with the passive entry system, the first door handle which is pulled will only open that
door to gain access to the vehicle. The remaining door and the liftgate will revert to central locking.
The locked door can be unlocked by operating the interior door release lever and the liftgate can be
released using the liftgate release button in the auxiliary lighting switch, the Smart Key liftgate
release button or the exterior liftgate release button.
From the 'Home' screen, select the 'Vehicle' screen and select 'Veh. Settings'. The 'Security' button
will highlighted by default. Select '2 stage unlock' and touch the on or off button to enable or diable
the single point entry feature.
Changing from central locking to single point entry and back again can also be carried out by pressing
the lock and unlock buttons on the Smart Key simultaneously. The turn signal indicators will flash for
4 seconds to confirm that the change has been performed.
Drive Away Locking

The drive away door locking feature locks the doors and the liftgate if they are unlocked when the
transmission selector lever is not in 'P' and the vehicle speed is more than 7 km/h (5 mph).
From the 'Home' screen, select the 'Vehicle' screen and select 'Veh. Settings'. The 'Security' button
will highlighted by default. Scroll the screen until the 'Drive away locking' section is displayed. Select
the drive away locking feature on or off by touching the applicable button on the TSD.
Smart Key Additional Features

The Smart Key has convenience buttons in addition to the lock/unlock buttons.
Panic alarm
A panic alarm feature allows the driver to activate the vehicle alarm system using the Smart Key. The
'panic' button, identified by a triangle symbol, can be pressed 3 times or pressed and held for more
than 3 seconds to activate the panic alarm.
Global Open/Close
A global open and close feature can be operated from the Smart Key. This feature allows the vehicle
windows to be opened/closed by a single press of the lock or unlock button. The button must be
pressed and held for more than 2 seconds to activate the global open/close feature.
NOTE:
Remote global close is not available in some markets, i.e. NAS market.
Liftgate Release
A liftgate release button can be pressed to open the liftgate. This will operate with car locked and
alarmed or unlocked. If the vehicle is locked and alarmed, when the liftgate release button is
pressed, the liftgate can be opened without triggering the alarm system. When the liftgate is
subsequently closed, the alarm will be re-activated.
Headlamp Convenience
A headlamp convenience button can be pressed to operate the headlamp to assist departure or
approach to the vehicle. A single press of the button will operate the headlamps for approximately
25 seconds after which they will automatically turn off. A second press of the button will turn off the
headlamps if the 25 second period has not been reached. Pressing the Stop/Start button within the
25 second period will also turn off the headlamp convenience feature.
Convenience Mode
When a door is opened, for a vehicle with either remote RF central locking or passive entry, the
vehicle’s electrical system initiates the convenience mode. The following systems become active:
• Memory - seat adjustment and steering column

• Interior and exterior lighting
• TSD and Audio
• Instrument cluster message centre
• Horn
• Cigar lighter and power socket.
Anti-Theft - Active
The complexity of the electronics involved with the anti-theft system, and the multiplexed
communication network which are connected to it, preclude the use of workshop general
electrical test equipment. Therefore, reference should be made to the manufacturer approved
diagnostic system for detailed instructions on testing the anti-theft system.
The manufacturer approved diagnostic system systematically tests and analyses all functions
and the various systems affected by it.
Where a fault is indicated, some basic diagnostic methods may be necessary to confirm that
connections are good and that wiring is not damaged before installing a new component.
Antenna
Removal
2 . Remove the keyless vehicle antenna.
Installation
1 . Install the keyless vehicle antenna.

Anti-Theft Alarm Horn (86.52.03)
Removal
1 . Make the pedestrian protection system safe.
Remove the 3 clips.
3 . Release the pedestrian protection actuator bracket.
Remove the 4 bolts.
4 . Remove the pedestrian protection actuator and bracket.

5 . Remove the anti-theft alarm horn.
Loosen but do not remove the 2 nuts.
Installation
1 . Install the anti-theft alarm horn.
2 . Install the pedestrian protection actuator and bracket.
3 . Secure the pedestrian protection actuator bracket.
Attach the wiring harness clips.

Install the 3 clips.
Rear Intrusion Sensor
Removal
2 . Remove the rear intrusion sensor.
Installation
1 . Install the rear intrusion sensor.

419-01B : Anti-Theft - Passive
General procedures
Anti-Theft Security Access

1. The complexity of the electronics involved with the passive anti-theft system of which the
security access is a part, and the multiplexed communication network which are connected to
it preclude the use of workshop general electrical test equipment. Therefore, reference should
be made to the Jaguar approved diagnostic system for detailed instructions on security access .
The Jaguar approved diagnostic system systematically tests and analyses all functions and the
various systems affected by it.
Key Programming Using Diagnostic
Equipment
1. The complexity of the electronics involved with the anti-theft, of which the key
programming is a part, and the multiplexed communication network which are connected to it
preclude the use of workshop general electrical test equipment. Therefore, reference should be
made to the Jaguar Approved Diagnostic System for detailed instructions on key
programming . The Jaguar approved diagnostic system systematically tests and analyses all
functions and the various systems affected by it.
All new keys must be programmed using IDS. When using IDS to programme new key(s), the
lost or obsolete key(s) will cease to function.
COMPONENT LOCATION
1 Starter motor and solenoid

3 Electric steering column lock (Not NAS)
4 RF receiver
5 Start control module
7 Low Frequency (LF) antennae - Passive start system (3 off)
INTRODUCTION
The Passive Anti-Theft System (PATS) prevents the vehicle from being driven away by unauthorized
persons. This is achieved by having uniquely coded keys (both passive and transponder) and an
encoded data exchange between multiple control modules. Unauthorized starting is prevented by
inhibiting the fuel, engine (spark, injectors and crank) and ignition systems from operating.
The PATS is a function of the 'Passive Start' system. The system uses the following components:
• 'Smart Key'
• LF antennae - 3 off
• RF receiver
• Keyless vehicle module
• Start control module
• CJB
• ECM
• Instrument cluster.
The system is automatic and requires no input from the driver. The engine start system is initiated
when the start/stop switch and the brake pedal are pressed simultaneously. Refer to Engine Controls
for details of the ignition modes. For additional information, refer to Electronic Engine Controls (303-
14 Electronic Engine Controls - Vehicles Without: Supercharger)
The engine management system will only allow engine crank, spark and injector functions when the
following conditions are met:
• A hardwired Park/Neutral signal is received from the Transmission Control Module (TCM)
• A hardwired ignition signal is received from the CJB
• A hardwired crank request signal is received from the CJB
• Encrypted data exchange between the instrument cluster and the ECM is verified.
Before the CJB will send the hardwired ignition signal, it must satisfactorily complete the following:
• Exchange encrypted data with the keyless vehicle module to validate the smart key
• Exchange encrypted data with the instrument cluster to authorize the ignition status.
Additionally, before the CJB will send the hardwired crank request signal it must receive the following
signals:
• Brake pressure signal from the ABS module which must be greater than a pre-determined
threshold
• Hardwired transmission in 'Park' (P) signal from the selector lever.
START CONTROL MODULE
The start control module is located in the floor console, at the rear of the arm rest. 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 any reason, 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'.
The Smart Key can be inserted into the start control module.
To insert the Smart Key, lift the arm rest on the floor console and slide back the spring loaded access
cover on the start control module. Insert the Smart Key, with the key fob loop uppermost, into the
slot. The start control module is motorized and will draw the Smart Key into the slot once inserted.
The start control module will then read the transponder within the Smart Key and, if the transponder
identification is valid, pass authorization to the instrument cluster on the Local Interconnect Network
(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 with a new CR2032 battery 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. The Smart Key can be removed by pushing downwards on the key
fob loop and releasing. The start control unit motor will then drive the Smart Key out from the slot.
LF ANTENNA
Three Low Frequency (LF) antennae for the passive start system are positioned in specific locations in
the vehicle. The LF antennae are positioned in the following locations:
• Behind center console, below heater assembly and audio modules.

• In floor console between the driver and passenger seats, below start control module.
• On the battery tray.
NOTE:
On vehicles with the passive entry system, three 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 is located on the Right Hand (RH) 'A' pillar. The module controls signal
transmissions to and from the Smart Key and provides authorization to allow the vehicle to be
entered and started. The module has a medium speed Controller Area Network (CAN) connection to
the Central Junction Box (CJB) for authorizing vehicle unlocking and starting.
RF RECEIVER
The RF receiver is located behind the overhead console. The receiver is available in two variants; 315
Mhz or 433 Mhz depending on market requirements. Transmissions are received from the Smart Key
for key identification and remote lock/unlock requests or requests for operation of additional
features.
CONTROL DIAGRAM
NOTE:
A = Hardwired; D = High speed CAN bus; N = Medium speed CAN bus; O = LIN bus
1 Battery
2 Megafuse (400 A)
3 Megafuse (175 A)
4 Megafuse (175 A)
5 CJB
8 Starter motor and solenoid
9 ECM
10 Electric steering column lock (Not NAS)
12 ABS module
14 RF receiver
At the request of the CJB, the keyless vehicle module prompts each of the LF antennae to output a LF
signal. When the Smart Key is within range, it detects the LF signals and responds with an RF
identification signal. The RF signal is detected by the RF receiver and passed to the keyless vehicle
module.
NOTE:
The LF antenna located in the rear bumper and in each door handle are only fitted if the vehicle
has the Passive Entry option.
The keyless vehicle module authorizes the Smart Key and passes this information to the CJB via the
medium speed CAN bus. Once the CJB receives the authorization and confirms response with internal
calculation, it passes the result to the instrument cluster on the medium speed CAN bus. Once the
CJB receives the authorization and confirms the response, it allows the ignition to be activated when
the start/stop switch is pressed.
On receipt of the authorization message, the instrument cluster initiates the unlocking of the electric
steering column lock (if fitted). Once the electric steering column lock is unlocked and power has
been removed, the instrument cluster will set its internal key status to valid. The instrument cluster
will pass this key valid authorization to the auxiliary junction box. Once the auxiliary junction box
receives the authorization and confirms the response with an internal calculation, it will enable the
Fuel Pump Driver Module (FPDM).
The CJB also controls the engine crank request. If the transmission selector lever 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.
NOTE:
If the Smart Key is not in the vehicle and an attempt is made to start the engine by pressing the
start/stop switch, a message 'SMART KEY NOT FOUND, PLEASE INSERT IN SLOT' is displayed in
the instrument cluster message center.
If the keyless vehicle module is unable to identify the Smart Key for any reason, the Smart Key can be
inserted into the start control module. The start control unit will then read the transponder within
the Smart Key and, if the transponder identification is valid, pass authorization to the instrument
cluster on the Local Interconnect Network (LIN) bus.
If a replacement Smart Key is required, 2 Integrated Diagnostic System (IDS) diagnostic procedures
are required to synchronize the passive start/entry and transponder functions of the Smart Key. If
any module, which is involved in the Smart Key authorization process, require replacement, an IDS
diagnostic procedure is also required to synchronize the replacement module into the system.
For a detailed description of the Anti-Theft - Passive system, refer to the relevant Description and
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 in floor console cubby box), 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 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 'Not In Park' switch (input to the
CJB) or 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:
Due to Smart Start both sides of Relay Coil are switched directly from ECM (If conditions correct)
Check that the Steering Column Lock correctly operates and the steering wheel can turn freely.
Check that the 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 0x03, 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.
LED
Ignition
Mode of Operation/Fault When Logged DTC Fault Indication
Status
Code
Transition 3 Seconds of
Prove out N/A from OFF N/A N/A steady
to ON illumination
OFF - Off or 0.5Hz

Vehicle flashing at 5%
Perimeter Anti-theft Control N/A N/A N/A
locked and duty cycle ± 20%
armed until Off
Start Control Unit already

Key Insert Any B1B0105 N/A No Indication
programmed
Start Control Unit status =

invalid response
Start Control Unit programming

error
Start Control Unit challenge

Key Insert OFF B1B0162 N/A No Indication
response error
Key Programming timer expired

or Key Auth Timer expired
Transponder challenge response

error
Transponder keys stored below

B&A/Dealer Any B1B0100 N/A No Indication
minimum number required
Transponder not programmed B&A/Dealer Any B1B0155 N/A No Indication
If the instrument cluster sends a 60 seconds of

'theft' key status to the ECM or 4Hz flashing at
the ECM returns a status EMS CAN 50% duty cycle
OFF to ON B1B3364 16
message containing the data communication followed by fault
'Disabled/Theft', the instrument code 16 flashing
cluster will set this DTC 10 times
During manufacturing a Target

ID is transferred from the ECM
when requested by the 60 seconds of
instrument cluster. The steady
instrument cluster stores this indication
B&A/Dealer OFF to ON B1B3305 22
unique vehicle number in followed by fault
EEPROM. If this ID fails to store code 22 flashing
in EEPROM correctly, the 10 times
instrument cluster will set this
DTC
60 seconds of
If the status message received
steady
from the ECM contains the data
indication
challenge response error, the Challenge/Response OFF to ON B1B3362 23
followed by fault
code 23 flashing
DTC
10 times
After the instrument cluster has

transmitted its first PATS idle
60 seconds of
message, it will start a 2 second
steady
timer running. If the PATS
Idle message indication
sequence does not complete OFF to ON B1B3387 24
missing followed by fault
(Cluster received the Enable
code 24 flashing
msg) within this time period the
10 times
DTC
diagnostic system.
419-02 : Remote Convenience
General procedures

WARNING: A garage door opening system that cannot stop or reverse itself after
detecting an object in its path does not meet current federal safety standards. To
decrease the risk of serious injury or death, do not use this HomeLink transmitter with
a door opening system that lacks stop and reverse features as required by federal
standards. This includes any garage door opening system manufactured before April 1,
1982. For more information, call HomeLink customer assistance at 1-800-355-3515.
1.
CAUTION: During this procedure, the system that you are programming will be
made to operate. Make sure that people or objects are clear of the garage door or gate
being programmed.
Verify the hand-held transmitter is operative.
2. Prepare for programming the universal transmitter by erasing all three channels by holding
down the two outside buttons until the red light begins to flash (20-30 seconds). Release both
buttons.
3. Select one of the three universal transmitter channels to be programmed by pressing the
desired button.
4. Hold the end of the hand-held transmitter 50-150mm (2-6 in) from the front surface of the
universal transmitter so that the red light can still be seen.
5. NOTE:
During programming, the hand-held transmitter may automatically stop transmitting after
two seconds, which may not be long enough to program the universal transmitter. If
programming this type of hand-held transmitter, continue to hold the button on the
universal transmitter while re-pressing the hand-held transmitter button every two
seconds (Canada only).
Use both hands to press the hand-held transmitter button and the desired button on the
universal transmitter. Do not release either button.
6. Hold down both buttons until the red light on the universal transmitter flashes, first slowly
and then rapidly. Release both buttons when the rapid flashing begins. The universal
transmitter has successfully learned the new frequency signal and can be used in place of the
hand-held transmitter(s).
7. NOTE:
If the hand-held transmitter appears to program the universal transmitter but does not
open the garage door, the garage door opener may have a ' code protected' or ' rolling
code' feature.
To operate, simply press the appropriate button on the universal transmitter. The red light is
on while the signal is being transmitted.
Training a Garage Door Opener Equipped

With ' Rolling Codes'
1. Program the hand-held transmitter to the universal transmitter.
2. Train the garage door opener receiver to recognize the universal transmitter.
1. Remove the cover panel from the garage door opener receiver.
2. Locate the training button on the garage door opener receiver. Location and color of the
button may vary by garage door opener manufacturer. Refer to the garage door opener
instruction manual or call HomeLink customer assistance at 1-800-355-3515.
3. Press the training button on the garage door opener receiver for 1-2 seconds.
4. Press the programmed universal transmitter button for as long as the universal
transmitter red light flashes (1-2 seconds). Release the button and re-press the button to
confirm that the universal transmitter is trained to the receiver.
5. The garage door opener should recognize the universal transmitter.
Erasing Channels
1. NOTE:
Individual channels cannot be erased, but can be reprogrammed using the procedures for
programming.
To erase all three programmed channels, hold down the two outside buttons until the red light
begins to flash (20-30 seconds). Release both buttons.
Universal Transmitter
2 . Visually inspect for obvious signs of mechanical damage.
Mechanical
• Damaged universal transmitter

• Damaged receiver
4 . If the concern is not visually evident, verify the concern and refer to the Symptom Chart. Refer to
the electrical circuit diagrams for schematic and connector information.
Symptom Chart
The universal transmitter is • Universal transmitter GO to Pinpoint Test

inoperative • Receiver unit G92661p1.
Pinpoint Tests

UNIVERSAL TRANSMITTER IS
INOPERATIVE
G92661t1 : CHECK THE ROOF CONSOLE ASSEMBLY OPERATION
1. Check the illumination of the interior lamp.
• Does the interior lamp illuminate?

-> Yes
.
-> No
Check and rectify fault with interior lamp circuit. TEST the system for normal operation.
G92661t2 : PROGRAM HAND-HELD TRANSMITTER INTO UNIVERSAL

TRANSMITTER
1. NOTE:
If the garage door is equipped with rolling codes, refer to Training a Garage Door Opener
Equipped With "Rolling Codes."
Program the universal transmitter.

• Did the universal transmitter program successfully?
-> Yes
The universal transmitter is OK. VERIFY receiver operation.
-> No
REPLACE the roof console assembly. TEST the system for normal operation.
419-07 : Navigation System
Specifications
Specifications
Item Nm lb-ft lb-in

Antenna - bolt 1.5 - 13
Display module to module bracket - bolt 3 - 26
Display module to module bracket - screw 2.5 - 22
Navigation system module to bracket - bolt 2 - 18
Navigation System
COMPONENT LOCATION
Part
Item Description
Number
2 Touch Screen Display
3 Integrated Control Panel
4 Microphone
6 AM/FM antenna
8 GPS antenna
9 Information and entertainment control module
10 Audio amplifier
Vehicle Information and Communication Systems (VICS) beacon antenna (Japan

11
only)
INTRODUCTION
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 or motorways and the quickest or shortest route. Directions to hospitals, museums,
monuments and hotels are also available. The computer uses map information stored on a DVD-ROM
to determine the best route for the journey and provide the driver with details of directions and
approaching junctions.
The navigation system is controlled from the integrated control panel and the Touch Screen Display
(TSD). Control signals from the touch screen display are sent on the MOST ring to the navigation
computer. The navigation computer uses a dedicated GVIF bus to transmit its video signals to the
TSD.
Vehicles with navigation systems also incorperate additional traffic information systems. These are
market dependant and are as follows:
• Japan-Voice recognition and VICS

• Europe-TMC
• NAS-No TMC, VICS or voice rrecognition
1 TSD (rear)
2 ICP
3 TSD (front)
4 IAM
5 ICM
NAVIGATION COMPUTER
The navigation computer is located in the rear loadspace next to the battery.
The navigation computer incorporates the following:
• GPS receiver
• VICS receiver (Japan only)
• Traffic Message Channel (TMC) receiver
The navigation computer is connected to the MOST bus. The navigation computer generates its own
graphics and transmits them to the TSD on a dedicated GVIF (Gigabyte video Interface) bus.
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-ROM drive. The drive is used to read map data from region
specific DVD's. The regions are as follows:
• Europe (3 discs)
• NAS (2 discs)
• Japan, Middle east and Australia (1disc)
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 GPS receiver receives information from between 1 and 8 satellites at any one time. This
information is received from the GPS antenna. The built in GPS receiver is used for calculating the
position (i.e. Latitude, longitude and height), direction and speed.
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.
For the Japanese market the navigation computer incorporates a VICS receiver. The VICS receiver,
receives information from the beacon antenna in the center of the instrument panel and the electric
FM antenna. The VICS system receiver allows the vehicle to receive information about traffic
conditions from roadside transmitters and adjust the navigation instructions accordingly.
For ceratin European markets the navigation computer incorporates the Traffic Message Channel
(TMC) receiver. The TMC receiver decodes TMC data. The navigation computer then displays this
information on the TSD and also re-routes the navigation guidance around any traffic hold ups. The
TMC data is received via the electric FM (frequency modulation) antenna via the antenna signal
splitter.
TOUCH SCREEN DISPLAY (TSD)
The Touch Screen Display (TSD) is located in the center of the instrument panel. TSD is a touch
sensitive 7 inch LCD (liquid crystal display) VGA screen containing 800 x 480 pixels in a 15:9 format.
The TSD is connected to the Information and Entertainment system on the Media Oriented Systems
Transport (MOST) ring. The MOST ring is a fibre optic communications data bus that allows high
speed transfer of control instructions and audio around the system.
The TSD processes its own video for system operation but receives the navigation graphics from the
navigation computer on a dedicated serial link called GVIF (Gigabit Video Interface).
The TSD is also the control interface for the following vehicle systems:
• Climate control
• Audio system
• Heated seats
• Customer programmable security features
• Cellular phone
• Vehicle settings
The TSD navigation control signals are sent on the MOST ring to the navigation computer,
GPS ANTENNA
The GPS (global positioning system) antenna is located in the rear liftgate spoiler. The GPS antenna is
connected to the GPS computer by a single co-axial cable and passes signals from the GPS satellites
to the navigation computers built in receiver for processing.
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
• In 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 (digital versatile disc) map until the signal is restored.
INFORMATION AND ENTERTAINMENT CONTROL MODULE
The Information and Entertainment Control Module (ICM) is located between the TSD and the IAM.
The ICM is mounted in the vehicle using four M6 bolts.
The ICM is the gateway between the vehicle MS CAN bus and the Information and Entertainment
system MOST bus.
INFORMATION AND ENTERTAINMENT CONTROL PANEL
The Information and Entertainment Control Panel is connected to the MS CAN bus. The ICP
incorperates switches for audio system control, climate control hazard warning lamps and the
navigation system. The navigation system is operated from the TSD via signals on the MOST ring.
Hard switches on the ICP send CAN signals to the ICM which transfers signals to the relevant module
on the MOST ring.
VICS BEACON ANTENNA (JAPAN ONLY)
VICS Beacon Antenna
The VICS beacon antenna is located on top of the instrument panel. The antenna receives infra red
and RF signals from road side transmitters. The Antenna is connected to the navigation computer
which incorperates a VICS reciever.
CONTROL DIAGRAM
NOTE:
A = Hardwired; D = High speed CAN bus; N = Medium speed CAN; P = MOST ring; Q = GVIF; T =
Coaxial
Part
Item Description
Number
2 Steering wheel controls

4 Audio amplifier
5 Speakers
6 Microphone
Vehicle Information and Communication Systems (VICS) beacon antenna (Japan

9
only)
10 GPS Antenna
11 AM/FM antenna splitter
12 AM/FM antenna
13 Integrated Control Panel
15 Clock spring
The system used to calculate the current position of the vehicle is called the GPS (global positioning
system) . The system utilizes satellites which are owned by the United States Department of Defense
(DoD). A total of 24 satellites 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 (global positioning system) signal is also known as the Precision Positioning Signal (PPS).
PPS predictable accuracy is:
• 22 meters horizontal accuracy

• 27.7 meters vertical accuracy
• 200 nanoseconds time accuracy.
The navigation system provides computer generated 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 or highways and the quickest or shortest route. Directions
to hospitals, museums, monuments and hotels are also available. The computer uses map
information stored on a DVD-ROM to determine the best route for the journey and provide the
driver with details of directions and approaching junctions.
The navigation system receives GPS (global positioning system) 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 drivers
pre-determined preferences or the default settings in the navigation computer.
The navigation system is accessed by pressing the navigation soft key on the TSD.
Navigation is initiated by the driver inputting a destination. This can be achieved by:
• Entering in an address using the TSD.

• Entering a post code.
• Choosing a previous destination.
• Choosing a point of interest from the map disc database.
• Chosing the home location
• Chosing a memory stroed 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:
• Traffic Message Channel (TMC)

• Vehicle Information and Communication System (VICS) (Japan only).
Traffic Message Channel (TMC)

The Traffic Message Channel (TMC) is a function of the FM (frequency modulation) Radio Data
System (RDS). The system broadcasts real-time traffic and weather information. Data messages are
received and decoded by the TMC receiver and passed onto the navigation system, which then
delivers them via the navigation system interface. TMC 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 events on the map can be viewed not
just the ones on the calculated route.
TMC traffic information systems conform to a global standard that has been adopted by traffic data
gatherers, information service providers, broadcasters and vehicle/receiver manufacturers. TMC
information is received via the normal FM (frequency modulation) radio antenna.
All TMC 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 data is currently broadcast in many European countries.
Vehicle Information and Communication System (VICS)

The VICS system supplies the navigation computer with 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 three routes:
• RF transmission
• Infra-red transmission
• FM (frequency modulation) multiplex transmissions.
The RF 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.
The Infra-Red transmissions are received by the beacon antenna mounted on the top of the
instrument panel.
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 (frequency modulation) transmissions are broadcast as part of the normal RDS FM (frequency
modulation) transmission. 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.
FM transmissions are received via the FM antenna and split from the normal FM transmissions by the
FM signal splitter.
Navigation System
For a detailed description of the navigation system, refer to the relevant Description and Operation
Navigation System

2 . Visually inspect for obvious signs of damage, water ingress and system integrity.
• Navigation system display

• Navigation system module
• GPS antenna
• Navigation system DVD player Mechanism • Wiring harness for damage and corrosion
• ABS Module
• Audio unit
Index.
Symptom Chart
• Electrical harness
open/short circuit, dis-
Poor satellite reception connected GO to Pinpoint Test G841057p1.
• Component failure
• No reception from satellite
Map disc will not
open/short circuit, dis- GO to Pinpoint Test G841057p2.
insert/eject connected
• Map disc failure
Black screen open/short circuit, dis-
(navigation map screen connected GO to Pinpoint Test G841057p3.
does not display) • Component failure
• GVIF cable
Navigation map screen
connected GO to Pinpoint Test G841057p4.
color is abnormal • Component failure
• GVIF cable
Vehicle’s current
connected
position mark turns GO to Pinpoint Test G841057p5.
independently • Vehicle on a turntable in a
parking building
Car current position open/short circuit, dis-
GO to Pinpoint Test G841057p6.
not stable connected
• Map disc
contaminated/damaged
Map display is
open/short circuit, dis- GO to Pinpoint Test G841057p7.
incomplete connected
• Incorrect market map disc
• Voice guidance soft key set

No navigation voice to OFF position
guidance • Volume level set too low GO to Pinpoint Test G841057p8.
• Interruption during map

disc update
No response to
pressing navigation GO to Pinpoint Test G841057p9.
connected
menu • Incorrect Navigation
Control Module (NCM)
installed
data received
'NO DVD PLEASE

• A disc other than the map
INSERT MAP DVD' Insert the correct map disc
disc is inserted
message is displayed
'UNABLE TO READ Check and install a new Navigation

DATA CONSULT YOUR Control Module (NCM) as required.
• DVD player abnormality
DEALER' message is Refer to the new module/component
displayed installation note at top of DTC Index.
Move the vehicle to a cool location, and

'UNABLE TO READ • Operating temperature has turn the engine OFF. Wait for a while,
been exceeded
DATA TEMPERATURE IS then verify conditions again. If the
• Navigation Control Module
TOO HIGH' message is (NCM) internal temperature around the Navigation
displayed temperature is high Control Module (NCM) is high, take
measures to lower temperature
'UNABLE TO READ DVD • Check map disc for

CORRECTLY CHECK IF contamination,
Clean the map disc and retest, replace
THE DVD IS DAMAGED deformation, cracks,
scratches or non-genuine the map disc
OR DIRTY' message is
displayed disc
'UNABLE TO READ
DATA CHECK IF MAP • Incorrect DVD map disc is Insert a map disc with the correct part
DVD IS CORRECT' inserted number
message is displayed
DTC Index
NOTE:
NOTE:
diagnostic system).
NOTE:
NOTE:
NOTE:
NOTE:
terminals.
• Satellite antenna Check satellite antenna connections. Refer to

Satellite
B1A8911 circuit - short to the electrical circuit diagrams and test
antenna ground satellite antenna circuit for short to ground
• Satellite antenna Check satellite antenna connections. Refer to

Satellite
B1A8913 circuit - open the electrical circuit diagrams and test
antenna circuit satellite antenna circuit for open circuit
• Satellite antenna - Install a new navigation system module,

Satellite
B1A891B circuit resistance refer to the new module installation note at
antenna above threshold the top of the DTC Index
B1D5514 Antenna #2 • TMC/VICS FM Check TMC/VICS FM antenna connections.

antenna circuit - Refer to the electrical circuit diagrams and
Circuit open test TMC/VICS FM antenna circuit for open
circuit
Check VICS antenna connections. Refer to

Antenna #3 • VICS antenna
B1D5614 the electrical circuit diagrams and test VICS
Circuit circuit - open
antenna circuit for open circuit
Check ABS module and Instrument Cluster

for speed related DTCs and refer to relevant
• Missing vehicle
U200531 Control Module DTC Index.
speed message
Instrument Cluster
Install a new navigation system module,

• Internal electronic
U300049 Control Module refer to the new module installation note at
failure
Using the manufacturer approved diagnostic

system check/amend the Car Configuration
Stored vehicle File parameter in block 2, byte 127 to match
• Incorrect car
configuration vehicle market/specification. If the DTC
U300055 configuration data
data does not received remains check navigation system module
match part number and ensure the correct
component is installed to vehicle
market/specification
Re-configure the RJB using the manufacturer

approved diagnostic system. Check
navigation module for DTCs and refer to the
DTC Index. Check CAN network integrity
using the manufacturer approved diagnostic
system
• Component or Check for additional DTCs and refer to DTC

U300098 Control module system over Index. Clear DTC and re-test/monitor
temperature condition for re-occurrence
• Circuit voltage
Carry out any pinpoint tests associated with
mismatch with
U300362 Battery voltage this DTC using the manufacturer approved
navigation control
module diagnostic system
Carry out any pinpoint tests associated with

• Circuit voltage
U300317 Battery voltage this DTC using the manufacturer approved
above threshold
diagnostic system
Pinpoint Tests
NOTE:
any prior approval Program is in operation, prior to the installation of a new
module/component.
NOTE:
Navigation Diagnostic Screen Access
• 1.With the vehicle at rest, place the ignition switch in either "ACC", "ON", or start the
engine.
• 2.On the "Menu" screen, press the top center of the screen for more than three
seconds.
• 3.Enter the PIN code, and then touch "OK". 660: Diagnosis Menu screen 661: System
Check screen (DTC code verification screen) 662: GPS Information screen.
• 4.The diagnostics screen will be displayed.
PINPOINT TEST G841057p1 : Poor

satellite reception
G841057t1 : SYSTEM CHECK FOR DTCs
1. Check the system for DTCs which may be logged.
• Are any system DTCs logged?
-> Yes
Carry out repair actions to correct the DTCs logged.
Check satellite reception. GO to Pinpoint Test G841057t3.
-> No
G841057t2 : RETRO-INSTALL INSTALLATIONS CHECK

1. Check to see if there are any retro-install installations (anti-theft, radar, etc.)
• Are there any retro-install installations?
-> Yes
Aftermarket items may cause either electrical or radio frequency interference that can cause satellite
reception to deteriorate.
Remove the power supply (including backup power supplies) from any aftermarket items installed. If
reception returns to normal after disconnection of aftermarket items, carry out the following. Alter
the installation position of any aftermarket items. Check satellite reception. GO to Pinpoint Test
G841057t3.
-> No
G841057t3 : SATELLITE RECEPTION CHECKS

1. Check the 'ST' column of the navigation diagnostics GPS information screen (PIN code 662) after 10
minutes have passed. There must be more than 4 ‘P’s displayed for accurate positioning. Check the
‘HDOP’ value, this must be less than 5.
• Are there more than 4 'P's displayed and is HDOP less than 5?
-> Yes
Satellite reception is normal.
-> No
Confirm the GPS antenna is connected to the navigation module.
Refer to the electrical circuit wiring diagrams and check the integrity of the coaxial cable and
connectors from the Navigation Control Module (NCM) to the GPS antenna.
Install a new GPS antenna or coaxial cable as required.
Re-check satellite reception.
PINPOINT TEST G841057p2 : Map disc

will not insert/eject
G841057t4 : CHECK NAVIGATION DISC SLOT SHUTTER
1. Check the navigation map disc slot shutter is open.
• Is the navigation map disc slot shutter is open?

-> Yes
-> No
Open the map disc slot shutter.
G841057t5 : CHECK NAVIGATION MAP DISC WILL INSERT/EJECT

1. Check that it is possible to insert/eject navigation map disc.
• Is it possible to insert/eject navigation map disc?
-> Yes
Operation is normal.
-> No
Refer to the electrical circuit diagrams and check power supply and ground connections to the
Navigation Control Module (NCM). If power supply and ground connections are good, install a new
Navigation Control Module (NCM) as required. Refer to the new module/component installation
note at top of DTC Index.
PINPOINT TEST G841057p3 : Black

screen (navigation map screen does not
display)
G841057t6 : CHECK SCREEN SAVER FUNCTION
1. Check the screen saver function operation.
• Does the screen saver function operate?
-> Yes
Press the display panel button. GO to Pinpoint Test G841057t8.
-> No
G841057t8 : CHECK DISPLAY BACKLIGHT

1. Check the display backlight operation.
• Does the display backlight operate?
-> Yes
Refer to the electrical circuit diagrams and check the GVIF cable between Navigation Control Module
(NCM) and HLDF screen is properly connected.
If the GVIF cable between Navigation Control Module (NCM) and HLDF screen is properly connected,
check and install a new GVIF cable as required. Refer to the new module/component installation
If the GVIF cable between Navigation Control Module (NCM) and HLDF screen is properly connected
and NOT damaged, check and install a new Navigation Control Module (NCM) as required. Refer to
the new module/component installation note at top of DTC Index.
Re-check the system.
-> No
Check the HLDF display.
PINPOINT TEST G841057p4 : Navigation

map screen colour is abnormal
G841057t9 : COLOUR BAR CHECK
1. Carry out the display diagnostics 'colour bar check' (PIN code 660).
• Are the results of the display diagnostics 'colour bar check' normal?
-> Yes
Check the HLDF display.
-> No
Check the condition of the map disc for dirt or scratches.
Refer to the electrical circuit diagrams and check the GVIF cable between Navigation Control Module
(NCM) and HLDF screen is properly connected.
If the GVIF cable between Navigation Control Module (NCM) and HLDF screen is properly connected,
check and install a new GVIF cable as required. Refer to the new module/component installation
If the GVIF cable between Navigation Control Module (NCM) and HLDF screen is properly connected
and NOT damaged, check and install a new Navigation Control Module (NCM) as required. Refer to
the new module/component installation note at top of DTC Index.
PINPOINT TEST G841057p5 : Vehicle’s

current position mark turns independently
G841057t10 : VEHICLES CURRENT POSITION MARK TURNS
INDEPENDENTLY
1. Determine if the ignition status was turned to Auxiliary or On, while the vehicle was in motion with
steering turned such as after an engine stall.
• Was ignition status set to Auxiliary or On?
-> Yes
The angular speed of the vehicle at the time of the ignition status change will be logged as the
standard value. To re-set the standard value, turn ignition status to 'OFF' then to 'Auxiliary' or 'On'
with the vehicle stationary.
Re-test the vehicle.
-> No
Check and install a new Navigation Control Module (NCM) as required. Refer to the new
module/component installation note at top of DTC Index.
PINPOINT TEST G841057p6 : Car

current position not stable
-> Yes
Re-check the system for car current position not stable.
-> No
G841057t12 : VEHICLE SPEED INPUT CHECK

1. Select Vehicle Sensor from the navigation diagnostic menu screen (PIN code 660), check Current
speed. The current speed must match the speedometer.
• From the Vehicle Sensor screen, does the current speed must match the speedometer?
-> Yes
-> No
Carry out MOST ring circuit checks.
Check the Anti-Lock Brake System Module for related DTCs and refer to the relevant DTC Index.
Carry out network integrity tests using the manufacturer approved diagnostic system. Refer to
electrical circuit diagrams and check CAN circuits if required. Repair wiring harness as required.
G841057t13 : CHECK NUMBER OF SATELLITES

1. From the navigation diagnostic GPS information screen (PIN code 662), check the number of
satellites displayed.
• Is the number of satellites displayed on the screen 0?
-> Yes
Carry out pinpoint test A "Poor Satellite Reception"
-> No
G841057t14 : CHECK IF SYMPTOMS ARE OCCURRING IN PARTICULAR

LOCATIONS
1. Confirm if the 'car current position not stable' symptom is occurring in particular locations.
• Is the 'car current position not stable' symptom occurring in particular locations?
-> Yes
Signal reflections from buildings or a particular location may be responsible.
-> No
Carry out pinpoint test A "Poor Satellite Reception"
PINPOINT TEST G841057p7 : Map
display is incomplete
-> Yes
Re-check the system for 'Map display is incomplete'.
-> No
G841057t16 : CHECK MAP DISC

1. Check map disc for contamination, deformation, cracks, scratches or non-genuine disc and correct
market.
• Has a fault been identified with the map disc?
-> Yes
Replace the map disc.
Re-check the system for 'Map display is incomplete'.
-> No
PINPOINT TEST G841057p8 : No

navigation voice guidance
G841057t17 : CHECK ALL AUDIO OUTPUT SYSTEMS
1. Check audio output across all systems.
• Is there sound output across all systems?
-> Yes
-> No
G841057t18 : CHECK VOICE GUIDANCE SOFT KEY

1. Check navigation screen menu, voice guidance soft key is not set to OFF position.
• Is the voice guidance soft key set to OFF position?
-> Yes
Set the voice guidance soft key to ON position.
Re-check the system
-> No
G841057t19 : VOLUME LEVEL CHECK

1. Check the volume level is not set too low.
• Is the volume level set too low?
-> Yes
Increase the volume level and re-test vehicle.
-> No
Refer to electrical circuit diagrams and check integrity of amplifier and speaker system wiring harness
and connectors.
G841057t20 : NAVIGATION VOICE ONLY NOT AUDIBLE

1. Press the 'Navigation voice repeat' soft key.
• After the navigation voice repeat soft key is pressed, can voice still not be heard even
though it has become louder?
-> Yes
-> No
PINPOINT TEST G841057p9 : No
response to pressing navigation menu
G841057t21 : NO RESPONSE TO PRESSING NAVIGATION MENU
1. Check that the engine was not turned 'OFF' during a navigation software update.
• Was the engine turned 'OFF' during a navigation software update?
-> Yes
Check the correct map disc is inserted into the Navigation Control Module (NCM). Start the engine
and allow to idle for 15 minutes Turn the engine 'OFF', and then start the engine again. Verify that
the navigation screen displays. Navigation was in the program update mode.
-> No

1. Check that the engine was not turned 'OFF' after inserting the new map disc.
• Was the engine turned 'OFF' after inserting the new map disc?
-> Yes
and allow to idle for 15 minutes Turn the engine 'OFF', and then start the engine again.
-> No

1. Check the "Loading" button on the navigation diagnostics screen (PIN code 660) has been pressed,
and "YES" has been selected.
• Has the "Loading" button on the navigation diagnostics screen been pressed, and has "YES"
been selected?
-> Yes
and allow to idle for 15 minutes Turn the engine 'OFF', and then start the engine again.
-> No
Refer to electrical circuit diagrams and check integrity of navigation system wiring harness and
connectors.

• Is DTC U300055 logged?
-> Yes
Using the manufacturer approved diagnostic system check/amend the Car Configuration File
parameter in block 2, byte 127 to match vehicle market/specification. If the DTC remains check
navigation system module part number and ensure the correct component is installed to vehicle
market/specification.
-> No

1. Turn the engine 'OFF', wait for a moment, and then turn the engine 'ON' again.
• Does the navigation screen fail to display even if the navigation button is pressed?
-> Yes
Check the HLDF is installed correctly.
Check the Navigation Control Module (NCM) is installed correctly.
-> No
Navigation System Antenna (86.62.06)

Removal
1 . Remove the rear spoiler.
For additional information, refer to Rear Spoiler (76.19.86.60)
3 . Remove the navigation system antenna.
Remove the 2 bolts.
Installation
1 . Install the navigation system antenna.

2 . Install the rear spoiler.

For additional information, refer to Rear Spoiler (76.19.86.60)
Navigation System Display Module
(86.62.07)
Removal
2 . Remove the instrument panel center reinforcement trim panel.
3
component.
Release the navigation system module bracket.

4 . NOTE:
Remove the navigation screen module.
Remove the trim panel veneer upper retaining clip.

Installation
1 . Install the navigation screen module.
Install the clip.
2 . Install the navigation system module bracket.
3 . Install the instrument panel center reinforcement trim panel.

Navigation System Module (86.62.05)
Removal
2 . Release the navigation system module bracket.
Remove the 4 nuts.
3 . Remove the navigation system module.

Installation
1 . Install the navigation system module.

419-08 : Cellurar Phone
Specifications
Specifications
Item Nm lb-ft lb-in

Cellular (Bluetooth) phone antenna 7 5 62
Transceiver module 6 4 53
Cellular Phone
COMPONENT LOCATION
3 Microphone

5 Speakers
7 Bluetooth antenna
10 Audio amplifier
INTRODUCTION
The cellular phone system is based on using the customers own Bluetooth capable handset with the
vehicle Information and Entertainment system.
NOTE:
There is no physical connection (cradle) between the phone handset and the Telephone Control
Module. Communications between the two components are purely Bluetooth. This can limit the
available functions dependant on the handset used.
The cellular phone system comprises the following components:
• Telephone Control Module

• Microphone
• Bluetooth antenna
The system allows the driver to send, receive and end phone calls using the Touch Screen Display
(TSD), steering wheel switches and voice recognition system.
Phone dialing is achieved using one of the following methods:
• Dialing a number using the TSD keypad

• Selecting a number from the handsets phonebook
• Selecting from the handsets 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 ring. This allows audio and control signals to be routed to and from the Telephone Control
Module.
CONTROL DIAGRAM
NOTE:
A=Hardwired; N=Medium speed CAN; P=MOST; T=Coaxial
3 Audio amplifier
4 Speakers
7 Bluetooth antenna
9 Microphone
10 Clock spring

Cellular Phone Antenna (86.51.17)

Removal
2 . Release the auxiliary junction box access cover.
3 . Remove the cellular phone antenna.
Remove the 2 nuts.

Installation
1 . Install the cellular phone antenna.
2 . Secure the auxiliary junction box access cover.
Secure in the clip.

Transceiver Module
Removal
2 . Remove the transceiver module.
Remove the 4 bolts.
Installation
1 . Install the transceiver module.

419-10 : Multifonction Electronic Modules
Specifications
Specifications
Item Nm lb-ft lb-in


COMPONENT LOCATION-MOST/LIN

4 SDARS/DAB module (where fitted)
6 Engine start control module
7 Audio amplifier
10 Drivers door module

COMPONENT LOCATION-MEDIUM SPEED CAN

6 Tire Pressure Monitoring System (TPMS) module
7 Convertible top control module (convertible vehicle only)
9 Passenger door control module
10 CJB
11 Parking aid control module
12 ATC control module

COMPONENT LOCATION-HIGH SPEED CAN
1 ECM
4 Pedestrian Protection System module

5 Headlamp leveling/adaptive front lighting module
7 Active Damping Control Module (ADCM)
8 Electric park brake module
9 RCM
10 L Gate
11 TCM
INTRODUCTION
The vehicle electrical system consists of a number of control modules connected via two multiplexed
CAN busses For additional information, refer to Communications Network (418-00 Module
Communications Network)
. The Instrument cluster acts as a gateway between the two CAN bus systems.
Lower speed control modules use a Local Interconnect (LIN) Bus. Control modules on the LIN bus are
generally configured to be master/slave i.e. one module controls other module(s).
The vehicle entertainment system uses a fibre optic bus system which uses the MOST protocol for
transmission of data and audio to the relevant components of the audio system.
Module Bus System Function Location
ECM HS CAN Controls the engine in response to Front LH side in engine

various sensor inputs. compartment adjacent
to bulkhead.
ABS HS CAN Controls the braking force applied to In the engine

the road wheels. compartment next to
the ECM.
Instrument cluster HS CAN Gateway between High speed and On the drivers side in
and MS Medium speed CAN, Gateway the instrument panel.
CAN LIN between the CAN busses and the LIN
Bus. bus
Parking aid control MS CAN. Control of parking sensors and Lower LH A post below
module routing of audio feedback to driver the CJB.
Navigation computer MOST, Route guidance out put based on In the luggage
GVIF inputs from GPS satellites and driver compartment to the
destination. right of battery.
RCM MS CAN. Controls the deployment of On the transmission

supplementary restraint tunnel between the
components. seats under the trim.
Tire Pressure MS CAN. Monitors the vehicle tires to warn of Behind the rear seats
Monitoring System deflation. next to the Auxiliary
(TPMS) module Junction Box.
TCM MS CAN. Electronic control of the automatic In the sump of the

gear change. transmission.
Steering column lock MS CAN. Inhibits the steering from being On the steering column.
turned without the proper security
parameters being met.
Headlamp HS CAN. Controls headlamp levels and RH foot well mounted

leveling/adaptive front adaptive front lighting system. against inner bulk head.
lighting module
Adaptive speed control HS CAN. Controls vehicle road speed in At the bottom of the RH
module relation to other vehicles when in A post.
speed control mode.
CJB MS CAN. Controls body functions and power In the passenger

distribution. compartment LH side on
the A post.
Auxiliary junction box MS CAN. Controls body functions and power In the center behind the
distribution. backrest of the rear
passenger seat.
Active Damping Control HS CAN. Controls the adjustment of the Behind the backrest of
Module (ADCM) dampers. the RH rear passenger
seat.
Electric park brake HS CAN. Controls the application and release Behind the auxiliary
module of the parking brake. junction box.
Air conditioning control MS CAN. Controls the operation of the climate Attached to the side of
module control/air-conditioning system. Air conditioning unit.
Information and MS CAN. Gateway between the MOST and Behind the Touch Screen
entertainment control CAN systems for information and Display and above the
module control distribution. integrated audio unit.
Drivers door module MS CAN. Memory/adjustment functions for In the drivers door
seats, steering column and mirrors behind the trim.
and security functions.
Passenger door module MS CAN. Memory/adjustment functions for In the passenger door
seats, steering column and mirrors behind the trim.
and security functions.
Integrated control MS CAN. Contains controls for entertainment Center of the instrument
panel system and air conditioning system panel surrounding the
Touch Screen Display.
Drivers seat module MS CAN. Controls seat positioning and Under the drivers seat.
memory seat functions.
Passenger seat module MS CAN. Controls seat positioning and Under the front
memory seat functions. passenger seat.
Keyless vehicle module MS CAN. Allows the vehicle to be opened and Right hand ‘A’ Post.
started without the use of a key.
L Gate MS CAN. Electronic control of the selected On top of the

gear/driving mode. transmission tunnel.
Key Start Control LIN Bus In the center consol.

Module
Pedestrian Protection HS CAN. Control and monitoring of Pedestrian On the RH side under
System module Protection System the wheel arch liner at
the top of the wheel
arch.
Multifunction Electronic Module

For a detailed description of the multifunction electronic control modules, refer to the relevant

2 . Visually inspect for obvious signs of electrical damage.
Electrical
• Fuse(s)
• Wiring Harness
DTC Index
NOTE:
NOTE:
The DTC Index in this section shows information for DTCs that could be logged in the Driver Door
Module (DDM) or Passenger Door Module (PDM). For diagnosis and testing information for:
Driver/Passenger Seat module.
Seats Information and Entertainment module.
Audio System Remote Keyless Entry module.
NOTE:
diagnostic system).
NOTE:
NOTE:
NOTE:
NOTE:
terminals.

Front Courtesy diagrams and test front
B109C15 • Short to power or open circuit
Light courtesy light circuit for short
to power or open circuit
B109D11 Front Courtesy • Short to ground Refer to the electrical circuit

Light courtesy light circuit for short
ground

Driver door double diagrams and test driver door
B10EB11 • Short to ground
locking motor double locking motor circuit
for short ground

diagrams and test driver door
Driver door double
B10EB15 • Short to power or open circuit double locking motor circuit
locking motor
for short to power or open
circuit

Passenger door
diagrams and test passenger
B10EC11 double locking • Short to ground
door double locking motor
motor
circuit for short ground

Passenger door diagrams and test passenger
B10EC15 double locking • Short to power or open circuit door double locking motor
motor circuit for short to power or
open circuit

Driver door central diagrams and test driver door
B110811 • Short to ground
locking motor central locking motor circuit
for short ground

diagrams and test driver door
Driver door central
B110815 • Short to power or open circuit central locking motor circuit
locking motor
for short to power or open
circuit

Passenger door
B110911 central locking • Short to ground
motor
diagnostic system
Passenger door Carry out any pinpoint tests

B110915 central locking • Short to power or open circuit
motor the manufacturer approved
diagnostic system

Left Mirror Heater
diagrams and test left mirror
B116311 Output short to • Short to ground
heater output circuit for short
ground
to ground

Left Mirror Heater
diagrams and test left mirror
B116315 Output short to • Short to power or open circuit
power

Right Mirror
diagrams and test right mirror
B116411 Heater Output • Short to ground
short to ground
to ground

Right Mirror
diagrams and test right mirror
B116415 Heater Output • Short to power or open circuit
short to power

Left Front Puddle
diagrams and test left front
B116511 Lamp Output short • Short to ground
puddle lamp output circuit for
to ground
short to ground
Left Front Puddle Refer to the electrical circuit

Lamp Output open diagrams and test left front
B116515 • Short to power or open circuit
load or short to puddle lamp output circuit for
power short to power or open circuit

Right Front Puddle
diagrams and test right front
B116611 Lamp Output short • Short to ground
puddle lamp output circuit for
to ground
short to ground
Right Front Puddle Refer to the electrical circuit

Lamp Output open diagrams and test right front
B116615 • Short to power or open circuit
load or short to puddle lamp output circuit for
battery short to power or open circuit
Front Power Install a new DDM/PDM, refer

B117E72 • Actuator stuck open
Window up to the new module
the DTC Index
Install a new DDM/PDM, refer

Front Power to the new module
B117E73 • Actuator stuck closed
Window up installation note at the top of
the DTC Index

B117F72 • Actuator stuck open
Window down installation note at the top of
the DTC Index

B117F73 • Actuator stuck closed
Window down installation note at the top of
the DTC Index

Front Window associated with this DTC using
B118929 • Signal invalid
Position Sensor the manufacturer approved
diagnostic system

Rear Window associated with this DTC using
B118A29 • Signal invalid
Position Sensor the manufacturer approved
diagnostic system

diagrams and test driver
B1A9411 Driver Mirror • Short to ground
mirror fold motor circuit for
short to ground

B1A9415 Driver Mirror • Short to power or open circuit
short to power or open circuit

B1A9511 Passenger Mirror • Short to ground
short to ground

B1A9515 Passenger Mirror • Short to power or open circuit
short to power or open circuit

diagrams and test LIN circuit
between driver switch pack
and DDM for short/open
• Value of signal protection
B1A9883 LIN Bus Circuit #1 circuits, clear DTC and re-test.
calculation incorrect
If DTC remains install a new
switch pack.
Window Control Switch
(86.25.08)

B1A9886 LIN Bus Circuit #1 • Signal Invalid circuits, clear DTC and re-test.
switch pack.
(86.25.08)

B1A9887 LIN Bus Circuit #1 • Missing Message circuits, clear DTC and re-test.
switch pack.
(86.25.08)

Driver Left/Right
B1C0911 Mirror Motor • Short to ground
left/right mirror motor circuit
Circuit
for short to ground

Driver Left/Right diagrams and test driver
B1C0915 Mirror Motor • Short to power or open circuit left/right mirror motor circuit
Circuit for short to power or open
circuit
B1C1011 Driver Up/Down • Short to ground Refer to the electrical circuit

Mirror Motor diagrams and test driver
Circuit up/down mirror motor circuit
for short to ground

Driver Up/Down diagrams and test driver
B1C1015 Mirror Motor • Short to power or open circuit up/down mirror motor circuit
Circuit for short to power or open
circuit

Passenger
B1C1111 Left/Right Mirror • Short to ground
Motor Circuit
diagnostic system

Passenger
B1C1115 Left/Right Mirror • Short to power or open circuit
Motor Circuit
diagnostic system

Passenger
B1C1211 Up/Down Mirror • Short to ground
Motor Circuit
diagnostic system

Passenger
B1C1215 Up/Down Mirror • Short to power or open circuit
Motor Circuit
diagnostic system

B1C1311 Mirror Motor • Short to ground up/down mirror motor
Feedback Circuit feedback circuit for short to
ground

B1C1315 Mirror Motor • Short to power or open circuit up/down mirror motor
power or open circuit
Driver Left/Right Refer to the electrical circuit

B1C1411 Mirror Motor • Short to ground diagrams and test driver
Feedback Circuit left/right mirror motor
feedback circuit for short to
ground

Driver Left/Right diagrams and test driver
B1C1415 Mirror Motor • Short to power or open circuit left/right mirror motor

Passenger
Up/Down Mirror
B1C1511 • Short to ground up/down mirror motor
Motor Feedback
Circuit
ground

Passenger
Up/Down Mirror
B1C1515 • Short to power or open circuit up/down mirror motor
Motor Feedback
Circuit

Passenger
Left/Right Mirror
B1C1611 • Short to ground left/right mirror motor
Motor Feedback
Circuit
ground

Passenger
Left/Right Mirror
B1C1615 • Short to power or open circuit left/right mirror motor
Motor Feedback
Circuit

diagrams and test window
C1B1411 Sensor Supply #1 • Short to ground
sensor supply circuit for short
to ground

diagrams and test window
C1B1415 Sensor Supply #1 • Short to power or open circuit
sensor supply circuit for short
Medium speed • Medium speed CAN Carry out any pinpoint tests
U001000 CAN associated with this DTC using
communication Bus
communication the manufacturer approved

Lost
message missing from CJB the manufacturer approved
with CJB
diagnostic system

With Driver Seat the manufacturer approved
Module (DSM) diagnostic system

Internal control
• Invalid configuration message DTC and retest. If the DTC is
U030000 module software
is received still logged suspect the
incompatibility
DDM/PDM, refer to the new
module installation note at

U200224 Switch • Signal stuck high remains, install a new
passenger side window switch
Carry out CAN network tests

U201011 Switch illumination • Circuit short to ground using the manufacturer
Carry out CAN network tests

U201012 Switch illumination • Circuit short to battery using the manufacturer
Cycle the ignition status and

re-test. If DTC remains, re-
Car Configuration
U201208 • Bus signal/message failures configure the RJB using the
Parameter(s)
diagnostic system

remains, install a new driver
U201324 Switch Pack • Signal stuck high side window switch pack.
(86.25.08)
Control module to the new module
U201444 • Data Memory Failure
hardware installation note at the top of
the DTC Index
Initial Re-configure the DDM/PDM

U210000 configuration not • No sub type information using the manufacturer
complete approved diagnostic system

to the new module
the DTC Index
Re-configure the relevant

module as new using the
Vehicle
diagnostic system and re-test.
U300255 Identification • Not configured
Number (VIN)
U300281 Identification transmitted, module for DTCs and refer to relevant
vehicle

• Mis-match of battery voltage,
U300362 Battery voltage of 2 volts or lower, between
DDM/PDM and RJB the manufacturer approved
diagnostic system
Driver Seat Module (DSM) (86.75.28)

Removal
1 . Remove the front seat.
For additional information, refer to Front Seat (76.70.01)
2 . Remove the front seat control module.
Installation
1 . Install the front seat control module.
2 . Install the front seat.

Information and Entertainment Module
(86.53.48)
Removal
2 . Remove the instrument panel center reinforcement trim panel.
3
component.
Release the navigation system module bracket.

4 . Remove the information and entertainment module.
Installation
1 . Install the information and entertainment module.

3 . Install the instrument panel center reinforcement trim panel.


Remote Keyless Entry (RKE) Module
Removal
NOTE:
This module is installed on the inside of the RH A-pillar above the footwell and does not change
with the hand of drive.

2
force is used.
Remove the RH side footwell trim panel.
Remove the 3 clips.
3 . Remove the keyless entry module.

Installation
1 . Install the keyless entry module.
Install the screws.
2 . Install the RH side footwell trim panel.


5. BODY AND PAINT
501 : Body and Paint
501-02 : Front End Body Panels

Removal
2
3 . NOTE:
Note the fitted position of the washers.
Remove the air deflector.

Loosen the 2 screws.
Remove the 2 nuts.
Installation
Tighten the nuts.
Tighten the screws.

Cowl Vent Screen (76.10.01)
Removal
CAUTION: Always protect paintwork and glass when removing exterior

components.

Remove the 3 clips.
2 . Remove the brake master cylinder cover.

Remove the 4 clips.
3 . Remove the windshield wiper arms.


Release the retaining clip.
Installation

3 . Install the brake master cylinder cover.

4 . Install the windshield wiper arms.

Fender Splash Shield (76.10.90)
Removal
2

4 . Remove the fender splash shield, rear section.

Remove the clip.
Remove the 2 nuts.
5 . Remove the fender splash shield, front section.

Installation
1 . Install the fender splash shield, front section.
2 . Install the fender splash shield, rear section.

Tighten the nuts.
Install the clip.


Removal
1
2 . NOTE:
Note the fitted position of the washers.
Remove the radiator splash shield.

3 . NOTE:
4 . Remove the 2 air deflectors.

Installation
1 . Install the air deflectors.
2 . Install the clips.

Tighten the screws.
501-03 : Body Closures
Specifications
Specifications
Item Nm lb-ft lb-in

Door check strap to body - bolt 12 9 -
Door check strap to door - nut 12 9 -
Door hinge - pin bolt 25 18 -
Hood to hinge - nut 23 17 -
Hood hinge to body - bolt 23 17 -
Lift-gate to hinge - bolt 23 17 -
Lift-gate hinge to body - nut 23 17 -
Luggage compartment lid to hinge - nut 23 17 -
Luggage compartment lid hinge to body - bolt 23 17 -
General procedures
Hood Alignment (76.16.02)

Actuator Aligners - Pedestrian Protection Hood Stops

501-119
1. With assistance, loosen the 8 nuts securing the hood to the hinges.
2. Release the hood support struts.
3. Lower the hood and check for alignment.

Body and Frame
• Adjust as necessary.
4. Raise the hood.
• Tighten the nuts to 25 Nm (18 lb.ft).

Connect the hood support struts.
5. Align the hood to the pedestrian protection actuators using special tools 501-119.
• Insert special tools 501-119, into the pedestrian protection actuators.
• Loosen the 8 bolts securing the pedestrian protection actuator stops to the hood.
• Gently close the hood so that the pedestrian protection hood stops are aligned to the
actuators.
• Open the hood.

Luggage Compartment Lid Alignment
(76.19.03)
1. Remove the luggage compartment floor panel.
2. Remove the luggage compartment lid striker panel.

• Remove the 4 Torx screws.
3. Remove the luggage compartment striker.

4. Remove the luggage compartment aperture seal.
5. Remove the luggage compartment lid struts.

• Release the 4 clips.
6. Loosen the luggage compartment lid hinge fixings.
• Loosen but do not remove the 4 nuts.
7. Make sure the gaps between the luggage compartment lid are all 3.5 mm.
8. Make sure the luggage compartment lid to rear bumper gap is 6.8 mm.
9. Tighten the luggage compartment lid hinge nuts to 23 Nm (17 lb.ft).
10. Loosen the luggage compartment lid hinge to body fixings.

• Loosen the 6 bolts.
11. Make sure the gaps between the luggage compartment lid are all 3.5 mm.
12. Tighten the luggage compartment lid hinge to body bolts, to 23 Nm (17 lb.ft).
13. Install the luggage compartment lid support struts.

• Secure the 4 clips.
14. With the luggage compartment lid closed, check the profile of the luggage compartment
lid to convertible top compartment lid, and luggage compartment lid to rear body side is flush;
adjust as necessary.
15. Install the luggage compartment lid aperture seal.
16. Install the luggage compartment lid striker.
17. Install the luggage compartment lid striker trim panel.

• Install the 4 Torx screws
18. Install the luggage compartment floor panel.

Liftgate Alignment (76.19.54.60)
1. Check the gap and profiles of the liftgate are correct.
Body and Frame
2. Remove the loadspace floor panel.
3. Remove the scuff plate trim panel.

4. Remove the liftgate hinge cover.

• Remove the 8 clips.
5. Loosen the liftgate striker.

• Loosen the 2 Torx bolts.
6. Loosen the liftgate to hinge Torx bolts.
7. With the liftgate closed, check the alignment of the liftgate to the roof panel. Profile of the
liftgate to roof panel should be 2 mm below flush.
8. Tighten the liftgate to hinge Torx bolts to 25 Nm (18 lb.ft).
9. Loosen the liftgate hinge to body nuts.

10. With the liftgate closed, check the alignment of the liftgate to the roof panel and bodyside
panel. The liftgate should be central in its aperture.
11. Tighten the liftgate hinge to body nuts to 25 Nm (18 lb.ft).
12. Secure the liftgate striker.

• Tighten the Torx bolts to 25 Nm (18 lb.ft).
13. Install the scuff plate trim panel.

• Install the 4 Torx screws
14. With the liftgate closed, check the profile of the liftgate to the bodyside panel. Adjust as
required.
15. Install the liftgate hinge cover.

• Secure with the clips.
16. Install the loadspace floor panel.

Hood (76.16.01)
Actuator Aligners - Pedestrian Protection Hood Stops

501-119
Removal
1 . With assistance, remove the hood.
Release the clips and disconnect the struts.
Remove the 8 nuts.
2 . NOTE:

Remove the hood seal end caps.
3 . Remove the hood seal.
Release the hood seal.
4 . Remove the hood pad.

5 . Remove the 2 secondary hood pads.
Remove the 4 clips.

Installation
1 . Install the secondary hood pads.
2 . Install the hood pad.
3 . Install the hood seal.
Install the clips.
Attach the hood seal.
4 . Install the hood seal end caps.
5 . With assistance install and align the hood.
Connect the struts and secure with the clips.
6 Align the hood to the pedestrian protection actuators using special tools 501-119.
.
Insert special tools 501-119 into the pedestrian protection actuators.
Loosen the 8 bolts securing the pedestrian protection actuator stops to the
hood.
Gently close the hood so that the pedestrian protection hood stops are
aligned to the actuators.
Open the hood.

Luggage Compartment Lid (76.19.01)
Removal
2 . Disconnect the 4 luggage compartment lid harness electrical connectors.

Remove the electrical harness clip.
4 . Release the electrical harness.

5 . Release the clips and disconnect the struts.

6 . With assistance, remove the luggage compartment lid.
Remove the 4 nuts.
7 . NOTE:
Remove the luggage compartment lid latch operating cable from the lock cylinder.
Release the cable from the clip.
8 . Remove the luggage compartment lid latch assembly.

9 . Remove the bump stops.

10 . Remove the luggage compartment lid lock cylinder.

Remove the 2 bolts.
12 . Remove the license plate lamp housing.
13 . Remove the luggage compartment lid finisher.

Disconnect the license plate lamp electrical connector.
Remove the grommets.
Remove the 4 bolts.
14 . Remove both rear lamp assemblies.

Remove the 6 nuts.
15 . Remove the luggage compartment lid wiring harness.

Release the 8 wiring harness securing clips.
16 Remove the luggage compartment lid decals.
. Wipe the luggage compartment lid to remove all traces of the
adhesive.
Polish the area to remove any bleaching.
Installation
1 . Install the luggage compartment lid decal.
Remove the backing from the decal.
Remove the protective cover from the decal.
Secure the decal to the luggage compartment lid.
Position and align the decal on the luggage compartment lid.
2 . Install the luggage compartment lid wiring harness.
3 . Install both of the rear lamp assemblies.

Install the nuts.
4 . Install the luggage compartment lid finisher.

Connect the license plate lamp electrical connector.
Secure the 4 clips.
Install the grommets.
Install the license plate lamp housing.
5 . Install the wiring harness.

Secure in the 9 clips.
6 . Install the luggage compartment lid lock cylinder.

7 . Install the bump stops.
8 . Install the luggage compartment lid latch assembly.

Install the 3 Torx bolts.
9 . Connect the luggage compartment lid latch operating cable to the lock cylinder.
Install the cable.
10 . With assistance, install the luggage compartment lid.

Install the 4 nuts.
11 . Install the luggage compartment lid support struts.

Secure in the 2 clips.


Door (76.28.04)
Removal

3 . Remove the window regulator motor.

4 . Release the front door inner weathershield.

5 . Remove the front door inner weathershield.

Release the front door interior handle cable.
6 . Release the door check strap from the body.

7 . Release the door harness from the door.

Release from the locating grommet.
8 . NOTE:
With assistance remove the component.
Remove the door.
Remove the 2 hinge bolts.
Installation
1 . With assistance, install the door assembly.
Lubricate the hinges and bolts tighten to 25 Nm (18 lb.ft).
2 . Install the door wiring harness.

Secure in the grommets.
Secure the clips.
3 . Install the door check strap.

4 . Install the front door inner weathershield.

Attach the front door interior handle cable.
5 . Secure the front door inner weathershield.

Secure the wiring harness clips.
6 . Install the window regulator motor.


Door Check Arm
Removal



5 . Remove the door check-strap.
Remove the 2 nuts.
Installation
1 . Install the door check strap.



Liftgate
Removal
2 . Disconnect the rear screen electrical connectors.
3 Release the body harness from the liftgate.

. Release the 15 clips.
Release the 2 harness grommets and withdraw the harness from
liftgate.
4 . NOTE:
Support the lifgate as necessary.
Release the liftgate support struts.

5 . With assistance, remove the liftgate.
Installation
1 . With assistance, install the liftgate.
2 . NOTE:
Support the lifgate as necessary.
Attach the liftgate support struts.

3 . Attach the body harness to the liftgate.
Secure the harness grommets into the liftgate.
4 . Disconnect the rear screen electrical connectors.

6 . Check and adjust the liftgate.

For additional information, refer to Liftgate Alignment (76.19.54.60)
501-05 : Interior Trim and Ornamentation
Specifications
Specifications
Item Nm lb-ft lb-in

B-pillar trim panel - screw 3 2 26
Door trim panel - screw 3 2 26
Parcel shelf - bolt 6 4 53
Door scuff-plate - screw 6 4 53
Luggage compartment scuff plate - bolt 4 3 35
Rear quarter trim panel - screw 3 2 26
Sun visor - screw 1 - 9
A-Pillar Trim Panel (76.13.31)

Removal
1 . NOTE:
Remove the A-pillar trim panel.

2 . Remove the cellular phone microphone.

Installation
1 . Install the cellular phone microphone.
2 . Install the A-pillar trim panel.

B-Pillar Trim Panel (76.13.28)
Removal
1 . Remove the parcel tray.
For additional information, refer to Parcel Shelf (76.67.06)
2 . Remove the sun visor.

For additional information, refer to Sun Visor (76.10.48)
3 . Remove the roof moulding.

4 . Release the B-pillar trim panel.

5 . Remove the B-pillar trim panel.

Installation
1 . Attach the B-pillar trim panel.
2 . Secure the B-pillar trim panel.

3 . Install the roof moulding.

4 . Install the sun visor.

5 . Install the parcel tray.

Removal
CAUTION: Correct installation of the oil filler cap can be obtained by tightening
the cap until an audible click is heard.
NOTE:
Naturally aspirated engine shown, supercharged engine is similar.
2 . Open the hood.
3 . Remove the oil filler cap.

Installation
2
. CAUTION: Correct installation of the oil filler cap can be obtained by
Install the oil filler cap.
3 . Close the hood.

Front Door Trim Panel (76.34.01)
Removal
1 . Remove the exterior mirror trim panel.
2 . Release the front door trim panel.

Remove the bolt cover.
3 . NOTE:
Remove the front door trim panel.

4 . Remove the front door latch remote control handle.

5 . Remove the grab handle cover.

6 . Remove the window control switch.
7 . Remove the seat control switch.

Installation
1 . Install the seat control switch.
2 . Install the window control switch.

3 . Install the grab handle cover.

4 . Install the front door latch remote control handle.

5
. CAUTION: Make sure that the cable remains correctly installed to the
front door trim panel.
Install the front door trim panel.

6 . Secure the front door trim panel.

Tighten the Torx bolts to 10 Nm.
Install the bolt cover.
7 . Install the exterior mirror trim panel.

8 Check the operation of the door latch remote control handle.

. With the door closed, check the latch operation of the door latch
remote control handle.
With the door closed, check the lock operation of the door latch
remote control handle.
Headliner (76.64.01)
Removal
1 . Remove the LH A-pillar upper trim panel.
For additional information, refer to A-Pillar Trim Panel (76.13.31)
2 . Remove the RH A-pillar upper trim panel.

3 . Remove the roof mouldings.

4 . Remove the LH B-pillar upper trim panel.

For additional information, refer to B-Pillar Trim Panel (76.13.28)
5 . Release the RH B-pillar upper trim panel.

6 . Remove the RH B-pillar upper trim panel.
7 . Remove the front overhead console.

8 . Remove the LH sun visor.

9 . Remove the RH sun visor.

10 . Remove the sun visor retaining clips.
Release the screw covers.
Remove the screws.
11 . Remove the headliner.

Release the clip.
Installation
1 . Install the headliner.
2 . Install the sun visor retaining clips.

Install the screws.
Install the screw covers.
3 . Install the RH sun visor.

4 . Install the LH sun visor.

5 . Install the front overhead console.

6 . Attach the RH B-pillar upper trim panel.

7 . Secure the RH B-pillar upper trim panel.

8 . Install the LH B-pillar upper trim panel.

For additional information, refer to B-Pillar Trim Panel (76.13.28)
9 . Install the roof mouldings.

10 . Install the RH A-pillar upper trim panel.

11 . Install the LH A-pillar upper trim panel.

Front Scuff Plate Trim Panel (76.13.81)
Removal
1 . Remove and discard the scuff plate decal.
Release the adhesive strip.
2 . Remove the front scuff plate trim panel.

Carefully release horizontally.
Installation
1 . Install the front scuff plate trim panel.
Align the component.
2 . Install the scuff plate decal.

Remove backing tape from adhesive strip.
Clean the adhesive contact area.
Scuff Plate Trim Panel (76.13.81)
Removal
1 . Remove the luggage compartment floor panel.
2 . Remove the tool kit tray.
3 . Remove the spare wheel and tire.

Remove the bolt.
4 . Remove the scuff plate trim panel.

Installation
1 . Install the scuff plate trim panel.
2 . Install the spare wheel and tire.

Install the bolt.
3 . Install the tool kit tray.
4 . Install the luggage compartment floor panel.

Sun Visor (76.10.48)
Removal
1 . Remove the sun visor.
Installation
1 . Install the sun visor.
Liftgate Upper Trim Panel (76.34.11)
Removal
1 . Remove the liftgate upper trim panel.
Installation
1 . Install the liftgate upper trim panel.
Liftgate Lower Trim Panel
Removal
1 . Remove the liftgate upper trim panel.
For additional information, refer to Liftgate Upper Trim Panel (76.34.11)
2 . Remove the warning triangle.

Release the clip.
3 . Remove the warning triangle retaining bracket.

4 . Remove the liftgate grab handle.

Installation
2 . Install the liftgate grab handle.

3 . Install the warning triangle retaining bracket.

4 . Install the warning triangle.

5 . Install the liftgate upper trim panel.

For additional information, refer to Liftgate Upper Trim Panel (76.34.11)
Rear Quarter Trim Panel - 2-Door
(76.13.73)
Removal
2 . NOTE:
Release the forward edge first.
Remove the scuff plate trim panel.

3 . Release the rear safety belt lower anchor.


Release the safety belt from the trim panel.
Installation
Position the safety belt through the trim panel.
Tighten the Torx bolts to 3 Nm (2.2 lb.ft).
2 . Secure the rear safety belt lower anchor.

Tighten the new Torx bolt to 45 Nm (33 lb.ft).


Rear Quarter Trim Panel - Convertible
(76.13.73)
Removal
2 . Remove the rear safety belt stalk trim panel.

3 . Remove the rear safety belt stalk.


5 . NOTE:
Support the convertible top lid.
Open the convertible top to the position shown.

Depress the switch.
6 . Release the convertible top hinge cover tension strap.

Release from the convertible top mechanism.
7 . Carefully remove the outer waist seal.

Release each end of the seal from the body.
8 . Release the convertible top lid seal.
9 . Release the front safety belt lower anchor.


Release the safety belt from the trim panel.
Installation
1 Install the rear quarter trim panel.
. Position the safety belt through the trim panel.
Secure with the clips (1).
Check the illustrated trim dimension (2), before tightening the Torx
bolt (3) to 3 Nm (2.2 lb.ft).
2 . Secure the front safety belt lower anchor.

3 . Attach the convertible top lid seal.

4 . Install the outer waist seal.

Attach the outer waist seal to the body.
5 . Attach the convertible top hinge cover tension strap.

Attach to the convertible top mechanism.
6 . Close the convertible top.

Depress the switch.

8 . Install the safety belt stalk.

9 . Install the rear safety belt stalk trim panel.


Rear Quarter Trim Sliding Panel
No Data Available
Loadspace Trim Panel - 2-Door
(76.13.73.60)
Removal
1 . Remove the battery cover.
2 . Remove the loadspace floor panel.
3 . Remove the tool kit tray.
4 . Remove the spare wheel and tire.

Remove the bolt.
6 . Remove the loadspace trim panel.

Remove the clip.
Installation
Install the clip.

3 . Install the spare wheel and tire.

Install the retaining bolt.
4 . Install the tool kit tray.
5 . Install the loadspace floor panel.

6 . Install the battery cover.
Install the 4 retainers.
Loadspace Trim Panel - Convertible
(76.13.73.60)
Removal
1 . Remove the battery cover.
2 . Remove the loadspace floor panel.

4 . Remove the luggage compartment retractable cover.

5 . Remove the luggage compartment retractable cover track.
Release the fabric cover.
6 . Remove the loadspace trim panel.

Remove the clip.
Installation
Install the clip.
2 . Install the luggage compartment retractable cover track.

Secure the fabric cover.
4 . Install the loadspace floor panel.
5 . Install the battery cover.

Install the 4 retainers.
6 . Install the luggage compartment retractable cover.

Luggage Compartment Lid Trim Panel
(76.19.05)
Removal
1 . Remove the warning triangle.
Release the clip.
2 . Remove the warning triangle retaining bracket.

3 . Remove the luggage compartment lid latch handle.

Remove the locking pin.
5 . NOTE:
Remove the luggage compartment lid grab handle.

Installation
1 . Install the luggage compartment lid grab handle.
Secure the clips.

3 . Install the luggage compartment lid latch handle.

Install the pin.
4 . Install the warning triangle retaining bracket.

5 . Install the warning triangle.

501-08 : Exterior Trim and Ornamentation
Specifications
Specifications
Item Nm lb-ft lb-in

A-post outer finisher (convertible) - screw 2 - 18
Luggage compartment lid finisher - screw 1.5 - 13
Sill applique to body - screw 4 3 35
Spoiler to luggage compartment lid - nut 5 4 44
Spoiler to luggage compartment lid - screw 5 4 44
Front Fender Moulding (76.10.48)

Removal
2 . Release the rear lower edge of the fender splash shield for access.
3
components.
Release the rear fender moulding clip.

Open the front door for access.
Carefully release the clip with a small screwdriver; access is through
the small aperture in the fender.
4 Release the fender moulding assembly.

. Working from behind the fender splash shield, carefully release the 5
clips.
5 . Remove the fender moulding assembly.

6 . Remove the inner grille.

7 . NOTE:
Remove the side repeater lamp.

8 . Carefully remove the decal.

Installation
1 . Install the decal.
2 . Install the side repeater lamp.

Secure the clip.
3 . Install the inner grille.

Secure the clips.
4 . Install the fender moulding assembly.

Secure the clips.

Rear Spoiler (76.19.86.60)
Removal
1 . Remove the high mounted stoplamp.
For additional information, refer to High Mounted Stoplamp (86.41.01)
2 . Release the rear spoiler.

Remove the 2 nuts.

Installation
1 . Install the rear spoiler.
Fit and tighten the Torx screws.
2 . Install the high mounted stoplamp.
For additional information, refer to High Mounted Stoplamp (86.41.01)
Rocker Panel Moulding (76.11.36)
Removal
1
2 . Remove the front scuff plate trim panel.

For additional information, refer to Front Scuff Plate Trim Panel (76.13.81)
3 . Release the rocker panel moulding lower edge.

Remove the 9 clips.
4
components.
CAUTION: Removal of the clips is a delicate procedure, damage will

NOTE:
When removing the seal, some clips may remain attached to the component.
These clips can be recovered and returned to their original fitted positions.
Release the rocker panel door seal lower for access.

5.
NOTE:
Apply a sharp horizontal force to release the clips.
Remove the rocker panel moulding.

Release the front and rear clips.
Installation
1 . Install the rocker panel moulding.
Align and secure the front and rear rocker panel clips.
2 . Install the aperture seal.

3 . Secure the rocker panel lower edge.

Install the clips.
4 . Install the front scuff plate trim panel.
For additional information, refer to Front Scuff Plate Trim Panel (76.13.81)
501-09 : Rear View Mirrors
Specifications
Specifications
Item Nm lb-ft lb-in

Exterior mirror - bolt 8 6 71
Rear View Mirrors

COMPONENT LOCATION
NOTE:
RHD (right-hand drive) shown, LHD (left-hand drive) mirror image.

1 Interior mirror
2 Driver's door mirror
4 Door mirror switches
6 Passenger door mirror
INTRODUCTION
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 labelled '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.
An electrochromic interior mirror is mounted on the windshield and contains a forward and a
rearward 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.
Some vehicles may be fitted with an interior mirror featuring an electronic compass with LED
(light emitting diode) display. The compass is a self contained unit and does not interface with
any other vehicle system or electronic control module. Details of how to set and calibrate the
compass can be found in the 'Mirrors' section of the Owner's Handbook.
Up to 2009 Model Year (MY), some vehicles have door mirrors with an electric foldback
feature. From 2009 MY, the mirror foldback feature is a standard fit in all markets. Where
fitted, mirror foldback can be operated manually or automatically.
Manual operation of mirror foldback is initiated with the vehicle stationary or moving at 20
km/h (12 mph) or less, by pressing then releasing the L and R mirror select buttons at the
same time. The first press of the mirror select buttons causes the two door mirrors to turn
inwards to the folded position and stop. A further press of the mirror select buttons causes the
door mirrors to turn outwards to the unfolded position and stop. If the mirror select buttons
are pressed while the door mirrors are moving, they stop and reverse direction until they reach
their original position. If one of the door mirrors has been manually folded, the two door
mirrors can be re-synchronized by an inward and outward operating cycle.
Automatic mirror foldback is selected and deselected on the vehicle settings menu of the
Touch Screen Display (TSD). Automatic operation is synchronised with the exterior locking
and unlocking of the vehicle (it does not work with interior locking and drive away locking).
If automatic operation is selected, the door mirrors fold when the vehicle is locked and unfold
when unlocked. However, the door mirrors will not unfold automatically if they have been
folded manually, even though automatic mode is selected on the TSD.
Automatic Mirror Foldback Selection on TSD

A thermal cut-out feature is incorporated to protect the mirror foldback motors. Thermal cut-
out only occurs with the door mirrors in the unfolded position, and resets after 5 minutes.
CONTROL DIAGRAM
NOTE:
A = Hardwired; N = Medium Speed CAN (controller area network) bus; O = LIN (local
interconnect network) bus
1 Battery
2 Megafuse (175A)
4 Door mirror switches
6 Driver's door mirror
7 Passenger door mirror
8 Interior mirror
10 Mega fuse
Rear View Mirrors

For a detailed description of the rear view mirrors, refer to the relevant Description and
Rear View Mirrors

• Fuse(s)
• Relay
• Exterior mirror(s)
• Switch
4 . If the cause is not visually evident, Check DDM/PDM for rear view mirror related 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 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.
NOTE:
NOTE:
NOTE:
tests.
NOTE:
NOTE:
terminals.

Refer to the electrical
Left Mirror
• Short to ground circuit diagrams and test
B116311 Heater Output
left mirror heater output
short to ground
Left Mirror • Short to power or open circuit diagrams and test
B116315 Heater Output circuit left mirror heater output
short to power circuit for short to power
or open circuit
Right Mirror
B116411 Heater Output
right mirror heater output
short to ground
Right Mirror • Short to power or open circuit diagrams and test
B116415 Heater Output circuit right mirror heater output
short to power circuit for short to power
or open circuit
B1A9411 Driver Mirror
driver mirror fold motor
• Short to power or open
B1A9415 Driver Mirror circuit
driver mirror fold motor
or open circuit
• Short to ground
B1A9511 Passenger Mirror passenger mirror fold
motor circuit for short to
ground
• Short to power or open circuit diagrams and test
B1A9515 Passenger Mirror circuit passenger mirror fold
LIN circuit between driver
switch pack and DDM for
LIN Bus Circuit short/open circuits, clear
B1A9883 calculation incorrect
#1 DTC and re-test. If DTC
switch pack.
(86.25.08)
LIN Bus Circuit • Signal Invalid short/open circuits, clear
B1A9886
switch pack.
(86.25.08)
LIN Bus Circuit • Missing Message short/open circuits, clear
B1A9887
switch pack.
(86.25.08)
Driver Left/Right circuit diagrams and test
• Short to ground
B1C0911 Mirror Motor driver left/right mirror
Circuit motor circuit for short to
ground
Driver Left/Right Refer to the electrical
B1C0915 • Short to power or open
Mirror Motor circuit diagrams and test
Circuit circuit driver left/right mirror
Driver Up/Down circuit diagrams and test
• Short to ground
B1C1011 Mirror Motor driver up/down mirror
ground
Driver Up/Down • Short to power or open circuit diagrams and test
B1C1015 Mirror Motor circuit driver up/down mirror
Passenger tests associated with this
• Short to ground
B1C1111 Left/Right Mirror DTC using the
Motor Circuit manufacturer approved
diagnostic system
Passenger • Short to power or open tests associated with this
B1C1115 Left/Right Mirror circuit DTC using the
diagnostic system
Passenger tests associated with this
• Short to ground
B1C1211 Up/Down Mirror DTC using the
diagnostic system
Passenger • Short to power or open tests associated with this
B1C1215 Up/Down Mirror circuit DTC using the
diagnostic system
Driver Up/Down circuit diagrams and test
• Short to ground
B1C1311 Mirror Motor driver up/down mirror
Feedback Circuit motor feedback circuit for
short to ground
Driver Up/Down • Short to power or open
driver up/down mirror
B1C1315 Mirror Motor circuit
motor feedback circuit for
Feedback Circuit
short to power or open
circuit
Driver Left/Right Refer to the electrical
• Short to ground
B1C1411 Mirror Motor circuit diagrams and test
Feedback Circuit driver left/right mirror
short to ground
Driver Left/Right • Short to power or open
driver left/right mirror
B1C1415 Mirror Motor circuit
Feedback Circuit
short to power or open
circuit
Passenger
Up/Down Mirror • Short to ground
B1C1511 passenger up/down mirror
Motor Feedback
Circuit
short to ground
Passenger circuit diagrams and test
Up/Down Mirror passenger up/down mirror
B1C1515 circuit
Motor Feedback motor feedback circuit for
Circuit short to power or open
circuit
Passenger
Left/Right Mirror • Short to ground
B1C1611 passenger left/right mirror
Motor Feedback
Circuit
short to ground
Passenger circuit diagrams and test
Left/Right Mirror passenger left/right mirror
B1C1615 circuit
Motor Feedback motor feedback circuit for
Circuit short to power or open
circuit
Medium speed
• Medium speed CAN tests associated with this
CAN
U001000 communication Bus DTC using the
communication
Bus
diagnostic system
• Logged when subscribed
Lost tests associated with this
CAN message missing from
U014000 communication DTC using the
CJB
with CJB manufacturer approved
diagnostic system
Lost
communication • Missing message
With Driver Seat
Module (DSM)
diagnostic system
Internal control Re-configure the RJB
U030000 • Invalid configuration
module software using the manufacturer
incompatibility message is received approved diagnostic
system. Clear the DTC
and retest. If the DTC is
DDM/PDM, refer to the
new module installation
Index
Clear DTC and re-test. If
• Signal stuck high DTC remains, install a
U200224 Switch
new passenger side
window switch
Carry out CAN network
Switch • Circuit short to ground tests using the
U201011
illumination manufacturer approved
diagnostic system
Switch • Circuit short to battery tests using the
U201012
diagnostic system
Cycle the ignition status
and re-test. If DTC
Car
• Bus signal/message failures remains, re-configure the
U201208 Configuration
RJB using the
Parameter(s)
diagnostic system
DTC remains, install a
• Signal stuck high new driver side window
U201324 Switch Pack
switch pack.
(86.25.08)
Install a new DDM/PDM,
Control module • Data Memory Failure refer to the new module
U201444
hardware installation note at the top
of the DTC Index
Re-configure the
Initial
• No sub type information DDM/PDM using the
U210000 configuration not
complete
diagnostic system
• Internal electronic failure refer to the new module
installation note at the top
of the DTC Index
Vehicle Re-configure the relevant
• Not configured
U300255 Identification module as new using the
Number (VIN) manufacturer approved
diagnostic system and re-
test. If DTC remains
install a new module, refer
to the new module
of the DTC Index
U300281 Identification check for DTCs and refer
previously installed to other
Number (VIN) to relevant DTC Index
vehicle
• Mis-match of battery Carry out any pinpoint

voltage, of 2 volts or lower, tests associated with this
U300362 Battery voltage between DDM/PDM and DTC using the
RJB manufacturer approved
diagnostic system
Auto-Dimming Interior Mirror (76.10.56)

Removal
1 . Remove the 2 interior mirror covers.
2 . Remove the interior mirror.

Rotate the mirror stem at its base to release from the windshield.
Installation
1 . Install the interior mirror.
Rotate the mirror stem at its base to secure to the windshield.
2 . Install the interior mirror covers.
Exterior Mirror (76.10.52)
Removal
2 . Remove the exterior mirror.

Installation
1 . Install the exterior mirror.
Secure the wiring harness in the clips.

Exterior Mirror Glass (76.10.53)
Removal
1 Remove the exterior mirror glass.
. Carefully apply pressure to the outer edge of the glass, to release the
2 clips.
Installation
1 . Install the exterior mirror glass.
Align the glass to the motor.
Apply an even pressure to secure glass to the clips.
2 . Check the operation of the exterior mirror.

Exterior Mirror Motor (76.10.57)
Removal
1 Remove the exterior mirror glass.
. Carefully apply pressure to the outer edge of the glass, to release the
2 clips.
2 . Remove the exterior mirror motor.

Installation
1 . Install the exterior mirror motor.
2 . Install the exterior mirror glass.

Align the glass to the motor.
Apply an even pressure to secure glass to the clips.
3 . Check the operation of the exterior mirror.

501-10 : Seating
Specifications
Specifications
Item Nm lb-ft lb-in

Front seat track to vehicle floor - bolt* 48 35 -
Rear seat support bracket - nut/screw 9 7 80
NOTE:
*New nut/bolt must be installed.
Seats
COMPONENT LOCATION

A Plan view
B Side view
INTRODUCTION
Front Seat Sport Variant
Front Seat Luxury Variant
Rear Seats
1 Removable center panel
Two variants of driver and passenger seat are available; 10-way sports and 16-way luxury.
The front seat frames are common to both the coupe and convertible and are equipped with
the following:
• Seat control switches (door mounted)

• Front seat cushion front height adjustment
• Front seat cushion rear height adjustment
• Front seat backrest adjustment
• Front seat head restraint adjustment
• Lumbar adjustment
• Front seat forward and backward adjustment
• Side air bag module
• Front seat backrest heating
• Front seat cushion heating
• Extendible seat-cushion (luxury variant only)
• Adjustable side bolsters (luxury variant only)
WARNING: Prior to removal of the front seats and before disconnecting the
front seat wiring harness electrical connectors (which includes the side air bag module
electrical connectors), the battery ground cable should be disconnected and a period of
at least 1 minute allowed to elapse. The same amount of care should be taken when
handling and storing the front seats, as would be taken when handling and storing air
bag modules.
The driver and passenger front seats, although almost identical, have some unique
components. The front driver seat has a seat position sensor and the front passenger seat has a
occupancy sensing system. In both instances the components form an integral part of the air
bag Supplemental Restraint System (SRS). For additional information, refer to Air Bag
Supplemental Restraint System (SRS) (501-20B)
The rear seat squabs are conventionally trimmed over a wire frame with a removable center
panel allowing access to the auxiliary junction box.
FRONT SEAT CONTROL SWITCHES

Sport Variant (10-way Adjustment)
Part
Item Description
Number
1 Backrest adjustment
2 Stored memory position button 3
5 Seat position memory store button
6 Lumbar adjustment, 2-way
Forward and backward adjustment, cushion front height and rear height
7
adjustment
Luxury Variant (16-way Adjustment)

Part
Item Description
Number
1 Backrest adjustment
5 Seat position memory store button
6 Seat cushion extension adjustment
7 Lumbar adjustment, 4-way
Forward and backward adjustment, cushion front height and rear height
8
adjustment
9 Bolster adjustment
The front seat control switches are installed in the driver and passenger door casings.
FRONT SEAT CONTROL COMPONENTS

A Drivers seat
B Passenger seat
1 Cushion front height and rear height adjustment motor
2 Height adjustment motor
3 Forward and rearward adjustment motor
4 Memory control module
5 Seat cushion extension motor (luxury variant only)
6 Lumbar pump solenoid
7 Lumbar/bolster pump
8 Backrest adjustment motor
9 Bolster pump solenoid
Seat position is monitored by the individual seat modules using seat track position Hall
sensors incorporated into the motors. This prevents the seat from being adjusted to a position
that will contact the surrounding interior trim or a rear seat passenger causing injury (clash
avoidance). Seat memory is standard on both drivers and passenger seats. Each seat memory
can be configured for 3 personality positions, which are set using the seat memory switch and
stored in the individual seat module.
The switches for electrically adjusting the seats are wired directly to the appropriate control
module, which controls the movement of the seat via Local Interconnect Network (LIN) serial
communication protocol.
NOTE:
In the event of a control module failure a fly lead behind the seat valance can be used to
connect a power source directly to the seat slide motor. This enables the seat to be moved
to gain access to the front and rear seat fixings. The seat can then be removed from the
vehicle in order to access the control module.

1 Fly lead
As part of the Pre-Delivery Inspection (PDI) each seat needs to perform a clash avoidance
check. This procedure is to ensure there is no contact between the seat trim and rear quarter
casing. If there is any contact between the seat trim and rear quarter casing the affected seat
must be recalibrated via the seat calibration routine in the Integrated Diagnostic System
(IDS). For more information refer to the PDI manual.
FRONT SEAT HEATING

1 Seat back heater
2 Seat cushion heater
Operation of the heated seats is controlled by the Automatic Temperature Control (ATC)
module. The ATC module receives a request from the Touch Screen Display (TSD) and sends
a message to the Central Junction Box (CJB), which then provides a feed to the seat heater
elements. For additional information, refer to Control Components (412-04)
ACTIVE FRONT HEAD RESTRAINTS

1 Head restraint support
2 Fabric tape
3 Headrest movement during rear end collision
4 Occupant movement during rear end collision
Both front seats are fitted with mechanical active head restraints that reduce injuries to the
spinal column and possible whiplash in the event of a rear collision. The 2 supports of the
head restraints inside the seat backrest are joined together with fabric tape. As the seat
occupant’s back and body weight presses against the fabric tape the head restraint moves
upwards and forwards mechanically by means of a pivot point. The movement of the headrest
cushions the occupant’s head, altering the posture and reducing the relative motion between
the body and the head. The head restraint then returns to it’s original position using a spring
return mechanism.
PASSENGER SEAT OCCUPANCY SENSOR

1 Occupancy sensor pad
2 Harness connector
3 Control module
Occupant monitoring provides the Restraints Control Module (RCM) with the occupancy
status of the front passenger seat.
The occupant detection system determines if the front passenger seat is occupied or
unoccupied. The system consists of a pressure sensor installed between the foam padding and
the cover of the front passenger seat cushion. From the occupancy status, and the status of the
front passenger safety belt, the instrument cluster determines the seat belt minder status. For
additional information, refer to Air Bag Supplemental Restraint System (SRS) (501-20B)
FRONT SEAT BACK TILT

1 Release cable
2 Release lever
The front seats tilt forward to allow access to the rear seats. To tilt the seat forward remove
the seat belt from the seat belt guide. Lift the lever and push the seat back forwards. The seat
back will latch when returned to the normal position. Ensure that the seat belt is returned to
the seat belt guide.
AUDIBLE AND VISUAL CONFIRMATIONS

A single chime audible confirmation is generated by the instrument cluster to provide
confirmation to the driver that the memory store operation has been successfully completed.
In addition to audible confirmation there is also a visual confirmation via the instrument
cluster message center. For additional information, refer to Instrument Cluster and Panel
Illumination (413-00)
STEERING COLUMN ADJUST

1 Rotary joystick control switch
The instrument cluster controls the electric adjustable steering column in a rake (up and
down) and reach (in and out). The steering column can be adjusted for rake and reach by
operating the rotary joystick control switch on the LH side of the steering column.
Easy Entry Exit

The 'Easy Entry Exit' mode provides automatic movement of the steering column to allow
easier entry to or exit from the vehicle.
This mode is selected by setting the steering column adjustment switch to the 'AUTO'
position.
If the 'Easy Entry Exit' feature fails to function, it can be activated as follows:
• Rotate the steering column adjust switch to the 'AUTO' position

• The instrument cluster will now display 'Column Adjust Auto' in the message center
For more information refer to the owners handbook.
Steering Column Control

Adjustment of the steering column is achieved by a single Direct Current (DC) motor. Each
adjustment movement is transmitted through a solenoid actuated clutch; 1 clutch for reach
movement and 1 for rake movement.
When engaged, a clutch can be released only if the system is unstressed. As the clutches are
mounted on the same motor spindle, the sequence for position adjustment is as follows:
• Engage the selected clutch by powering the appropriate solenoid

• After a time period (approximately 0.1 of a second), the motor is powered in the
desired direction. When the motor reaches the stop position the solenoid and motor is
released/unpowered. The clutch remains engaged under stress
• At the start of the next adjustment the motor is powered in the opposite direction to
enable the clutch to disengage when the stress is released.
Simultaneous rake and reach movements are not possible since the motor must reverse
direction as soon as the first axis has reached its required position.
Steering column rake and reach is controlled via potentiometer feedback.
MEMORY CONTROL MODULE

1 Memory control module
The memory control module, located under the drivers and passengers seat, relies upon a
number of inputs to control various outputs. As with all electronic control modules, the unit
needs information regarding the current operating conditions of the engine and other related
systems before it can make calculations, which determine the appropriate outputs.
CONTROL DIAGRAMS
Driver Seat
NOTE:
A = Hardwired; N = CAN bus; O = LIN bus
Part
Item Description
Number
1 Battery
2 Megafuse (175A)
3 Megafuse (175A)
5 Driver seat heating elements
6 Heated steering wheel
7 Heated steering wheel module
Controller Area Network (CAN) input and output signals to and from
8
various other vehicle systems
9 Driver lumbar pump
10 Driver cushion extend motor
11 Driver fore/aft adjustment motor
12 Driver recline adjustment motor
13 Driver height adjustment motor
14 Driver rake adjustment motor
15 Driver Seat Module (DSM)
16 Driver seat Hall sensor (seat position)
17 Driver seat switch pack
Passenger Seat
NOTE:
A = Hardwired; N = CAN bus; O = LIN bus
Part
Item Description
Number
1 Battery
2 Megafuse (175A)
3 Megafuse (175A)
5 Passenger seat heating elements
6 Passenger rake adjustment motor
7 Passenger height adjustment motor
8 Passenger recline adjustment motor
9 Passenger fore/aft adjustment motor
10 Passenger cushion extend motor
11
12 Passenger lumbar pump
13 Passenger Seat Module
14 Passenger seat Hall sensor (seat position)
15 Passenger seat switch pack
Drivers Memory Seat
The memory control module can store up to 3 different driver seating, mirror and steering
column positions. The numbered memory and single memory store switches control memory
storage and recall operations. Each switch is a momentary action push switch.
Memory Store
Drivers Seat
Once the driver's seat, steering column and exterior mirrors have been adjusted, the vehicle is
able to memorise these settings for future use by using the following procedure:
• Push the memory button M, the red Light Emitting Diode (LED) will illuminate for
five seconds
• Whilst the LED is illuminated, press button 1, 2 or 3 to memorise the current settings
The LED will extinguish, and a chime will sound to confirm that the settings have been
memorised. If the ignition is in the 'ON' mode, the message centre will display a confirmation
message.
Passenger Seat
The procedure to memorise a passenger seat position is the same as that for the driver's seat
with two exceptions. There will be no chime or message to confirm the settings.
Memory Recall
Memory recall has 3 memory positions stored for the seats, steering column and exterior
mirrors. The switches for this function are located on driver and passenger door side trim
panel. Pressing the appropriate numbered memory switch allows the seat to start moving to
the position appropriate to that memory. When the switch is released the system will operate
in manual mode. This means that when the switch is released, the seat will stop moving. In
order to reach the intended memory position, the switch must not be released until all
movement has stopped.
When a memory recall is initiated, to limit the overall current consumption, only 2-seat axis
will move towards their intended position at any one time.
Both mirrors move simultaneously about the vertical axis first (left/right), and then, once all
vertical axis movements are complete, about the horizontal axis (up/down). To minimise the
number of mirror drives required, a method of sharing is implemented, which dictates that all
movement about 1 axis is complete before movement about the other axis commences.
Immediate Adjustment
Pressing one of the manual adjustment switches will initiate the corresponding motor for that
axis until the switch is released.
Only 2 seat motors can be driven at any one time.
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 axis 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 axis 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.
Initialisation
When a replacement memory control module is fitted to a seat it should be calibrated via IDS
diagnostic tester so that the control module can learn the seats absolute position.
Battery Monitor
If the battery voltage drops below 10.5 Volts, then the memory control 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.
Stand-by Mode
The memory control module supports a stand-by mode to keep power consumption to a
minimum.
If the control module is being prevented from entering stand-by mode due to motor
movement, memory recall or switch operation, then it will enter stand-by mode when the
current function has terminated.
NOTE:
In the case of a memory recall, all memory recall operations should be carried out before
entering stand-by mode, not just the current motor movement.
The control module will exit stand-by mode if there is any CAN bus activity.
The exchange of information between the diagnostic unit and the memory control module is
via the medium-speed CAN bus. There is a non-volatile Electronic Erasable Programmable
Read Only Memory (EEPROM) for saving detected errors. Its contents are not lost when the
power supply is disconnected. Only the IDS diagnostic tester can erase the error memory.
Seats
For a detailed description of the seats and seat operation, refer to the relevant Description and
Seats

NOTE:
Prior to carrying out any diagnosis, ensure the vehicle battery is in a good serviceable
condition, refer to the battery care manual.
• Fuses
• Harnesses for
• Security, condition and correct installation of
damage/corrosion
seat components and fixings
• Damaged/corroded pins
4 . If the cause is not visually evident, verify the concern and refer to the Symptom Chart,
Symptom Chart
• Seat module Set ignition ON. Re-check
has gone into seat function from switch-
sleep mode pack. Check for DTC
No seat movement from switch-pack
• Seat switch- B1A9887 and refer to DTC
(including no memory recall)
pack LIN, Index. Check for DTC
power or B1A9888 and refer to DTC
ground circuit - Index
open circuit
• Seat switch-
pack LIN
circuit - short to
power, ground
Seat movement from switch-pack

occurs in inch mode (after 2 second • Motor Hall
delay from switch operation) - When sensor on
Check for DTCs, B1B8731,
seat axis movement is requested from affected axis is
B1B9131, B1B8931,
the seat switch-pack the requested seat not connected
B1B9331, B106331 and
axis moves a short distance (after a 2 or not receiving
refer to DTC Index. Re-
second delay from switch operation) expected
calibrate affected seat
then stops. This behaviour could occur signals
on any seat axis (slide, height, squab,
tilt or cushion)
Check Instrument Cluster
and DDM/PDM for DTCs,
Seat movement from switch-pack
U020800, U012600,
occurs in inch mode - When seat axis
U015500, U019900,
movement is requested from the seat
• MS CAN fault U014200 and refer to
switch-pack the requested seat axis
relevant DTC Index. Check
moves a short distance then stops. This
CAN network integrity
behaviour will occur on ALL seat axis
using manufacturer
(slide, height, squab, tilt and cushion)
Re-calibrate affected seat
• Seat module is Re-configure the affected
Seat moves forward/rearwards via the in seat module as a 'New
slide axis when the seat squab is tipped manufacturing Module' using the
forwards/rearwards mode manufacturer approved
diagnostic system
When seat squab axis is moved to its
Re-calibrate the affected
maximum recline position the squab • Seat is out of
seat. Check for DTC
makes contact with the rear quarter calibration
U300146 and refer to DTC
casing causing the squab to twist and
Index
bend
• Carry out the
pinpoint test
Front seat fore/aft movement not GO to Pinpoint Test
associated to
functioning G841635p1.
this Symptom
• Carry out the

pinpoint test
GO to Pinpoint Test
Front seat excessive fore/aft free play associated to
G841635p2.
this Symptom
Front seat fore/aft movement noisy • Carry out the GO to Pinpoint Test
pinpoint test G841635p3.
associated to
this Symptom
• Carry out the

Front seat height, tilt and/or seat pinpoint test
GO to Pinpoint Test
extension motor movement not associated to
G841635p4.
functioning this Symptom
• Carry out the

pinpoint test
Front seat height, tilt and/or extension GO to Pinpoint Test
associated to
movement noisy G841635p5.
this Symptom
DTC Index

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:
NOTE:
NOTE:
tests.
NOTE:
NOTE:
terminals.

B1C02- Memory Store Switch • Signal stuck high
this DTC using the
24 - signal stuck high
diagnostic system.
B1C03- Memory #1 Switch - • Signal stuck high
this DTC using the
24 signal stuck high
diagnostic system.
this DTC using the
diagnostic system.
this DTC using the
diagnostic system.
B1B94- Seat Height Up Switch • Signal stuck high
this DTC using the
diagnostic system.
Seat Height Down tests associated with
B1B95- • Signal stuck high
Switch - signal stuck this DTC using the
24
high manufacturer approved
diagnostic system.
Seat Slide Forward tests associated with
24
diagnostic system.
Seat Slide Backward tests associated with
24
diagnostic system.
Seat Recline Up tests associated with
B1C00- • Signal stuck high
24
diagnostic system.
Seat Recline Down tests associated with
B1C01- • Signal stuck high
24
diagnostic system.
B1B98- Seat Tilt Up Switch - • Signal stuck high
this DTC using the
diagnostic system.
B1B99- Seat Tilt Down Switch • Signal stuck high
this DTC using the
diagnostic system.
B1065- Cushion extend switch • Signal stuck high
this DTC using the
diagnostic system.
B1066- Cushion retract switch • Signal stuck high
this DTC using the
diagnostic system.
B1067- Lumbar in switch - • Signal stuck high
this DTC using the
diagnostic system.
B1068- Lumbar out switch - • Signal stuck high
this DTC using the
diagnostic system.
B1069- Lumbar up switch - • Signal stuck high
this DTC using the
diagnostic system.
B106A- Lumbar down switch - • Signal stuck high Carry out any pinpoint
24 signal stuck high tests associated with
this DTC using the
diagnostic system.
B106B- Bolster inflate switch - • Signal stuck high
this DTC using the
diagnostic system.
B106C- Bolster deflate switch • Signal stuck high
this DTC using the
diagnostic system.
Seat Height Motor • Circuit Short to Battery or tests associated with
B1B86-
Relay - circuit short to Open this DTC using the
15
battery or open manufacturer approved
diagnostic system.
Seat Height Motor tests associated with
B1B86- • Circuit Short to Ground
Relay - circuit short to this DTC using the
11
diagnostic system.
Seat Slide Motor • Circuit Short to Battery or tests associated with
B1B88-
Relay - circuit short to Open this DTC using the
15
diagnostic system.
Seat Slide Motor tests associated with
11
diagnostic system.
Seat Tilt Motor Relay • Circuit Short to Battery or tests associated with
B1B90-
- circuit short to Open this DTC using the
15
diagnostic system.
Seat Tilt Motor Relay tests associated with
- circuit short to this DTC using the
11
diagnostic system.
Seat Recline Motor • Circuit Short to Battery or
B1B92- tests associated with
Relay - circuit short to Open
15 this DTC using the
battery or open
diagnostic system.
Seat Recline Motor tests associated with
11
diagnostic system.
Seat Cushion
• Circuit Short to Battery or tests associated with
B105F- Extension Motor
Open this DTC using the
15 Output - circuit short
to battery or open
diagnostic system.
Seat Cushion
B105F- Extension Motor • Circuit Short to Ground
this DTC using the
11 Output - circuit short
to ground
diagnostic system.
Lumbar Motor Relay - • Circuit Short to Battery or tests associated with
B1D94-
circuit short to battery Open this DTC using the
15
or open manufacturer approved
diagnostic system.
B1D94- Lumbar Motor Relay - • Circuit Short to Ground
this DTC using the
11 circuit short to ground
diagnostic system.
Seat Height Motor tests associated with
B1B87- • No Signal
Speed/Position Sensor this DTC using the
31
- no signal manufacturer approved
diagnostic system.
Seat Tilt Motor tests associated with
31
diagnostic system.
Seat Slide Motor tests associated with
31
diagnostic system.
Seat Recline Motor tests associated with
31
diagnostic system.
Seat Cushion
B1063- Extension Motor • No Signal
this DTC using the
31 Speed/Position Sensor
- no signal
diagnostic system.
Seat Headrest Motor tests associated with
B1064- • No Signal
31
diagnostic system.
General failure on seat tests associated with
B113A- • General failure
lumbar - no sub type this DTC using the
00
information manufacturer approved
diagnostic system.
Multiple failure on tests associated with
B113B- • Multiple failure
lumbar 4W - no sub this DTC using the
00
type information manufacturer approved
diagnostic system.
B1138- Lumbar control C - • Circuit short to ground
this DTC using the
diagnostic system.
B1138- Lumbar control C - • Circuit short to battery
this DTC using the
12 circuit short to battery
diagnostic system.
B1138- Lumbar control C - • Circuit open
test lower lumbar
13 circuit open
inflate control circuit
for open circuit.
B1139- Lumbar control D - • Circuit short to ground
this DTC using the
diagnostic system.
B1139- Lumbar control D - • Circuit short to battery
this DTC using the
diagnostic system.
B1139- Lumbar control D - • Circuit open Refer to the electrical
13 circuit open circuit diagrams and
test lower lumbar
deflate control circuit
for open circuit.
B1136- Lumbar control A - • Circuit short to ground
this DTC using the
diagnostic system.
B1136- Lumbar control A - • Circuit short to battery
this DTC using the
diagnostic system.
B1136- Lumbar control A - • Circuit open
test upper lumbar
13 circuit open
deflate control circuit
for open circuit.
B1137- Lumbar control B - • Circuit short to ground
this DTC using the
diagnostic system.
B1137- Lumbar control B - • Circuit short to battery
this DTC using the
diagnostic system.
B1137- Lumbar control B - • Circuit open
test upper lumbar
13 circuit open
inflate control circuit
for open circuit.
Seat Bolster Inflate tests associated with
B105D- • Circuit short to ground
Output - circuit short this DTC using the
11
to ground manufacturer approved
diagnostic system.
Seat Bolster Inflate • Circuit Short to Battery or tests associated with
B105D-
Output - circuit short Open this DTC using the
15
to battery or open manufacturer approved
diagnostic system.
Seat Bolster Deflate
B105E- • Circuit short to ground tests associated with
Output - circuit short
11 this DTC using the
to ground
diagnostic system.
Seat Bolster Deflate • Circuit Short to Battery or tests associated with
B105E-
Output - circuit short Open this DTC using the
15
to battery or open manufacturer approved
diagnostic system.
Check LIN network for
B1A98- LIN Bus Circuit #1 - • Signal Invalid
interference/EMC
86 signal invalid
related issues.
Refer to electrical
test LIN Bus between
B1A98- LIN Bus Circuit #1 - • Bus off
seat switch pack and
88 bus off
control module for
short to ground or
power.
LIN Bus Circuit #1 -
• Value of signal protection Check LIN network for
B1A98- value of signal
calculation incorrect interference/EMC
83 protection calculation
related issues.
incorrect
Refer to electrical
test LIN Bus between
seat switch-pack and
B1A98- LIN Bus Circuit #1 - • Missing Message
control module for
87 missing message
open circuit, check
power and ground
supplies to switch-
pack.
Install a new
CAN Initialisation DSM/PSM, refer to the
U1A14- • Internal electronic failure
failure - internal new module
49
electronic failure installation note at the
top of the DTC Index.
Medium speed Can tests associated with
U0010- • Bus off
communication Bus - this DTC using the
88
bus off manufacturer approved
diagnostic system.
Lost communication • Lost communication with tests associated with
U0140-
with CJB - no sub type CJB this DTC using the
00
diagnostic system.
Lost communication • Lost communication with Carry out any pinpoint
U0142-
with RJB - no sub type RJB tests associated with
00
information this DTC using the
diagnostic system.
Lost communications
• Lost communications with tests associated with
U0155- with instrument cluster
instrument cluster this DTC using the
00 - no sub type
information
diagnostic system.
Lost communication
• Lost communication with tests associated with
U0199- with Driver Door
DDM this DTC using the
00 Module (DDM) - no
sub type information
diagnostic system.
Vehicle Identification match. Corrupt VIN data Install original module,
U3002- Number (VIN) - being transmitted, module check for DTCs and
81 invalid serial data previously installed to other refer to relevant DTC
received vehicle Index.
Re-configure the RJB

approved diagnostic
Internal control system. Clear the DTC
U0300- module software and retest. If the DTC
message is received
00 incompatibility - no is still logged suspect
sub type information the DSM/PSM, refer to
the new module
approved diagnostic
Stored vehicle system. Clear DTC and
U3000- configuration data re-test. If the DTC
data received
55 does not match - not remains suspect the
configured DSM/PSM, refer to the
new module
approved diagnostic
system. Check
U3000- Control Module - • Missing message DSM/PSM for DTCs
87 missing message and refer to the DTC
Index. Check CAN
network integrity using
the manufacturer
approved diagnostic
system.
Place DSM/PSM in to
Build/end of line mode • Manufacturing mode has
U1A4C- customer mode using
active - event not been removed
68 manufacturer approved
information
diagnostic system.
Install a new
Control module - DSM/PSM, refer to the
U3000- • Internal electronic failure
internal electronic new module
49
failure installation note at the
Check for DTCs that
Control module
• Calibration/parameter could indicate power
U3001- improper shutdown -
memory failure failure to the module
46 calibration/parameter
and refer to the DTC
memory failure
Index.
Battery voltage - • Circuit voltage below tests associated with
U3003-
circuit voltage below threshold this DTC using the
16
threshold manufacturer approved
diagnostic system.
Battery voltage - • Circuit voltage above tests associated with
U3003-
circuit voltage above threshold this DTC using the
17
diagnostic system.

NOTE:
NOTE:
NOTE:
NOTE:
tests.
NOTE:
NOTE:
terminals.

Carry out On Demand Self Test
(ODST) using manufacturer
approved diagnostic system to
confirm the fault is present.
diagrams and check LH fans
pwr circuit for open circuit.
• LH fans pwr circuit,
Check LH fans rtn circuit for
open circuit
open circuit. Check for any
• LH fans rtn circuit,
disconnected connectors or
open circuit
damaged connector pins. Check
• Connectors
blower motor assembly for open
B10B9- Blower Control - disconnected
circuit. Refer to the new
13 circuit open • Connector pin damage
• Blower motor
assembly open circuit
if the Climate Control Seat
• Climate Control Seat
Module is suspect. Carry out On
Module failure
Demand Self Test (ODST) using
diagnostic system to confirm
rectification. Alternatively carry
out any pinpoint tests associated
with this DTC using the
diagnostic system.
• Mechanical restriction Check for mechanical restriction
in blower motor or debris in blower motor
assembly assembly. Carry out On Demand
• LH fans pwr circuit, Self Test (ODST) using
B10B9- Blower Control -
short to ground manufacturer approved
4B over temperature
• LH fans rtn circuit, diagnostic system to confirm the
short to ground fault is present. Refer to the
• Blower motor electrical circuit diagrams and
assembly, short to check LH fans pwr circuit for
ground short to ground. Check LH fans
• Climate Control Seat rtn circuit for short to ground.
Module failure Check blower motor assembly
for short to ground. Refer to the
DTC Index if the Climate
Control Seat Module is suspect.
confirm rectification.
diagrams and check RH fans
pwr circuit for open circuit.
• RH fans pwr circuit,
Check RH fans rtn circuit for
open circuit
open circuit. Check for any
• RH fans rtn circuit,
open circuit
damaged connector pins. Check
• Connectors
blower motor assembly for open
B1157- Blower Control disconnected
circuit. Refer to the new
13 "B" - circuit open • Connector pin damage
• Blower motor
assembly open circuit
Module failure
diagnostic system.
Check for mechanical restriction
• Mechanical restriction
or debris in blower motor
in blower motor
assembly. Carry out On Demand
assembly
Self Test (ODST) using
• RH fans pwr circuit,
Blower Control short to ground
B1157- diagnostic system to confirm the
"B" - over • RH fans rtn circuit,
4B fault is present. Refer to the
temperature short to ground
• Blower motor
check RH fans pwr circuit for
assembly, short to
short to ground. Check RH fans
ground
rtn circuit for short to ground.
Check blower motor assembly
Module failure for short to ground. Refer to the
DTC Index if the Climate
• RH seat back thermal diagrams and check, RH seat
electric device + back thermal electric device +
circuit, open circuit circuit for open circuit. Check
• RH seat back thermal RH seat back thermal electric
electric device - device - circuit for open circuit.
circuit, open circuit Check RH seat cushion thermal
• RH seat cushion electric device + circuit for open
thermal electric device circuit. Check RH seat cushion
+ circuit, open circuit thermal electric device - circuit
• RH seat cushion for open circuit. Check for any
Right Thermal thermal electric device disconnected connectors or
B120E- Electric Device - circuit, open circuit damaged connector pins. Check
13 Control - circuit • Connectors climate seat backrest thermal
open disconnected electric device assembly for
• Connector pin damage open circuit. Check climate seat
• Climate seat backrest cushion thermal electric device
thermal electric device assembly for open circuit. Refer
assembly, open circuit to the new module/component
• Climate seat cushion installation note at the top of the
thermal electric device DTC Index if the Climate
assembly, open circuit Control Seat Module is suspect.
• Climate Control Seat Carry out On Demand Self Test
Module failure (ODST) using manufacturer
Alternatively carry out any
this DTC using the manufacturer
• RH seat back thermal Carry out On Demand Self Test
Right Thermal
electric device + (ODST) using manufacturer
Electric Device
B120E- circuit, short to ground approved diagnostic system to
Control - circuit
19 • RH seat back thermal confirm the fault is present.
current above
electric device - Refer to the electrical circuit
threshold
circuit, short to ground diagrams and check, RH seat
• RH seat cushion back thermal electric device +
thermal electric device circuit for short to ground.
+ circuit, short to Check RH seat back thermal
ground electric device - circuit for short
• RH seat cushion to ground. Check RH seat
thermal electric device cushion thermal electric device
- circuit, short to + circuit for short to ground.
ground Check RH seat cushion thermal
• Climate seat backrest electric device - circuit for short
thermal electric device to ground. Check climate seat
assembly, short to backrest thermal electric device
ground assembly for short to ground.
• Climate seat cushion Check climate seat cushion
thermal electric device thermal electric device assembly
assembly, short to for short to ground. Refer to the
ground new module/component
• Climate Control Seat installation note at the top of the
Module failure DTC Index if the Climate
• Restriction in thermal Check for blockage or
electric device airpath restriction in thermal electric
• RH seat back thermal device airpath. Carry out On
electric device + Demand Self Test (ODST) using
circuit, short to ground manufacturer approved
• RH seat back thermal diagnostic system to confirm the
electric device - fault is present. Refer to the
circuit, short to ground electrical circuit diagrams and
• RH seat cushion check, RH seat back thermal
Right Thermal thermal electric device electric device + circuit for short
B120E- Electric Device + circuit, short to to ground. Check RH seat back
4B Control - over ground thermal electric device - circuit
temperature • RH seat cushion for short to ground. Check RH
thermal electric device seat cushion thermal electric
- circuit, short to device + circuit for short to
ground ground. Check RH seat cushion
• Climate seat backrest thermal electric device - circuit
thermal electric device for short to ground. Check
assembly, short to climate seat backrest thermal
ground electric device assembly for
• Climate seat cushion short to ground. Check climate
assembly, short to device assembly for short to
ground ground. Refer to the new
• Climate Control Seat module/component installation
Module failure note at the top of the DTC Index
diagnostic system.
• The Climate Control
Seat Module LH
cushion sensor input
circuit temperature
exceeds 65 Degrees C
continuously for more
than 4 seconds during
Check for blockage or
cooling
restriction in thermal electric
device fan exhaust vent. Check
Left Seat Cushion - Seat Module LH
for restricted thermal electric fan
B120F- component or cushion sensor input
movement. Carry out On
98 system over circuit temperature is
temperature greater than 110
Degrees C for more
rectification.
heating
• Blocked or restricted
thermal electric device
fan exhaust vent
• Restricted thermal
electric fan movement
• RH seat cushion Carry out On Demand Self Test

sensor circuit, open (ODST) using manufacturer
circuit approved diagnostic system to
• RH seat cushion confirm the fault is present.
sensor rtn circuit, open Refer to the electrical circuit
Right Seat Cushion
circuit diagrams and check, RH seat
B1223- Temperature
• Connectors cushion sensor circuit for open
13 Sensor - circuit
disconnected circuit. Check RH seat cushion
open
• Connector pin damage sensor rtn circuit for open
• Climate seat cushion circuit. Check for any
temperature sensor disconnected connectors or
assembly, open circuit damaged connector pins. Check
• Climate Control Seat Climate seat cushion
Module failure temperature sensor assembly for
open circuit. Refer to the new
diagnostic system.
• LH seat back thermal diagrams and check, LH seat
electric device + back thermal electric device +
circuit, open circuit circuit for open circuit. Check
• LH seat back thermal LH seat back thermal electric
electric device - device - circuit for open circuit.
circuit, open circuit Check LH seat cushion thermal
• LH seat cushion electric device + circuit for open
thermal electric device circuit. Check LH seat cushion
+ circuit, open circuit thermal electric device - circuit
• LH seat cushion for open circuit. Check for any
Left Thermal thermal electric device disconnected connectors or
B1224- Electric Device - circuit, open circuit damaged connector pins. Check
13 Control - circuit • Connectors climate seat backrest thermal
open disconnected electric device assembly for
• Connector pin damage open circuit. Check climate seat
• Climate seat backrest cushion thermal electric device
thermal electric device assembly for open circuit. Refer
assembly, open circuit to the new module/component
• Climate seat cushion installation note at the top of the
thermal electric device DTC Index if the Climate
assembly, open circuit Control Seat Module is suspect.
• Climate Control Seat Carry out On Demand Self Test
Module failure (ODST) using manufacturer
B1224- Left Thermal • LH seat back thermal Carry out On Demand Self Test
19 Electric Device electric device + (ODST) using manufacturer
Control - circuit circuit, short to ground approved diagnostic system to
current above • LH seat back thermal confirm the fault is present.
threshold electric device - Refer to the electrical circuit
circuit, short to ground diagrams and check, LH seat
• LH seat cushion back thermal electric device +
thermal electric device circuit for short to ground.
+ circuit, short to Check LH seat back thermal
ground electric device - circuit for short
• LH seat cushion to ground. Check LH seat
thermal electric device cushion thermal electric device
- circuit, short to + circuit for short to ground.
ground Check LH seat cushion thermal
• Climate seat backrest electric device - circuit for short
thermal electric device to ground. Check climate seat
assembly, short to backrest thermal electric device
• Climate seat cushion Check climate seat cushion
thermal electric device thermal electric device assembly
assembly, short to for short to ground. Refer to the
ground new module/component
• Climate Control Seat installation note at the top of the
Module failure DTC Index if the Climate
• Restriction in thermal Check for blockage or
electric device airpath restriction in thermal electric
• LH seat back thermal device airpath. Carry out On
electric device + Demand Self Test (ODST) using
circuit, short to ground manufacturer approved
• LH seat back thermal diagnostic system to confirm the
electric device - fault is present. Refer to the
Left Thermal
circuit, short to ground electrical circuit diagrams and
B1224- Electric Device
• LH seat cushion check, LH seat back thermal
4B Control - over
thermal electric device electric device + circuit for short
temperature
+ circuit, short to to ground. Check LH seat back
ground thermal electric device - circuit
• LH seat cushion for short to ground. Check LH
- circuit, short to device + circuit for short to
ground ground. Check LH seat cushion
• Climate seat backrest thermal electric device - circuit
thermal electric device for short to ground. Check
assembly, short to climate seat backrest thermal
ground electric device assembly for
• Climate seat cushion short to ground. Check climate
assembly, short to device assembly for short to
ground ground. Refer to the new
• Climate Control Seat module/component installation
diagnostic system.
diagrams and check, RH seat
back sensor circuit for open
• RH seat back sensor circuit. Check RH seat back
circuit, open circuit sensor rtn circuit for open
• RH seat back sensor circuit. Check for any
rtn circuit, open circuit disconnected connectors or
• Connectors damaged connector pins. Check
Right Seat Back
disconnected Climate seat back temperature
B1225- Temperature
• Connector pin damage sensor assembly for open circuit.
13 Sensor - circuit
• Climate seat back Refer to the new
open
temperature sensor module/component installation
assembly, open circuit note at the top of the DTC Index
• Climate Control Seat if the Climate Control Seat
Module failure Module is suspect. Carry out On
diagnostic system.
Left Seat Back • LH seat back sensor Carry out On Demand Self Test
B1229-
Temperature circuit, open circuit (ODST) using manufacturer
13
Sensor - circuit • LH seat back sensor approved diagnostic system to
open rtn circuit, open circuit confirm the fault is present.
• Connectors Refer to the electrical circuit
disconnected diagrams and check, LH seat
• Connector pin damage back sensor circuit for open
• Climate seat back circuit. Check LH seat back
temperature sensor sensor rtn circuit for open
assembly, open circuit circuit. Check for any
• Climate Control Seat disconnected connectors or
Module failure damaged connector pins. Check
Climate seat back temperature
sensor assembly for open circuit.
Refer to the new
diagnostic system.
• RH cushion fan speed, diagrams and check, RH cushion
Right Seat Cushion circuit short to ground fan speed for circuit short to
Blower Speed • Blower motor ground. Check blower motor
B122A- Sensor - circuit assembly, short to assembly for short to ground.
11 short to ground - ground Refer to the new
circuit short to • Climate Control Seat module/component installation
ground Module failure note at the top of the DTC Index
rectification.
• RH cushion fan speed,
Right Seat Cushion circuit short to power
B122A- Blower Speed • Blower motor
12 Sensor - circuit assembly, short to
short to battery power
diagrams and check, RH cushion
fan speed for circuit short to
Module failure power. Check blower motor
assembly for short to power.
Refer to the new
rectification.
• RH seat back fan
speed, circuit short to
back fan speed for circuit short
ground
Right Seat Back to ground. Check blower motor
• Blower motor
B122B- Blower Speed assembly for short to ground.
assembly, short to
11 Sensor - circuit Refer to the new
ground
short to ground module/component installation
Module failure
rectification.
• RH seat back fan
power
Right Seat Back to power. Check blower motor
• Blower motor
B122B- Blower Speed assembly for short to power.
assembly, short to
power
short to battery module/component installation
Module failure
rectification.
B122C- Left Seat Cushion • LH cushion fan speed, Carry out On Demand Self Test
11 Blower Speed circuit short to ground (ODST) using manufacturer
Sensor - circuit • Blower motor approved diagnostic system to
short to ground assembly, short to confirm the fault is present.
ground Refer to the electrical circuit
• Climate Control Seat diagrams and check, LH cushion
Module failure fan speed for circuit short to
ground. Check blower motor
assembly for short to ground.
Refer to the new
rectification.
• LH cushion fan speed, diagrams and check, LH cushion
circuit short to power fan speed for circuit short to
Left Seat Cushion • Blower motor power. Check blower motor
B122C- Blower Speed assembly, short to assembly for short to power.
12 Sensor - circuit power Refer to the new
short to battery • Climate Control Seat module/component installation
rectification.
• LH seat back fan confirm the fault is present.
speed, circuit short to Refer to the electrical circuit
ground diagrams and check, LH seat
Left Seat Back
• Blower motor back fan speed for circuit short
B122D- Blower Speed
assembly, short to to ground. Check blower motor
11 Sensor - circuit
short to ground
• Climate Control Seat Refer to the new
Module failure module/component installation
rectification.
• LH seat back fan
diagrams and check, LH seat
power
Left Seat Back to power. Check blower motor
• Blower motor
B122D- Blower Speed assembly for short to power.
assembly, short to
power
short to battery module/component installation
Module failure
rectification.
Seat Module RH
cushion sensor input
circuit temperature
cooling
Right Seat Cushion Seat Module RH
B122E- - component or cushion sensor input
Degrees C for more
rectification.
heating
fan exhaust vent
• The Climate Control Check for blockage or

Right Seat Back - Seat Module RH seat restriction in thermal electric
B122F- component or back sensor input device fan exhaust vent. Check
98 system over circuit temperature for restricted thermal electric fan
temperature exceeds 65 Degrees C movement. Carry out On
continuously for more Demand Self Test (ODST) using
than 4 seconds during manufacturer approved
cooling diagnostic system to confirm
• The Climate Control rectification.
Seat Module RH seat
back sensor input
circuit temperature is
greater than 110
Degrees C for more
heating
fan exhaust vent

Seat Module LH seat
back sensor input
circuit temperature
cooling
Left Seat Back - Seat Module LH seat
B1230- component or back sensor input
Degrees C for more
rectification.
heating
fan exhaust vent
• The Climate Control Check for blockage or

Seat Module has restriction in seat back thermal
detected an input electric device fan ducts. Check
temperature difference seat back thermal electric device
greater than expected fan exhaust vent is clear. Check
B1231- Right Seat - fluid
between RH seat back for blockage or restriction in
7A leak or seal failure
sensor and RH seat cushion thermal electric
cushion sensor device fan ducts. Check seat
• Climate seat back cushion thermal electric device
assembly airpath fan exhaust vent is clear. Carry
leaking out On Demand Self Test
• Climate seat cushion (ODST) using manufacturer
assembly airpath approved diagnostic system to
leaking confirm rectification.
• Seat assembly
damaged

Seat Module has
detected an input
restriction in seat back thermal
temperature difference
electric device fan ducts. Check
greater than expected
seat back thermal electric device
between LH seat back
fan exhaust vent is clear. Check
sensor and LH cushion
for blockage or restriction in
sensor
B1232- Left Seat - fluid seat cushion thermal electric
• Climate seat back
7A leak or seal failure device fan ducts. Check seat
assembly airpath
cushion thermal electric device
leaking
fan exhaust vent is clear. Carry
• Climate seat cushion
out On Demand Self Test
assembly airpath
leaking
• Seat assembly
damaged

diagrams and check, LH seat
• LH seat cushion
cushion sensor circuit for open
sensor circuit, open
circuit. Check LH seat cushion
circuit
sensor rtn circuit for open
• LH seat cushion
circuit. Check for any
sensor rtn circuit, open
circuit
Left Seat Cushion damaged connector pins. Check
• Connectors
B1235- Temperature Climate seat cushion
disconnected
13 Sensor - circuit temperature sensor assembly for
• Connector pin damage
open open circuit. Refer to the new
• Climate seat cushion
temperature sensor
assembly, open circuit
Module failure
diagnostic system.
diagrams and check the power
and ground connections to the
module. Using the manufacturer
Medium Speed • Medium Speed CAN
complete a CAN network
U0010- CAN communication bus
integrity test. Refer to the
88 Communication off
Bus - bus off
check the CAN network.
check Central Junction Box for
DTCs and refer to the relevant
• CAN harness link
DTC Index. Using the
between Climate
Control Seat Module
diagnostic system, carry out
and Central Junction
network integrity test. Refer to
Lost Box malfunction
the electrical circuit diagrams
Communication • The Climate Control
U0140- and check Central Junction Box
With Body Control Seat Module has not
00 power and ground circuits for
Module - no sub received the expected
open circuit. Check CAN
type information CAN signal from the
harness between Climate
Central Junction Box
Control Seat Module and
within the specified
Central Junction Box, repair as
time interval
necessary. Alternatively carry
diagnostic system.
• CAN harness link approved diagnostic system,
between Climate check Rear Junction Box for
Control Seat Module DTCs and refer to the relevant
and Rear Junction Box DTC Index. Using the
Lost
malfunction manufacturer approved
Communication
• The Climate Control diagnostic system, carry out
U0142- With Body Control
Seat Module has not network integrity test. Refer to
00 Module "B" - no
received the expected the electrical circuit diagrams
sub type
CAN signal from the and check Rear Junction Box
information
Rear Junction Box power and ground circuits for
within the specified open circuit. Check CAN
time interval harness between Climate
Control Seat Module and Rear
Junction Box, repair as
diagnostic system.
check Instrument Cluster for
DTCs and refer to the relevant
DTC Index. Using the
between Climate
Control Seat Module
Lost and Instrument Cluster
Communication network malfunction
the electrical circuit diagrams
With Instrument • The Climate Control
U0155- and check Instrument Cluster
Panel Cluster (IPC) Seat Module has not
00 power and ground circuits for
Control Module - received the expected
open circuit. Check CAN
no sub type CAN signal from the
information Instrument Cluster
within the specified
Instrument Cluster, repair as
time interval
diagnostic system.
check Information and
Entertainment Control Module
between Climate
relevant DTC Index. Using the
Control Seat Module
and Information and
Entertainment Control
Module network
Lost the electrical circuit diagrams
malfunction
Communication and check Information and
U0156- • The Climate Control
With Information Entertainment Control Module
00 Seat Module has not
Center "A" - no sub power and ground circuits for
received the expected
type information open circuit. Check CAN
CAN signal from the
Information and
Entertainment Control
Information and Entertainment
Module within the
Control Module, repair as
specified time interval
diagnostic system.
U0300- Internal Control • Incorrect or invalid Using the manufacturer
00 Module Software software has been approved diagnostic system, re-
Incompatibility - installed configure the Climate Control
no sub type Seat Module and the Rear
information Junction Box. Carry out On
rectification. Refer to the new
Module is suspect.
• The Engine Control
Module has
Invalid Data transmitted engine Using the manufacturer
Received From speed quality factor approved diagnostic system,
U0401-
ECM/PCM - no CAN signal at a check Engine Control Module
00
sub type specific value for a for DTCs and refer to the
information greater than expected relevant DTC Index.
time period.

approved diagnostic system, re-
Control Module configure the Climate Control
Configuration • Calibration Seat Module and the Rear
U2101-
Incompatible - no incomplete/corrupt Junction Box. Carry out On
00
sub type Demand Self Test (ODST) using
rectification.
Module failure
Refer to the new
Control Module - module/component installation
U3000- Module
system internal note at the top of the DTC Index
04 microprocessor failed
failures if the Climate Control Seat
internal ROM and/or
Module is suspect.
RAM checksum test
• Mismatch in battery Refer to the electrical circuit

voltage of 2 volts or diagrams and check that power
more between the supply voltage at Climate
measured battery Control Seat Module and Rear
Battery Voltage -
U3003- voltage at the Climate Junction Box is not different by
signal compare
62 Control Seat Module more than 2 volts. Rectify as
failure
and the battery voltage required. Carry out On Demand
signal sent from the Self Test (ODST) using
Rear Junction Box manufacturer approved
diagnostic system.
Pinpoint Tests
PINPOINT TEST G841635p1 : Front seat

fore/aft movement not functioning
G841635t1 : Check for front seat forward-rearward seat
motor operation
1.
WARNING: 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.
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
-> No
G841635t2 : 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.

motor
1. Set ignition status to 'OFF'. 2. Disconnect front seat forward-rearward seat motor
connector. 3. 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.
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.

excessive forward-rearward free play
G841635t4 : Check front seat for excessive forward-
rearward free play
1.
of workshop manual.
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
-> No
Install and tighten all accessible front seat frame fixings to correct torque and re-check for
excessive free play.
G841635t5 : 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
-> No
The front seat frame is operating correctly. Submit Electronic Product Quality Report (EPQR)
with any further query.
G841635t6 : 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.

forward-rearward movement noisy
G841635t7 : Compare front seat forward-rearward
movement noise to other front seat
1.
of workshop manual.
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
-> No
G841635t8 : 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
-> No
G841635t9 : 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
G841635t10 : 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
-> No
The front seat frame is now operating correctly.

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.

height, tilt and/or seat extension motor
movement not functioning
G841635t12 : Check front seat height, tilt or extension
motor
1. Set ignition status to ' OFF'. 2. Disconnect front seat height, tilt or extension motor
connector. 3. 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.
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.

height, tilt and/or extension movement noisy
G841635t13 : Compare the height, tilt or extension
movement noise with the other front seat
1.
of workshop manual.
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
-> No
G841635t14 : 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
-> No
G841635t15 : 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 G841635t16.
-> No
G841635t16 : 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.
Front Seat (76.70.01)

Removal
1 . Release the front seat.
Position the front seat fully forwards.
Remove the bolt covers.
Remove and discard the 2 rear bolts.
2 . Position the front seat fully rearwards.

4 . With assistance, remove the front seat.

Remove and discard the front 2 Torx bolts.
Installation
1 . With assistance, install the front seat.
Install the new bolts and tighten to 40 Nm (30 lb.ft).

3 . Secure the front seat.

Position the front seat fully forwards.
Install the new bolts and tighten to 40 Nm (30 lb.ft).
Install the bolt covers.
Front Seat Backrest Cover (76.70.15)
Removal

3 . Remove the front seat head reatraint.

4 . Remove the front seat head restraint guide tubes.

Release from the seat frame.
5 . Remove the front seat backrest tilt handle.
Remove the screw.
6 . Remove the front seat backrest tilt handle trim panel.

7 . Release the front seat backrest cover lower tension straps.
8 . Release the 9 front seat backrest cover rear panel retaining clips.
Release from the backrest cover.
9 . Release the 5 front seat backrest cover lower retaining clips.
10 . Release the front seat backrest cover central tension straps.

11 . Remove the side air bag module.

Release the backrest cover.
12 . Release the front seat backrest cover upper tension straps.

Withdraw from the backrest pad.
13 . Remove the front seat backrest cover.
Remove the 16 hog rings.
Installation
1 . Install the front seat backrest cover.
Install the 16 hog rings.
2 . Secure the front seat backrest cover upper tension straps.

Pass through the backrest pad.
Attach to the seat frame.
3 . Install the side air bag module.

Attach the backrest cover.
4 . Secure the front seat backrest cover central tension straps.

5 . Secure the front seat backrest cover lower retaining clips.

6 . Secure the front seat backrest cover rear panel retaining clips.
Attach to the backrest cover.
7 . Secure the front seat backrest cover lower tension straps.

8 . Install the front seat backrest tilt handle trim panel.

9 . Install the front seat backrest tilt handle.

Install the screw.
10 . Install the front seat head restraint guide tube.

Secure in the seat frame.
11 . Install the front seat head reatraint.

Front Seat Control Switch (86.75.46)
Removal
2 . Remove the front seat control switch.

Installation
1 . Install the front seat control switch.
Fit and tighten the Torx screws.

Front Seat Cushion Cover (76.70.33)
Removal


4 . Release the front seat cushion outer trim panel.

5 . Remove the front seat cushion outer trim panel.

6 . Remove the front seat hinge covers.

Remove the hinge cover retainers.
8 . Remove the front seat cushion assembly.

Release and disconnect the 2 electrical connectors.
Release the Velcro strap.
9 . Remove the front seat cushion cover.
10 . Using WDS, calibrate a new front seat cushion cover.
Installation
1 . Install the front seat cushion cover.
2 . Secure the front seat cushion assembly.

Secure the Velcro strap.
Attach the clips.
4 . Install the front seat cushion outer trim panel.

5 . Secure the front seat cushion outer trim panel.

6 . Install the front seat hinge covers.

Attach the hinge cover retainers.


Front Seat Lumbar Motor (86.75.44)
Removal


5 . Release the front seat lumbar assembly.
Remove the clip.
6 . Remove the front seat lumbar assembly.
Installation
1 . Install the front seat lumbar assembly.
2 . Secure the front seat lumbar assembly.

Install the clip.

5 . Install the front seat head reatraint.

Front Seat Recliner Motor (86.75.04)
Removal



5 . Remove the front seat hinge cover.

Remove the hinge cover retainer.
6 . Remove the front seat backrest cover.
For additional information, refer to Front Seat Backrest Cover (76.70.15)
7 . Remove the front seat backrest pad.

8 . Release the front seat lumbar assembly.

Remove the clip.
9 . Remove the front seat lumbar assembly.
10 . Release the front seat recliner motor.

Remove the front seat backrest shaft clip.
Remove the front seat backrest shaft.
11 . Remove the front seat recliner motor.

Drill out the rivet.
Installation
Removal
Installation
Rear Seat Backrest (76.70.38)
Removal
1 . Remove the LH rear seat cushion.
For additional information, refer to Rear Seat Cushion (76.70.37)
2 . Repeat the above procedure for the RH seat cushion.
3 . Remove the auxiliary junction box access cover.

Release the clip.

Installation
2 . Install the auxiliary junction box access cover.

Align the pegs and secure the clip.
3 . Install the LH rear seat cushion.

4 . Install the RH rear seat cushion.

Rear Seat Cushion (76.70.37)
Removal
2 . Remove the rear seat cushion.

Installation
1 . Install the rear seat cushion.

Front Seat Backrest Heater Mat (86.75.14)
Removal




8 . Remove the front seat backrest heater mat.

Installation
1 . Install the front seat backrest heater mat.




Front Seat Cushion Heater Mat (86.75.13)
Removal




6 . Remove the front seat hinge covers.

Remove the hinge cover retainers.

10 . Remove the front seat cushion heater mat.

Carefully release from the seat cushion pad.
Installation
1 . Install the front seat cushion heater mat.
Secure to the seat cushion pad.

Attach the clips.





Seat Track
Removal



6 . Remove the front seat safety belt pretensioner.
7 . Release the seat module bracket.

Remove and discard the cable tie.
8 . Remove the seat track assembly.
Installation
1 . Install the seat track assembly.
Tighten the new Torx bolts to 45 Nm (33 lb.ft).
2 . Secure the seat module bracket.

Secure the harness with a cable tie.
3 . Install the front seat safety belt pretensioner.


Attach the clips.


Assembly & disassembly
Rear Seat Backrest - Vehicles With:

40/20/40 Split Seat (76.70.48)
Disassembly
1 . Remove the rear outer seat backrest.

2 . Remove the rear seat head restraint.
3 . NOTE:
Detach the rear seat head restraint retaining post.
4 . NOTE:
Remove the rear seat head restraint retaining post.

5 . Detach the rear seat outer backrest cover.
6 . Detach the rear seat backrest cover and cushion.
7 . Remove the rear seat backrest cover and cushion.

• Disconnect the rear seat backrest heater pad electrical connector.
8 . Disconnect the rear seat lumbar support electrical connector.

9 . Detach the rear seat lumbar support control valve.
10 . Remove the rear seat lumbar support.
11 . Disconnect the rear seat head restraint motor electrical connector.
12 . Remove the rear seat head restraint motor.

Assembly

501-11 : Glass, Frames and Mechanisms
Specifications
Specifications
Item Nm lb-ft lb-in

Door glass into clamp - bolt 8 - 71
Door glass regulator motor to door - screw 4 - 35
Door glass regulator to door - nut/bolt 8 - 71
Door glass regulator to door - screw 4 - 35
Rear quarter glass, seal-carrier (coupe) - screw 4 - 35
Rear quarter glass, regulator motor (convertible) - nut 9 - 80
General procedures
Door Window Motor Initialization

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.
Door Window Glass Adjustment (76.31.03)
CAUTION: Protect the surrounding components.
NOTE:
Final door glass alignment or adjustment, can be carried out without the need to remove
the interior door trim panel.
1. Check the alignment of the front door glass.
2. Open the door.
3. Remove the 4 screw covers.
4. Using a 4mm Allen key, rotate the side adjusters to achieve lateral alignment with the rear
quarter glass.
5. NOTE:
The glass must be in the lowered position to access the adjusters.
NOTE:
The glass should have 6mm +/- 2mm engagement into the upper seal, the glass may not
have equal engagment when the 8mm door to rear quarter glass is set.
Using a extended 5mm Allen key, rotate the lower adjusters to adjust the glass height and
achieve a parallel 8mm gap between the rear quarter and the door.
6. Install the screw covers.
7. Check the alignment of the front door glass.
8. When the window glass adjustment is complete the window motor will need to be
calibrated, to do this power the window fully up and continue to hold the switch for a further
3 seconds.

COMPONENT LOCATION - WINDSHIELD AND
BACKLIGHT

A Coupe
B Convertible
1 Rain sensor mounting boss and interior mirror mounting button
2 Coupe backlight
3 Convertible backlight
4 Windshield
COMPONENT LOCATION - DOOR GLASS AND REAR
QUARTER GLASS MECHANISMS
NOTE:
Convertible shown, coupe similar.

2 Passenger window motor
3 Passenger door switch pack
4 RH quarter glass assembly (convertible only)
6 LH quarter glass assembly (convertible only)
7 Driver window motor
8 Driver door switch pack
9 Driver door module
INTRODUCTION
The windshield, which is constructed of 5.5 mm laminated glass with a black obscuration
band, is bonded and sealed to the body aperture using Polyurethane (PU) adhesive. The
mounting boss for the rain sensor is also PU bonded to the inner surface of the screen and is
common to the coupe and convertible. The mounting button for the interior mirror is attached
to the windshield using adhesive. A vertical fine-wire multi-strand element, located between
the glass laminations, is available as an option, except for North American Specification
(NAS) vehicles, to de-ice and demist the windshield and is controlled from the Touch Screen
Display (TSD). The backlight is 4 mm tempered glass, green tinted and heated and bonded to
the liftgate using PU adhesive. The windshield and backlight, except for the convertible
model, are direct glazed to the body.
The door glass on both models is a frameless system with 5 mm green tempered glass. Both
the driver and passenger window glass is operated electrically and raised and lowered by a
Bowden cable mechanism.
Each door glass automatically drops when the door is opened or when the convertible top is
raised or lowered, and raises when either the door is shut or the top is fully raised and latched
in position (glass drops fully on hood operation). The door glass can be closed via the Smart
Key. Glass operation is internally controlled from switch packs located in the driver and
passenger door arm rests via their respective control modules. The switch packs are
illuminated when the sidelights are on.
CONTROL DIAGRAM
NOTE:
A = Hardwired; N = CAN bus
Part
Item Description
Number
1 Battery
2 Megafuse (175A)
3 Megafuse (175A)
6 Convertible top control module (convertible only)
7 Passenger door switch
9 Rear quarter lift motors (convertible only)
10 Convertible top switch (convertible only)
11 Passenger window motor
12
13 Driver window motor
14 Driver door module
15
16 Driver door switch pack
The windshield and coupe backlight are supplied as assemblies complete with trim, which is
directly bonded to the glass.
The convertible backlight is high frequency welded to the canopy and the outer seal is stitched
and bonded to the top. On both models, the heated backlight remains on for 21 minutes after
being switched on unless it is manually switched off before the time delay expires.
Front Door Glass Assembly

1 Front door glass
2 'A' piller guide rail
3 Window motor
4 Bowden cables
5 'B' piller guide rail
One-touch up operation causes the door glass to fully close unless an object is detected ('Anti-
trap') or the glass is within 45 mm of top of travel when the door is opened. If the 'Anti-trap'
regulator detects an object, the glass will drop fully open or to 200 mm below the obstruction.
All door glass operates with the ignition in either 'Accessory' mode or 'On' mode and after the
ignition enters 'Off' mode, until either door is opened.
The front windows must be programmed for one-touch operation in order for the convertible
top to operate correctly. Failure to program the windows results in a 10 second opening delay
once the top is unlatched. The windows can be manually programmed for one-touch operation
using the following procedure:
• Engine running
• Raise window up to the top seal and release switch
• Raise again until window stops moving
• Release switch
• Raise again
• Lower window fully
• Release switch
• Press lower for a further 0.5 seconds until a relay is heard to CLICK
NOTE:
Before commencing work within a door interior, all Warnings and Notes within the
appropriate Removal and Installation procedures must be read and fully understood.
To re-learn the glass operating characteristics, the associated door must be closed (door ajar
switch inactive). The glass must then be driven fully down and held stalled at the bottom of its
travel for a minimum of 1 second. The glass is finally driven to the fully up position and held
stalled for a minimum of 1 second. The re-learning procedure must also be accomplished to
regain the automatic glass closing sequence.
REAR QUARTER GLASS

The coupe rear quarter glass is a fixed 4 mm, tempered, green-tinted unit fitted by a single
bolt fixing on the lower front corner of the glass assembly, and a pin into the body at the rear.
Convertible Rear Quarter Glass Assembly

1 Convertible rear quarter glass
2 Base plate
3 Window motor
4 Lift plate
The rear quarter glass of the convertible is 5 mm, tempered, semi-flush and green tinted. A
drum and wire system provides automatic full glass drop when the top is lowered. Rear glass
control is incorporated in the convertible top switch, which is located in the roof console.
When lowering the rear quarters of the convertible at vehicle speeds up to 24 km/h (15 mph),
failure to release the switch on operation of the audible alarm will result in lowering of the
top.
Rear quarter glass is automatically powered to the bottom position when the top is lowered
and further operation is inhibited until the top is raised and latched.
The rear quarters are operated automatically, up or down, when raising or lowering the
convertible top. If the door glass is in the raised position when a request to close the top is
made, the door glass and the rear quarters will be powered to the bottom of their travel. When
the top is fully raised all glass will be powered up to close, rear quarters first followed by the
door glass, forming a seal with the top.
If the front glass has been either fully or partially lowered manually, the rear quarters only
will be powered up. If the power supply to the driver or passenger door module is
disconnected (battery disconnected, module unplugged or fuse removed) then the
glass/system must re-learn the glass operating characteristics. The last known glass position is
regarded as top of travel by one touch operation until re-learning has taken place. One touch
down, manual up and down control and the automatic lowering of the glass for door opening
are unaffected.

For a detailed description of the Glass, Frames and Mechanisms, refer to the relevant

• Fuse(s)
• Window motor
• Window glass
• Loose or corroded electrical connector(s)
• Window regulator
• Switch
• Circuit(s)
4 . If the concern is not visually evident, check for Diagnostic Trouble Codes (DTCs) and
refer to the DTC Index.
DTC Index

NOTE:
NOTE:
NOTE:
NOTE:
tests.
NOTE:
NOTE:
terminals.

Front Power • Actuator stuck open refer to the new module
B117E72
Window up installation note at the top
of the DTC Index
Front Power • Actuator stuck closed refer to the new module
B117E73
Window up installation note at the top
of the DTC Index
Front Power • Actuator stuck open refer to the new module
B117F72
Window down installation note at the top
of the DTC Index
Front Power • Actuator stuck closed refer to the new module
B117F73
Window down installation note at the top
of the DTC Index
Front Window • Signal invalid
B118929 DTC using the
Position Sensor
diagnostic system
Rear Window • Signal invalid tests associated with this
B118A29
Position Sensor DTC using the
diagnostic system
LIN Bus Circuit short/open circuits, clear
B1A9883 calculation incorrect
switch pack.
(86.25.08)
LIN Bus Circuit • Signal Invalid short/open circuits, clear
B1A9886
switch pack.
(86.25.08)
LIN Bus Circuit • Missing Message short/open circuits, clear
B1A9887
switch pack.
(86.25.08)
C1B1411 Sensor Supply #1
window sensor supply
• Short to power or open circuit diagrams and test
C1B1415 Sensor Supply #1 circuit window sensor supply
or open circuit
Medium speed
• Medium speed CAN tests associated with this
CAN
U001000 communication Bus DTC using the
communication
Bus
diagnostic system
Lost Carry out any pinpoint
• Logged when subscribed
U014000 communication tests associated with this
CAN message missing from
with CJB DTC using the
CJB manufacturer approved
diagnostic system
Lost
communication • Missing message
with Driver Seat
Module (DSM)
diagnostic system
approved diagnostic
Internal control • Invalid configuration
and retest. If the DTC is
U030000 module software message is received
incompatibility
DDM/PDM, refer to the
new module installation
Index
• Signal stuck high DTC remains, install a
U200224 Switch
new passenger side
window switch
Switch • Circuit short to ground tests using the
U201011
diagnostic system
Switch • Circuit short to battery tests using the
U201012
diagnostic system
Cycle the ignition status
and re-test. If DTC
Car
• Bus signal/message failures remains, re-configure the
U201208 Configuration
RJB using the
Parameter(s)
diagnostic system
DTC remains, install a
• Signal stuck high new driver side window
U201324 Switch Pack
switch pack.
(86.25.08)
Control module • Data Memory Failure refer to the new module
U201444
hardware installation note at the top
of the DTC Index
Initial • No sub type information Re-configure the
U210000
configuration not DDM/PDM using the
complete manufacturer approved
diagnostic system
• Internal electronic failure refer to the new module
of the DTC Index
Re-configure the relevant
module as new using the
Vehicle diagnostic system and re-
• Not configured
U300255 Identification test. If DTC remains
Number (VIN) install a new module, refer
to the new module
of the DTC Index
previously installed to other
vehicle
• Mis-match of battery Carry out any pinpoint

voltage, of 2 volts or lower, tests associated with this
U300362 Battery voltage between DDM/PDM and DTC using the
RJB manufacturer approved
diagnostic system
Front Door Window Glass (76.31.01)

Removal
1 . Raise the window glass.




7 . Remove the front door window glass.

Collect the clamp and rubber washer.
Installation
1 . Install the front door window glass.
Attach the clamp and rubber washer.
2 NOTE:
. The window must be fully raised when carrying out measurements.
Align the front door window glass longitudinally.

Position the window, forwards or rearwards, glass edge should be
44mm from edge of door as shown in dimension 'A'.
3 NOTE:
. To adjust the window hold the locknut and turn the centre spindle.
Align the front door window glass horizontally.

Release the retaining nut.
Align the glass to door, glass should be 12mm from door as shown in
dimension 'B'.
Tighten the retaining nut to 10 Nm (7 lb.ft).




Front Door Window Regulator Motor
(76.31.45)
Removal



Installation


Front Door Window Regulator
Removal





Release each end of the seal from the door frame.
8 . Remove the front door window glass.

Collect the clamp and rubber washer.
9 . Remove the window regulator assembly.

Release the rubber lining from the glass channel.
Remove the bolt.
Remove the nut.
Installation
1 . Install the window regulator assembly.
Install the rubber lining to the glass channel.
2 . Install the front door window glass.

Attach the clamp and rubber washer.
4 NOTE:
. The window must be fully raised when carrying out measurements.
Align the front door window glass longitudinally.

Position the window, forwards or rearwards, glass edge should be
44mm from edge of door as shown in dimension 'A'.
5 NOTE:
. To adjust the window hold the locknut and turn the centre spindle.
Align the front door window glass horizontally.
Release the retaining nut.
Align the glass to door, glass should be 12mm from door as shown in
dimension 'B'.
Tighten the retaining nut to 10 Nm (7 lb.ft).





Window Control Switch (86.25.08)
Removal
1 . Remove the grab handle cover.
2 . Remove the window control switch.

Installation
1 . Install the window control switch.
2 . Install the grab handle cover.

Rear Quarter Window Glass - Convertible
(76.31.31)
Removal
NOTE:
The procedure to remove and install the rear quarter window glass is shown in the rear
quarter window regulator motor procedure.
1 . Remove the rear quarter window glass.

For additional information, refer to Rear Quarter Window Regulator Motor (86.25.11)
Installation
1 . Install the rear quarter window glass.
For additional information, refer to Rear Quarter Window Regulator Motor (86.25.11)
Windshield Glass (76.81.40)
Removal

components.
CAUTION: Always protect the interior components when removing body glass.
CAUTION: 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 both A-pillar trim panels.

3 . NOTE:
Disconnect the heated windshield electrical connectors.
4 . Remove the rain sensor.

For additional information, refer to Rain Sensor (84.12.10)
5
. WARNING: Eye protection must be worn.
CAUTION: The two shaded areas in the graphic indicate the position of a
body patch, that covers a body joint. Take care not to trap the cutting tool in the
body joint.
With assistance, remove the windshield glass.

Carefully cut through the sealant using a glazing knife or cutting wire.
Attach the suction cups.
Installation
1 . Carefully remove the sealant from the body to leave a smooth surface.
2 . Install the windshield glass.

Use masking tape to establish reference marks as an alignment aid.
3 . Remove the windshield glass.

4 . Apply etch primer to any bare metal.
5 . Apply primer over the etch primer.
6 . Apply glass primer to the sealant face on the windshield glass and allow to cure.
7 . Apply activator over the old sealant on the windshield glass and allow to cure.
8 Fit a pre-cut nozzle to the sealer cartridge, remove the lid, shake out the crystals and fit
. the cartridge to the applicator gun.
Modify the nozzle to achieve a bead section in the shape of a right
angle triangle with a base of 8 mm and a vertical height of 12 mm.
9 . Apply a continuous bead of sealant to the windshield glass as shown.
10 . With assistance, install the window glass.

Lightly press the window glass to seat the sealer.
11 Test the sealer for leaks, apply additional sealer if necessary. If water is used, allow
. sealer to dry before testing. Spray water around the glass and check for leaks. Mark
any area that leaks. Dry the glass and sealer then apply additional sealer.
12 . Install the rain sensor.

For additional information, refer to Rain Sensor (84.12.10)
13 . Connect the heated windshield electrical connectors.
14 . Install the A-pillar trim panels.


Rear Quarter Window Glass - 2-Door
(76.31.31)
Removal
1 . Release the door aperture seal.

Remove the bolt.
Installation
2 . Attach the door aperture seal.

Rear Quarter Window Regulator Motor
(86.25.11)
Removal
1 . Remove the rear quarter trim panels.
2 . Close the convertible top to the position shown.
3 . Open the convertible top to the position shown.
4 . Remove the safety belt retractor assembly.

5 . Release the rear speaker housing.
6 . Remove the rear speaker housing.

Remove the 6 bolts.
7 . Remove the safety belt guide.

Loosen the Torx bolt.
Release each end of the seal from the body.
9 . Remove the rear quarter window glass inner seal.

10 . NOTE:
Convertible top frame assembly show removed for clarity.
Remove the rear quarter closing panel.

11 . Remove the rear quarter window glass motor cover.
12
. CAUTION: Make sure rear quarter is covered and protected, failure to
Remove the rear quarter window glass motor.

Remove the 3 nuts.

Remove the 2 bolts.
Remove the nut.
Installation
2
. CAUTION: Make sure rear quarter is covered and protected, failure to
Install the rear quarter window glass motor.

Install the nuts but do not fully tighten at this stage.
3 . Install the rear quarter window glass motor cover.

Tighten the screws.
4 . Install the rear quarter closing panel.

5 . Install the rear quarter window glass inner seal.


Attach the outer waist seal to the body.
7 . Install the safety belt guide.

8 . Install the rear speaker housing.
9 . Secure the wiring harness.

10 . Install the safety belt retractor assembly.

Install a new Torx bolt and tighten to 45 Nm (33 lb.ft).
12 . Raise the rear quarter glass and check seal penetration.
13 Carefully close the adjacent door ensuring that the glass does not contact the rear
. quarter glass.
14 . Loosen the lower adjuster locknut.
15 Move the rear quarter glass to achieve a parallel 8mm gap, between the front edge of
. the rear quarter glass and rear edge of the door glass.
16 . Tighten the lower adjuster locknut to 9 Nm (7 lb.ft).
17 . Loosen the upper adjuster locknut.
18 Turn the upper adjuster to achieve, lateral alignment of the rear quarter glass upper
. edge, with the top seal.
19 . Tighten the upper adjuster locknut to 9 Nm (7 lb.ft).
20 . Loosen the rear adjuster locknut.

21 Turn the rear adjuster to achieve, lateral alignment of the rear quarter glass rear edge,
. with the top seal.
22 . Tighten the rear adjuster locknut to 9 Nm (7 lb.ft).
23 . Install the rear quarter trim panels.

For additional information, refer to Rear Quarter Trim Panel - Convertible
(76.13.73)
501-12 : Instrumentation Panel and Console
Specifications
Specifications
Item Nm lb-ft lb-in

Armrest to console - screw 6 4 53
Center console installation fixing points - screw 6 4 53
Centre console, side trim panel to console - screw 6 4 53
Instrument panel to A-post - bolt 20 15 -
Instrument panel upper retainers - bolt 20 15 -
Instrument panel bracket to console - bolt 9 7 80
Instrument Panel
COMPONENT LOCATION

1 Instrument panel end cap
2 Passenger airbag
3 Cross car beam
4 Instrument panel end cap
5 Energy absorbing brackets (2 off)
6 Floor console
INTRODUCTION
The instrument panel incorporates a magnesium cross car beam and 2 deformable, energy
absorbing brackets. The brackets are rivetted to the cross car beam and are not serviceable
items.
The instrument panel electrical harness is mounted along the cross car beam and connects into
the main vehicle harness via 4 connectors, 2 located either end of the instrument panel. To
access the connectors the instrument panel end covers can be removed by releasing a series of
spring clips.
A further 3 connectors, located below the instrument panel, are used to connect the instrument
panel harness to the Left Hand (LH) and Right Hand (RH) front end harnesses. Finally, 2
connectors located below the floor console connect the instrument panel harness to the
telematics harness.
The floor console provides a location for the selector lever and the parking brake module. The
floor console is secured to the transmission tunnel and to the cross car beam by a series of M6
bolts and trim fixings. The floor console electrical harness connects into the telematics
harness via a single connector.
Floor Console (76.25.01)

Removal



5 . Release the 2 Torx latches.

6 . Release the LH side floor console electrical harness connector blocks.
7 . Release the RH side floor console electrical harness connector blocks.

8 . Release the wiring harness clip.

9 . Disconnect the gear selector assembly electrical connector.
10 . Remove the gear selector assembly.

11 . NOTE:
Release the gear selector cable at the abutment.

Loosen the locknut.
12 . Remove the parking brake switch.
13 . Remove the ashtray trim panel.

14 . Release the floor console.

Lift and carefully withdraw from the instrument panel.
Disconnect the cigar lighter electrical connector.
Disconnect the keyless vehicle module electrical connector.
16 . NOTE:
Remove the ashtray.

Remove the ashtray insert.
17 . Remove the cigar lighter.

18 . Remove the keyless start control module trim cover.
19 . Remove the floor console lid.

20 . Remove the keyless start control module.

21 . Remove the cubby box liner.

22 . Remove the floor console rear extension bracket.
23 . Remove the floor console central mounting bracket.

Installation
1 . Install the floor console central mounting bracket.
2 . Install the floor console rear extension bracket.

3 . Install the keyless start control module.

4 . Install the cubby box liner.
5 . Install the floor console lid.

6 . Install the keyless start control module trim cover.

7 . Install the cigar lighter assembly.
8 . Install the ashtray.

9 Install the floor console.

. Connect the cigar lighter electrical connector.
Connect the keyless vehicle module electrical connector.
Align the floor console with the Torx latch spigots and secure the
latches.
Install the Torx bolts, tighten the M6 bolts to 10 Nm (7 lb.ft) and the
M8 bolts to 25 Nm (18 lb.ft).
10 . Install the ashtray trim panel.

11 . Install the parking brake switch.

12 . NOTE:
Install the gear selector cable to the floor console abutment.

Tighten the locknut to 15 Nm (11 lb.ft).
13 . Install the gear selector assembly.

14 . Connect the gear selector assembly electrical connector.
15 . Install the RH side floor console electrical harness connector blocks.

16 . Install the LH side floor console electrical harness connector blocks.

17 . Secure the Torx latches.




Removal
1 . Depress the footbrake and move the gear selector lever to NEUTRAL.
2.
Release the floor console veneer trim panel.

3 Remove the floor console veneer trim panel.

. Disconnect the engine START/STOP switch electrical connector.
Disconnect the automatic speed limiter (ASL) switch electrical
connector.
4 . NOTE:
NOTE:
Remove the switches.

Depress the 2 retaining clips.
5 . Remove the gear selector lever surround trim panel.

Remove the wire clip.
Installation
1 . Install the gear selector lever surround trim panel.
Install the wire clip.
2 . Install the switches.

4 . Return the gear selector lever to PARK.

Glove Compartment (76.52.03)
Removal
1 . Remove the instrument panel end trim panel.
2

Remove the 3 clips.
3 . Release the glove compartment.

4 . Remove the glove compartment.
Release the glove compartment lamp assembly.
Installation
1 . Install the glove compartment.
Install the lamp assembly.

3 . Install the instrument panel end trim panel.

Release the door aperture seal.
Install the aperture seal.
Instrument Panel (76.46.01)
Removal
NOTE:
correct.


3 . Remove both cowl side trim panels.

LH side only: Remove the screw and remove hood release lever.
Release the leading edge of the scuff plate.

5 Remove both instrument panel support brackets.
. Remove the self-tapping hexagonal screw from the instrument panel
carrier.
Remove the 2 bolts.
6 . Disconnect the instrument panel harness ground cable.

Remove the nut.
7 . Disconnect the 4 instrument panel LH side electrical connectors.
8 . Disconnect the 3 instrument panel RH side electrical connectors.

9 Release the instrument panel electrical harness from the RH side of the transmission
. tunnel.
Remove the nut and disconnect the ground cable.
Remove and discard the 2 cable ties.
10 . Disconnect the steering column intermediate shaft from the steering column.
Remove the bolt.
11 . Carefully remove the instrument panel windshield register trim.

12 . Remove the 2 instrument panel carrier bolts, accessed through the upper trim panel.
13
. CAUTION: Protect the surrounding trim from damage when changing
the component.
CAUTION: Cover fiber optic cable connectors to minimize dust ingress

and avoid bending the cables in a radius of less than 30 mm.
Remove the instrument panel assembly.

Remove the 4 A-pillar instrument panel carrier bolts.
With assistance, release and remove.
Installation
1
. CAUTION: Make sure the the electrical harness is not trapped during the
installation.
With assistance, install the instrument panel assembly.
Align the pegs and install the bolts.
Evenly and progressively tighten the bolts to 20 Nm (15 lb.ft).
2
. CAUTION: Make sure that the self tapping screw engages in the
previously cut groove. Damage to the instrument panel carrier may result if this
process is not followed.
Install the instrument panel carrier bolts, access through the upper trim panel.
3 . Install the instrument panel windshield register trim.

4 . Connect the instrument panel RH electrical connections
5 . Connect the instrument panel LH side electrical connectors.
6 . Install the instrument panel electrical harness to the RH side of the transmission
tunnel.
Install the ground cable.
Install new cable ties.
7 . Connect the steering column intermediate shaft to the steering column.

8 . Install the instrument panel harness ground cable.

9
. CAUTION: Make sure that the self tapping screw engages in the
previously cut groove. Damage to the instrument panel carrier may result if this
process is not followed.
Install both instrument panel support brackets.

Tighten the self-tapping hexagonal headed screw to 9 Nm (7 lb.ft).

11 Install the cowl side trim panels.

. Align the pegs and secure the clip.
Install the rocker panel scuff plate.
LH side only: Install the hood release lever and secure with the
screw.

13 . Reconnect the battery ground cable.

Overhead Console (76.13.69)
Removal
1 . Remove the front overhead console.
Installation
1 . Install the front overhead console.
Instrument Panel Lower Trim Panel
(76.46.11)
Removal

3.
Carefully release and remove the rheostat switch assembly.

4

5 . Release the MOST diagnostic port.

Release the vehicle diagnostic port.
Installation
1 . Install the rheostat switch assembly and align the instrument panel lower trim panel.
Secure the switch assembly clips.
Connect the switch assembly electrical connector.

Install and secure the diagnostic socket.
Align the clips.
3 . Install the MOST diagnostic port.
Secure the clip.



501-14 : Handles, Locks, Latches and Entry Systems
Specifications
Specifications
Item Nm lb-ft lb-in

Door, exterior handle bezel - screw 6 - 53
Door lock cylinder - screw 6 - 53
Door lock actuator to door rear panel - screw 7 - 62
Door striker to B-post - screw 9 - 80
Hood release mechanism to A-post - bolt 9 - 80
Hood release handle to mechanism 3 - 27
Luggage compartment lid, latch actuator to lid - screw 20 15 -
Luggage compartment lid, lock cylinder - screw 3 - 26
Luggage compartment lid, striker to back panel - screw 25 18 -
Liftgate, latch actuator to lid - screw 20 15 -
Liftgate, lock cylinder - screw 3 - 26
Liftgate, striker to back panel - screw 25 18 -
Handles, Locks, Latches and Entry

Systems
COMPONENT LOCATION - CENTRAL LOCKING
SYSTEM (Sheet 1 of 2)
Part
Item Description
Number
2 Start/Stop button
Right Hand (RH) door handle keyless LF antenna (only with passive
3
entry option fitted)
4 Central locking RF receiver
5 LF antenna (located on battery bracket)
LF antenna (located in rear bumper - only with passive entry option
6
fitted)
Left Hand (LH) door handle keyless LF antenna (only with passive entry
7
option fitted)
9 LF antenna (center console)
10 LF antenna (instrument panel)
11 Smart Key
COMPONENT LOCATION - CENTRAL LOCKING

SYSTEM (Sheet 2 of 2)

1 Electric steering column lock
2 Fuel flap release switch
3 Liftgate release switch
4 RH interior door handle
5 RH exterior door handle
6 RH door latch and motor
7 Fuel flap release motor
8 Liftgate emergency key barrel
9 Liftgate external release switch
10 Liftgate latch and motor
11 Door emergency key barrel (LH door only)
12 LH exterior door handle
13 LH door latch and motor
14 LH interior door handle
15 Hood release lever
16 Hood latches and hood ajar switch
INTRODUCTION
The hinged panels are secured with latches and strikers. A remotely operated Central Locking
System (CLS) controls the locking and unlocking of the door latches.
Two levels of CLS are available; remote central locking and an optional passive entry system.
CENTRAL LOCKING SYSTEM (CLS)

A Radio Frequency (RF) Smart Key, without an integrated key, is a standard fitment allowing
the vehicle to be locked and unlocked by pressing the appropriate handset buttons. The Smart
Key is available in three variants depending on market requirements. These can be identified
by a suffix change to the base part number as follows:
• AA = 315 MHz
• BA = 433 MHz
• CA = 315 MHz Low power.
A new Passive Entry and Passive Start system is introduced. This 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. The passive start system is a standard fitment on
all vehicles and allows the driver to start the vehicle without the use of a vehicle key. The
system is combined with the passive anti-theft immobilization system. For additional
information, refer to Anti-Theft - Passive (419-01B)
Emergency access to the vehicle is provided by a concealed key barrel located in the LH door
handle only and in the liftgate. An emergency, removable key is fitted into the Smart Key.
Operation of either key barrel unlocks the vehicle but does not disarm the alarm system. On
European market vehicles, the emergency liftgate key barrel is concealed behind the license
plate. The key barrel in the LH door is covered by a plastic cover which can be removed by
inserting the blade of the emergency key into a slot in the underside of the cover.
The vehicle can be centrally locked and unlocked using the emergency key barrel. If the alarm
is not armed the vehicle can be centrally unlocked. If the alarm is armed only the LH door can
be opened using the emergency key 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 door handle
release levers. Central locking and unlocking can also be performed using lock and unlock
buttons on the Touch Screen Display (TSD).
The driver can select locking options, single point entry or drive away locking for example,
from a menu available on the TSD.
Central Locking - RF Remote System

The RF CLS provides locking and unlocking of the vehicle from inside and outside of the
vehicle. The system provides additional security by double locking the doors and liftgate from
outside the vehicle.
The system is operated using buttons on the Smart Key. RF signals from the Smart Key are
received by a RF receiver located in the overhead console, above the windshield. The RF
receiver is available in two variants depending on market requirements. These can identified
by a suffix change to the base part number as follows:
• AA = 315 MHz
• BA = 433 MHz.
Additional buttons on the Smart Key provide for the convenience operation of the liftgate
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 Start
The passive start system, which is standard on all vehicles, uses the Smart Key as a driver
identification and authorisation device. The system is controlled by a keyless vehicle module
located on the RH 'A' pillar. Three Low Frequency (LF) antennae (six if passive entry option
is fitted) are positioned in specific locations in the vehicle and transmit a LF signal to the
Smart Key.
On receipt of the LF signals, the Smart Key transmits a RF signal which is received by the
remote receiver. Once the keyless vehicle module has approved the Smart Key, the ignition
status is changed to 'accessory' by the Central Junction Box (CJB). The ignition can be
switched on by pressing the 'start/stop' button, located in the center console. Starting of the
vehicle is achieved by simultaneously depressing the brake pedal and pressing the 'start/stop'
button. The engine can be switched off by pressing the start/stop button for a second time.
NOTE:
The Smart Key does not need to be in the vicinity of the vehicle to switch the engine off.
In the event that the passive start system is unable to authorize the Smart Key, a start control
unit is located in the center armrest. The start control unit allows the Smart Key to be inserted
into a slot and allows the Smart Key transponder data to be exchanged in a conventional
manner. Once the transponder data is authorized, the CJB permits the ignition to be switched
on.
Passive Entry
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 for the passive
entry system in addition to the passive start system.
The passive entry system is controlled by the keyless vehicle module and the six LF antennae.
When the Smart Key is within one meter of the vehicle it receives the LF signals from the
keyless vehicle module and the LF antennae and responds with an RF transmission of its
authorization code. The RF signal is received by the RF receiver and passed to the keyless
vehicle module which checks and approves the code as valid. The keyless vehicle module
transmits this information to the CJB. The CJB then passes an unlock request to the door
modules. When a door handle is pulled or the exterior liftgate release button is pressed, the
applicable door module will allow the doors or the liftgate to be unlocked and opened.
Locking of the vehicle is performed by pressing a button located on each exterior door handle
with the Smart Key within a one meter range of the vehicle. When the button is pressed, the
Smart Key transmits a RF 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 in a one meter range of the vehicle.
If a door, liftgate or hood is ajar when an attempt to lock the vehicle is made, an error tone is
emitted and the ajar panel will not lock. For additional information, refer to Anti-Theft -
Active (419-01A)
LATCHES
Two hood latches are located on the bulkhead, below the windscreen. A hood release lever is
located below the instrument panel on the LH 'A' pillar and is connected with a Bowden cable
to the latches. A hood ajar switch is integrated in the LH hood latch.
The door latches are located at the rear of each door and engage with a striker on the 'B' pillar.
Each door latch motor assembly contains microswitches for lock and unlock and door ajar.
Two 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 auxiliary junction box 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 the doors are closed and activate the central locking system. If a door
is ajar the locking feature is inhibited.
The liftgate latch is attached to the bottom of the liftgate. The latch can be released
electrically by pressing the interior release button located in the auxiliary lighting switch, the
exterior release button located in the licence plate finisher or the liftgate release button on the
Smart Key. On North American Specification (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 liftgate interior trim.
The fuel filler is electrically locked by a motor located on the fuel flap housing. The flap is
locked when the vehicle is locked and alarmed and can be released by pressing the fuel flap
release switch located in the auxiliary lighting switch.
CONTROL DIAGRAM - PASSIVE ENTRY SYSTEM

NOTE:
A = Hardwired
Part
Item Description
Number
1 Battery
2 Megafuse (175A)
3 Megafuse (175A)
4 CJB
5 Start/Stop switch
6 Stop lamp switch
LF antenna ( LH exterior door handle - only with passive entry option
9
fitted)
10 Unlock pull switch
11 Lock push switch
12 LH Door handle, latch motor and clutch
13 RH door handle, latch motor and clutch
14 Lock push switch
15 Unlock pull switch
LF antenna (RH exterior door handle - only with passive entry option
16
fitted)
17 LF antenna (rear bumper - only with passive entry option fitted)
18 LF antenna (battery bracket)
19 LF antenna (center console)
20 LF antenna (Instrument panel)
21 RF remote receiver
22 Exterior liftgate release switch
CONTROL DIAGRAM - CENTRAL LOCKING

SYSTEM
NOTE:
A = Hardwired
1 Battery
2 Megafuse (175A)
3 Megafuse (175A)
4 CJB
5 LH door handle pull switch
6 LH door latch motor assembly
7 Liftgate external release switch
8 LH door module
9 Fuel flap motor
10 Liftgate motor assembly
11 RH door latch motor assembly
12 RH door handle pull switch
13 RH door module
14 Auxiliary lighting switch (Liftgate and fuel flap release switches)

For a detailed description of handles, locks, latches and entry systems, refer to the relevant
Handles, Locks, Latches and Entry Systems

• Misaligned door(s), hood or luggage
• Fuse(s)
compartment lid
• Wiring harness
• Door latch(s)
• Actuating rod(s)
• Door lock actuator(s)
• Exterior door handle(s)
• Remote transmitter batteries
• Interior door handle(s)
• Vehicle battery
• Door lock cylinder
• Remote transmitter
• Cable(s)
• Door lock switch(s)
• Luggage compartment lid exterior release switch
4 . If the cause is not visually evident, check for Diagnostic Trouble Codes (DTCs) and refer
to the DTC Index.
DTC Index

NOTE:
NOTE:
NOTE:
NOTE:
tests.
NOTE:
NOTE:
terminals.

FL unlock pull • No subtype information associated with this DTC
B10C100
switch defect using the manufacturer
• Signal stuck high - button
FL unlock pull associated with this DTC
B10C124 stuck in active position
switch error using the manufacturer
FR unlock pull • No subtype information associated with this DTC
B10C300
switch defect using the manufacturer
FR unlock pull associated with this DTC
TR unlock pull associated with this DTC
Exterior Trunk Carry out any pinpoint tests
Antenna - • Circuit intermittent associated with this DTC
B10C61F
general using the manufacturer
electrical error approved diagnostic system
Interior Trunk Carry out any pinpoint tests
B10C71F
Interior Center Carry out any pinpoint tests
B10C81F
Interior Front Carry out any pinpoint tests
B10C91F
FL Latch Switch associated with this DTC
B10CC24 stuck in active position
Clutch error using the manufacturer
FR Latch Switch associated with this DTC
B10CE24 stuck in active position
Clutch error using the manufacturer
FL lock button associated with this DTC
B10D124 stuck in active position
error using the manufacturer
FR lock button associated with this DTC
B10D324 stuck in active position
error using the manufacturer
CAN • No subtype information associated with this DTC
U001000
communication using the manufacturer
Bus approved diagnostic system
Lost
• Missing message associated with this DTC
with CJB
Lost
• Missing message associated with this DTC
with RJB
Lost • Missing message Carry out any pinpoint tests
U015500
communication associated with this DTC
with instrument using the manufacturer
cluster approved diagnostic system
Internal control • Invalid configuration DTC and retest. If the DTC
U030000 module software message is received is still logged suspect the
incompatibility remote keyless entry
Install a new RF receiver,
Receiver refer to the new
• No subtype information
U201F00 communication module/component
error installation note at top of
DTC Index
diagrams and test RF
Receiver
• Line open receiver communication
U201F13 communication
circuit to remote keyless
error
entry module for short to
ground or open circuit
Receiver
• Transmission error associated with this DTC
U201F87 communication
error
Configure the Remote
Control
• No subtype information Keyless Entry module using
U210000 Module/ECU
not configured
diagnostic system
Control
Module/ECU • No subtype information
U210100 the manufacturer approved
unexpected data
diagnostic system
values
Install a new remote keyless
• Internal electronic failure entry module, refer to the
new module installation note
U300281 Identification check for DTCs and refer to
Number (VIN) relevant DTC Index
other vehicle

U300362 Battery voltage voltage, of 2 volts or associated with this DTC
lower, between remote using the manufacturer
keyless entry module and approved diagnostic system
RJB
Door Lock Cylinder Cover

Removal
1
. CAUTION: Make sure that excessive force is not used. Failure to follow
this instruction may result in damage to the vehicle.
2.
3.
Installation
1
. CAUTION: Make sure that the door lock cylinder cover is pushed firmly
in the sequence shown to install all 3 clips, and that the door lock cylinder cover is
securely attached to the vehicle. Failure to follow this instruction may result in
damage to the vehicle.
Exterior Door Handle (76.58.07)
Removal
All vehicles
1 . NOTE:
Remove the screw sufficiently, only to release the component.
Remove the door lock cylinder.
Position the door seal aside for access.
Remove the screw cover.
Loosen the Torx screw to release the lock.
2 . Release the front door exterior handle.

Vehicles with keyless entry
3
. CAUTION: Take extra care not to damage the wiring harnesses.
CAUTION: Make sure the electrical connector is securely in the service position,
before disconnection. If the connector springs back after disconnection the internal door
trim panel will have to be removed for access.
Position the electrical connector in the service position.
Carefully pull on the harness to position the electrical connector at the door
panel (1).
Use a small screwdriver to align the electrical connector with its service
location (2).
While retaining its alignment, push on the electrical connector to 'click' it

into its service location (3).
Installation
Release the electrical connector from the service position.
All vehicles
2 Install the exterior door handle.
.
Use a length of cord to hold the lock lever against spring pressure, while
engaging the outside handle.
3 . Install the door lock cylinder.
Install the screw cover.
Re-position the seals if required.

Front Door Lock Actuator (76.37.74)
Removal
1 . Remove the window regulator.
For additional information, refer to Front Door Window Regulator
2 . Release the door latch.

3 . Remove the door lock cylinder.

4 . Release the front door exterior handle.

5 . Remove the front door exterior handle.
Release from the door handle mechanism.
6 . Remove the door handle mechanism and latch assembly.

Release the retainer.
7 . NOTE:
Detach the door release cable from the door handle mechanism.
8 . Detach the door lock cable from the door latch.

9 . Remove the door handle mechanism and latch assembly security panel.
Drill out the rivet.
Installation
1 . Install the door handle mechanism and latch assembly security panel.
Install the new rivet.
2 . Attach the door lock cable to the door latch.

3 . Attach the door release cable to the door handle mechanism.

4 . Install the door handle mechanism and latch assembly.
5 . Install the front door exterior handle.

Attach to the door handle mechanism.
6 . Secure the front door exterior handle.


8 . Secure the door latch.
9 . Install the window regulator.

For additional information, refer to Front Door Window Regulator
Front Door Lock Cylinder (76.37.71)
Removal
1 . Remove the door lock cylinder.
Installation
Luggage Compartment Lid Latch Actuator
(76.19.25)
Removal
2 . Remove the luggage compartment lid latch operating cable from the lock cylinder.
3 . Remove the luggage compartment lid latch assembly.

Installation
1 . Install the luggage compartment lid latch assembly.
Install the 3 Torx bolts.
Install the cable.

Luggage Compartment Lid Lock Cylinder
(76.19.19)
Removal
2 . Remove the luggage compartment lid latch operating cable from the lock cylinder.
3 . Remove the luggage compartment lid lock cylinder.

Remove the bolt.
Installation
1 . Install the luggage compartment lid lock cylinder.
Install the bolt.
Install the cable.

Liftgate Lock Cylinder
Removal
2 . Remove the liftgate lock cylinder.

Release the liftgate lock cylinder cable.
Remove the liftgate lock cylinder housing.
Installation
1 . Install the liftgate lock cylinder.
Install the liftgate lock cylinder housing.
Fit and tighten the Torx screw.
Attach the liftgate lock cylinder cable.

Liftgate Latch Actuator (86.25.65.60)
Removal
2 . Remove the liftgate latch.

Release the liftgate latch cable.
Remove the 3 bolts.
Installation
1 . Install the liftgate latch.
Attach the liftgate latch cable.

Radio Frequency (RF) Receiver
Removal

Installation

Keyless Vehicle Front Antenna
Removal
1 . Remove the navigation system display module.

Remove and collect the center of the clips.
Installation
2 . Install the navigation system display module.

Keyless Vehicle Center Antenna
Removal

Installation

Hood Latch
Removal
For additional information, refer to Pedestrian Protection Hood Actuator LH
For additional information, refer to Pedestrian Protection Hood Actuator RH
2 . Release the hood latch.

Remove the 2 bolts.
3 . Remove the hood switch.

4 . Remove the hood latch.

Release the latch cable.
5 . Remove the pedestrian protection latch actuator.
Installation
1 . Install the pedestrian protection latch actuator.
2 . Install the hood latch.

Attach the latch cable.
3 . Install the hood switch.

4 . Secure the hood latch.


501-16 : Wipers and Washers
Specifications
Specifications
Item Nm lb-ft lb-in

Windshield washer reservoir - screw 9 - 79
Windshield wiper arm to spindle - nut 23 17 -
Windshield wiper motor and wiper spindles to bulkhead - screw 9 - 79
Wipers and Washers

COMPONENT LOCATION

1 Washer reservoir bottle and filler neck
2 Wiper arms/blades (2 off)
3 Wiper/washer control switch
4 Rain sensor
5 Mounting arm and pivot shaft
6 Wiper motor
9 RH headlamp power wash jet
10 LH headlamp power wash jet
INTRODUCTION
The wipers have two speed controls, low and high, and an intermittent wipe mode. The wipers
will park automatically irrespective of their position, when the ignition is in power mode 3
(OFF) or the control switch is selected.
A timed jet function eliminates the trail of washer fluid left on the windshield after a wiping
action and reduces fluid consumption by only operating the washer jets on the up stoke of the
wiper arms.
Within the wiper and washer system the following features can be attained:
• Adjustable interval intermittent wiping

• Speed dependant wiping
• Programmable wash and wipe sequencing
• Automatic moisture sensitive wiping (rain sensor).
Moisture sensitive wiping will be initiated when the vehicle is running and not in the PARK
or NEUTRAL gear selection. The wiper switch must be in the AUTO position.
The system and features are controlled by the Central Junction Box (CJB).
CONTROL DIAGRAM
NOTE:
A = Hardwired: N = CAN bus
Part
Item Description
Number
1 Battery
2 Megafuse (175A)
4
5 Column switch
7
8 Rain sensor
9 Reservoir fluid level sensor
10 Windshield washer pump
11 Headlamp powerwash pump
12 Wiper motor
Wipers and Washers

For a detailed description of the wipers and washers, refer to the relevant Description and

• Wiper blade(s) • Fuse(s)
• Wiper pivot arm shaft • Wiring harness
• Washer reservoir • Electrical connector(s)
• Hose(s) • Washer pump(s)
• Washer jet(s) • Wiper motor
4 . If the cause is not visually evident, verify the symptom and refer to the manufacturer
Headlamp Washer Jet (84.20.08)

Removal
WARNING: Vehicles fitted with Xenon headlamps, the following precautions

must be observed. Failure to comply may result in exposure to ultra violet rays, severe
electric shock, burns or the risk of explosion. Ensure the headlamps are switched off at
all times. Eye and hand protection must be worn. Never switch on the lamps or test the
bulbs with the lamp holder released from the headlamp.

2 . Open the hood.
3
components.
Release the headlamp assembly.

Remove the 3 bolts.
Release the locating pegs.
4 . Disconnect the washer jet hose.

5 . Remove the LH headlamp assembly.
6 . Remove the headlamp washer jet.

Installation
1 . Install the headlamp washer jet.

Position the locating pegs.
3 . Connect the washer jet hose.
4 . Secure the headlamp assembly.

Tighten the bolts.
5 . Close the hood.

Headlamp Washer Pump (84.20.21)
Removal
1


4 . Remove the headlamp washer pump.


Installation
2 . Install the windshield washer pump.



Rain Sensor (84.12.10)
Removal
1 . Remove the interior mirror.
For additional information, refer to Auto-Dimming Interior Mirror (76.10.56)
2 . NOTE:
Remove the rain sensor.

Remove the clip.
Installation
1 . NOTE:
Install the rain sensor.

Install the clip.
2 . Install the interior mirror.
For additional information, refer to Auto-Dimming Interior Mirror (76.10.56)
Windshield Washer Pump (84.10.21)
Removal
1


4 . Remove the windshield washer pump.


Installation



Windshield Washer Reservoir (84.10.01)
Removal
NOTE:
1

3 . Remove the windshield washer reservoir filler neck.

Release the clip.
4 . Release the washer reservoir.

Remove the 2 bolts.
5 . NOTE:
Remove the windshield washer reservoir.

Disconnect the 2 washer jet hoses.
6 . NOTE:
Remove the washer reservoir low level sensor.

7 . Remove the headlamp washer pump.

8 . Remove the windshield washer pump.

9 . Remove the filler neck seal.
10 . Remove the rubber mount.

Installation
1 . Install the rubber mount.
2 . Install the filler neck seal.

Install a new seal.
4 . Install the headlamp washer pump.

Install a new seal.
5 . NOTE:
Install the washer reservoir low level sensor.

Install a new seal.
6 . NOTE:
Install the windshield washer reservoir.

Connect the washer jet hoses.
7 . Install the windshield washer reservoir filler neck.

Release the clip.


Windshield Wiper Motor - LHD RWD
(84.15.13)
Removal
2
. WARNING: Do not work on or near the engine if the engine is hot. Failure
to follow these instructions may result in personal injury.
Remove the cowl vent screen.


4
. CAUTION: Care must be taken whilst removing the engine compartment
bolts. Failure to follow this instruction may result in damage to the A/C pipes.
NOTE:
Remove the engine compartment braces.


6 . Using a suitable tool, remove the hood release cable clip.
7 . Remove the secondary bulkhead center panel.

Remove the nut.
8 . Release the brake booster vacuum hose.

9 . Release the secondary bulkhead RH panel.
Remove the air conditioning (A/C) pipe bracket bolt.
Remove the coolant expansion tank mounting bracket bolt.
Remove the remaining 2 bolts.
10 . Disconnect the windshield wiper motor electrical connector.

Detach the wiring harness clip.
11 . Remove the windshield wiper motor and linkage mechanism.

Remove the 3 bolts.
12 . Disconnect the connecting rod.
13 . NOTE:
Note the original position of the windshield wiper motor crank arm.
Remove the windshield wiper motor.

Rotate the windshield wiper motor crank arm 90 degrees clockwise.
Remove the 3 bolts.
Installation
1 . NOTE:
Note the original position of the windshield wiper motor crank arm.
Rotate the windshield wiper motor crank arm 90 degrees clockwise.
2 Install the windshield wiper motor.

. Tighten the 3 bolts to 5 Nm.
Rotate the windshield wiper motor crank arm 270 degrees clockwise
to the original position.
3 . Install the windshield wiper motor and linkage mechanism.

Loosely install the 3 bolts.
Tighten bolt 1 to 9 Nm.
4 . Install the secondary bulkhead RH panel.
5 . Install the secondary bulkhead center panel.

Attach the hood release cable clip.
Attach the 3 wiring harness clips.
Secure the 4 clips.
6 . Position the brake booster vacuum hose to one side.




10 Carry out the windshield wiper motor park operation.

. Switch the ignition on.
Turn on the windshield wipers and make sure that the wiper spindles
perform a full cycle.
Turn off the windshield wipers.

Windshield Wiper Motor - RHD RWD
(84.15.13)
Removal


4 . Remove the secondary bulkhead panel.

Remove the nut.
5 . Release the engine compartment RH side wall.

Remove the 4 bolts.
6 . Remove the windshield wiper motor.
Remove the 3 bolts.
Installation
1 . Install the windshield wiper motor.
2 . Install the engine compartment RH side wall.

3 . Install the secondary bulkhead panel.




Wiper Pivot Arm (84.15.03)
Removal

components.
1 . Open the hood.
2 . Remove the RH air intake cover.

Remove the 3 clips.
3
. CAUTION: Wipers arms do not lock in the upright position. Windshield
damage may occur if the wiper pivot arms are allowed to drop against the glass.
NOTE:
Remove the windshield wiper arms.

Remove the 2 nuts.
Disconnect the 2 washer jet blocks from the cowl vent screen.
4 . Remove the wiper blades.
Installation
1 . Install the wiper blades.
Position the locating clip in the upright position.
Position the blade at the end of the arm.
Secure the clip.
Repeat for the other side
2
. CAUTION: Incorrect fitting of the wiper pivot arms will result in damage
to the bonnet on closure.
NOTE:
Align the wiper with the mark on the windscreen.
NOTE:
Install the windshield wiper arm.

Make sure the spindle is free from contamination.
Apply gentle pressure on the pivot arm hinge to make sure the pivot
arm is located evenly.
Lightly tighten the nut.
Align the tip of the wiper blade with the mark on the windshield.
Install the covers.
Connect the washer jet hose block.
Repeat for the other side.
3 . Install the RH air intake cover.

501-18 : Convertible Top
Specifications
Specifications
Item Nm lb-ft lb-in

Convertible top, base plate to BIW - nut 25 18 -
Convertible top to base plate - nut 25 18 -
Convertible top, compartment lid striker - bolt 9 - 80
Convertible top, compartment lid trim panel - screw 1 - 9
Convertible top, compartment lid moulding - screw/nut 4 - 35
Convertible top striker to body - bolt 23 17 -
Convertible top header rail - screw 1 - 9
Hydraulic system, lift cylinder and motor - bolt 8 6 71
Luggage separator mounting bracket - bolt 4 - 35
General procedures

Alignment
1. Check the alignment of the convertible top lid. Adjust, if required, using the steps below.
2. NOTE:
Support as necessary.

• Depress the switch.
3. NOTE:
Release the convertible top lid latches.

• Loosen the 6 bolts.
4. Release the convertible top lid lift cylinder bracket.

• Loosen the 3 nuts.
• Push the convertible top lift cylinder bracket fully rearwards.
• Tighten the 3 nuts to 1 Nm (1 lb.ft).
5. Close the convertible top compartment lid.

6. With the convertible top compartment lid closed, check the alignment of the lid to the
body. The lid should be central in its aperture. The profile of the lid to the body should be
flush.
7. Install the convertible lid cylinder bracket lower nuts.

8. NOTE:

9. Secure the convertible top lid latches.

10. Install the convertible lid cylinder bracket upper nut.

• Tighten the nut to 10 Nm (7 lb.ft).
Convertible Top Alignment
NOTE:
This procedure details how to align a new convertible top assembly.
1. Align the convertible top to the dimensions shown using the procedure below.
2. With assistance, install the convertible top assembly.

• Install and lightly tighten the nuts.
4. Close the convertible top.

• Using an Allen key, manually latch the convertible top.
5. Ensure the forward edge of the convertible top has an equal 7mm gap to the header panel.
6. Open the convertible top.
• Using an Allen key, manually release the convertible top latches.
7. Open the convertible top compartment lid.
8.
CAUTION: Under no circumstances must the base plate fixing nuts be loosened
or removed. Each base plate fixing nut can be identified by a large aluminium spacer.
Release the convertible top assembly.

• Loosen the 6 nuts.
9. Adjust the convertible top.

• Loosen the 2 locknuts.
• Adjust the convertible top as necessary.
• Tighten the locknuts to 25 Nm (18 lb.ft).
10. Secure the convertible top assembly.

• Lightly tighten the nuts.


16. Secure the convertible top assembly.

Convertible Top Base Plate Adjustment
1. Remove the convertible top assembly.
2. Remove the convertible top base plates.

• Remove the 6 nuts.
• Collect the washers.
3. Adjust the 6 base plate height adjustment washers, so they are 3mm below the underside of
the base plates.
4. Install the convertible top base plates.

• Make sure the base plates are installed central to the studs.
• Install the washers.
• Lightly tighten the nuts.
5. With assistance, install the convertible top assembly.

• Install and lightly tighten the nuts.

9. Ensure the rear edge of the convertible top has an equal 3mm gap to the convertible top
compartment lid and rear quarter glass outer seal seal.

12. With assistance, remove the convertible top assembly.

13. Remove the convertible top base plates.

• Collect the washers.
14. Adjust the 6 base plate adjustment washers to the necessary height.
15. Install the convertible top base plates.

• Align the base plates to the studs as necessary.
• Install the washers.
16. Install the convertible top assembly.

Convertible Top
COMPONENT LOCATION

1 Front latch motor
2 RH front latch plate
3 RH actuation lever assembly
4 Valve block and motor
5 LH actuation lever assembly
7 LH front latch plate
INTRODUCTION
The power-operated convertible top consists of a fabric canopy with a 'Thinsulate' inner liner,
which is fitted to a steel frame with cast linkages.
The fully automatic flush mounted aluminum tonneau panel conceals the stowed top and
incorporates the Roll-over Protection System doors in its trim panel. The top has a low-stack
height of 200 mm (7.9 in) and manual roller blind luggage separator to optimize the luggage
compartment volume. The open and close time of the top is approximately 17 seconds
depending on ambient temperature and battery voltage.
A heated glass backlight is high frequency welded to the canopy.
A pump motor and valve block provides hydraulic power to open and close the top while an
electric motor controls a tension bow system to latch and unlatch the top. A single hold-down
switch located in the roof console operates the top. This switch also operates the rear quarter
glass.
In the event that the top cannot be powered to the raised or lowered position, provision is
made for manual operation.
For information regarding convertible top operation, manual operation and the removal and
installation of the luggage separator, refer to the Owner's Handbook.
CAUTION: The convertible top frame is located on the vehicle body accurately
using a steel adjuster plate; under no circumstances must the top steel adjuster plates be
released. For more information refer to the adjuster plate section.
COMPONENTS
A control module, located behind the LH rear seat, controls the power-operated convertible
top. The control module operates the top based on data received on the Controller Area
Network (CAN) bus and from the hardwired components described below:
A - Tension Bow Sensors

1 Tension bow piston tube assembly
2 Tension bow 'In' sensor
3 Tension bow 'Out' sensor
The tension bow sensors are Hall effect sensors located in the tension bow piston tube
assembly. The piston tube assembly is located next to the LH tension bow linkage. These
sensors inform the control module as to the position of the convertible top tension bow
assembly.
B - Main Bow Sensors

1 Main bow piston tube assembly
2 Main bow 'In' sensor
3 Main bow 'Center' sensor
4 Main bow 'Out' sensor
The main bow sensors are Hall effect sensors located in the main bow piston tube assembly.
The piston tube assembly is located on the RH main bearing bracket assembly. These sensors
sense the position of the main bow piston so the control module knows the exact position of
the convertible top.
C - Tonneau Panel Open Sensor

1 Tonneau panel piston tube assembly
2 Tonneau panel open sensor
The tonneau panel open sensor is a Hall effect sensor located in the tonneau panel piston tube
assembly. The piston tube assembly is located between the RH base latch plate and the lever
assembly. This sensor informs the control module of when the tonneau panel is in the open
position so the convertible top can be stowed.
D - Tonneau Panel Switch 1

1 Emergency release cable
2 Tonneau panel switch
Tonneau panel switch 1 is located on the RH lever assembly. This switch is a normally open
microswitch that, when switched to ground, informs the control module that the RH side of
the tonneau panel is closed.
E - Pump Motor Temperature Sensor

1 Tension bow up solenoid valve
2 Tension bow down solenoid valve
3 Tonneau panel solenoid valve
4 Hydraulic pump
5 Hydraulic fluid reservoir
The hydraulic fluid temperature sensor is a Negative Temperature Coefficient (NTC) sensor,
which is integral to the pump assembly. The sensor informs the control module as to the
temperature of the hydraulic fluid. If the fluid temperature exceeds a predetermined value, the
control module will stop pump operation to prevent the valve block from overheating. Once
the fluid temperature decreases below the predetermined value, the control module will then
resume pump operation.
F - Tonneau Panel Switch 2

1 Tonneau panel switch
Tonneau panel switch 2 is located on the LH latch base plate assembly. This switch is a
normally open microswitch that, when switched to ground, informs the control module that
the LH side of the tonneau panel is closed.
G- Luggage Separator Position Sensor

1 Cargo net
2 Luggage separator (roller blind)
3 Luggage separator position sensor
The Luggage separator position sensor is a Hall effect sensor located on the LH luggage
separator housing bracket. The sensor informs the control module of when the separator is in
the correct position. When the separator is in the correct position there is enough space in the
luggage compartment to stow the convertible top when open.
H - Front Latch Open and Close Sensors

1 Latch plate
2 Front latch open sensor
3 Front latch closed sensor
The front latch open and closed sensors are Hall effect sensors located in the LH front latch
plate. These sensors inform the control module of when the latch is in the open or closed
position.
I - Convertible Top Latched Sensor

1 Latching bracket
2 Hall sensor
The convertible top latched sensor is a Hall effect sensor located in the LH latching bracket.
The sensors function is to inform the control module of when the convertible top is in the
closed position.
J - Convertible Top Open and Close Switch

1 Open and Close switch
2 Overhead console
The convertible top open and close switch is located in the overhead console. The switch is a
momentary switch that is normally open. When switched to ground the convertible top will
start its open or close motion depending on which operation has been requested.
Adjuster Plate
The convertible top frame, actuation levers and main bow hydraulic cylinder assembly is
located on the vehicle body accurately using a steel adjuster plate, which is set to the body
using adjustable shims.
1 Steel adjuster plate
2 Adjuster
CAUTION: Under no circumstances must the top steel adjuster plates be

released, as they are set and adjusted to the body during manufacture, providing an
accurate location for the convertible top frame. Service action and special tools will be
required to reset the plate if this area of the vehicle requires service.
Tonneau Panel Cover

A fully automatic flush mounted aluminum tonneau cover panel protects the stowed top.
WARNING: Special care must be taken when carrying out maintenance in the
area underneath the aluminum tonneau cover. After approximately five minutes the
hydraulic pressure is lost due to the release of the spool valves to prevent the valves
overheating. A suitable support must be used to prevent the aluminum tonneau cover
falling when the hydraulic pressure is released.
The aluminum tonneau cover panel trim also incorporates Roll Over Protection hoop doors.
The roll over protection system is deployed through the hoop doors and rear screen in the
event of a vehicle roll over situation. For additional information, refer to Air Bag
Supplemental Restraint System (SRS) (501-20 Supplemental Restraint System)
1 Hoop doors
2 Aluminum tonneau cover panel
The hydraulic pump, motor and valve block assembly is located in the RH luggage area. The
fluid reservoir is filled with Pentosin hydraulic oil. Two fluid levels are marked on the pump
reservoir body, the upper mark denotes the fluid level when the top is fully lowered and the
lower mark denotes the level when the top is fully raised. The hydraulic pump supplies a
maximum pressure of approximately 140 bar during convertible top operation. When the
pump is idle the system pressure is approximately 0.1 bar.
NOTE:
The convertible top hydraulic system is 'self-bleeding' and does not require action to
expel trapped air.
CONTROL DIAGRAM
NOTE:
A = Hardwired; N = CAN bus
Part
Item Description
Number
1 Battery
2 Megafuse (175A)
4
5 Convertible top latched sensor
6 Tonneau panel sensor
7 Front latch open sensor
8 Front latch close sensor
9 Front latch motor
10 RH quarter glass motor
11 LH quarter glass motor
12 Main bow sensors (3 off)
13 Tension bow sensors (2 off)
14 Tonneau panel switch 1
15
16 Tonneau panel switch 2
17 Pump motor temperature sensor
18 Pump motor
19 Luggage separator position sensor
21 Convertible top open and close switch
The convertible top is opened and closed using four hydraulically controlled pistons. Two
main bow pistons in the top frame are fixed to the body and lift the complete top assembly
into and out of the stowage area. Two tension bow pistons open and close the tension bow at
the rear of the convertible top. This allows clearance for the tonneau cover panel to be opened
when the top is being retracted in to the luggage compartment. It also seals the rear of the top
with the tonneau cover panel when the top is opened.
The top and rear quarter glasses are operated using a hold-down switch located in the
overhead console. The convertible top will only open if:
• The vehicle speed is below 24km/h (15mph)

• The tonneau panel is closed
• The luggage separator is in position
• The hydraulic fluid temperature sensor confirms pump is not overheated
The front windows must be programmed for one-touch operation in order for the convertible
top to operate correctly. Failure to program the windows results in a ten second opening delay
once the top is unlatched. The windows can be manually programmed for one-touch operation
using this procedure:
• Ignition ON
• Raise window up to the top seal and release
• Raise again until window stops moving
• Release
• Raise again
• Lower window fully
• Release
• Press lower for a further 0.5 seconds until a relay is heard to CLICK
A luggage compartment separator prevents items from moving into the area in which the
convertible top is stowed. The luggage separator incorporates a Hall effect proximity sensor,
which prevents the convertible top from operating unless the separator is in the fully deployed
position.
The aluminum tonneau cover is secured in the closed position by a mechanically controlled
cable operated latching system. The cables are tensioned using a mechanical lever assembly
operated by the movement of the covers hydraulic piston. The latches are released by spring
tension when the covers hydraulic piston releases the tension in the cables.
The aluminum tonneau cover is raised and lowered hydraulically by a single piston.
The convertible top incorporates a fully automatic latch and unlatch tension rod system,
which uses an electric motor with a gearbox and flexible shafts to latch and unlatch the top.
Failure of a tension rod, motor gearbox or latch motor will prevent the top from unlatching. In
the event of either of these failures it is possible to release each of the top latches manually.
OPERATION LOGIC
CONVERTIBLE TOP - CLOSED TO OPEN PROCESS
Each stage of the convertible top ‘closed-to-open’ process is described below. This is
accompanied with the corresponding ‘Data-Logger’ values which can be monitored using
Jaguar Approved Diagnostic Equipment. These values can be found in the ‘Body Modules’
area of the diagnostic equipment.
Stage 1: Convertible Top - fully closed

NOTE:
The luggage compartment lid must be closed and latched.
• Press and hold the open switch (A), this will signal the convertible top control module
to commence the opening process. (Data-Logger: Convertible Top Switch inputs –
Convertible top DOWN switch – ON).
• The control module will signal the door glass and rear quarter glass to be powered for
4 seconds to the lowered position. (Data-Logger: Convertible Top motor outputs –
Rear Quarter down - ON).
• An audible chime will confirm the start of the convertible top opening process.
• The control module will confirm that the ‘open’ sensor in the front latch (B) is not
transmitting a signal; verifying the front latch is closed. (Data-Logger: Convertible
Top position sensor inputs – Front latch open sensor - INACTIVE).
• Once this is confirmed the front latch motor is powered to release the roof latches
from the header strikers. (Data-Logger: Convertible Top module motor outputs - Latch
motor open – ON).
Stage 2: Convertible Top - unlatched from header

• The control module will confirm the ‘open’ sensor in the front latch (A) is transmitting
a ‘front latch open’ signal; verifying the front latch has opened. (Data-Logger:
Convertible Top position sensor inputs – Front latch open sensor - ACTIVE).
• The control module will confirm the sensor in the top latch (B) is not transmitting a
‘latched’ signal; verifying the front latch has opened. (Data-Logger: Convertible Top
position sensor inputs - Convertible Top latched sensor - INACTIVE)
• The control module will confirm the ‘in’ sensor in the tension bow cylinder (C) is not
transmitting a ‘tension bow up’ signal. (Data-Logger: Convertible Top position sensor
inputs – Tension bow piston IN sensor - INACTIVE).
• Once confirmed the control module energizes the ‘tension bow up’ solenoid valve (D-
1) and powers the hydraulic pump (D-2) in the raise direction. (Data-Logger:
Convertible Top module motor outputs – tension bow valve 2 - ON).
Stage 3: Tension Bow - raised

• The control module will confirm the ‘in’ sensor in the tension bow cylinder (A) is
transmitting a ‘tension bow up’ signal. (Data-Logger: Convertible Top position sensor
inputs – Tension bow piston IN sensor - ACTIVE).
• The control module will confirm the ‘open’ sensor in the tonneau panel cylinder (B) is
not transmitting a ‘tonneau open’ signal; verifying the tonneau panel is closed. (Data-
Logger: Convertible Top position sensor inputs – Convertible top lid compartment
cover piston out sensor - INACTIVE).
• Once confirmed the control module energizes the tonneau panel solenoid valve (C).
(Data-Logger: Convertible Top module motor outputs – Compartment cover valve 1 –
ON).
Stage 4: Tonneau Panel and Convertible Top - raised

• The control module will confirm the ‘open’ sensor in the tonneau panel cylinder (A) is
transmitting a ‘tonneau panel open’ signal. (Data-Logger: Convertible Top position
sensor inputs – Convertible top lid compartment cover piston out sensor – ACTIVE).
• Once confirmed the control module powers the hydraulic pump (B) in the raise
direction. (Data-Logger: Convertible Top module motor outputs - Convertible top
right pump - ON).
• The control module will confirm the ‘out’ sensor in the main bow cylinder (C) is not
transmitting a signal; verifying the convertible top is not open. (Data-Logger:
Convertible Top position sensor inputs - Main bow piston OUT sensor - INACTIVE).
• Once confirmed the control module powers the hydraulic pump (D) in the lower
direction. (Data-Logger: Convertible Top module motor outputs - Convertible top left
pump - ON).
• The control module will confirm the ‘center’ sensor in the main bow cylinder (E)
transmits a momentary signal; verifying the convertible top is opening. (Data-Logger:
Convertible Top position sensor inputs - Main bow piston CENTER sensor -
ACTIVE).
• Once confirmed the control module de-energizes the ‘tension bow up’ solenoid valve
(F). (Data-Logger: Convertible Top module motor outputs – Tension bow valve 2 -
OFF).
Stage 5: Tonneau Panel - raised, and Convertible Top -
lowered
• The control module will confirm the ‘out’ sensor in the main bow cylinder (A) is
transmitting a signal; verifying the convertible top is open. (Data-Logger: Convertible
Top position sensor inputs - Main bow piston OUT sensor - ACTIVE).
• The control module will confirm the tonneau panel switches (B) and (C), which are
wired in series, are not transmitting a signal; verifying the tonneau panel is not
latched. (Data-Logger: Convertible Top Switch inputs – Convertible top lid
compartment cover latch status - OFF).
• Once confirmed the control module de-energizes the tonneau panel solenoid valve
(D), powering the tonneau panel closed. (Data-Logger: Convertible Top module motor
outputs – Compartment cover valve 1 – OFF).
Stage 6: Convertible Top - fully open

• The control module will confirm the tonneau panel switches (A) and (B) which are
wired in series are transmitting a signal; verifying the tonneau panel is latched. (Data-
Logger: Convertible Top Switch inputs – Convertible top lid compartment cover latch
status - ON).
• Once confirmed the control module powers the hydraulic pump (C) off. (Data-Logger:
Convertible Top module motor outputs - Convertible top left pump - OFF).
• An audible chime will confirm the completion of the convertible top opening cycle.
CONVERTIBLE TOP - OPEN TO CLOSE PROCESS

Each stage of the convertible top ‘open-to-close’ process is described below. This is
accompanied with the corresponding ‘Data-Logger’ values which can be monitored using
Jaguar Approved Diagnostic Equipment. These values can be found in the ‘Body Modules’
area of the diagnostic equipment.
Stage 7: Convertible Top - fully open

• Press and hold the open switch (A), this will signal the convertible top control module
to commence the closing process. (Data-Logger: Convertible Top Switch inputs –
Convertible top UP switch - ON).
• The control module will confirm the ‘open’ sensor in the tonneau panel cylinder (B) is
not transmitting a ‘tonneau panel open’ signal; verifying the tonneau panel is closed.
(Data-Logger: Convertible Top position sensor inputs – Convertible top lid
compartment cover piston out sensor – INACTIVE).
• Once confirmed the control module will: Transmit a signal to the door control module
to lower the door glass, if required. Energize the tonneau panel ‘open’ solenoid (C-1).
(Data-Logger: Convertible Top module motor outputs – Compartment cover valve 1 –
ON) Power the hydraulic pump (C-2) in the lower direction. (Data-Logger:
Convertible Top module motor outputs - Convertible top left pump - ON).
• An audible chime will confirm the beginning of the convertible top closing process.
Stage 8: Tonneau Panel - primed for opening

• As the tonneau panel is powered open the ‘open’ sensor in the tonneau panel cylinder
(A) will transmit a ‘tonneau open’ confirmation signal to the control module. (Data-
Logger: Convertible Top position sensor inputs – Convertible top lid compartment
cover piston out sensor – ACTIVE).
• Once confirmed the control module will power the hydraulic pump (B) in the lower
direction. (Data-Logger: Convertible Top module motor outputs - Convertible top left
pump - ON).
Stage 9: Tonneau Panel - open

• The control module will confirm the ‘in’ sensor in the main bow cylinder (A) is not
transmitting a convertible top raised signal. (Data-Logger: Convertible Top position
sensor inputs - Main bow piston IN sensor - INACTIVE).
• Once confirmed the control module energizes the ‘tension bow up’ solenoid valve (B-
1) and powers the hydraulic pump (B-2) in the raise direction. (Data-Logger:
Convertible Top module motor outputs – Tension bow valve 2 – ON). (Data-Logger:
Convertible Top module motor outputs - Convertible top left pump - OFF). (Data-
Logger: Convertible Top module motor outputs - Convertible top right pump - ON).
NOTE:
The ‘tension bow up’ solenoid valve (B-1) remains energized.
Stage 10: Convertible Top and Tension Bow - raised

• The control module will confirm the ‘in’ sensor in the main bow cylinder (A) is
transmitting a signal to indicate the convertible top is raised. (Data-Logger:
Convertible Top position sensor inputs - Main bow piston IN sensor - ACTIVE).
• The control module will confirm the ‘in’ sensor in the tension bow cylinder (B) is
transmitting a ‘tension bow up’ signal; verifying the tension bow is in the raised
position. (Data-Logger: Convertible Top position sensor inputs – Tension bow piston
IN sensor - ACTIVE).
• The control module will confirm the tonneau panel switches (C) and (D) which are
wired in series are not transmitting a signal; verifying the tonneau panel is not latched.
(Data-Logger: Convertible Top Switch inputs – Convertible top lid compartment
cover latch status - OFF).
• Once confirmed the control module de-energizes the tonneau panel solenoid valve (E),
powering the tonneau panel closed. (Data-Logger: Convertible Top module motor
outputs – Compartment cover valve 1 – OFF).
Stage 11: Tonneau Panel - closed

• The control module will confirm the tonneau panel switches (A) and (B) which are
wired in series are transmitting a tonneau panel closed signal. (Data-Logger:
Convertible Top Switch inputs – Convertible top lid compartment cover latch status -
ON).
• The control module will confirm the ‘out’ sensor in the tension bow cylinder (C) is not
transmitting a signal; verifying the tension bow is in the raised position. (Data-Logger:
Convertible Top position sensor inputs – Tension bow piston OUT sensor -
INACTIVE).
(D-1), and energizes the ‘tension bow down’ solenoid valve (D-2), causing the tension
bow to lower. (Data-Logger: Convertible Top module motor outputs – Tension bow
valve 2 – OFF). (Data-Logger: Convertible Top module motor outputs – Tension bow
valve 3 – ON).
Stage 12: Tension Bow - lowered

• The control module will confirm the ‘out’ sensor in the tension bow cylinder (A) is
transmitting a signal; verifying the tension bow is in the lowered position. (Data-
Logger: Convertible Top position sensor inputs – Tension bow piston OUT sensor -
ACTIVE).
• Once confirmed the control module switches off the hydraulic pump, and energizes
the ‘tension bow up’ solenoid valve (B). (Data-Logger: Convertible Top module
motor outputs - Convertible top right pump - OFF). (Data-Logger: Convertible Top
module motor outputs – Tension bow valve 2 – ON).
• The control module will confirm that the ‘close’ sensor in the front latch (C-1) is not
transmitting a signal; verifying the latches are open. (Data-Logger: Convertible Top
position sensor inputs – Front latch closed sensor – INACTIVE).
• Once confirmed control module powers the front latch motor to pull the convertible
top down and direct the convertible top’s latch claws to latch onto the header strikers.
(Data-Logger: Convertible Top module motor outputs - Latch motor close - ON).
• When the convertible top is fully latched, the ‘open’ latch sensor (C-2) signal is lost,
and the sensor (C-1) and convertible top latched sensor (D) signals are supplied.
(Data-Logger: Convertible Top position sensor inputs – Front latch open sensor –
INACTIVE). (Data-Logger: Convertible Top position sensor inputs – Front latch
closed sensor – ACTIVE). (Data-Logger: Convertible Top position sensor inputs –
Convertible top latched sensor – ACTIVE).
• The control module will confirm the sensor in the top latch (D) is transmitting a
signal. (Data-Logger: Convertible Top position sensor inputs – Convertible top latched
sensor – ACTIVE).
• Once confirmed the control module switches off the latch motor. (Data-Logger:
Convertible Top module motor outputs - Latch motor close - OFF).
Stage 13: Convertible Top - latched
• The control module will confirm the ‘close’ sensor (A) in the front latch is
transmitting a signal. (Data-Logger: Convertible Top position sensor inputs –
Convertible top latched sensor – ACTIVE).
(B-1), and the ‘tension bow down’ solenoid valve (B-2). (Data-Logger: Convertible
Top module motor outputs – Tension bow valve 2 – OFF). (Data-Logger: Convertible
Top module motor outputs – Tension bow valve 3 – OFF).
• The control module powers for 4 seconds: both rear quarter glass windows to the
raised position, followed by the door glass windows to the raised position. (Data-
Logger: Convertible Top module motor outputs - Rear quarter up - ON).
• The control module will confirm that all windows are fully closed.
• An audible chime will confirm the completion of the convertible top closing process.
Convertible Top
For a detailed description of the Convertible Top operation, refer to the relevant Description

• Fuses
• Luggage separator position • Wiring harness
• Luggage compartment lid is closed • Correct engagement of electrical
• Latching assemblies/mechanisms connectors
• Loose or corroded connections
4 . If the cause is not visually evident, verify the symptom and refer to the Symptom Chart,
Symptom Chart
There is a ten • Door window glass
second delay in upper and lower Carry out the 'Door Window Motor
convertible top parameters have not Initialization' procedure.
movement when been set Door Window Motor Initialization
switch is operated
Rear quarter Press and hold convertible top switch in
window glass is not close position. The door window glass
• Glass sticking in seals
fully closed/raised will be driven down, then the rear
• Battery voltage low
when convertible quarter window glass will be driven up
top close cycle is for four seconds, followed by the door
complete window glass to fully closed. Check
battery is in fully charged and
serviceable condition. Refer to the
battery care manual
Manually latch the convertible top
Glass will not raise
• Latched signal is not compartment lid by pushing the
after the convertible
being seen convertible top compartment lid cylinder
top has been raised
forward until the latch has travelled over
manually
center
• Latched signal is not Carry out the convertible top
Glass will not raise being seen compartment lid latch over center
bracket setting procedure
Excessive gap • Convertible top
between front edge header latch not in Manually open the latch when pushing
of convertible top fully open position the front of the convertible top upwards
and windshield when latched with until the fork is seen to locate on the pin
header when convertible top - the top can then be re-latched manually
manually closed
• Ignition set to OFF Move convertible top to fully open
Convertible top when convertible top position, this is recognised by the
module memory lost is mid cycle module as a safe start position which
will allow cycle to be re-started
DTC Index

NOTE:
NOTE:
NOTE:
NOTE:
tests.
NOTE:
NOTE:
terminals.

Convertible top up • Signal Stuck Low associated with this DTC
B107923
switch using the manufacturer
Convertible top • Signal Stuck Low associated with this DTC
B107A23
down switch using the manufacturer
• Convertible top pump
diagrams and test convertible
Convertible top motor circuit - short to
B107B15 top pump motor circuit for
pump motor power, high resistance
resistance
• Convertible top pump Refer to the electrical circuit
Convertible top motor circuit - short to diagrams and test convertible
B107B11
pump motor ground top pump motor circuit for
short to ground
• Convertible top rear Refer to the electrical circuit
quarter motor circuit - diagrams and test convertible
Convertible top
B107C15 short to power, high top rear quarter motor circuit
rear quarter motor
resistance for short to power, high
resistance
• Convertible top rear Refer to the electrical circuit
Convertible top quarter motor circuit - diagrams and test convertible
B107C11
rear quarter motor short to ground top rear quarter motor circuit
for short to ground
• Convertible top latch
diagrams and test convertible
Convertible top motor circuit - short to
B107D15 top latch motor circuit for
latch motor power, high resistance
resistance
Convertible top • Convertible top latch
B107D11 diagrams and test convertible
latch motor motor circuit - short to
top latch motor circuit for
ground short to ground
• Convertible top Refer to the electrical circuit

Convertible top compartment lid valve1 diagrams and test convertible
B107E15 compartment lid circuit - short to power, top compartment lid valve1
valve 1 high resistance circuit for short to power,
high resistance
• Convertible top Refer to the electrical circuit
Convertible top
compartment lid valve1 diagrams and test convertible
B107E11 compartment lid
circuit - short to ground top compartment lid valve1
valve 1
• Tension bow valve 2 Refer to the electrical circuit
Tension bow valve circuit - short to power, diagrams and test tension bow
B107F15
2 high resistance valve 2 circuit for short to
• Tension bow valve 2
Tension bow valve diagrams and test tension bow
B107F11 circuit - short to ground
2 valve 2 circuit for short to
ground
• Tension bow valve 3 Refer to the electrical circuit
Tension bow valve circuit - short to power, diagrams and test tension bow
B108015
3 high resistance valve 3circuit for short to
• Tension bow valve 2
Tension bow valve diagrams and test tension bow
B108011 circuit - short to ground
3 valve 2 circuit for short to
ground
Convertible top
• No signal associated with this DTC
B107031 compartment lid
piston out sensor
Tension bow • No signal associated with this DTC
B107131
piston in sensor using the manufacturer
Tension bow • No signal associated with this DTC
B107231
piston out sensor using the manufacturer
Main bow piston • No signal associated with this DTC
B107331
in sensor using the manufacturer
Main bow piston • No signal
B107431 associated with this DTC
out sensor
Main bow piston • No signal associated with this DTC
B107531
centre sensor using the manufacturer
Front latch open • No signal associated with this DTC
B107631
sensor using the manufacturer
Front latch close • No signal associated with this DTC
B107731
sensor using the manufacturer
Convertible top • No signal associated with this DTC
B107831
latched sensor using the manufacturer
Convertible top
• No signal associated with this DTC
B113531 compartment lid
switch
CAN • Bus off associated with this DTC
U001088
communication using the manufacturer
Bus approved diagnostic system
Lost • Lost communication
U014000 communication CJB
CJB
Lost • Lost communication
U014200 communication with RJB
with RJB
communication associated with this DTC
U015500 with Instrument Cluster
with Instrument using the manufacturer
Cluster approved diagnostic system
Lost • Lost communication Carry out any pinpoint tests
communication with Driver Door associated with this DTC
U019900
with Driver Door Module (DDM) using the manufacturer
Module (DDM) approved diagnostic system
Lost
• Lost communication Carry out any pinpoint tests
communication
with Passenger Door associated with this DTC
U020000 with Passenger
Module (PDM) using the manufacturer
Door Module
(PDM)
• RJB car configuration
diagnostic system. Clear
Control module data is not compatible
DTCs and re-test. If DTC still
U030000 software with the convertible top
logged, suspect convertible
incompatibility module
top module. Refer to new
top of DTC Index
Invalid data
• Signal incorrect after
received from Check DDM for DTCs and
U049A67 event
Driver Door refer to DTC Index
Module (DDM)
Invalid data
• Signal incorrect after
received from Check PDM for DTCs and
U050167 event
Passenger Door refer to DTC Index
Module (PDM)
Install a new convertible top
• Internal electronic
CAN initialisation module, refer to the new
U1A1449 failure
failure module installation note at the
Set convertible top to
• Manufacturing mode
Build/end of line customer mode using
U1A4C68 has not been removed
mode active manufacturer approved
diagnostic system
U300316 Battery voltage threshold
• Circuit voltage above
U300317 Battery voltage threshold
Convertible Top Compartment Lid Latch, Over Center

Bracket Setting Procedure
1 . Set hydraulic pump to manual override.
2 . Set ignition status to OFF.
3 . Open the convertible top compartment lid to access the top fixing nut of the latch bracket
on the right hand wheelhouse and slacken the nut.
4 . Slacken the two lower fixing nuts of the latch bracket on the right hand wheel house, these
can be accessed through the luggage compartment.
5 . Position the mechanism to the fully over center position, then push the bracket forward
until the cylinder is at it's shortest length, then release.
6 . Tighten the two lower fixing nuts to 9Nm, open the convertible top compartment lid and
tighten the top fixing nut to 9Nm.

Removal
1 . Remove the rear quarter trim panels.
2 . Remove the RH loadspace trim panel.

3
. CAUTION: Do not loosen the Allen bolt more than 2 complete turns.
Failure to follow this instruction may result in damage to the vehicle.
NOTE:
The ignition must be switched off.
Release the convertible top system pressure.

Loosen the Allen bolt up to a maximum of 2 complete turns.
4 . Disconnect the convertible top hydraulic pump electrical connectors.
5 . Release the convertible top hydraulic pump.

Remove the 3 bolts.
7 . Release the convertible top fluid lines and harness.

Release the 2 fluid line and harness clips.
8 . NOTE:
Support the convertible top compartment lid.
Release the convertible top compartment lid RH lift cylinder.

10
. CAUTION: Under no circumstances must the base plate fixing nuts be
loosened or removed. Each base plate fixing nut can be identified by a large
aluminium spacer.
NOTE:
This step requires the aid of other technicians.
Remove the convertible top assembly.

Remove the 8 nuts.
Installation
1 . Install the convertible top assembly.
2 . Align the convertible top assembly.

For additional information, refer to Convertible Top Alignment
4 . NOTE:
Support the convertible top compartment lid.
Attach the convertible top compartment lid RH lift cylinder.

5 . Secure the convertible top fluid lines and harness.

Secure the fluid line and harness clips.
Install new cable ties.
7 . Secure the convertible top hydraulic pump.

8 . Connect the convertible top hydraulic pump electrical connectors.
9 . NOTE:
Tighten the convertible top system pressure Allen bolt.

Tighten to 2 Nm.
10 Install the RH loadspace trim panel.

. For additional information, refer to Loadspace Trim Panel - Convertible
(76.13.73.60)
11 . Install the rear quarter trim panels.

For additional information, refer to Rear Quarter Trim Panel - Convertible
(76.13.73)
Convertible Top Headliner (76.86.16)
Removal
1 . Remove the header rail upper trim panel.
For additional information, refer to Header Rail Upper Trim Panel (76.86.20)
2 . Remove the convertible top hydraulic pump access panel

Release the clip.
3
NOTE:

4 . Release the convertible top compartment lid.

Release using the cable.
5 . NOTE:

Raise the rear of the convertible top.
6 . Release the rear edge of the converible top headliner.

Remove the securing bracket.
7 . Release the headliner from the rear window.

Release from the Velcro strip.
8 . Release the heated rear window wires from the headliner.

Disconnect both heated rear window electrical connectors.
Release the heated rear window wires from the headliner.
9 Reposition the rear window

. Fold over the rear window to allow access to the headliner retaining
screws.
10 . NOTE:
Take note of the routing.
NOTE:
Release the headliner rear tension straps.

Release the 2 springs.
11 . Release the headliner from the rear of the convertible top frame.
12 . NOTE:
Release the headliner central tension straps.

13 . Release the headliner from the center of the convertible top frame.
14 . Release the headliner from the front of the convertible top frame.
Remove the 2 bolts.
Collect the retaining bracket.
Installation
1
. CAUTION: Ensure grease from latching mechanisms does not contact the
headliner.
Secure the headliner to the front of the convertible top frame.

Position the the retaining bracket.
Install and tighten the screws.
2 . Secure the headliner to the center of the convertible top frame.

3 . NOTE:
Attach the headliner central tension straps.

4 . Secure the headliner to the rear of the convertible top frame.

5 . NOTE:
Take note of the routing.
NOTE:
Attach the headliner rear tension straps.

Attach the springs.
6 Reposition the rear window

. Fold over the rear window to allow access to the headliner retaining
screws.
Fold the rear window into fitted position.
7 . Secure the heated rear window wires to the headliner.

Attach the heated rear window wires to the headliner.
8 . Secure the rear edge of the converible top headliner.

Position the securing bracket.
9 . NOTE:
Close the convertible top compartment lid.

10 . Install the header rail upper trim panel.

11 . NOTE:

Tighten to 2 Nm.
12 . Install the convertible top hydraulic pump access panel

Secure in the clip.
13 . Operate the convertible top fully in each direction.

Depress the switch.
Convertible Top Latch (76.86.19)
Removal
2 . Release the convertible top locking mechanism rod.

3 . NOTE:
Electrical connector is installed on the LH latch only.
Release the convertible top latch assembly.

4 . Remove the convertible top latch assembly.

Remove the 4 nuts.
Release the drive cable.
Installation
1 . Install the convertible top latch assembly.
Attach the drive cable.
2 . Attach the convertible top locking mechanism rod.


Header Rail Upper Trim Panel (76.86.20)
Removal
1 . Release the convertible top front latches.
Depress the switch.

Installation
2 . Close the the convertible top.

Depress the switch.
Header Rail Weatherstrip
Removal
1 . Open the convertible top.
Depress the switch.
2 . Release the header rail weatherstrip.

Remove the 4 clips.
3 . Remove the header rail weatherstrip.

Release from the header rail.
Installation
1 . Install the header rail weatherstrip.
Attach to the header rail.
2 . Secure the header rail weatherstrip.

Install the clips.

Depress the switch.
Removal
Depress the switch.
2 . Release the convertible top compartment lid lift cylinder.

Release the clip.
3 . With assistance, remove the convertible top compartment lid.

Remove the 4 bolts.
4 . Remove the convertible top compartment lid buffers.
Release the clips.
5 . Remove the convertible top compartment lid pad.

6 . Remove the convertible top compartment lid lift cylinder spigot.
7 . Remove the convertible top compartment lid strikers.

Remove the 4 bolts.
8 . Remove the convertible top compartment moulding.
Remove the 10 nuts.
9 . Remove the convertible top compartment trim panel.

Installation
1 . Install the convertible top compartment trim panel.
2 . Install the convertible top compartment moulding.

3 . Install the convertible top compartment lid strikers.

4 . Install the convertible top compartment lid lift cylinder spigot.
5 . Install the convertible top compartment lid pad.

6 . Install the convertible top compartment lid buffers.

Release the clips.
7 . Check the convertible top compartment lid profile.

Loosen the locknut.
Adjust the striker.
Check the convertible top compartment lid profile.
8 . With assistance, install the convertible top compartment lid.

9 . Attach the convertible top compartment lid lift cylinder.

10 . Close the convertible top compartment lid.

Remove the support.
Depress the switch.
11 . If required, adjust the convertible top compartment lid.

Convertible Top Compartment Lid Trim
Panel
Removal
Depress the switch.

Release the clips.

Remove the 10 nuts.
5 . Remove the convertible top compartment trim panel.

Installation
1 . Install the convertible top compartment trim panel.



Release the clips.

Remove the support.
Depress the switch.
Convertible Top Compartment Lid Hinge
Removal
1 . Remove the convertible top compartment lid.
For additional information, refer to Convertible Top Compartment Lid
2 . Remove the convertible top compartment lid hinge.

Remove the 3 bolts.
Installation
1 . Install the convertible top compartment lid hinge.
2 . Install the convertible top compartment lid.

Moulding
Removal
Depress the switch.

Release the clips.

Remove the 10 nuts.
Installation


Release the clips.

Remove the support.
Depress the switch.
Removal
1 . NOTE:

Depress the switch.
2 . Release the luggage compartment retractable cover rail upper tension strap.
3 . Release the convertible top lid latch.

Remove the 3 bolts.
4 . Release the convertible top lid position switch

Release the switch.
5 . Release the convertible top latch release cable.
Installation
1 . Attach the convertible top latch release cable.
Tighten the Torx bolt.
Install the clip.
2 . Secure the convertible top lid position switch.

Attach the switch.
3 . Secure the convertible top lid latch.

4 . NOTE:

Convertible Top Compartment Lid Release
Cables
Removal
1 . NOTE:

Depress the switch.


4 . Release the convertible top electrical connector

5 . Release the LH convertible top lid latch.

Remove the 3 bolts.
6 . Release the convertible top lid position switch
7 . Release the convertible top lid lift cylinder.

Release the clip.
8 . Release the convertible top lid lift cylinder bracket.

Remove the 2 lower nuts.
Loosen the upper retaining nut.
9 . Release the convertible top latch release cables.
10 . Release the convertible top lid lift cylinder bracket release cables.
Loosen the 2 locknuts.
Remove the clip.
11 . Remove the convertible top lid release latch cables.

Installation
1 . Install the convertible top lid release latch cables.
2 . Attach the convertible top lid lift cylinder bracket release cables.
Loosen the 2 locknuts.
Remove the clip.
3 . Attach the convertible top latch release cables.

4 . Attach the convertible top lid lift cylinder.

5 . Secure the convertible top lid lift cylinder bracket.

6 . Secure the convertible top lid position switch.

7 . Secure the LH convertible top lid latch.

8 . Secure the convertible top electrical connector.

9 . Install the RH loadspace trim panel.

12 . If required, adjust the convertible top compartment lid.

and Cable Assembly
Removal
1 . NOTE:

Depress the switch.


4 . Release the convertible top electrical connector

5 . Release the convertible top lid latch and cable assembly.

Release the cables from the 7 clips.
6 . Release the convertible top lid lift cylinder.
Release the clip.
7 . Release the LH convertible top lid latch.

Remove the 3 bolts.
8 . Release the convertible top lid RH latch.

Remove the 3 bolts.
9 . Remove the convertible top lid latch and cable assembly.
Release the emergency release cable.
Installation
1 . Install the convertible top latch and cable assembly.
Attach the emergency release cable.
2 . Secure the convertible top lid RH latch.

3 . Secure the LH convertible top lid latch.

4 . Attach the convertible top lid lift cylinder.

5 . Secure the convertible top lid latch and cable assembly.

Secure the cables in the clips.
6 . Secure the convertible top electrical connector.



9 . NOTE:

Convertible Top Motor
Removal
2 . Release the convertible top latch motor.

3 . Remove the convertible top latch motor.

Remove the 2 nuts.
Release the latch motor drive cables.
Installation
1 . Install the convertible top latch motor.
Attach the drive cables.

Hydraulic System, Lift Cylinder and Motor
Removal
2
NOTE:

3 Disconnect the convertible top hydraulic pump electrical connectors.

. Release the 2 electrical connectors from the convertible top pump
bracket.
4 . Release the convertible top hydraulic pump.

Remove the 3 bolts.
5.
Disconnect the convertible top hydraulic pump hoses.

Release the hose retaining clamp.
6 . Remove the convertible top hydraulic pump.
Installation
1 . Install the convertible top hydraulic pump.
2 . Connect the convertible top hydraulic pump hoses.

Attach the hoses and position the retaining clamp.
Tighten the Allen bolts to 10 Nm.
3 . Secure the convertible top hydraulic pump.

4 . Connect the convertible top hydraulic pump electrical connectors.
Secure the electrical connectors to the convertible top pump bracket.
5 . Fill the convertible top pump with the correct amount of fluid.
Remove the convertible top fluid filler plug.
Top-up the convertible top fluid.
Install the convertible top fluid filler plug.

7 . Cycle the convertible top to bleed the hydraulic system.

Convertible Top Module
Removal


4 . Remove the convertible top module.

Remove the 2 nuts.
Installation
1 . Install the convertible top module.


Convertible Top Rear Panel Lower
Weatherstrip
Removal
Depress the switch.
2 . Release the rear edge of the convertible top rear panel lower weatherstrip.
Remove the main carrier.

Depress the switch.
4.
CAUTION: Make sure that filings and swarf do not enter the component.
CAUTION: LH illustration shown, RH is similar.
Remove the convertible top rear panel lower weatherstrip C-post carriers.
Release the seal.
Drill out the 6 rivets.
5
. CAUTION: LH illustration shown, RH is similar.
Remove the convertible top rear panel lower weatherstrip.

Carefully release the convertible top rear panel lower weatherstrip
from the outer material.
Installation
1 Install the convertible top rear panel lower weatherstrip carriers.
. Install the convertible top rear panel lower weatherstrip C-post carrier
to the seal.
Install the convertible top rear panel lower weatherstrip seal to the
main carrier.
2
. CAUTION: Make sure that the seal is correctly positioned and does not
move during installation. Failure to follow this instruction may result in damage
to the vehicle.
Make sure that the seal is correctly positioned.

Make sure that the datum mark is positioned 142mm from the edge of
the main carrier.
Repeat the operation for the other side.
3 Install the convertible top rear panel lower weatherstrip and carriers assembly.
. Clamp the convertible top outer material between the convertible top
rear lower weatherstrip seal and the roof frame.
Install and secure the rivets in the sequence shown.

Depress the switch.
5 Secure the rear edge of the convertible top rear panel lower weatherstrip.
. Install the Torx screws and tighten to 4 Nm in the sequence shown.
Make sure that the datum marks are still positioned 142mm from the
edge of the main carrier.

Depress the switch.
Convertible Top Tension Cylinder
Removal
1 . Release the convertible top front latches.
Depress the switch.

Release the clip.
3
NOTE:

4 . Release the convertible top compartment lid.

Release using the cable.
5 . NOTE:
6 . Release the cylinder cover.

7 . Release the hydraulic cylinder.

8
. CAUTION: Fluid loss is unavoidable care must be taken to protect the
interior of the vehicle.
Disconnect the hydraulic cylinder lines.

Withdraw the hydraulic lines from the cylinder, remove and discard
the O-rings.
9 . Remove the hydraulic cylinder.

Remove and discard the 3 cable ties.
RH hydraulic cylinder only: Disconnect the electrical connector.
Installation
1 . Connect the hydraulic cylinder lines.
Lubricate and install the new O-rings.
Connect the hydraulic lines to the cylinder.
2 . Install the hydraulic cylinder.

RH hydraulic cylinder only: Connect the electrical connector.
3 . Install the cylinder cover.

5 . NOTE:

Tighten to 2 Nm.

Secure in the clip.

Depress the switch.
Convertible Top Compartment Lid Lift
Cylinder
Removal
Depress the switch.

Release the clip.
3
NOTE:

4 . Remove the convertible top compartment lid lift cylinder cover.
Release the clip.
Release the lift cylinder
5 . Release the convertible top compartment lid lift cylinder.

Disconnect the 2 fluid lines.
6 . Remove the convertible top compartment lid lift cylinder.
Release the clip.
Installation
1 . Install the convertible top compartment lid lift cylinder.
2 . Install the convertible top compartment lid lift cylinder cover.

Attach the lift cylinder.
3 . Secure the convertible top compartment lid lift cylinder.

Connect the 2 fluid lines.
4 . NOTE:

5 . NOTE:

Tighten to 2 Nm.
6 . Cycle the convertible top to bleed the hydraulic system.
7 . Check the convertible top fluid level.

Secure in the clip.
Convertible Top Material (76.86.12)
Removal
1 . Remove the converible top headliner.
For additional information, refer to Convertible Top Headliner (76.86.16)
2 . NOTE:
Note the fitted position of the spacers
Remove the convertible top front seal carriers.

Release the seal.
Collect the spacers.
3 . Remove the convertible top side seal carriers.

Release the seal.
Drill out the 6 rivets.
4 . Carefully release the convertible top outer material from the rear seal.
5 . NOTE:
Note the routing of the convertible top tension cables.
Release the convertible top tension cables.

Remove and discard the 4 clips.
Release the tension cables from the convertible top frame.
Withdraw from the convertible top material.
6 . Release the convertible top retaining straps.
7 . Release the front edge of the convertible top material.

8 . Remove the convertible top outer material.
Release the convertible top material from the frame.
Installation
1 . Install the convertible top outer material.
Secure the convertible top material to the frame.
2 . Secure the front edge of the convertible top material.

3 . Secure the convertible top outer material retaining straps.

4 Feed the tension cables through the convertible top outer material ensuring the correct
. routing.
Attach the tension cables to the convertible top frame.
Install new clips.
5 Secure the convertible top to the rear seal.

. Carefully open the rear seal sufficiently to locate the convertible top
outer material.
Attach the convertible top outer material.
Clamp the seal to retain the outer material.
6 . Install the convertible top side seal carriers.

Install the rivets.
Attach the seal.
7 . Install the convertible top front seal carriers.

Attach the seal.
8 . Install the converible top headliner.

For additional information, refer to Convertible Top Headliner (76.86.16)
Convertible Top Striker
Removal
1 . Open the convertible top.

3 . Remove the header rail.

4 . Remove the convertible to latch striker.

Installation
1 . Install the convertible to latch striker.
Secure the wiring harness clip.
2 . Install the header rail.

Tighten the screws.
3 . Secure the convertible to latch striker.



501-19 : Bumpers
Specifications
Specifications
Item Nm lb-ft lb-in

Foam to front bumper beam (ROW markets) - screw 6 - 53
Front bumper cover - guide screw 18 13 -
Front bumper cover to vehicle panels - screw 4 - 35
Front bumper undertray to vehicle - screw 4 - 35
Rear bumper beam to crash tubes - bolt 15 11 -
Rear bumper cover to panel brackets - screw 4 - 35
Rear bumper, crash tubes to vehicle - nut 23 17 -

Removal
1


4 Remove the crush pad.

. Remove the 3 clips.
Vehicles with a pedestrian impact sensor only: Remove 2 additional
bolts.

Remove the 3 clips.
6 . Remove the front bumper.
Remove the 8 bolts.
7 . NOTE:
Remove the ambient air temperature sensor.
Installation
1 . Install the ambient air temperature sensor.
2 . Install the front bumper.
3 . Install the air deflectors.

Secure the clips.
4 Install the crush pad.

. Secure the clips.
Vehicles with a pedestrian impact sensor only: Install the additional
bolts and tighten to 10 Nm (7 lb.ft).


Removal
All vehicles
1

3 . Remove the headlamps.

5
components.
NOTE:
Remove the front bumper cover.
6 . NOTE:
Remove the towing eye cover.

7 . Remove the front fog lamp.
Repeat the above procedure for the other lamp.
Remove the 2 clips.

9 . If installed: Remove the parking aid sensor.
10 . If installed: Remove the license plate.
11 . If installed: Remove the license plate panel.
Remove the 3 clips.

13 . Remove the radiator grille.

14 . Remove the radiator lower grille.
15 . Remove the front fog lamp bezel.

All vehicles
16 . Remove the wiring harness.
Installation
All vehicles

2 . Install the front fog lamp bezels.
Secure the clips.
3 . Install the radiator lower grille.
All vehicles
4 . Install the radiator grille.
5 . Install the license plate panel.
6 . Install the license plate.
7 . Install the parking aid sensors.
Install the clips.
9 . Install the front fog lamps.
10 . Install the towing eye cover.
11 NOTE:
.
Make sure the bumper cover spigots are aligned with the locating holes in the fenders.
NOTE:
Install the front bumper cover.
Align the spigots and clips.
Install and tighten the upper mounting bolts to 5 Nm (4 lb.ft), tighten the
remaining bolts to 10 Nm (6 lb.ft).

14 . Align and secure both fender splash shields.

15 . Install the headlamps.
Rear Bumper (76.22.27)
Removal

components.
1

3 . With assistance, remove the bumper.

Remove the 4 bolts.
4 . Remove the 2 crush tubes.

Remove the 8 nuts.
Installation
1 . Install the 2 crush tubes.
2 . With assistance, install the bumper.

3 . Install the rear bumper cover.

Rear Bumper Cover (76.22.74)
Removal
All vehicles
1
2 . Remove both rear wheels and tires.

3 . Remove the LH rear quarter trim panel.

4 . Remove the RH rear quarter trim panel.
Remove the clip.

5 . Release the rear lower edge of the LH fender splash shield.
6
. CAUTION: Take great care when removing the rear lamp assembly as the forward
point of the lens can be easily damaged.
Remove the rear lamp assembly.
Remove the 2 nuts.

7 . NOTE:
Naturally aspirated graphic shown, supercharged is similar.
Remove 4 clips from the lower edge of the bumper cover.
8 . Remove 3 bolts from the LH rear wheel arch.

9 . Remove 2 bolts from the LH inner quarter panel.
10 . Disconnect the bumper harness electrical connector.

11 . Release the exhaust sound enhancement vacuum pump assembly.
Remove the bolt.

All vehicles
12 . With assistance, remove the rear bumper cover.
Remove the 6 bolts.
Release the wiring harness grommet.
Release the harness.
13 . NOTE:
Remove the LH tire pressure antenna.

Remove the 2 clips.
14 . Remove the bumper harness.
15 . Remove the bumper insert.
Remove the 2 clips.

17 . Remove the lower trim panel.
Remove the 2 bolts.

18 . Remove the 20 clips.
Installation
All vehicles
1 . Install the clips.
2 . Install the lower trim panel.
3 . Install the parking aid sensor.
4 . Install the bumper insert.

Install the clips.
5 . NOTE:
Install the wiring harness.
Install the clips.
7 . With assistance, install the rear bumper cover.
Install the wiring harness.

8 . Attach the exhaust sound enhancement vacuum pump.
Secure the wiring harness clip.

All vehicles
9 . Secure the lower edge of the bumper cover.
10 . NOTE:
Install the rear lamp assembly.
12 . Install the RH rear quarter trim panel.
Install the clip.
13 . Install the LH rear quarter trim panel.

14 . Install the wheels and tires.

501-20A : Safety Belt System
Specifications
Specifications
Item Nm lb-ft lb-in

Front safety belt anchorage - bolt* 35 26 -
Front safety belt retractor - bolt* 35 26 -
Rear safety belt anchorage - bolt* 35 26 -
Rear safety belt retractor - bolt* 35 26 -
Rear safety belt buckle - bolt* 35 26 -
* Install new nut/bolt.

Safety Belt System

COMPONENT LOCATION
NOTE:
Seat belts and retractors are a single assembly.

1 RH front seat belt
2 RH front seat belt retractor
3 RH rear seat belt buckle
4 RH rear seat belt retractor
5 LH rear seat belt retractor
6 LH rear seat belt retractor
7 LH front seat belt buckle
8 LH front seat belt
9 LH front seat belt buckle
10 RH front seat belt buckle
INTRODUCTION
A three point safety belt is installed in all seating positions. Each seatbelt has Emergency
locking retractor (ELR) functionality.
The ELR function incorporates a lift shaft locking system with webbing sensor and car
sensing activating mechanisms. The webbing sensor activates the locking mechanism if the
webbing is subjected to a sharp pull. The car sensor activates the locking system if the vehicle
is subjected to sudden deceleration or severe tilt angle.
All second row passengers and NAS front Passenger ELR's are enhanced with Automatic
Locking Retractors (ALR).
The ALR allows webbing to be extracted to activate a ratchet device. This device allows
webbing to be cinched tight to facilitate child seat fitment. With seatbelt webbing tensioned in
ALR mode the seatbelt is always locked.
All row 1 driver and passenger ELRs incorporate an electrically activated webbing tension
reducer (comfort device). This device is activated at vehicle ignition on and insertion of
seatbelt tongue into buckle.
A safety belt warning indicator is installed in the instrument cluster to remind the front seat
occupants to fasten their safety belts. The warning indicator illuminates if the safety belt of an
occupied front seat is not fastened. On NAS vehicles the beltminder system will ignore the
state of the passenger safety belt for the first 75 seconds after ignition on. The warning
indicator remains illuminated until the safety belt of each occupied front seat is fastened, or
the ignition is switched off.
FRONT SAFETY BELTS

The retractor of each front seatbelt is attached to the related B pillar mounting bracket. The
webbing runs from the retractor through a fixed D loop bracket mounted to B pillar upper to
an anchor point on the sill.
The retractor for each front safety belt incorporates a load limiter that allows the retractor reel
to partially unwind when the load on the webbing exceeds a predetermined limit.
The buckle for each front safety belt is attached to a pretensioner secured to the inboard side
of the related front seat frame. Each buckle incorporates a safety belt buckle sensor that
provides a status input to the RCM (restraints control module) , which uses the input to
determine the air bag and pretensioner activation strategies. The RCM (restraints control
module) also relays the status of the safety belts to the instrument cluster on the high speed
CAN (controller area network) bus.
Belt Minder Function

Safety Belt Warning Indicator
The belt minder function provides warnings to the driver if the appropriate front safety belts
are not fastened when driving. The belt minder function is controlled by the instrument cluster
using:
• High speed CAN (controller area network) bus messages, from the RCM (restraints
control module) , to monitor the status of the front safety belts.
• An input from the occupant detection system to monitor the status of the front
passenger seat.
When the ignition is switched to on, the instrument cluster illuminates the safety belt warning
indicator until one of the front safety belts is fastened or the belt minder function is triggered.
The belt minder function is triggered when the ignition switch is in accessory/convenience
and the following conditions coexist:
• The belt minder function is enabled.

• Vehicle speed is 8 km/h (5 mph) or more.
• The vehicle is not in reverse.
• The driver safety belt or, if the front passenger seat is occupied, the front passenger
safety belt, is unfastened.
When the belt minder is triggered, the instrument cluster generates the following warnings for
10 seconds.
• Flashes the safety belt warning indicator at 2 Hz.

• Sounds a repeating chime in sequence with the flashing safety belt warning indicator.
After 10 seconds, the repeating chime is discontinued and the safety belt warning indicator
changes from flashing to continuously illuminated for 20 seconds. While the trigger
conditions still coexist, the warnings are repeated every 30 seconds until one of the following
occurs:
• 5 minutes has elapsed from when the warnings were first triggered.
• The safety belt of each occupied front seat is fastened.
• The ignition mode is position 0.
• The vehicle speed decreases to 5 km/h (3 mph).
For non NAS vehicles the belt minder function can be enabled and disabled using the driver
safety belt switch. The instrument cluster changes the state of the belt minder function if,
within 60 seconds of first entering ignition mode II, the driver safety belt is fastened and
unfastened nine times. Successful completion of the change is indicated by a single chime and
the safety belt warning indicator flashing five times, at 2 Hz. The belt minder function can
also be enabled and disabled using IDS.
SECOND ROW SAFETY BELTS

The retractor of each second row safety belt is attached to the rear shelf immediately behind
the seat. The retractors are located in the center of the shelf. The webbing runs from the
retractor, to an anchor point in the center of the vehicle either side of the transmission tunnel.
The seat belt buckles are attached to the vehicle body on the outer side of the seat.
Safety Belt System

For a detailed description of the safety belt system, refer to the relevant Description and
Safety Belt System

1 . Verify the customer concern by operating the safety belt.
• Loose webbing
• Damaged/frayed webbing • Warning indicator bulb
• Safety belt retractor
3 . If the fault is not visually evident determine the symptom(s) and proceed to the Symptom
Chart.
Symptom Chart
• Broken tooth on
Normal Mode - Occupant retractor sensor gear. REFER to the Component
Restraint System inoperative • Loose webbing. Tests in this section.
• Broken tooth on
Automatic Locking Retraction retractor sensor gear. REFER to the Component
System (ALR) Inoperative. • Loose webbing. Tests in this section.
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 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 will 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. Where 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 will 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 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.
• 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 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 could and 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.
Front Safety Belt Buckle (76.73.49)

Removal


5 . Remove the front seat safety belt pretensioner.

Installation
1 . Install the front seat safety belt pretensioner.


Rear Safety Belt Buckle (76.73.50)
Removal
1 . Remove the rear seat cushion.
2 . Remove the rear safety belt stalk trim panel.

3 . Remove the rear safety belt stalk.

Installation
1 . Install the safety belt stalk.
2 . Install the rear safety belt stalk trim panel.

3 . Install the rear seat cushion.
Rear Safety Belt Retractor - 2-Door
(76.73.18)
Removal
1 . Remove the parcel tray.
2 . Release the safety belt.

Remove and discard the safety belt lower anchor nut.
3 . Remove the safety belt assembly.

Installation
1 . Install the safety belt assembly.
2 Secure the safety belt.

. Attach the safety belt lower anchor, install a new nut and tighten to
30 Nm (22 lb.ft).
3 . Install the parcel tray.

Front Safety Belt Retractor (76.73.10)
Removal

3 . Remove the safety belt retractor assembly.

Installation
1 . Install the safety belt retractor assembly.

Rear Safety Belt Retractor - Convertible
(76.73.18)
Removal
1 . NOTE:
Support the convertible top lid.

Depress the switch.

3 . Release the rear seat backrest trim panel.

Remove the 2 clips.
Remove the 2 bolts.
Position the rear seat backrest trim panel aside.
4 . Remove the rear safety belt trim panel.

Remove the 2 nuts.
5 . Release the safety belt.

Remove and discard the safety belt lower anchor nut.
6 . Remove the safety belt assembly.
Release the safety belt.
Installation
1 . Install the safety belt assembly.
Position the safety belt through the rear seat backrest trim panel.
2 Secure the safety belt.

. Attach the safety belt lower anchor, install a new nut and tighten to
30 Nm (22 lb.ft).
3 . Install the rear safety belt trim panel.
4 . Install the rear seat backrest trim panel.

Install the clips.

6 . Close the the convertible top.

Depress the switch.
501-20B : Supplementary Restraint System
Specifications
Specifications
Item Nm lb-ft lb-in

Airbag crash sensor to B-post - bolt 8 - 71
Airbag crash sensor to radiator support - bolt 8 - 71
Child upper anchorage (coupe) - bolt 25 18 -
Roll-over protection unit to back seat panel - bolt 25 18 -
Restraints control module - nut 8 - 71
General procedures
Air Bag Disposal

Deployed Air Bag
1.
WARNING: Always wear safety glasses when repairing an air bag supplemental
restraint system (SRS) vehicle and when handling an air bag module. Failure to follow
Deployed air bag modules are to be disposed of as special waste and must comply with local
environmental requirements, if in doubt, contact Authority for disposal requirements.
2. NOTE:
The storage, transportation, disposal, and/or recycling of air bag module components
must be carried out in accordance with all applicable federal, state and local regulations
including, but not limited to, those governing building and fire codes, environmental
protection, occupational health and safety, and transportation.
Modules removed and deployed by Jaguar service are to be returned to the importer for
disposal.
Undeployed Air Bag — Inoperative

1.
WARNING: Carry a live air bag module with the air bag and trim cover or
deployment door pointed away from your body. This will reduce the risk of injury in the
event of an accidental deployment. Failure to follow this instruction may result in
personal injury.
WARNING: All inoperative air bag modules have been placed on the Mandatory
Return List. All discolored or damaged air bag modules must be treated the same as any
inoperative live air bag being returned. Failure to follow this instruction may result in
personal injury.
Remove the inoperative driver air bag module or passenger air bag module. For additional
information see or in this section.
Undeployed Air Bag — Scrapped Vehicle
1.
WARNING: Always wear safety glasses when repairing an air bag supplemental
restraint system (SRS) vehicle and when handling an air bag module. Failure to follow
WARNING: Carry a live air bag module with the air bag and trim cover or
deployment door pointed away from your body. This will reduce the risk of injury in the
event of an accidental deployment. Failure to follow this instruction may result in
personal injury.
WARNING: Remote deployment is to be carried out outdoors with all personnel

at least 6.1 meters (20 feet) away to ensure personal safety. Due to the loud report which
occurs when the air bag is deployed, hearing protection is required. Failure to follow
WARNING: Do not place the driver or passenger air bag module with the trim
cover or deployment door facing down, as the forces of the deploying air bag can cause
it to ricochet and cause personal injury. Failure to follow this instruction may result in
personal injury.
Equipment required: Universal deployment tool-Part N° 418-S135 and 12V Battery.
2. The deployment procedure should be carried out outdoors away from other personnel.
3. Remove any loose debris from around air bag. Make sure that no flammable liquids are
present.
4. Disconnect the battery ground and positive cables.
5. Disconnect the relevant air bag module electrical connector.
6. Connect the appropriate adaptor lead to the restraint device.

7. Connect the deployment lead to the adaptor lead. Pass wire of the deployment tool through
window, close all doors, leave window with lead for deployment tool open.
8.
WARNING: Before proceeding, make sure precautions have been taken to warn
personnel of a possible loud noise upon activation. Do not allow anybody to approach
closer to restraint device than six meters. Failure to follow this instruction may result in
personal injury.
Move as far from restraint device as possible and connect the tool clips to a 12V vehicle
battery.
9.
WARNING: Do not handle the deployed device immediately after activation - it

may be hot. Allow the unit to cool for at least 20 minutes. Cooling modules should be
continuously monitored to make sure heat does not create a fire with spilled liquids or
other debris. Failure to follow this instruction may result in personal injury.
Deploy the module by depressing both switches on the tool. If activation does not occur,
disconnect battery from tool and seek advise from Jaguar Engineering and wait for further
instructions.
10. Repeat procedure for all air bags in vehicle.
11. The vehicle is now to be scrapped in the normal manner with modules installed.
Disposal of live air bag modules for driver

air bag module, passenger air bag module
and side air bag module, using tyres
1. Equipment required: Deployment tool 418-S135, Battery (12V), Safety goggles to BS2092
grade 2, Rubber gloves to PrEN 374 class 2, Ear protectors that have been measured to BS.EN
24869, Particulate respirator to EN 149 grade FFP2S.
2. The deployment procedure should be carried out outdoors, away from other personnel.
3. Stack four scrap tyres, securing together with heavy gauge wire or cable. While
disconnected from any electrical power source, connect deployment harness and place air bag
adaptor portion under tyre stack, ready for connection to air bag.
4.
WARNING: Power must not be connected during this step. Failure to follow this
CAUTION: Make sure the connector is not in contact with the inflator or it will
be damaged during the test.
Connect air bag to air bag connector, make sure the locking sleeve is fully engaged. Position
the air bag with the cover facing upwards.
5. Make sure battery connections of deployment harness are ten meters away from the tyre
stack
6. Remove any loose parts from around the air bag. Make sure that no flammable liquids are
present.
7.
personal injury.
battery.
8.

instructions.
9. Allow the air bag to cool for at least 20 minutes. Cooling modules should be continuously
monitored to make sure heat does not generate a fire with spilled liquids or other debris.
10. Remove the air bag from the tyre stack and seal in a plastic bag, ready for disposal.
11. In the event of any problems or queries arising from this procedure, contact Jaguar
Engineering.
Disposal of side curtain air bag module

using tyres
1. Equipment required: Deployment tool 418-S135, Battery (12V), Safety goggles to BS2092
grade 2, Rubber gloves to PrEN 374 class 2, Ear protectors that have been measured to BS.EN
24869, Particulate respirator to EN 149 grade FFP2S.
2. The deployment procedure should be carried out outdoors, away from other personnel.
3.
WARNING: Make sure that the tyre stack is stable before and after deployment.
Failure to follow this instruction my result in personal injury.
Stack scrap tyres of a sufficient height to mask the side curtain air bag module, securing
together with heavy gauge wire or cable. While disconnected from any electrical power
source, connect deployment harness and place air bag adaptor portion under tyre stack, ready
for connection to air bag.
4.
WARNING: Power must not be connected during this step. Failure to follow this
CAUTION: Make sure the connector is not in contact with the inflator or it will
be damaged during the test.
Connect air bag to air bag connector, make sure the locking sleeve is fully engaged. Position
the air bag into the tyres with the inflator canister at the lowest point.
5. Make sure battery connections of deployment harness are ten meters away from the tyre
stack
6. Remove any loose parts from around the air bag. Make sure that no flammable liquids are
present.
7.
personal injury.
battery.
8.

instructions.
9. Allow the air bag to cool for at least 20 minutes. Cooling modules should be continuously
monitored to make sure heat does not generate a fire with spilled liquids or other debris.
10. Remove the air bag from the tyre stack and seal in a plastic bag, ready for disposal.
11. In the event of any problems or queries arising from this procedure, contact Jaguar
Engineering.
Air Bag Supplemental Restraint System

(SRS)
COMPONENT LOCATION - SHEET 1 OF 3

1 Passenger air bag
3 Drivers air bag
4 Clock spring
5 RCM

1 RH side air bag
2 Crash sensor
3 RH safety belt pre-tensioner
4 LH safety belt pre-tensioner
5 Crash sensor
6 LH side air bag
7 Seat occupancy/occupant classification sensor
8 Passenger seat position sensor (where fitted)
9 Seat occupancy classification system control module
10 Driver seat position sensor
11 Crash sensor
12 Crash sensor
13 Safety belt tension sensor

1 RH side air bag
2 Crash sensor
3 RH safety belt pre-tensioner
4 LH safety belt pre-tensioner
5 Roll over protection system hoop (convertible only)
6 Roll over protection system hoop (convertible only)
7 Crash sensor
8 LH side air bag
9 Seat occupancy/occupant classification sensor
10 Passenger seat position sensor (where fitted)
11 Seat occupancy control module
12 Driver seat position sensor
13 Crash sensor
14 Crash sensor
INTRODUCTION
WARNING: All pyrotechnic devices are dangerous. Before performing any

procedures on any pyrotechnic device, read all information contained within the
Standard Workshop Practices section of this manual. For additional information, refer
to Standard Workshop Practices (100-00)
The SRS (supplemental restraint system) provides additional protection for occupants in
certain vehicle accident conditions.
The SRS (supplemental restraint system) comprises the following sub-systems:
• Driver and passenger front air bag system.

• Roll over protection system (convertible only).
• Driver and passenger side air bag system.
• Safety belt pretension system.
• Passenger occupancy detection system
• Passenger occupancy classification system
The SRS (supplemental restraint system) features selective activation of the air bags and
safety belt pre-tensioners, and two stage driver and passenger air bags. The RCM (restraints
control module) monitors internal and external sensors and activates the required safety belt
pre-tensioners, air bags and roll-over protection hoops (convertible only) if the sensors detect
an impact or roll-over above preset limits.
The Roll-over Protection System comprises two spring loaded hoops located behind the rear
seat. The hoops incorporate a pin to break the rear screen glass as the hoop is released. The
hoops are released by a pyrotechnic device when the RCM (restraints control module) detects
a roll-over condition.
RESTRAINTS CONTROL MODULE
The RCM (restraints control module) is 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 (restraints control module) 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 (restraints control module) determines which elements of the SRS are to be
deployed by using two internal areas:
Crash severity evaluation

This area evaluates crash severity by using data from the RCM (restraints control module)
internal accelerometer, the front crash sensor and the safety belt buckle sensor. Based on this
data, the RCM (restraints control module) decides which level of air bag module deployment
is required and forwards the information to the second area, the deployment handler.
Deployment handler
The status of the seat track position sensor(s) and safety belt buckle sensors are examined
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 (restraints control module) internal accelerometer to make a deployment
decision. The RCM (restraints control module) 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 (restraints control module) together with the storing of fault
codes.
The RCM (restraints control module) drives the SRS (supplemental restraint system) indicator
on the instrument pack via a CAN (controller area network) 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 (restraints control module) 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 (restraints control module) 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 (restraints control module) performs a self test and
then performs cyclical monitoring of the system. If a fault is detected the RCM (restraints
control module) stores a related fault code and illuminates the air bag warning indicator. The
faults can be retrieved by IDS (Integrated Diagnostic System) over the CAN (controller area
network) bus. If a fault that could cause a false fire signal is detected, the 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 AIR BAG MODULE
The driver air bag module is controlled by the RCM (restraints control module) 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 AIR BAG MODULE

1 Passenger air bag module cover
2 Passenger air bag module retainer
3 Passenger air bag module container
4 Passenger air bag module inflator
The passenger air bag module is controlled by the RCM (restraints control module) 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.
SIDE AIR BAG MODULE

1 Side air bag
2 Seat frame
3 Side air bag electrical connector
The side air bag module is mounted in the outboard bolster of each front seat and uses
compressed gas to inflate. It provides protection for the thorax (the part of the trunk between
the neck and the abdomen) and the head. In an air bag deployment situation, it deploys
through the stitch seam in the side bolster. To ensure the air bag always emerges at the same
point, a chute is attached to the inside of the trim cover and wrapped around the air bag
module.
IMPACT SENSORS
Two front impact sensors are attached to the body behind the radiator grille. The RCM
(restraints control module) processes the crash data sent by the crash sensor against stored
data, and deploys the front air bags and pretensioners.
Two side impact sensors are mounted at the base of the B-pillars to facilitate lateral impact
sensing. In the event of a side impact, the RCM (restraints control module) processes the
crash data against the stored data. The RCM (restraints control module) will deploy the side
air bag module on the side the deployment request was initiated.
SEAT POSITION SENSOR(S)

1 Seat position sensor
2 Seat rail
3 Floor runner
4 Seat position trigger
A seat position sensor is installed on the driver seat and, up to VIN (vehicle identification
number) B03409, some front passenger seats. The seat position sensor allows the RCM
(restraints control module) to detect when the seat is forward of a given point on the seat
track. The seat position sensor consists of a Hall effect sensor attached to the seat frame and a
target plate on the seat base. While the ignition is on, the RCM (restraints control module)
supplies the sensor with a power supply of 12V nominal, and monitors the return voltage.
When the seat frame moves forwards, the sensor moves over the target plate, which changes
the reluctance of the sensor. The change of voltage is detected by the RCM (restraints control
module) 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 target plate.
When a seat is forward of the switching point, the RCM (restraints control module) increases
the time delay between firing the two stages of the inflator in the driver or passenger air bag,
as applicable. When the seat is rearward of the switching point, the RCM (restraints control
module) uses the normal time delay between firing the two stages.
SAFETY BELT SENSOR
The buckle of each front safety belt incorporates a Hall effect sensor that provides a safety
belt status signal to the RCM (restraints control module) . The RCM (restraints control
module) broadcasts the status of the two front safety belts on the high speed CAN (controller
area network) bus for use by the instrument cluster. In the event of a front impact the RCM
(restraints control module) will deploy the pretensioners provided the safety belt buckles are
fastened. The safety belt buckle pretensioners have a lower deployment threshold than that
required by the air bags. Hence it is possible during a minor collision, which exceeds the
deployment threshold, that only the safety belt buckle pretensioners will deploy. For
additional information, refer to Safety Belt System (501-20 Safety Belt System)
PRETENSIONERS

2 Pyrotechnic pretensioner
3 Safety belt buckle
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.
Each pretensioner has a tube containing an inflator and a piston. The inflator is connected to
the RCM (restraints control module) . The piston is attached to a steel cable, the opposite end
of which is attached to the safety belt buckle.
On receipt of a fire signal from the RCM (restraints control module) , the inflator generates
nitrogen gas that rapidly expands to drive the piston along the tube, pulling the cable and
drawing the safety belt buckle downwards.
AIR BAG WARNING INDICATOR
The air bag warning indicator consists of a amber LED (light emitting diode) behind a graphic
in the tachometer of the instrument cluster.
Operation of the air bag warning indicator is controlled by a high speed CAN (controller area
network) bus message from the RCM (restraints control module) to the instrument cluster.
The RCM (restraints control module) illuminates the air bag warning indicator if a fault is
detected, and for approximately 6 seconds during the indicator 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 (restraints
control module) with the occupancy status of the front passenger seat. The RCM (restraints
control module) uses this and the seat buckle status in the evaluation of the firing strategy for
the passenger front air bag, side air bag, and pretensioner.
SAFETY BELT SWITCHES

A safety belt switch is installed in the buckle of each front safety belt to provide the RCM
(restraints control module) with status signals of the related safety belts. When a safety belt is
unfastened the switch outputs a low current to the RCM (restraints control module) . When
the safety belt is fastened the switch outputs a high current to the RCM (restraints control
module) .
OCCUPANT DETECTION SYSTEM

1 Seat occupancy sensor pad
2 Harness connector
3 Control module
The occupant detection system can only determine if the front passenger seat is occupied or
unoccupied. The occupant detection system consists of a captive sensor mat installed between
the foam padding and the cover of the front passenger seat cushion and a control module.
The mat's output is fed to the control module which gives either empty or occupied state
signal to the instrument cluster. The instrument cluster illuminates the safety belt minder lamp
when it detects that the seat is occupied and the safety belt is not engaged.
OCCUPANT CLASSIFICATION SYSTEM

1 Belt tension sensor
2 Pressure pad
3 Occupant classification system control module
The occupant classification system can determine if the front passenger seat is unoccupied,
occupied by a small person, or occupied by a large person. The occupant classification system
consists of:
• A pressure pad, installed under the cushion of the front passenger seat, which is
connected to a pressure sensor
• A safety belt tension sensor, integrated into the anchor point of the front passenger
safety belt
• An occupant classification module, installed under the front passenger seat.
The pressure pad is a silicone filled bladder. Any load on the pressure pad is detected by the
pressure sensor.
The safety belt tension sensor is a strain gauge that measures the load applied by the safety
belt anchor to the anchor bolt. The sensor is located in the lower safety belt anchor point.
Safety Belt Tension Sensor

The occupant classification module supplies a reference voltage to the pressure sensor and the
safety belt tension sensor and, from the returned signals, measures the loads acting on the
pressure pad and the safety belt tension sensor. The load measurement from the safety belt
tension sensor is used to produce a correction factor for the load measurement from the
pressure pad. The tightness of the safety belt affects the load acting on the pressure pad, so
without the correction factor the occupant classification module cannot derive an accurate
occupancy status.
The occupant classification module translates the load readings into a seat occupancy status
and transmits the result to the RCM (restraints control module) , on a dedicated high speed
CAN (controller area network) bus link. The occupant classification module incorporates two
load limits for the seat cushion: When the load exceeds the lower limit, but is less than the
upper limit, the occupant is classified as small; when the upper limit is exceeded, the occupant
is classified as large.
The occupant classification system has 4 possible states which are detailed in the following
table.
Air Bag
Classification Seat Status Passenger Air Bag Status Indicator
Status
Empty Empty Disabled Off
Occupied The seat is occupied by a small Passenger air bag/Thorax On
inhibit person or child restraint is air bag operation is
being used disabled
Occupied The seat is occupied by a large Passenger air bag/Thorax Off
allow person air bag operation is enabled
Error - Passenger air bag/Thorax On
air bag operation is
disabled
ROLL OVER PROTECTION SYSTEM

The roll over protection system fitted to the convertible vehicle comprises two roll over
protection hoops located behind the rear seat. The roll over protection system is controlled by
the RCM (restraints control module) . The RCM (restraints control module) has an internal
roll over sensor which triggers the pyrotechnic latches that hold the roll over protection hoops
in place.
Roll Over Protection Hoops

NOTE:
A= Deployed, B= Normal state

1 Hoop retaining latch-deployed
2 Hoop retaining latch
3 Roll over protection hoop-deployed
4 roll over protection hoop
5 Roll over protection hoop latch pin
6 Roll over protection hoop latch
The roll over protection system hoops are located behind the rear seat underneath the tonneau
cover. The tonneau cover has two hatches set into it to allow the hoops to break through once
triggered. The hoops are spring loaded and held in place by a pyrotechnic latch. The latch is
fired in response to a trigger from the RCM (restraints control module) . Once fired the latch
opens and the hoops are released. As the hoops move upwards a ratchet in the body of the
hoops locks into place and prevents the hoops from being forced back down by the weight of
the vehicle. Once deployed the hoops cannot be re-set and should be replaced with new
components.
The hoops have a small pin mounted on top which breaks the rear screen if the convertible top
is up. This allows clear passage for the roll over protection hoops to operate.
CONTROL DIAGRAM
NOTE:
A = Hardwired connection: D = High speed CAN (controller area network)

1 Front crash sensor
2 Drivers air bag
3 Passenger air bag
4 Front crash sensor
5 ECM
7 Side crash sensor
8 Thorax air bag
9 Roll over protection hoop
10 Safety belt buckle switch
11 Safety belt pre-tensioner
12 Seat position sensor(s)
13 Safety belt pre-tensioner
14 Safety belt buckle switch
15 Roll over protection hoop
16 Thorax air bag
17 Driver safety belt tension sensor
18 OCS control module
19 OCS sensor
21 Side crash sensor
22 Clock spring
23 RCM
In a collision, the sudden deceleration or acceleration is measured by the safing sensor in the
RCM (restraints control module) and by the impact sensors. The RCM (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 or
pretensioners. During a collision, the RCM (restraints control module) only fires the air bags
and pretensioners if the safing sensor confirms that the data from the remote sensor(s)
indicates an impact limit has been exceeded. The RCM (restraints control module) also
monitors the vehicle for a roll-over accident using the internal roll-over sensor.
The RCM (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 2, belt unfastened.
• Front impact, driver and passenger air bags stage 1, belt fastened.
• Front impact, driver and passenger air bags stage 2, belt fastened.
• Rear impact.
• LH (left-hand) side impact.
• RH (right-hand) side impact.
• Roll-over.
The front impact thresholds increase in severity from pretensioners, through to driver and
passenger air bag stage 2, belt fastened.
Firing Strategies
The safety belt pretensioners are fired when either the pretensioner impact limit or the roll-
over limit is exceeded. The RCM (restraints control module) only fires the pretensioners if the
related safety belt is fastened. For the front passenger pretensioner to fire, the seat must also
be occupied by a person.
The driver and passenger air bags are only fired in a frontal impact that exceeds the stage 1
threshold. Both stages of the inflator in the driver and passenger air bags are fired. At impacts
between the stage 1 and 2 thresholds, the delay between the firing of the two stages varies
with the severity of the impact; the more severe the impact the shorter the delay. At stage 2
impact thresholds and above, the two stages of the inflator are fired almost simultaneously.
The time delay between firing the two stages of the inflator is increased if the related seat is
forward of the seat position sensor switching point.
If a side impact limit is exceeded, the RCM (restraints control module) fires the side air bag
on that side of the vehicle.
If multiple impacts occur during a crash event, after responding to the primary impact the
RCM (restraints control module) will output the appropriate fire signals in response to any
further impacts.
Crash Signal
When the RCM (restraints control module) outputs any of the fire signals, it also outputs a
hard wired crash signal to the ECM (engine control module) and changes the high speed CAN
(controller area network) bus output message from 'no crash' to 'crash condition'. The high
speed CAN (controller area network) bus message is used by the CJB (central junction box) .
On receipt of the crash signals:
• The ECM (engine control module) disables the fuel pump.

• The auxiliary junction box enters the crash mode and: Activates all of the unlock
signals of the vehicle locking system, even if the vehicle is already unlocked,
repeatedly for 3 seconds, in case a lock button is pressed during the crash. Ignores all
locking and superlocking inputs until the crash mode is cancelled, when it returns the
locking system to normal operation. Activates all of the courtesy lamps, except for the
approach lamps. The activated courtesy lamps remain on until crash mode is
cancelled, when they return to normal operation. Activates the hazard warning lamps.
The hazard warning lamps remain on until crash mode is cancelled.
The crash mode is cancelled by cycling the ignition mode.

Air Bag Supplemental Restraint System

(SRS)
For a detailed description of the supplemental restraint system, refer to the relevant
WARNING: TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE

PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED
BEFORE REPAIRING OR REPLACING ANY AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) COMPONENTS. TO DEPLETE THE BACKUP
POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE
AND WAIT ONE MINUTE. FAILURE TO FOLLOW THIS INSTRUCTION MAY
RESULT IN PERSONAL INJURY.
NOTE:
Given the legal implications of a restraints system failure, harness repairs to Air Bag
module circuits are not acceptable. Where the text refers to "REPAIR the circuit", this
will normally mean the replacement of a harness.
Electrical
• Battery condition, state of charge
• Make sure all electrical connector(s) are engaged correctly on the air bag circuits
• Wiring harness
• Air bag module(s)
• Make sure the restraints control module (RCM) is correctly installed
• Fuse(s)
• Sensor(s)
• Pretensioner(s)
• Warning lamp bulb(s)
to the DTC Index.
Given the complexity of the system and the potential for damage/injury, the preferred method
of diagnosis is via the Manufacturer approved diagnostic system.
If the Manufacturer approved diagnostic system is not available, use a scan tool to extract
DTCs and refer to the DTC Index.
DTC Index

NOTE:
NOTE:
NOTE:
NOTE:
tests.
NOTE:
NOTE:
terminals.

B000111 Driver Frontal Stage 1 • Driver front stage 1 air bag Refer to electrical
Deployment Control circuit - short to ground circuit diagrams and
test driver front stage
1 air bag circuit for
short to ground
Refer to electrical
• Driver front stage 1 air bag circuit diagrams and
Driver Frontal Stage 1
B000112 circuit - short to power test driver front stage
Deployment Control
short to power
Carry out the pinpoint
• Circuit resistance below
Driver Frontal Stage 1 this DTC using the
B00011A threshold
Deployment Control manufacturer
approved diagnostic
system
• Circuit resistance above
B00011B threshold
approved diagnostic
system
Re-configure the
RCM using the
Driver Frontal Stage 1 • Signal plausibility failure
B000164 manufacturer
Deployment Control
approved diagnostic
system
B000211 circuit - short to ground test driver front stage
Deployment Control
short to ground
B000212 circuit - short to power test driver front stage
Deployment Control
short to power
B00021A threshold
approved diagnostic
system
• Circuit resistance above tests associated with
B00021B threshold this DTC using the
Deployment Control
manufacturer
approved diagnostic
system
Re-configure the
RCM using the
Driver Frontal Stage 2 • Signal plausibility failure
Deployment Control
approved diagnostic
system
• Passenger front stage 1 air
Passenger Frontal circuit diagrams and
bag circuit - short to
B001011 Stage 1 Deployment test passenger front
ground
Control stage 1 air bag circuit
for short to ground
Passenger Frontal • Passenger front stage 1 air circuit diagrams and
B001012 Stage 1 Deployment bag circuit - short to power test passenger front
for short to power
Passenger Frontal • Circuit resistance below
this DTC using the
B00101A Stage 1 Deployment threshold
manufacturer
Control
approved diagnostic
system
Passenger Frontal • Circuit resistance above
this DTC using the
B00101B Stage 1 Deployment threshold
manufacturer
Control
approved diagnostic
system
Re-configure the
Passenger Frontal RCM using the
• Signal plausibility failure
B001064 Stage 1 Deployment manufacturer
Control approved diagnostic
system
• Passenger front stage 2 air
Passenger Frontal circuit diagrams and
bag circuit - short to
B001111 Stage 2 Deployment test passenger front
ground
for short to ground
Passenger Frontal • Passenger front stage 2 air circuit diagrams and
B001112 Stage 2 Deployment bag circuit - short to power test passenger front
for short to power
Passenger Frontal • Circuit resistance below
B00111A Stage 2 Deployment threshold
this DTC using the
Control
manufacturer
approved diagnostic
system
Passenger Frontal • Circuit resistance above
this DTC using the
B00111B Stage 2 Deployment threshold
manufacturer
Control
approved diagnostic
system
Re-configure the
Passenger Frontal RCM using the
B001164 Stage 2 Deployment manufacturer
Control approved diagnostic
system
• Left side air bag circuit - circuit diagrams and
Left Side Air Bag
B002011 short to ground test left side air bag
Deployment Control
ground
• Left side air bag circuit - circuit diagrams and
Left Side Air Bag
B002012 short to power test left side air bag
Deployment Control
power
Left Side Air Bag this DTC using the
B00201A threshold
approved diagnostic
system
Left Side Air Bag this DTC using the
B00201B threshold
approved diagnostic
system
Re-configure the
RCM using the
Left Side Air Bag • Signal plausibility failure
Deployment Control
approved diagnostic
system
• Right side air bag circuit - circuit diagrams and
Right Side Air Bag
B002811 short to ground test right side air bag
Deployment Control
ground
Right Side Air Bag Refer to the electrical
B002812 • Right side air bag circuit -
Deployment Control circuit diagrams and
short to power test right side air bag
power
Right Side Air Bag this DTC using the
B00281A threshold
approved diagnostic
system
Right Side Air Bag this DTC using the
B00281B threshold
approved diagnostic
system
Re-configure the
RCM using the
Right Side Air Bag • Signal plausibility failure
Deployment Control
approved diagnostic
system
• Driver safety belt sensor circuit diagrams and
Driver Safety Belt
B005011 circuit - short to ground test driver safety belt
Sensor
sensor circuit for
short to ground
• Driver safety belt sensor circuit diagrams and
Driver Safety Belt circuit - short to power or test driver safety belt
B005015
Sensor open circuit sensor circuit for
short to power or
open circuit
Driver Safety Belt • Circuit current out of range this DTC using the
B00501D
Sensor manufacturer
approved diagnostic
system
Re-configure the
RCM using the
Driver Safety Belt • Signal plausibility failure
Sensor
approved diagnostic
system
• Passenger safety belt
Passenger Safety Belt sensor circuit - short to
B005211 test passenger safety
Sensor ground
belt sensor circuit for
short to ground
• Passenger safety belt circuit diagrams and
Passenger Safety Belt sensor circuit - short to test passenger safety
B005215
Sensor power or open circuit belt sensor circuit for
short to power or
open circuit
Passenger Safety Belt • Circuit current out of range this DTC using the
B00521D
Sensor manufacturer
approved diagnostic
system
Re-configure the
RCM using the
Passenger Safety Belt • Signal plausibility failure
Sensor
approved diagnostic
system
• Driver safety belt
Driver Safety Belt circuit diagrams and
pretensioner circuit - short
B007011 Pretensioner test driver safety belt
to ground
Deployment Control pretensioner circuit
for short to ground
• Driver safety belt
Driver Safety Belt circuit diagrams and
B007012 Pretensioner test driver safety belt
to power
Deployment Control pretensioner circuit
for short to ground
Driver Safety Belt • Circuit resistance below
this DTC using the
B00701A Pretensioner threshold
manufacturer
Deployment Control
approved diagnostic
system
Driver Safety Belt • Circuit resistance above
this DTC using the
B00701B Pretensioner threshold
manufacturer
Deployment Control
approved diagnostic
system
Re-configure the
Driver Safety Belt RCM using the
B007064 Pretensioner manufacturer
Deployment Control approved diagnostic
system
Passenger Safety Belt Refer to the electrical
• Passenger safety belt
B007211 Pretensioner circuit diagrams and
Deployment Control test passenger safety
to ground belt pretensioner
ground
• Passenger safety belt circuit diagrams and
Passenger Safety Belt
pretensioner circuit - short test passenger safety
B007212 Pretensioner
to power belt pretensioner
Deployment Control
power
Passenger Safety Belt • Circuit resistance below
this DTC using the
B00721A Pretensioner threshold
manufacturer
Deployment Control
approved diagnostic
system
Passenger Safety Belt • Circuit resistance above
this DTC using the
B00721B Pretensioner threshold
manufacturer
Deployment Control
approved diagnostic
system
Re-configure the
Passenger Safety Belt RCM using the
B007264 Pretensioner manufacturer
system
Left Front Impact • Left front impact sensor circuit diagrams and
B009011 Sensor circuit - short to ground test left front impact
Communications Line sensor circuit for
short to ground
Left Front Impact • Left front impact sensor circuit diagrams and
B009012 Sensor circuit - short to power test left front impact
short to power
Re-configure the
RCM using the
Left Front Impact • Signal plausibility failure
Sensor
approved diagnostic
system
• Left side impact sensor circuit diagrams and
Left Front Impact
circuit - open circuit test left front impact
B009081 Sensor
• Sensor fault sensor circuit for open
Communications Line
circuit fault. Install a
new sensor as
necessary.
Front Impact Severity
Sensor
Install a new front
• Performance or incorrect
Left Front Impact impact sensor.
B009092 operation
Sensor Front Impact Severity
Sensor
Left Front Impact • Component internal failure this DTC using the
B009096
Sensor manufacturer
approved diagnostic
system
Left Side Impact • Left side impact sensor circuit diagrams and
B009211 Sensor circuit - short to ground test left side impact
short to ground
Left Side Impact • Left side impact sensor circuit diagrams and
B009212 Sensor circuit - short to power test left side impact
short to power
Re-configure the
RCM using the
Left Side Impact • Signal plausibility failure
Sensor
approved diagnostic
system
test left side impact
sensor circuit for open
• Left side impact sensor circuit fault. Install a
Left Side Impact
circuit - open circuit new sensor as
B009281 Sensor
• Sensor fault necessary.
Communications Line
Side Impact Sensor -
Convertible
(76.73.53)
2-Door (76.73.53)
Install a new side
impact sensor.
• Performance or incorrect Side Impact Sensor -
Left Side Impact
B009292 operation Convertible
Sensor
(76.73.53)
2-Door (76.73.53)
Left Side Impact • Component internal failure this DTC using the
B009296
Sensor manufacturer
approved diagnostic
system
Right Front Impact • Right front impact sensor circuit diagrams and
B009511 Sensor circuit - short to ground test right front impact
short to ground
Right Front Impact • Right front impact sensor circuit diagrams and
B009512 Sensor circuit - short to power test right front impact
short to power
Re-configure the
RCM using the
Right Front Impact • Signal plausibility failure
Sensor
approved diagnostic
system
test left front impact
• Left side impact sensor
Right Front Impact sensor circuit for open
circuit - open circuit
B009581 Sensor circuit fault. Install a
• Sensor fault
Communications Line new sensor as
necessary.
Front Impact Severity
Sensor
Install a new front
Right Front Impact impact sensor.
B009592 operation
Sensor Front Impact Severity
Sensor
Right Front Impact • Component internal failure this DTC using the
B009596
Sensor manufacturer
approved diagnostic
system
Right Side Impact • Right side impact sensor circuit diagrams and
B009711 Sensor circuit - short to ground test right side impact
short to ground
Right Side Impact Refer to the electrical
B009712 • Right side impact sensor
Sensor circuit diagrams and
Communications Line circuit - short to power test right side impact
sensor circuit for
short to power
Re-configure the
RCM using the
Right Side Impact • Signal plausibility failure
Sensor
approved diagnostic
system
Install a new side
impact sensor.
Right Side Impact • Performance or incorrect Side Impact Sensor -
B009781 Sensor operation Convertible
Communications Line (76.73.53)
2-Door (76.73.53)
Install a new side
impact sensor.
• Performance or incorrect Side Impact Sensor -
Right Side Impact
B009792 operation Convertible
Sensor
(76.73.53)
2-Door (76.73.53)
Right Side Impact • Component internal failure this DTC using the
B009796
Sensor manufacturer
approved diagnostic
system
Occupant • Internal module failure Install a new OCS
B00A049
Classification System module
Occupant • Missing calibration Install a new OCS
B00A054
Re-configure the
• Component is fitted but not
RCM using the
Occupant configured in equipment
B00A064 manufacturer
Classification System set
approved diagnostic
system
Occupant • Invalid serial data received Install a new OCS
B00A081
Refer to electrical
check seat harness for
Occupant • Bus 'OFF' open circuit or backed
B00A088
Classification System out connector. Carry
out CAN network
integrity tests using
the manufacturer
approved diagnostic
system
Occupant Install a new OCS
B00A092 operation
Occupant • Incorrect assembly Install the correct

B00A095
Classification System assembly
Refer to electrical
Occupant • Component internal failure check seat harness for
B00A096
Classification System open circuit or backed
out connector. Install
a new OCS module
Driver Seat Track • Driver seat position sensor circuit diagrams and
B00B511 Position Restraints circuit - short to ground test driver seat
Sensor position sensor circuit
for short to ground
• Driver seat position sensor circuit diagrams and
Driver Seat Track
circuit - short to power or test driver seat
B00B515 Position Restraints
open circuit position sensor circuit
Sensor
for short to power or
open circuit
Driver Seat Track
• Circuit current out of range this DTC using the
B00B51D Position Restraints
manufacturer
Sensor
approved diagnostic
system
Re-configure the
Driver Seat Track RCM using the
B00B564 Position Restraints manufacturer
Sensor approved diagnostic
system
Refer to electrical
Occupant Belt Tension • Component internal failure check safety belt
B00C096
Sensor tension sensor circuit
for open circuit or
backed out connector
• Passenger seat position
Passenger Seat Track circuit diagrams and
sensor circuit - short to
B00C511 Position Restraints test passenger seat
ground
Sensor position sensor circuit
for short to ground
B00C515 Passenger Seat Track • Passenger seat position Refer to the electrical
Position Restraints sensor circuit - short to circuit diagrams and
Sensor power or open circuit test passenger seat
position sensor circuit
for short to power or
open circuit
Passenger Seat Track
• Circuit current out of range this DTC using the
B00C51D Position Restraints
manufacturer
Sensor
approved diagnostic
system
Re-configure the
Passenger Seat Track RCM using the
B00C564 Position Restraints manufacturer
Sensor approved diagnostic
system
Passenger Air bag Cut Re-configure the
Off Switch and Seat RCM using the
• Not configured
B00DF55 Track Position Sensor manufacturer
equipped approved diagnostic
simultaneously system
• Restraint
Check CAN network
System
• Events information using manufacturer
B00D268 Malfunction
approved diagnostic
Indicator 1
system

Restraint System
• Missing message this DTC using the
B00D287 Malfunction Indicator
manufacturer
1
approved diagnostic
system
Refer to electrical
• Passenger Air bag De- circuit diagrams and
Restraint System
activation (PAD) lamp test Passenger Air bag
B00D511 Passenger Disable
circuit - short to ground De-activation (PAD)
Indicator
lamp circuit for short
to ground
Refer to electrical
• Passenger Air bag De- circuit diagrams and
Restraint System activation (PAD) lamp test Passenger Air bag
B00D515 Passenger Disable circuit - short to power, De-activation (PAD)
Indicator open circuit lamp circuit for short
to power or open
circuit
Refer to electrical
B1A0016 Supply voltage • Circuit voltage below
threshold test RCM ignition
supply circuit for
short to ground or
open circuit
Refer to electrical
• Circuit voltage above circuit diagrams and
B1A0017 Supply voltage threshold test RCM ignition
supply circuit for
short to power
Install a new RCM,
refer to the new
• Internal electronic failure
B1A0049 All internal faults module installation
note at top of the
DTC Index
Driver Stage 1 Air Bag circuit diagrams and
• Incorrect assembly
B1A1795 Squib Short Circuit To check pins are
Ignition Loop installed into correct
connector cavities
Driver Stage 2 Air Bag circuit diagrams and
connector cavities
Passenger Stage 1 Air
Bag Squib Short • Incorrect assembly
B1A2195 check pins are
Circuit To Ignition
installed into correct
Loop
connector cavities
Passenger Stage 2 Air
Bag Squib Short • Incorrect assembly
Circuit To Ignition
Loop
connector cavities
Driver Safety Belt
Pretensioner Squib • Incorrect assembly
Short Circuit To
Ignition Loop
connector cavities
Passenger Safety Belt
Pretensioner Squib • Incorrect assembly
Short Circuit To
Ignition Loop
connector cavities
Left Side Air Bag Refer to the electrical
B1A2995 Squib Short Circuit To circuit diagrams and
Ignition Loop check pins are
connector cavities
Right Side Air Bag circuit diagrams and
connector cavities
• Air bag deployed signal circuit diagrams and
Air Bag Deployed circuit - short to ground or test air bag deployed
B1A5514
Signal open circuit signal circuit for short
to ground or open
circuit
Re-configure the
RCM using the
Air Bag Deployed • Signal plausibility failure
B1A5564 manufacturer
Signal
approved diagnostic
system
• Left roll over protection circuit diagrams and
Left Roll Over
system circuit - short to test left roll over
B1D7611 Protection System
ground protection system
Deployment Control
circuit - short to
ground
• Left roll over protection circuit diagrams and
Left Roll Over
system circuit - short to test left roll over
power protection system
Deployment Control
circuit - short to
power
Left Roll Over • Circuit resistance below
this DTC using the
B1D761A Protection System threshold
manufacturer
Deployment Control
approved diagnostic
system
Left Roll Over • Circuit resistance above
this DTC using the
B1D761B Protection System threshold
manufacturer
Deployment Control
approved diagnostic
system
Re-configure the
Left Roll Over RCM using the
B1D7664 Protection System manufacturer
system
Left Roll Over circuit diagrams and
B1D7695 Protection System check pins are
Deployment Control installed into correct
connector cavities
• Right roll over protection circuit diagrams and
Right Roll Over
system circuit - short to test right roll over
ground protection system
Deployment Control
ground
• Right roll over protection circuit diagrams and
Right Roll Over
system circuit - short to test right roll over
power protection system
Deployment Control
power
Right Roll Over • Circuit resistance below
this DTC using the
B1D771A Protection System threshold
manufacturer
Deployment Control
approved diagnostic
system
Right Roll Over • Circuit resistance above
this DTC using the
B1D771B Protection System threshold
manufacturer
Deployment Control
approved diagnostic
system
Re-configure the
Right Roll Over RCM using the
B1D7764 Protection System manufacturer
system
Right Roll Over circuit diagrams and
B1D7795 Protection System check pins are
Deployment Control installed into correct
connector cavities
• Bus off this DTC using the
U000188 CAN Bus
manufacturer
approved diagnostic
system
Lost Communication • Missing message Carry out the pinpoint
U010000
With ECM tests associated with
this DTC using the
manufacturer
approved diagnostic
system
Lost Communication tests associated with
With Anti-Lock Brake • No subtype information this DTC using the
U012100
System (ABS) Control manufacturer
Module approved diagnostic
system
Lost Communication
• Missing message this DTC using the
U015587 With Instrument
manufacturer
Cluster
approved diagnostic
system
Re-configure the
RCM with the latest
Internal control module • Mis-match between vehicle
level software using
U030055 software and RCM software levels
the manufacturer
incompatibility
approved diagnostic
system
Install a new RCM,
Impact Telegrams • Signal has too many refer to the new
U1A0266 reached maximum of 3 transitions module installation
stored note at top of the
DTC Index
CAN Signal Car using the
• Missing message
U1A0387 Configuration manufacturer
Parameters HS approved diagnostic
system
Install a new RCM
module, refer to the
• Not configured
U1A1455 Volcano Initialisation new module
Re-configure the
RCM with the latest
Control Module Main • Not programmed level software using
U201A51
Calibration Data the manufacturer
approved diagnostic
system
Install correct RCM,
• Incorrect component
Control Module refer to the new
U201B4A installed
Calibration Data #2 module installation
note at the top of the
DTC Index
Re-configure the
RCM using the
manufacturer
approved diagnostic
system. Clear DTC
Control Module • Not programmed
U201B51 and re-test, if DTC
Calibration Data #2
RCM, refer to the
new module
Install correct RCM,
• Incorrect component refer to the new
Control Module
U201C4A installed module installation
Calibration Data #3
note at the top of the
DTC Index
Re-configure the
RCM using the
manufacturer
approved diagnostic
system. Clear DTC
Control Module • Not programmed
U201C51 and re-test, if DTC
Calibration Data #3
RCM, refer to the
new module
match. Corrupt VIN data Install original
Vehicle Identification being transmitted, module module, check for
U300281
Number (VIN) previously installed to DTCs and refer to
other vehicle relevant DTC Index
Front Impact Severity Sensor

Removal
NOTE:
The LH front impact severity sensor is illustrated, removal of the RH sensor is a similar
procedure.
1 . Open the hood.

3 . Remove the front impact severity sensor.

Remove the 2 bolts.
Installation
1 . Install the front impact severity sensor.

Driver Air Bag Module (76.73.39)
Driver air bag module remover

501-120
Removal

3 . Using the special tool remove the driver air bag module.
Rotate the steering wheel for access to slots.

Installation


Front Passenger Seat Occupant
Classification Sensor (76.73.60)
Removal
WARNING: The front passenger seat occupant classification sensor is available

only as a service kit. No attempt should be made to replace individual components.





7 . Release the pre-tensioner harness and disconnect the electrical connector.

8 . Release the seat module bracket.
Remove and discard the cable tie.
9 . Release the occupant classification module from the seat module bracket.
10 . Release the harness assembly from the seat module bracket.
12 . Release the harness from the lumbar assembly.
13 . Release the harness from the seat airbag and backrest frame.
14 . Release the occupant classification assembly from the seat cushion frame.
15 . NOTE:
Seat harness is part of the occupant classification sensor assembly.
NOTE:
Note the routing of the seat harness.
Remove the passenger seat cushion and occupant classification sensor assembly.
Installation
2 . Secure the passenger seat cushion and occupant classification sensor assembly.
Attach the clips.
3 . Secure the occupant classification assembly to the seat cushion frame.

4 . Secure the harness to the seat airbag and backrest frame.
Secure the wiring harness with the clip.
5 . Attach the harness to the lumbar assembly.

7 . Attach the harness assembly to the module bracket.

8 . Secure the seat module bracket.

Secure the harness with a cable tie.




15 . Using IDS, calibrate a new front seat cushion.

1) • Select the 'Vehicle Configuration' tab.
2) • Select ' Setup and Configuration'.
3) • Select 'Seats'.
4) • Select 'Seat Cover Replacement'.
Restraints Control Module (RCM)
(76.73.48)
Removal
1 . Connect WDS to the vehicle and up-load the relevant data.



For additional information, refer to Radio Frequency (RF) Receiver
5 NOTE:
. If the SRS component is to be replaced, the bar code of the new unit must be
recorded.
NOTE:
The RCM will record and store impact data. The module must be replaced when
three records are noted.
Remove the restraints control module (RCM).

Remove the 3 bolts.
Installation
1 . Install the RCM.

For additional information, refer to Radio Frequency (RF) Receiver


Passenger Air Bag Module (76.73.37)
Removal


4 . Remove the navigation system display module.

5 . NOTE:
Remove the center register.


7.
Remove the driver side register trim panel.

8 . Remove the instrument panel passenger side reinforcement trim panel.

9 . Remove the passenger side register.

10 . Release the glove compartment.
11 . Remove the glove compartment.

Release the glove compartment lamp assembly.
12 .
Carefully release and remove the rheostat switch assembly.

13 . Release the MOST diagnostic port.

Release the vehicle diagnostic port.
15
the component.
Remove the instrument cluster surround.

16 . Remove the instrument cluster.

Raise the steering column finisher for access to the lower screws.
17 . Remove the in-vehicle temperature sensor.
18
the component.
Release the instrument panel upper trim.

Collect the compression limiters.
Release the glove box support bracket.
With assistance, separate the components.
19 . Disconnect the passenger air bag ground cable.
20 . Disconnect the passenger air bag module 2 electrical connectors.


22 . Remove the passenger air bag module.
Installation
1 . Install the passenger air bag module.

3 . Connect the passenger air bag module electrical connectors.
4 . Connect the passenger air bag ground cable.

Install the Torx bolt and tighten to 6 Nm (4 lb.ft).
5 . Install the instrument panel upper trim.

With assistance, align the components.
Install the compression limiters.
6 . Install the in-vehicle temperature sensor.
7 . Install the instrument cluster.

Install the screws.
8 . Install the instrument cluster surround.

Install the screws.
9 . Install the MOST diagnostic port.

Secure the clip.

Install and secure the diagnostic socket.
Align the clips.
11 . Install the rheostat switch assembly and align the instrument panel lower trim panel.
Secure the switch assembly clips.
Connect the switch assembly electrical connector.
12 . Install the glove compartment.

Install the lamp assembly.
13 . Install the passenger side register.

14 . Install the instrument panel passenger side reinforcement trim panel.

15 . Install the driver side register trim panel.


17 . NOTE:
Carefully install the center register.

18 . Install the navigation system display module.




Side Air Bag Module (76.73.47)
Removal




8 . Remove the side air bag module.

Release the backrest cover.
Installation
1 . Install the side air bag module.
Attach the backrest cover.




Rollover Protection Unit
Removal


4 . Release the rear seat backrest trim panel.

Remove the 2 clips.
Remove the 2 bolts.
Position the rear seat backrest trim panel aside.
5 . Remove the rear seat backrest retaining bracket.

6 . Remove the roll over protection unit.

Installation
1 . Install the roll over protection unit.
2 . Install the rear seat backrest retaining bracket.

3 . Install the rear seat backrest trim panel.

Install the clips.



Side Impact Sensor - Convertible (76.73.53)
Removal
2 . Remove the side impact sensor.

Remove the 2 bolts.
Installation
1 . Install the side impact sensor.

Side Impact Sensor - 2-Door (76.73.53)
Removal
2 . Remove the side impact sensor.

Remove the 2 bolts.
Installation
1 . Install the side impact sensor.

501-20C : Pedestrian Protection System
Specifications
Specifications
Item Nm lb-ft lb-in

Pedestrian impact sensor strip - screw 6 - 53
Deployable hood, crash sensor to front bumper beam - bolt 8 - 71
Contact sensing system module to front bumper - screw 6 - 53
Hood deployment support bracket to vehicle - bolt* 8 - 71
Hood deployment striker to hood - bolt* 8 - 71
Pyrotechnic device to hood latch - bolt* 9 - 80
Hood deployment actuator bracket to body - screw* 8 - 71
Hood deployment actuator - screw* 8 - 71
Hood secondary latch to deployment actuator - nut* 9 - 80
CAUTION: *Refer to Removal and Installation procedures for important

information.

COMPONENT LOCATION

1 RH accelerometer
2 RH hood actuator
3 RH hood latch
4 LH hood latch
5 LH hood actuator
6 Pedestrian protection system control module
7 LH accelerometer
8 Pedestrian Contact Sensor (PCS)
INTRODUCTION
WARNING: All pyrotechnic devices are dangerous. Before performing any

procedures on any pyrotechnic device, read all information contained within the
Standard Workshop Practices section of this manual. For additional information, refer
to Standard Workshop Practices (100-00)
The Pedestrian Protection System control module receives an impact signal from Pedestrian
Contact Sensor (PCS) and two accelerometers mounted on the front bumper beam. The
control module interprets the signals to determine whether impact is with a pedestrian or other
object, such as a traffic cone. When the control module detects a valid impact signal and the
vehicle is in the 15 to 45 kph speed range, it fires the two pyrotechnic hood latch release units
and two pyrotechnic actuators which opens the hood approximately 130 mm.
The Pedestrian Protection System is factory fit only to non Federal vehicles.
CONTROL MODULE
The control module is secured to the underside of the wing behind the wheelarch liner with
two screws. The control module is hardwired to the other system components and is also
connected to the High Speed (HS) CAN bus. The control module receives ambient air
temperature, Ignition state and vehicle reference speed on the HS CAN bus.
The Control Module uses signals from the Pedestrian Contact Sensor (PCS) and the
accelerometers to determine if the impact on the bumper is a pedestrian or an other object.
The system will always deploy where the control module determines a pedestrian impact. The
system minimizes deployment for other impacts that are similar to pedestrian impact, such as
traffic cones.
PEDESTRIAN CONTACT SENSOR (PCS)

1 Sensor module
2 Sensor backing strip/rear cover
3 Fibre optic cable
4 Foam insert
5 Sensor front cover
The PCS is located in a slot behind the bumper foam on the front bumper beam and is secured
with a single fixing.
At the end of the sensor next to the fixing there is a PCB and fibre optic transceiver, which is
connected to a fibre optic cable configured in a loop. The PCS uses this fibre optic loop to
detect an impact by measuring the amount of light returned to the fibre optic transceiver. A
reduction in light levels occurs when the PCS is deformed by an impact. The PCS monitors
the level of light returned from the loop, if a reduction of a predetermined magnitude is
measured a trigger signal will be sent to the control module.
HOOD LATCH

1 Latch claw
2 Spring
3 Pyrotechnic pin
4 Latch pawl
The hood latches are located at either side of the trailing edge of the hood. Each latch is
released by a small pyrotechnic pin, which is fired in response to a signal from the control
module. The pyrotechnic pin engages with the latch pawl which is holding the latch claw
closed. Once the pawl is moved by the pyrotechnic pin the latch claw is released and the
return spring moves the latch claw to the open position allowing the hood to move open under
the pressure of the hood actuator.
Hood Latch Deployment

NOTE:
A = Latched; B = Deployed

1 Latch pawl
2 Latch claw
3 Pyrotechnic pin
HOOD ACTUATOR
The hood actuators are pyrotechnic air bags. The hood actuators are located just forward of
the hood latches on either side of the hood. The actuators comprise a pyrotechnic device to
raise the hood, a secondary hood latch mechanism and a tether sleeve. Once fired a locking
device mounted on top of the actuator couples with the secondary hood latch before the airbag
inflates to raise the hood. This ensures that the hood can only deploy to a pre-determined
height (approximately 130 mm). As the hood actuator is fired two prongs located in the
secondary latch housing are moved out of their retaining clamp. The prongs are spring loaded
to grip the secondary hood latch striker securing it to the actuator tether cone.
Hood Actuator and Secondary Latch

1 Secondary hood latch striker plate
2 Secondary hood latch body
3 Secondary hood latch
4 Secondary hood latch spring
5 Secondary hood latch retaining bracket
7 Hood actuator assembly
ACCELEROMETER
Two accelerometers are mounted on the rear of the bumper beam. The accelerometers
measure the amount of inertia when an impact occurs and send a signal to the control module.
This signal is used by the control module to calculate the firing of the Pedestrian Protection
System. The accelerometers are modified crash sensors. The sensors have a lower detection
range than front/side crash sensors to enable them to detect lower level impacts and therefore
assist in the object discrimination process.
CONTROL DIAGRAM
NOTE:
A = Hardwired connection; D = High speed CAN bus

2 ECM
3 Diagnostic socket
4 CJB
5 Hood latch
6 Accelerometer
7 Hood actuator
8 Accelerometer
9 Pedestrian Contact Sensor (PCS)
10 Hood actuator
11 Hood latch
12 Pedestrian protection system control module
The system is designed to help reduce head and lower leg injuries when a pedestrian has been
hit by a vehicle. This is achieved in two main ways:
• Bumper design
• Pyrotechnic deployment of the hood.
The front bumper of the vehicle has been designed with a profile which encourages the
pedestrians lower leg to lift upwards rolling around the front of the bumper surface. The
bumper is constructed of energy absorbing foam and plastics and is designed to be softer
around the top part of the bumper than the middle. This helps reduce injuries to the
pedestrians lower leg.
As the pedestrians leg rolls around the bumper it deforms the bumper and the sensor beneath.
If the predetermined parameters are met the Pedestrian Protection System control module
fires the pyrotechnic hood latch pins which opens the hood latch claw. This is followed by the
pyrotechnic actuator firing to force the hood upwards. As the hood moves upwards the
secondary hood latch automatically engages with the secondary hood latch striker plate
locking the hood and the body together via the tether cone attached to the hood actuator. This
ensures that the hood only rises a set amount. The raising of the hood creates a more
cushioned effect between the vehicle and the pedestrian. The hood actuators will deflate
within 3 seconds of deployment to improve visibility. The secondary hood latch remains
connected to the hood when the hood actuators have deflated and can be released by
squeezing the two latch forks together, either by hand or with a pair of pliers.
The hazard warning lights will be activated and can only be switched off by pressing the
engine Start/Stop button to turn the engine OFF and ON again (without pressing the brake
pedal) to revert to the convenience mode.
A warning message CHECK PEDESTRIAN SYSTEM will appear on the message center and
the vehicle must be immediately recovered to the nearest Jaguar Dealer/Authorised Repairer.
The vehicle must not be driven once the bonnet has been deployed.
Hood Actuator-Deployed

1 Secondary hood latch
2 Secondary hood latch spring
3 Tether cone
4 Secondary hood latch retaining bracket
6 Hood actuator
7 Secondary hood latch body
8 Secondary hood latch striker plate
Function Value
Operating speed 15-45 kph
Hood deployment height 130mm
Hood deployment time (approx) 30ms

For a detailed description of the pedestrian protection system, refer to the relevant Description

• Ensure dummy electrical connector is
installed to the Pedestrian Protection module
• Damaged, loose, or missing • Blown fuse(s)
fixings or components • Damaged, loose or corroded connectors
• Wiring harness
• Damaged Pedestrian Protection module
to the DTC Index.
DTC Index
CAUTION: Prior to carrying out any pinpoint tests on the pedestrian protection
system the back-up power supply must be depleted. Disconnect the battery and wait two
minutes for the back-up power supply to deplete.

NOTE:
NOTE:
NOTE:
NOTE:
tests.
NOTE:
NOTE:
terminals.

• Left hood latch deployment circuit diagrams and test
Left hood latch control circuit - short to left hood latch
B100211
deployment control ground deployment control
ground
• Left hood latch deployment
Left hood latch control circuit - short to
B100212 left hood latch
deployment control power
deployment control
Left hood latch control circuit - circuit
B10021A DTC using the
deployment control resistance below threshold
diagnostic system
Left hood latch • Left hood latch deployment Carry out any pinpoint
B10021B
deployment control control circuit - circuit tests associated with this
resistance above threshold DTC using the
diagnostic system
Left hood latch control circuit - circuit
B10021C DTC using the
deployment control voltage out of range
diagnostic system
Disconnect latch actuator
connector, clear DTC
and re-test. If DTC
remains along with
additional DTCs, install a
• Incorrect component new pedestrian
Left hood latch
B10024A installed protection module.
deployment control
Pedestrian Protection
Module If DTC cleared
install a new latch
actuator.
Latch Actuator
• Right hood latch
diagrams and test right
Right hood latch deployment control circuit
B100011 hood latch deployment
deployment control - short to ground
control circuit for short
to ground
• Right hood latch
diagrams and test right
Right hood latch deployment control circuit
B100012 hood latch deployment
deployment control - short to power
to power
• Right hood latch Carry out any pinpoint
deployment control circuit tests associated with this
Right hood latch
B10001A - circuit resistance below DTC using the
deployment control
diagnostic system
Right hood latch
B10001B - circuit resistance above DTC using the
deployment control
diagnostic system
Right hood latch
B10001C - circuit voltage out of DTC using the
deployment control
range manufacturer approved
diagnostic system
B10004A Right hood latch • Incorrect component Disconnect latch actuator
deployment control installed connector, clear DTC
and re-test. If DTC
remains along with
new pedestrian
protection module.
install a new latch
actuator.
Latch Actuator
• Left hood deployment
diagrams and test left
Left hood control circuit - short to
B100311 hood deployment control
deployment control ground
ground
• Left hood deployment Refer to electrical circuit
Left hood control circuit - short to diagrams and test left
B100312
deployment control power hood deployment control
Left hood control circuit - circuit
diagnostic system
B10031B DTC using the
deployment control resistance above threshold
diagnostic system
diagnostic system
Disconnect hood actuator
and re-test. If DTC
remains along with
Left hood new pedestrian
B10034A installed
deployment control protection module.
install a new hood
actuator.
Hood Actuator LH
• Right hood deployment
Right hood control circuit - short to
B100111 right hood deployment
deployment control ground
to ground
Right hood control circuit - short to
B100112 right hood deployment
deployment control power
to power
Right hood control circuit - circuit
diagnostic system
B10011B DTC using the
deployment control resistance above threshold
diagnostic system
diagnostic system
Disconnect hood actuator
and re-test. If DTC
remains along with
• Incorrect component new pedestrian
Right hood
B10014A installed protection module.
deployment control
install a new hood
actuator.
Hood Actuator RH
• Pedestrian impact sensor
Pedestrian impact circuit diagrams and test
B100613 circuit - open circuit
sensor pedestrian impact sensor
circuit for open circuit
B100611 circuit - short to ground
ground
B100612 circuit - short to power
Install a new pedestrian
Pedestrian impact • Component internal failure impact sensor.
B100696
sensor Pedestrian Impact
Sensor
Pedestrian impact circuit - signal below
sensor allowable range
diagnostic system
Pedestrian impact impact sensor.
B10064A installed
sensor Pedestrian Impact
Sensor
Pedestrian impact circuit - current out of
B10061D DTC using the
sensor range
diagnostic system
Pedestrian impact • Sensor fault
B10068F DTC using the
sensor
diagnostic system
Pedestrian impact • No signal
sensor
diagnostic system
DTC using the
• Performance or incorrect manufacturer approved
Pedestrian impact
B100692 operation diagnostic system. Install
sensor
new crush pad and air
deflectors (even if no
damage is apparent).
• Signal bias level out of
Pedestrian impact range/zero adjustment
sensor failure
diagnostic system
Pedestrian impact • Missing calibration
sensor
diagnostic system
• Left pedestrian protection
Left pedestrian circuit diagrams and test
accelerometer circuit -
B100513 protection left pedestrian protection
open circuit
accelerometer accelerometer circuit for
open circuit
short to ground
short to ground
short to power
short to power
Install a new left
Left pedestrian pedestrian protection
• Component internal failure
B100596 protection accelerometer.
accelerometer Pedestrian Protection
Accelerometer
Left pedestrian • Signal below allowable tests associated with this
B100584 protection range DTC using the
accelerometer manufacturer approved
diagnostic system
Install a new left
Left pedestrian • Incorrect component pedestrian protection
B10054A protection installed accelerometer.
Accelerometer
Left pedestrian tests associated with this
• Erratic
B10058F protection DTC using the
diagnostic system
Left pedestrian tests associated with this
• No signal
B100531 protection DTC using the
diagnostic system
Right pedestrian • Right pedestrian protection Refer to electrical circuit
B100413
protection accelerometer circuit - diagrams and test right
accelerometer open circuit pedestrian protection
accelerometer circuit for
open circuit
• Right pedestrian protection
Right pedestrian diagrams and test right
B100411 protection pedestrian protection
short to ground
short to ground
• Right pedestrian protection
Right pedestrian diagrams and test right
B100412 protection pedestrian protection
short to power
short to power
Right pedestrian tests associated with this
• Component internal failure
diagnostic system
Right pedestrian • Signal below allowable tests associated with this
B100484 protection range DTC using the
diagnostic system
Install a new right
Right pedestrian • Incorrect component pedestrian protection
B10044A protection installed accelerometer.
Accelerometer
• Erratic
B10048F protection DTC using the
diagnostic system
• No signal
diagnostic system
Lost • Lost communication with tests associated with this
U012100 communication ABS module DTC using the
with ABS module manufacturer approved
diagnostic system
Lost • Lost communication with
U010000 communication ECM
DTC using the
with ECM
diagnostic system
Lost • Lost communication with tests associated with this
U014200 communication RJB DTC using the
with RJB manufacturer approved
diagnostic system
High speed CAN • Not configured
communication Bus
diagnostic system
High speed CAN • Not configured
communication Bus
diagnostic system
High speed CAN • Bus off
communication Bus
diagnostic system
protection module.
• Signal has too many
Permanent memory Module Install new
U1A0266 transitions/events
store full crush pad and air
deflectors (even if no
damage is apparent).
approved diagnostic
system. Clear DTC and
Stored vehicle • Incorrect car configuration re-test. If the DTC
U300055 configuration data data received remains suspect the
does not match pedestrian protection
system, refer to the new
module installation note
Index
protection module, refer
• Internal electronic failure
U300049 Control module to the new module
• Missing message Re-configure the RJB
U300087 Control Module
approved diagnostic
system. Check pedestrian
protection module for
DTCs and refer to the
DTC Index. Check CAN
network integrity using
the manufacturer
approved diagnostic
system
• Circuit voltage below tests associated with this
U300316 Battery voltage threshold DTC using the
diagnostic system
• Circuit voltage above tests associated with this
U300317 Battery voltage threshold DTC using the
diagnostic system
Vehicle speed • Invalid signal
P193429 DTC using the
signal
diagnostic system
Ambient air tests associated with this
• Invalid signal
P007129 temperature sensor DTC using the
range/performance manufacturer approved
diagnostic system
Control module protection module.
U201B4A installed
calibration data #2 Pedestrian Protection
Module
Re-configure the
pedestrian protection
module using the
diagnostic system. Clear
Control module • Not programmed
U201B51 DTC and re-test, if DTC
calibration data #2
pedestrian protection
module.
Module
Place module into normal
Initial configuration • Module is in Plant mode operation mode, by
U210000
not complete running the new module
programming
application, using the
diagnostic system
other vehicle

approved diagnostic
Internal control • Invalid configuration and retest. If the DTC is
U030000 module software message is received still logged suspect the
incompatibility pedestrian protection
module installation note
Index
Pedestrian Protection Module

Removal
NOTE:
The pedestrian protection module must be renewed if the system has deployed on 3
occasions.
2 . Remove the front LH fender splash shield.

3 . Remove the pedestrian protection module.

Installation
1 . Install the pedestrian protection module.
2 . Install the front LH fender splash shield.


Pedestrian Impact Sensor
Removal
1

3 . Remove the pedestrian impact sensor.

Installation
1 . Install the pedestrian impact sensor.

Pedestrian Protection Latch Actuator
Removal
1 . Remove the pedestrian protection hood actuator and bracket.
2 . Remove the pedestrian protection latch actuator.

Installation
1 . Install the pedestrian protection latch actuator.
2 . Install the pedestrian protection hood actuator and bracket.

Pedestrian Protection Accelerometer
Removal

Remove the 7 clips.
3 . Remove the pedestrian protection accelerometer.

Remove the 2 bolts.
Installation
1 . Install the pedestrian protection accelerometer.

Pedestrian Protection Hood Actuator LH
Removal
2 . Remove the pollen filter.

For additional information, refer to Pollen Filter (76.10.09)


Remove the 4 bolts.

6 . Remove the pedestrian protection actuator.

Installation
1 . Install the pedestrian protection actuator.



5 . Install the pollen filter.

For additional information, refer to Pollen Filter (76.10.09)
Pedestrian Protection Hood Actuator RH
Removal

Remove the 3 clips.

Remove the 4 bolts.

5 . Remove the pedestrian protection actuator.

Installation
1 . Install the pedestrian protection actuator.



Carefully secure the clips
501-25A : Body Repairs – General Information
Body Repairs
General Information
Introduction
The all-new Jaguar XK Aluminium is unique in the industry as a complete Aluminium

monocoque body structure, as distinct from an Aluminium spaceframe with separate
Aluminium exterior panels. Developed from aircraft industry methods, where strength and
light weight are critical, Jaguar’s manufacturing process produces a massively strong but very
light structure that is both rivetted and epoxy-bonded.
The key to the XK's character is Jaguar's industry-leading bonded and rivetted aluminium
monocoque body structure, introduced with the latest XJ saloons. The aluminium body
incorporates the latest thinking in epoxy bonding and riveting techniques to produce a chassis
that is very safe and very light. In fact, the new XK's aluminium chassis is significantly lighter
and stiffer in both coupe and convertible form than the steel model it replaces. The coupe
chassis is over 30 percent stiffer than the previous XK, while the convertible is an impressive
50 percent. It also offers a 10 percent improvement in power to weight ratio. The XK
Aluminium is up to 90 percent stiffer and 180kg lighter than key rivals, with a kerb weight of
just 1595kg.
The XK takes the Lightweight Vehicle concept a step further with extended use of
Aluminium castings and extrusions, as well as pressed Aluminium panels. Its remarkable
strength and light-weight come from both the way the bodyshell is constructed and the use of
new jointing technologies developed by Jaguar and its suppliers.
Jaguar guarantee high quality standards by ensuring that mechanical strength properties are
tried and tested in numerous computer simulations, crash tests, by testing materials and by
employing sophisticated manufacturing technologies. In the event of repairs it is vital that the
production quality standards are upheld. This requires a well-equipped workshop, and places
particular emphasis on the qualifications of the workshop technicians. Up-to-date knowledge
of current manufacturing technologies and continuous training on new repair methods and
techniques are vital for high-quality body repairs. The model-specific repair manuals and the
general repair techniques provide valuable support when undertaking body repairs. Always
follow the repair instructions published in this manual. Failure to observe this instruction can
result in serious impairment of vehicle safety. All specified safety requirements must be met
after the work has been carried out.
Vehicle Design
Body
There is only a single welded joint in the XK coupe body, the one 'cosmetic' joint is on the
roof. This has an environmental benefit in that the body construction needs no high electrical
current, produces no welding sparks or fumes, and needs no water for cooling. All other joints
in the XK shell are formed using self-piecing rivets applied by hydraulic pressure against a
fixed tool. Where access to only one side of the joint is possible, as in some of the new
extruded box sections, a new riveting process has been developed; and where particularly
high stiffness is required in a joint, a combination of riveting and bonding is used - with the
adhesive bond in effect creating a continuos joint which is stronger than a similar, rivetted-
only joint. All visible exterior panels are bonded to the underlying structure, and a new
automated seam-sealing process seals all relevant areas of the shell before painting, to ensure
that no gaps are missed.
In the XK, a secondary front bulkhead of aluminium and composite materials help reduce
noise transmission from the engine compartment and provides a dry area under the bonnet for
accommodating electrical components. The new structure also has the benefits in refinement;
castings used for the mounting points for the engine, transmission and suspension make those
points significantly stiffer, further reducing transmitted noise and helping to improve
suspension dynamics. In terms of long-term strength, Jaguar's all-aluminium shell has
durability approaching twice that of a traditional spot-welded steel body.
Another major advantage of this lightweight vehicle technology is that all the necessary
stiffness is in the structure of the body shell, with a very large rectangular-section side sills.
So the convertible, even without a roof, does not need the traditional stiffening panels seen on
many other convertibles - meaning no added weight and no penalty in stiffness or refinement.
The XK's all-aluminium doors are each over 6kg lighter than an equivalent steel door and
their mountings are significantly stiffer, which allows for smaller gaps. Mounting the window
glass rails directly to the aluminium castings at the front and rear of the door gives better
sealing from the frameless layout, and an impressively solid sound seal.
Passenger Safety Cell

Beyond the exceptional body integrity and built-in deformation zones, the all-new XK
Aluminium is also available with a host of other safety solutions for protecting pedestrians as
well as car occupants. Those include the shape and construction of the bumpers and bonnet,
plus a completely new technology, the pedestrian deployable bonnet, (European Models).
This is deployed upwards away from its rear edge, in milliseconds, in the event of a
pedestrian impact. This forms a safety zone between the bonnet and the engine and other
under-bonnet hard areas to reduce significantly the potential for injuries.
Crumple Zone
Safety is another major benefit of this very strong construction method. That is partly inherent
in aluminium as a material, which absorbs significantly more energy per kilogramme of
material weight than steel when it is deformed. But the strength advantage does not only
apply to high-speed impacts, it also means lower-speed accident repair costs are kept to a
minimum. The reduction in the number of joints in the XK further increases strength, and the
front of the body is protected by easily replaced 'crush cans' that absorb the energy in impacts
up to 15kph.
Contents
This manual includes technical data and information for the Jaguar XK Aluminium range.
The information contained within is valid at the time of production and incorporates:
• Who should use this manual?

• Aluminium information
• Category 'A' and 'B' definition
• Equipment
• Panel replacement times
• Fixings
• Bonding
• Tolerances and gap specification
• Body alignment
The methods described for panel replacement operations have been obtained from a study of
physical repair operations.
In line with Jaguars continuous improvement programme, information and data contained will
be updated periodically.
All activities described within are based on the use of genuine Jaguar Parts, tools and
approved materials.
Aluminium
The design of the modern motor vehicle attempts to overcome two conflicting needs:
• Fuel economy - lighter, aerodynamic and fuel sensitive technology.

• High levels of comfort - this often equates to higher specifications and more
accessories.
Aluminium alloy is the ideal material to meet these demands; it provides a lighter vehicle
body with improved rigidity. Aluminium is different from traditional steel, with the correct
knowledge and suitable tools it is easily repaired.
There are two Aluminium alloys discussed in this manual, the attributes detailed in the
following table should be considered when deciding to repair or replace:
6111 5754
Material 6000 Series is a Magnesium / 5000 Series is an Aluminium alloy with
Description Silicon / Copper Aluminium Magnesium content.
alloy.
Location on This alloy is used mainly in the Internal structural panels Thickness: 1.0 -
Vehicle outer body panels. Thickness: 3.0mm
0.9 - 2.0mm
Attributes High dent resistance. Strength and durability.
Repairability Yes - Light damage only. Yes - Light damage only. Limited
straightening is acceptable.
Heat During Yes - caution material sensitive Yes - must be heated to maintain original
Repair to heat. Range: 140 - 160°C alloy properties. Ideal panel temperature:
Ideal panel temperature: 150°C 250°C
Notes Equipment: Hot air gun. Use Equipment: Heat inducer. Use panel
panel temperature indicator temperature indicator strips. Heat must be
strips. applied and maintained during the
straightening process.
Other materials are used in the construction of the XK Aluminium range, however, repair of
these materials is not covered as they fall outside the scope of this manual.
Steel: Used in seat belt anchorages, hinge reinforcements and various small brackets and
mountings.
The following illustration shows the panels covered by this manual and the alloys used.
Galvanic Corrosion and Housekeeping

Galvanic corrosion is the 'cross-contamination' of dissimilar metals, in this case Aluminium
and steel. Avoidance of galvanic corrosion is an important issue to be considered in the repair
of Aluminium bodied vehicles.
Precautions to prevent the contamination of exposed bare Aluminium surfaces should be

taken. Good housekeeping / cleanliness should be adopted throughout repairs and especially
prior to welding, pre-treatment and adhesive bonding.
The repair environment requires control and protection from dust and debris from
conventional steel body repairs. All equipment must be clearly identified and used solely on
Aluminium.
Tools should be kept clean and in good order. Steel fastenings are coated to prevent galvanic
corrosion. Fastenings should be examined during repairs and where damaged or suspect must
be renewed
The use of graphite, "penetrating" oil, or copper based anti-seize compounds upon the steel
fixings is not recommended.
Who Should Use This Information?

The information and repair methods listed are designed as an aid for Jaguar Approved Body
Repair Facilities achieving the Jaguar approved Bodyshop Operating Standards. The relevant
section should be read completely before commencing any repairs. Only technicians who
have successfully completed the approved XK Aluminium range training programme should
work on the model. Jaguar Approved Bodyshop Operating Standards require that the skills of
technicians be regularly assessed and that any training needs identified are addressed within a
reasonable time. This information complements the Jaguar training programme.
Definition of Category 'A' and 'B'

Category 'A'
• NOTE:
Specific equipment and facilities are required to carry out Category 'A' repairs, see
equipment.
•
Damage that requires panel(s) to be replaced with any one or combination of the
following procedures:
• Welded panel
• Bonded panel
• Panel secured with fixings
• The following list identifies Category 'A' procedures
Category 'A' procedures
• Hood. For additional information, refer to Hood (501-03 Body Closures)

• Front bumper cover. For additional information, refer to Front Bumper Cover (501-19
Bumpers)
• Front bumper. For additional information, refer to Front Bumper (501-19 Bumpers)
• Auxiliary front crossmember. For additional information, refer to Auxiliary Front
Crossmember (501-27 Front End Sheet Metal Repairs)
• Front Crossmember. For additional information, refer to Front Crossmember (501-27
Front End Sheet Metal Repairs)
• Fender apron panel front extension. For additional information, refer to Fender Apron
Panel Front Extension (501-27 Front End Sheet Metal Repairs)
• Side member deformation element. For additional information, refer to Side Member
Deformation Element (501-27 Front End Sheet Metal Repairs)
• Front side member side extension mounting. For additional information, refer to Front
Side Member Side Extension Mounting (501-27 Front End Sheet Metal Repairs)
• Front side member side extension. For additional information, refer to Front Side
Member Side Extension (501-27 Front End Sheet Metal Repairs)
• Front side member to deformation element bracket. For additional information, refer
to Front Side Member To Deformation Element Bracket (501-27 Front End Sheet
Metal Repairs)
• Front side member extension. For additional information, refer to Front Side Member
Extension (501-27 Front End Sheet Metal Repairs)
• Suspension top mount. For additional information, refer to Suspension Top
Mount (501-27 Front End Sheet Metal Repairs)
• Front wheel house. For additional information, refer to Front Wheelhouse (501-27
• Front side member. For additional information, refer to Front Side Member (501-27
• Fender apron panel reinforcement. For additional information, refer to Fender Apron
Panel Reinforcement (501-27 Front End Sheet Metal Repairs)
• Fender apron panel. For additional information, refer to Fender Apron Panel (501-27
• Fender apron panel closing panel. For additional information, refer to Fender Apron
Panel Closing Panel (501-27 Front End Sheet Metal Repairs)
• Front fender. For additional information, refer to Front Fender (501-27 Front End
Sheet Metal Repairs)
• Door For additional information, refer to Door (501-03 Body Closures)
• A-pillar outer panel. For additional information, refer to A-Pillar Outer Panel (501-29
Side Panel Sheet Metal Repairs)
• A-pillar assembly. For additional information, refer to A-Pillar Assembly (501-29
Side Panel Sheet Metal Repairs)
• Rocker panel. For additional information, refer to Rocker Panel (501-29 Side Panel
• Quarter panel assembly. For additional information, refer to Quarter Panel Assembly
- Vehicles Without: Convertible Top (501-30 )
For additional information, refer to Quarter Panel Assembly - Vehicles With:
Convertible Top (501-30 )
• Rear outer wheelhouse half. For additional information, refer to Rear Outer
Wheelhouse Half (501-30 Rear End Sheet Metal Repairs)
• Rear wheelhouse outer. For additional information, refer to Rear Wheelhouse
Outer (501-30 Rear End Sheet Metal Repairs)
• Rear side member closing panel. For additional information, refer to Rear Side
Member Closing Panel (501-30 Rear End Sheet Metal Repairs)
• Rear side member reinforcement panel. For additional information, refer to Rear Side
Member Reinforcement Panel (501-30 Rear End Sheet Metal Repairs)
• Rear side member (section). For additional information, refer to Rear Side Member
Section (501-30 Rear End Sheet Metal Repairs)
• Spare wheel well. For additional information, refer to Spare Wheel Well (501-30 Rear
End Sheet Metal Repairs)
• Back panel assembly. For additional information, refer to Back Panel Assembly (501-
30 Rear End Sheet Metal Repairs)
• Liftgate.
• Rear bumper cover. For additional information, refer to Rear Bumper Cover (501-19
Bumpers)
• Rear bumper. For additional information, refer to Rear Bumper (501-19 Bumpers)
• Roof panel. For additional information, refer to Roof Panel (501-28 Roof Sheet Metal
Repairs)
•
•
Category 'B'
• Damage associated to bolt on panel(s) that are replaced, or light surface damage to
exterior cosmetic panels. The following list identifies Category 'B' procedures
Category B procedures
• Hood. For additional information, refer to Hood (501-03 Body Closures)

• Front bumper cover. For additional information, refer to Front Bumper Cover (501-19
Bumpers)
• Front bumper. For additional information, refer to Front Bumper (501-19 Bumpers)
• Auxiliary front crossmember. For additional information, refer to Auxiliary Front
Crossmember (501-27 Front End Sheet Metal Repairs)
• Front Crossmember. For additional information, refer to Front Crossmember (501-27
• Fender apron panel front extension. For additional information, refer to Fender Apron
Panel Front Extension (501-27 Front End Sheet Metal Repairs)
• Side member deformation element. For additional information, refer to Side Member
Deformation Element (501-27 Front End Sheet Metal Repairs)
• Front side member side extension mounting. For additional information, refer to Front
Side Member Side Extension Mounting (501-27 Front End Sheet Metal Repairs)
• Front side member side extension. For additional information, refer to Front Side
Member Side Extension (501-27 Front End Sheet Metal Repairs)
• Front fender. For additional information, refer to Front Fender (501-27 Front End
• Door For additional information, refer to Door (501-03 Body Closures)
• Liftgate.
• Rear bumper cover. For additional information, refer to Rear Bumper Cover (501-19
Bumpers)
• Rear bumper. For additional information, refer to Rear Bumper (501-19 Bumpers)
Equipment
All Jaguar approved body repair facilities are expected to be equipped in line with Jaguar
Body and Paint Centre of Excellence Operating Standards.
The approved body equipment for the XK Aluminium range is listed as either:
• Category 'A'
• Category 'B'
All approved equipment is available on a Worldwide basis from:
Country Phone Fax

Austria +800-291714 +800-291694
Belgium (flemish) 00800-36733731 00800-36733292
Belgium (french) 0800-36733732 0800-36733292
Denmark +800-36733732 +800-36733292
Finland +800-36733732 +800-36733292
France 0800-904986 0800-901329
Germany 0800-3673373 0800-3673329
Greece 00800-49129046 00800-49129057
Hungary +800-36733732 +800-36733292
Ireland 1800-409574 1800-409580
Italy 0800-790959 0800-780959
Netherlands 00800-36733732 00800-36733292
Norway +800-36733732 +800-36733292
Poland 00800-4911241 00800-4911240
Portugal +800-36733732 +800-36733292
Spain 900-998303 900-998304
Sweden +800-36733732 +800-36733292
Swiss french 00800-36733732 00800-36733292
Swiss German 00800-36733731 00800-36733291
Turkey 00800-44910087 00800-44910096
UK 0800-214390 0800-281705
All other markets +49 2203 106199 +49 2203 106241
A copy of the approved equipment standards for category 'A' and 'B' repair facilities is
available on request from:
Jaguar Equipment Programme
Unit 6
Wollaston Crescent
Burnt Mills Industrial Estate
Basildon
Essex
SS13 1QD
0800 214390
Alternatively, you can access the programme via their website: www.eqseurope.com
Panel Replacement Times

Panel replacement times are available for the following:
• Front end sheet metal. For additional information, refer to Front End Sheet
Metal (501-27 Front End Sheet Metal Repairs)
• Side panel sheet metal. For additional information, refer to Side Panel Sheet
Metal (501-29 Side Panel Sheet Metal Repairs)
• Rear end sheet metal. For additional information, refer to Rear End Sheet Metal (501-
30 Rear End Sheet Metal Repairs)
• Roof sheet metal. For additional information, refer to Roof (501-28 Roof Sheet Metal
Repairs)
Fixings
There are five groups of fixings used on the XK Aluminium range, other than conventional
nuts and bolts. It is important that the correct procedures are followed for the removal and
replacement of these fixings and, where applicable, the correct tools are used.
Self-Piercing Rivet (SPR)
Self-Piercing Rivets are available in various sizes dependant on the size of the "stack" of
panels to which they are fitted. A "stack" refers to the combined gauge of the panels being
Rivetted. The following table identifies the sizes and part numbers available:
NOTE:
It is important to identify and select the correct size fixing by referencing this table prior
to installation.
Size Stack Jaguar Service Number

4.8mm x 5.0mm 3.0mm C2C 20589
4.8mm x 7.0mm 4.0mm C2C 20590
4.8mm x 8.0mm 5.0mm C2C 20591
4.8mm x 8.5mm 5.5mm C2C 20592
4.8mm x 9.0mm 6.0mm C2C 20593
4.8mm x 9.5mm 6.5mm C2C 20594
4.8mm x 11.0mm 8.0mm C2C 20595
Removal: The ESN50 is the approved removal tool for Self Piercing Fixings. The ESN50 can
be used with an optional, larger, 200mm "C" frame for improved access. Where tool access is
impossible, remove fixings using approved drill bits.
Installation: The ESN50 is the approved installation tool for Self Piercing Fixings. Where the
original panel is being refitted, the new fixings should be placed adjacent to the original. Only
where the ESN50 cannot be used, or there is insufficient space on the panel, should the
fixings be replaced with Hemloks, unless the repair method dictates otherwise.
Using the ESN50: Ensure there is access for the ESN50 on both sides of the fixing to be
removed / installed, including the optional "C" frame if required. Removal: Align the plunger
and anvil over the fixing and depress the trigger. Depressing the trigger will allow the plunger
to act on the fixing and remove it from the panel. Installation: Note: Prior to replacing a self
piercing fixing, a test, using identical materials from waste panels, should be performed, to
ensure that all settings are correct and an acceptable joint has been achieved.
Load new fixing into ESN50. Align the ESN50 over the fixing position and depress the
trigger. As the trigger is depressed the ESN50 will clamp itself onto the work piece and install
the fixing.
Hemlok (rivet)
Hemloks are available in various sizes dependant on the size of the "stack" of panels to which
they are fitted. A "stack" refers to the combined gauge of the panels being Rivetted. The
following table identifies the sizes and part numbers available:
NOTE:
It is important to identify and select the correct size fixing by referencing this table prior
to installation.
Size Stack Jaguar Service Number
6.4mm x 13.7mm 1.5mm - 3.0mm C2S 11487
6.4mm x 15.0mm 2.8mm - 4.8mm C2C 7792
6.4mm x 17.0mm 4.8mm - 6.8mm C2C 10349
6.4mm x 19.0mm 6.8mm - 8.8mm C2C 9818
6.4mm x 20.0mm 7.5mm - 9.5mm C2C 22613
6.4mm x 21.0mm 8.8mm - 10.8mm C2C 9966
Removal: Hemloks are not used in production, however, if a previous repair has been carried
out they may be present. Remove the centre of the fixing using a 4mm punch - in some
instances it may be necessary to loosen the centre using a hardened centre punch. Once the
centre has been removed, drill out the remnant using a 6.5mm Cryobit drill bit. Remove all
debris.
Installation: The Genesis G4 is the approved installation tool for Hemloks. Prior to
replacement ensure the fixing hole has been drilled to 6.5mm, using Cryobit drill bit and all
debris has been removed.
Using the Genesis G4: Ensure the fixing hole has been drilled to 6.5mm and all debris has
been removed. Check that you have the correct size Hemlok for replacement and insert it into
the Genesis G4. Use the weight of the Genesis G4 to apply light pressure as the Hemlok is
inserted into its hole. Depress the trigger which will tighten the Hemlok in the hole, the
wasted stud will be ejected into the Genesis G4 once a pre-determined pressure is reached.
Monobolt (rivet)
Removal: Remove the centre of the fixing using a 4mm punch - in some instances it may be
necessary to loosen the centre using a hardened centre punch. Once the centre has been
removed, drill out the remnant using a 6.5mm Cryobit drill bit. Remove all debris.
Installation: The Genesis G4 is the approved installation tool for Monobolts. Prior to
replacement ensure the fixing hole has been drilled to 6.5mm, using Cryobit drill bit and all
debris has been removed.
been removed. Insert a new Monobolt into the Genesis G4, (there is only one size of
Monobolt used on the XK Aluminium Range). Use the weight of the Genesis G4 to apply
light pressure as the Monobolt is inserted into its hole. Depress the trigger which will tighten
the Monobolt in the hole, the wasted stud will be ejected into the Genesis G4 once a pre-
determined pressure is reached.
Countersunk Monobolt (rivet)
Countersunk Monobolts are used in replacement where a Self-Piercing Rivet, (SPR), cannot
be replicated and where a Hemlok cannot be used because a flush surface is required.
Removal:Countersunk Monobolts are not used in production, however, if a previous repair

has been carried out they may be present. Remove the centre of the fixing using a 4mm punch
- in some instances it may be necessary to loosen the centre using a hardened centre punch.
Once the centre has been removed, drill out the remnant using a 6.5mm Cryobit drill bit.
Remove all debris.
Installation:The Genesis G4 is the approved installation tool for Monobolts. Prior to

replacement ensure the fixing hole has been drilled to 6.5mm, using Cryobit drill bit, the hole
has been countersunk, using a countersink drill bit and all debris has been removed.
been removed, check Countersunk Monobolt sits flush with panel. Insert a new Countersunk
Monobolt into the Genesis G4, (there is only one size of Countersunk Monobolt used on the
XK Aluminium Range). Use the weight of the Genesis G4 to apply light pressure as the
Countersunk Monobolt is inserted into its hole. Depress the trigger which will tighten the
Countersunk Monobolt in the hole, the wasted stud will be ejected into the Genesis G4 once a
pre-determined pressure is reached.
Ejot (flow drilled screw)
Removal: Ejots are removed using a T30 Torx driver.
Installation: An Ejot can only be reused where its original thread remains and is intact, Ejots
are installed using a T30 Torx Driver. Where new panels have been fitted and no original
threaded Ejot hole exists, a Hemlok fixing should be used.
If the Ejot cannot be re-used, and the original thread remains intact, then a Torx screw (C2C
1964) can be used in its place.
Torx Screw and Rivnut
A Torx Screw and Rivnut are used where the fitment of a Hemlok would give a poor cosmetic
appearance. There are also occasions where the Torx Screw and Rivnut replaces a Monobolt,
where there is no access for the Genesis G4. The Rivnut acts as the thread. The Rivnut is
installed using the Wurth HES412 Rivet Nut Thread Setter, (Part No: 964948900).
Description Jaguar Service Number

Rivnut (G) C2C 10348
Torx screw (J) C2G 1964
Removal: The removal of the Torx Screw is carried out using a T30 Torx Driver. The Rivnut
is not an original fixing.
Installation: The Torx Screw is installed using a T30 Torx Driver. The Rivnut is installed
using the Wurth HES412 Rivet Nut Thread Setter, (Part No: 964948900).
Bonding
This section provides information on the bonded joints used in repair throughout the
XK Aluminium body. The following topics are covered:
• Equipment
• Materials
• Bonding Pre Treatment
• Bonding Application
It is a pre-requisite that any person undertaking any repairs which involve panel bonding has
attended Jaguar Approved Training and has achieved the correct skill level to undertake these
processes. Bonding is classed as a Category 'A' repair.
Equipment
The approved bonding equipment consists of:
• Pyrosil gas applicator kit

• Approved two-pack adhesive applicator
Materials
The materials listed in this section are those approved to be used on the XK Aluminium range
in conjunction with the repairs shown in this manual.
Consumable Material Supplier

Weld crack Penetrant Rocol Jaguar Equipment
Programme
Weld crack Developer Rocol Jaguar Equipment
Programme
Weld crack Cleaner Rocol Jaguar Equipment
Programme
Bonding primer SurAlink GP15 Jaguar Equipment
Programme
Bonding adhesive Structural adhesive DP490 3M
Bonding adhesive Structural adhesive 8115 3M
Cavity foam DM4330 foam 3M
Semi rigid sealer 0893 – 2251 Wurth
Seam sealer Terostat 1K PUR 11272C Teroson
(4500010)
Cleaner/De-greaser 08984 3M
Cleaner/De-greaser 3608S DuPont
MIG weld wire (6111) 4043 / 4047 filler wire Fronius dealer network
MIG weld wire (5754) 5554 filler wire Fronius dealer network
Abrasive discs Roloc bristle discs 07528 3M
Self-Pierce fixings (all JEPC Jaguar Dealer Network
variants)
Hemlok fixings (all variants) JEPC Jaguar Dealer Network
Bonding Pre Treatment

Pre-treating the panels to be bonded, as described in this section, promotes the improved
adhesion of the bonding adhesive.
The pre-treatment is carried out using the approved "Pyrosil kit". The kit contains all of the
equipment required to perform the pre-treatment process.
Bonding without pre-treatment will reduce the performance of the joint.
The pre-treatment application is a two stage process:
• Chemical application via a flame

• Coupling Agent
Performing the Pre-treatment Application
• NOTE:
Apply caution when using a naked flame. Remove all risk of combustion Do not
overheat the alloy Move the flame over the work piece at a constant velocity
•
Remove any original adhesive, or E-Coat from new panels
• Clean surface to be treated using approved pre-cleaner / degreaser
• Using the Pyrosil torch, pass the flame, (use the blue tip which is the oxidisation
flame), across the surface of the joint.
• Immediately brush primer onto panel surface and allow to dry
The application is colourless and has no visual indication.
Apply the bonding adhesive immediately after the pre-treatment process.
Bonding Application
The approved bonding adhesive is supplied in a two pack cartridge
A two-pack cartridge gun with a disposable mixing nozzle is used for the application of the
adhesive
www.JagDocs.com
Apply a 5mm "zig zag" bead directly to either the replacement panel or vehicle structure
Ensure a continuous bead of adhesive surrounds fixing holes
On completion the mixing nozzle must be discarded. Ensure an air tight seal is provided for
the cartridges.
NOTE:
The curing process of the adhesive begins once mixed and has a working time of approx
30 minutes
Aluminium Welding
Health and Safety
Refer to equipment manufacturers' manual.
Set Up / Equipment Check

Refer to equipment manufacturers operator's manual.
Weld Process
This section provides information on aftermarkets Aluminium welding for the XK
Aluminium range. It covers the following areas:
• Equipment:Metal Inert Gas (MIG)

• Materials:Extruded and pressed Aluminium sheet alloy.
• Weld Structure:Fusion welding process: Metal Inert Gas (MIG)
• Weld Procedures: Pre-weld, test weld, weld and post weld checks.
• Weld Types:
Lap Weld
Butt Weld
Plug Weld
It is a pre-requisite that any person undertaking Category 'A' welding on the XK Aluminium
range is fully qualified in Aluminium Welding.
Equipment
Approved equipment obtained from the Jaguar Equipment Programme:
• Fronius Aluminium Edition - Metal Inert Gas (MIG) Welder.

• Speedglas with Adflo face shield / weld mask.
• Approved fume extractor.
• Stainless Steel Brush.
• Personal Protection Equipment (PPE)
Materials
Prior to any welding activity, it is necessary to identify the type of material to be welded. The
XK Aluminium range is constructed from a number of Aluminium Alloys, each has different
attributes that should be considered prior to the weld process.
Body Materials
The repair methods shown focus on the replacement of:
• Pressed Aluminium Alloy sheet - 6111 - Used in skin-panels.

• Extruded Aluminium Alloy - 5754 - Used in structural panels.
Weld Wire
The approved weld wires for these alloys are:
• 6111 - 4043 or 4047 filler wire.

• 5754 - 5554 filler wire.
Weld Structure
The approved aftermarkets weld process is based on Fusion Welding.:
• Metal Inert Gas (MIG) Welding
The approved MIG welder uses DC current. The Electrode, (filler wire), is Positive Pole and
the work piece is Negative Pole. The arc burns between a melting electrode, (which also acts
as the filler wire) and the work piece. The shielding gas is :
Inert
• MIG - (Argon, Helium or a mixture of these).
Successful Aluminium welding is partly dependent on the removal of surface Oxidisation.
Oxide MUST be removed prior to welding.The oxide melts at a different temperature:
• Aluminium melting temperature - approximately 660°C.

• Aluminium Oxide melting temperature - approximately 2040°C.
Fronius Pulsed MIG
The 2700 Alu Edition utilises a 100% digitally controlled power source, this produces
final weld attributes of:
• Smoothness.
• Refinement.
• Consistency.
• Repeatability.
The accuracy of the approved equipment enables the delivery of one droplet of wire per pulse.
This enables welding of incredibly thin parent material, i.e 0.6mm sheet can be welded using
a 1.2mm filler wire.
The approved MIG welder uses Direct Current, (DC) and does not produce High Frequency,
(HF), at start up, (initial arc).
Safety Precautions
The following safety precautions should always be implemented:
• Disconnect the vehicle battery.

• Isolate the Electronic Control Modules (ECMs).
• Remove any ECMs within 500mm of the weld area.
Weld Procedures
Pre-weld
Prior to starting any weld procedure you should:
• Disconnect the vehicle battery.

• Isolate the ECM.
The Aluminium surfaces MUST be cleaned prior to welding. Cleaning will aid penetration
and avoid contamination. There are three steps to this process:
1. Clean Surface
• To remove wax and any other contaminants use a chemical surface cleaner, either:
Jaguar approved product: DuPont 3608S. Alternatively, an Isopropyl based product.
2. Remove Oxide
• This can be achieved through a number of processes: Stainless Steel brush. 80 Grit
abrasive paper. Non-Metallic scuff pad.
• Note, if a Stainless Steel brush is used it should not be contaminated by use on a steel
vehicle.
3. Remove Oxide Dust
• Remove dust with a lint free cloth.
Note: Oxide builds up very quickly, therefore, perform steps 2 and 3 immediately prior to
welding. If left for a period of time, steps 2 and 3 should be repeated.
Equipment Set Up
The approved welding equipment for the XK Aluminium range is the "Fronius 2700 Alu
Edition". The user should always refer to the operators manual for detailed instructions.
The following provides an overview of the set-up procedure:
• Health and Safety - read operators manual.

• Check correct power supply.
• Check gas supply.
• Check all equipment parts - safety check.
• Attach power cables, connect to supply.
• Purge gas bottle, attach.
• Attach clamp.
Test Weld
A test weld using identical coupons from waste panels should take place prior to working on
the vehicle. The test piece is then visually checked and destructively tested to ensure all
settings are correct and an acceptable weld has been achieved.
Prior to starting, the following should be checked:
• Gas - Correct for the type of job.

• Filler Wire - Correct for the type of material to be welded.
An effective weld should demonstrate the following qualities:
• All visible weld surfaces shall be clean, bright and of a uniform profile.
• The weld seam should show uniform height and width over its entire length.
• There shall be complete fusion between the surfaces of the work piece and the weld
metal deposit.
Correct level of penetration will be visible at the rear of the coupon as a fine continuous line.
Effective Weld Length
The effective weld length is the weld seam as described in the Body Repair Sections. The
effective weld length does not include allowances for the run-in/run-out, or termination
defects, (start / stop), of the weld seam. It is permissible that the overall weld length is longer
than detailed in the repair section, as the overall weld will include a minimum of 5mm at both
the start and the stop of the weld seam, provided the function of the part is not affected, or the
weld finishes on the edge of a panel.
Post Weld Checks
Weld inspections take the form of a visual examination and destruction testing.
Visual Examinations
A visual examination of fusion welds should be carried out in accordance with the acceptance
criteria detailed in the Imperfections / Defect Levels table.
Defect
Imperfection Details Limits
Type
Burn-through Burn holes Not permitted
Seam offset, Incomplete fusion Not permitted within effective weld length
sides melted
away
Cracks Any form of cracking is Not permitted
not permitted at any
position along the entire
length of the weld seam
Fused weld Limited acceptance. Not permitted on visible
spatter surfaces or in areas where functional
performance of the part is affected, e.g. mating
surfaces, sealing surfaces, etc. In such instances
spatter is to be removed. All loosely adherent
spatters must be removed.
Visible ignition Local melting of parent Permitted provided functional performance of the
marks metal due to arc component is not affected.
Open end crater Reduces the cross Not permitted
sectional area of the weld
seam
Visual pores Not permitted
Weld skip Discontinuity / Not permitted at any position along the entire
interruption in weld seam length of the weld seam
Nominal effective weld lengths are detailed within the appropriate body repair section. Weld
lengths may be greater than that specified providing the part remains functional.
Dye penetrate testing MUST be used for detection of discontinuities, such as cracks, laps,
folds, porosity and lack of fusion that are open to the surface of the material. Typical defects
include start, (cold start / incomplete fusion) and stop, (crater cracking), defects within a
fusion weld run. In addition to this lack of fusion / coalescence at the weld toe, solidification
cracks in the weld bead may also be detected.
Non-destructive Crack Inspection Process
Use the product as listed in the Approved Materials Section, this product is supplied within
the Category 'A' tool kit. The product is an aerosol applied dye system. It is designed to
penetrate the finest cracks and flaws to facilitate detection, the system includes: Cleaner,
Penetrant and Developer.
The process is as follows:
• 1. Use the cleaner to de-grease/clean the test area, then wipe with a lint free cloth.
• 2. When the surface is completely dry apply the penetrant. Cover the test area and
allow a minimum contact time of 10 minutes
• 3. Remove excess penetrant from the surface with a lint free cloth wetted with the
cleaner.
• Apply a THIN film of the developer and leave for a minimum of 10 minutes to draw
up the retained dye from flaws or cracks.
• Suspect areas should then be examined under natural or electric light for signs of flaws
and/or cracks. Cracks will show up as lines whilst porosity will appear as pin holes.
Destructive Testing
Each test weld should be pulled apart to check the quality and penetration of the weld. Visual
examination should be conducted to evaluate and detect all the characteristic/defects detailed
in the Imperfection and Defect Levels Table.
Types of Welded Joint

This section identifies the three types of joint used in Category 'A' panel replacement. It is not
a guide to welding, as all Category A repairers will have staff who are suitably qualified in
welding Aluminium. This section highlights the key points for each weld type.
Lap Joint
Key Points
• Run-In/Out distance of 5mm.

• Minimum overall length of 20mm.
• Must use Start / Finish tabs.
Butt Joint
Key Points
• Run-In/Out distance of 5mm.

• Minimum overall length of 20mm.
• Must use Start/Finish tabs.
• Nominal penetration of fillet required.
Plug Weld
Key Points
• Hole size 10mm.

• Position of MIG nozzle - vertical.
501-25B : Body Repairs – Corrosion Protection
Corrosion Protection
General
The application of additional corrosion protection following body repair is not necessary and
not recommended.
However, it is important to be aware of galvanic corrosion and take steps to prevent its
occurance.
Galvanic Corrosion
Galvanic corrosion is the 'cross-contamination' of dissimilar metals, in this case Aluminium
and Steel. Avoidance of galvanic corrosion is an important issue to be considered in the repair
of Aluminium bodied vehicles.
Precautions to prevent the contamination of exposed bare Aluminium surfaces should be

taken. Good housekeeping / cleanliness should be adopted throughout repairs and especially
prior to welding, pre-treatment, (Pyrosil), and adhesive bonding.
The repair environment requires control and protection from dust and debris from
conventional steel body repairs. All equipment must be clearly identified and used solely on
Aluminium.
Tools should be kept clean and in good order. Steel fastenings are coated to prevent galvanic
corrosion. Fastenings should be examined during repairs and where damaged or suspect must
be renewed
The use of graphite, "penetrating" oil, or copper based anti-seize compounds upon the steel
fixings is not recommended.
Where the OE surface protection, (paint), is removed, it must be reinstated to the

recommended standard.
Only Jaguar Cars Ltd original bodywork components and Jaguar Cars Ltd approved repair
materials, (sealer, paint, etc), are to be used for bodywork repairs.
501-25C : Body Repairs – Water Leaks
Water Leaks
General
• If water leaks occur after bodywork repairs, the cause can be established using the
checks described below. A systematic and logical procedure is required to locate water
leaks. Before beginning extensive checks, a thorough visual inspection must be carried
out.
• Visual Inspection The following characteristics may indicate existing leaks: Check the
clearance and accurate fit of ancillary components such as the hood, tailgate, liftgate,
doors, and so on. Check for correct fit and possible damage to sealing elements such
as blanking plugs, rubber door seals, and so on. Check water drain holes for
unhindered flow.
• Various tests can be used to provide further information on possible leaks: Water test
Washer test Road test Chalk (powder) test
Practical execution of tests and checks

Water test
NOTE:
Never aim a jet of water directly at a rubber seal.
• Carry out the water test with a second person present (in the passenger compartment).
• Use variable washer nozzles (concentrated water jet to fine spray mist).
• Start in the lower section and spray the whole area, working upwards in stages.
Washer test
• Further tests can be carried out in the washer system.

• Some leaks originate here, or only occur here.
• The relevant passenger compartment should be checked using a torch during the wash
procedure.
Road test
• If no leaks are located during the tests above, road tests should be carried out on wet
roads.
• Road tests under various conditions: At various speeds. On various road surfaces
(asphalt to cobbles). With loaded or unloaded vehicle. Driving through puddles (splash
water).
Chalk test (powder test)
• In this test, the clamping load and the bearing surface of the seal are checked.
• Performing the test: Dust the door seal with powder or coat with chalk. Coat the
bearing surface of the seal with a thin film of vaseline. Slowly close the door and open
it again. Check the width and continuity of the imprint on the door seal.
Other test equipment
• Other equipment such as stethoscopes, UV lamps, special mirrors or ultrasound

measuring instruments can be used to locate leaks.
Rectifying the leak using recommended tools, auxiliary

equipment and materials
• Tools and auxiliary equipment: Dry, absorbent cloths Variable washer nozzle Torch,
fluorescent tube Mirror Compressed air Seal lip installer Wet/dry vacuum cleaner
Sealing compound compressor Remover for interior trim Cutter blade or pocket knife
Wedge (wood or plastic) Hot air blower Special mirror for concealed leaks Air flow
checker Sealing compound (tape and plastic compound) Multi-purpose sticker
Clinched flange sealer Window sealing compound Water shield (PVC) Double-sided
adhesive tape for water shield Methylated spirit (available from trade outlets) PU
adhesive Silicone remover Tar remover
Water leaks according to mileage or running time

Increasing mileage has an effect on the problem of leaks in a vehicle. Possible influencing
factors are:
• Servicing and maintenance of seals: No maintenance, lack of maintenance or incorrect

maintenance Using an incorrect agent
• Damaged seals: As a result of aging, wear or incorrect handling/assembly.
• Heavy soiling of the vehicle: Heavy soiling of a vehicle can seriously impair the
function of water drainage channels in particular, and also of rubber seals.
• Age-related factors: Environmental factors UV radiation Extreme climatic conditions
• Corrosion can have a serious impact on bodywork, in particular as a result of: Lightly
or heavily rusted seal carriers Rusted body seal welds Perforation corrosion
Water leaks after body repairs

If a vehicle develops a leak after body repairs, the following points must be taken into
consideration in particular:
• The correct seating of ancillary components and their seals must be checked.
• The correct alignment of doors/tailgate and liftgate must be checked. The associated
seals must not be damaged and must be installed correctly.
• Check that panel seams are correctly sealed.
• The correct seating of rubber grommets must be checked.
• Directly-glazed windows must have correct and complete bonding.
Water drainage system

If a vehicle develops water leaks, then areas into which water is routed or drained should be
checked first.
Water drainage system (illustration for reference only)

1 Water drainage, front
2 Water drainage, side and rear
3 Roof drainage
4 Engine compartment drainage
Water leaks, diagnosis and corrective action: Front

passenger compartment
Windscreen
• Diagnosis: Ingress of water into A-pillar area or instrument cluster area and rocker
panel area.
• Cause: Breaks in adhesive beads
• Corrective action: The breaks in adhesive beads can be located from inside by using
compressed air. The leak can be identified from outside by the escaping air. The
second test method is by means of a water test. The outer trims must be raised
carefully using a plastic wedge. The leak should be located from inside by a second
assistant.
Side windows
In the case of side windows, the same problems can arise as for a windscreen. The same
corrective actions must therefore be used.
Door seal
• Diagnosis: Water ingress in the lower part of the interior door trim or in the rocker
panel area.
• Cause: The water shield fitted behind the interior door trim exists to drain off water
that has entered the door via the drainage holes, either downwards or outwards. If the
water shield seal is damaged or has been fitted incorrectly, then water can get into the
passenger compartment. In addition to this, the drainage holes can become clogged
with leaves, dirt or excess cavity protection agents. Water gathers in the door and
ingresses into the passenger compartment. Check water shield for damage or correct
fitting. If the water shield needs to be re-bonded, then approved seam sealer should be
used. Before the water shield is installed, the drainage holes must be checked for
unhindered flow.
Door seals
• Diagnosis: Ingress of water into the rocker panel area

• Cause: Insufficient clamping load between seal and door.
• Corrective action: Check clamping load: The easiest way to check the clamping load
of a seal to the respective bearing surface is by means of a paper strip test. This
consists of trapping strips of paper at various points between the door and the seal, and
fully closing the door. If it is possible to pull out the paper with no great resistance,
then the clamping load is too low. NOTE:
When adjusting the clamping load, the profile alignment of the relevant
components must always be taken into consideration.
•
Adjust the clamping load: The clamping load is normally adjusted using the striker.
When doing so, the edge alignment from the door to the side panel, or from the front
door to the rear door must be taken into account. Another setting method is to realign
the panel flange for the seal mounting. The clamping load is increased by moving the
flange towards the door. NOTE:
Do not realign the flange too far in the direction of the door, as this can reduce the
bearing surface of the seal to the door.
•
Check the bearing surface: Apply chalk evenly to the surface of the seal. Evenly coat
the bearing surface of the door with vaseline. Close the door fully, the lock must
engage. Open the door. The imprint of the chalk (bearing surface) can be identified in
the film of vaseline. The bearing surface should be at least 5mm across at all points.
• Other causes: The door seal must completely seal the door where it meets the
bodywork. Water can ingress directly or indirectly into the interior of the vehicle if the
seal is damaged at any point.
• Corrective action: A damaged or worn door seal must always be renewed in full.
When renewing the seal, the following must be taken into account: Always fit the seal
first in the area of the narrow radii (corner points). Next, secure the seal to the flange
evenly by tapping lightly with a rubber hammer. The installed seal must not be kinked
at any point.
NOTE:
The prescribed length of a seal must not be shortened.
• Other cause: The door seal is attached to the welded flange all the way round. If this
welded flange is uneven or damaged at any point (usually in areas with small radii)
then this point could be subject to leaks. A stretched seal carrier can also cause a leak.
In both cases, water gets into the vehicle interior under the seal carrier.
• Corrective action: Align the deformed welded flange using a hammer and anvil block,
prevent and, if necessary, repair any paint damage.
Sliding roof/tilting roof
• Diagnosis: Ingress of water at sliding roof aperture

• Cause: The sliding roof/tilting roof is installed in a water trap. The water drains off via
the water trap, water drain holes and drain hoses. The drain hoses lead downwards on
both sides via the A-pillar and B-pillar. The drain holes or drain hoses can become
clogged with leaves, dirt, underbody protection and so on.
• Corrective action: NOTE:
In the case of a sliding or tilting roof, the external rubber seal and the lock
actuator or latch mechanism must be checked first of all.
•
Check the water trap for leaks. Check the drain hoses for leaks and for correct
connection to the water trap. Check the drainage system for unhindered flow, and
blow out with compressed air if necessary. Check the external seal and the correct
adjustment of the sliding roof.
Liftgate
• Diagnosis: Ingress of water into rear headlining area and luggage area.
• Cause: The leak problems of the tailgate and liftgate correspond to those of the doors.
In addition to this, the area to be sealed is much bigger. The routing holes for cables
and hoses must also be sealed. The rubber grommets for the routing holes must be
checked for damage and correct seating (fully unhooked). The mounting points of the
liftgate hinges may leak.
• Corrective action: Check the rubber grommets and renew if necessary. Check the
hinge mounting points, and re-seal with sealing compound if necessary.
Forced air extraction
• Diagnosis: Ingress of water into side luggage compartment area

• Cause: The forced air extraction for the vehicle interior is located in the quarter panel
lower extension. The rubber flap of the forced air extraction must be able to move
freely.
• Corrective action: Remove the forced air extraction. Check the seal area between the
bodywork and housing, as well as the rubber flap. Renew seal if necessary.
Rear window
• Diagnosis: Ingress of water into the luggage compartment area

• Cause: Rear window leaking. Check for leak in the same way as for leaking
windscreen.
501-26 : Body Repairs – Vehicle Specific Information
and Tolerance Checks
Body and Frame

NOTE:
Dimensions are always to the hole center.
Front end dimensions The following dimensions are on the front end of the vehicle.
Detail Dimension
'A' - Rear fender fixing hole 1802.6X, 814.9Y, 964Z
'B' - Rear fender fixing hole to front fender fixing hole 778.7
'C' - Bumper beam top outboard fixing hole 593.5X, 473.7Y, 678.5Z
'D' - Spring mount, forward inboard hole 1304X, 471.4Y, 948.2Z
'E' - Upper arm, top fixing hole 1175.5X, 468.8Y, 862.8Z
'F' - Front fender, fixing hole 1030.4X, 752.6Y, 884.9Z
'G' - Front fender fixing hole to rear fender fixing hole 1749.2
Body side dimensions
Detail Dimension
'A' - Top door hinge, rearward fixing hole 2136.05X, 807.4Y, 894.2Z
'B' - Bottom door hinge, rearward fixing hole 2138.7X, 818.2Y, 593.5Z
'C' - Door striker fixing, top hole 3352.4, 792.7Y, 728.7Z
'D' - Body side rear tooling hole 4607.3X, 786.9Y, 819.03Z
Underbody dimensions
Detail Dimension
'A' - Front sub-frame front fixing to front sub-frame rear fixing 982.6
'B' - Front sub-frame front fixing 893.1X, 419.5Y, 494Z
'C' - Front spring mount, large hole 1342.9X, 434.4Y, 934.2Z
'D' - Front sub-frame rear fixing 1409.8X, 416.25Y, 493Z
'E' - A-frame rear fixing hole 2237.3X, 703.4Y, 282.2Z
'F' - K-frame front fixing hole 3517X, 704Y, 287.6Z
'G' - Rear sub-frame front fixing hole 3791.7X, 454.5Y, 403.1Z
'H' - Rear spring mounting, large hole 4222.7X, 482.4Y, 755Z
'I' - Rear sub-frame rear fixing hole 4366.5X, 507.6Y, 595Z
'J' - K-frame rear fixing hole 4550X, 528Y, 583.1Z
'K' - Rear sub-frame front fixing to rear sub-frame rear fixing 1120.3
Rear end body dimensions
Detail Dimension
'A' - Liftgate, hinge fixing rear hole 3686X, 427Y, 1312.6Z
'B' - Tail lamp, outboard fixing hole 4761.1X, 709.5Y, 881Z
'C' - Liftgate striker fixing hole 4985.5X, 71Y, 712.4Z
'D' - Rear bumper inner fixing hole 4676.2X, 396.3Y, 618Z
'E' - Liftgate spigot strut fixing hole 4268.9X, 445.3Y, 1201.8Z
'F' - Liftgate, hinge fixing rear hole to liftgate striker fixing hole 1475.0
Gap and Profile dimensions

Gap and profile information on the front end of the vehicle
Detail Gap Profile

'a' - Hood to front bumper 4.0 ±1.7 -1.0 ±1.1
'b' - Fender to head lamp 2.0 ±1.6 -1.0 ±1.5
'c' - Hood to fender 3.5 ±1.1 -1.0 ±1.0
Gap and profile information on the side of the vehicle
Detail Gap Profile

'd' - Door to fender 4.0 ±1.0 0.0 +0.5 -1.5
'e' - Door to bodyside panel 4.0 ±1.0 0.0 ±0.5
'f' - Door glass to rear quarter glass 8.0 ±2.0 0.0 ±1.0
'g' - Bodyside panel to rear bumper 0.0 +0.5 -0.0 0.0
'h' - Rear lamp to bodyside panel 2.0 ±0.5 0.0 ±1.0
Gap and profile information on the rear end of a Coupe vehicle
Detail Gap Profile

'j' - Liftgate to bodyside panel 3.5 ±1.2 -5.0 ±1.2
'k' - Rear lamp to rear fog lamp 4.0 ±1.0 -1.0 ±1.0
Gap and profile information on the rear end of a Cabriolet vehicle
Detail Gap Profile

'l' - Convertible hood to convertible hood compartment lid 3.0 ±3.0 N/A
'm' - Convertible hood compartment lid to luggage compartment lid 5.5 ±1.5 0.0 ±1.0
'n' - Luggage compartment lid to body side panel 3.5 ±1.0 -1.0 ±1.0
'p' - Tail lamp to indicator lamp 4.0 ±1.6 0 ±1.7
501-27 : Front End Sheet Metal Repairs
Specifications
Specifications
Item Nm lb-ft lb-in

Auxiliary front crossmember - bolt 25 18 -
Front fender - bolt 10 7 -
Front crossmember to fender apron panel front extension - bolt 20 15 -
Front crossmember to fender apron panel reinforcement - bolt 30 22 -
Front crossmember to front side member extension- bolt 25 18 -
Front crossmember to headlamp mounting bracket - bolt 9 - 80
Front side member A - -
Front side member, side extension - bolt 25 18 -
Front side member, side extension mounting - bolt 70 52 -
Front side member to deformation element bracket A - -
Side member deformation element - bolt 70 52 -
A = refer to Removal and Installation procedure.

Front End Sheet Metal

Front end service panels
Item Description Service part No

1 Front bumper cover
2 Front bumper
3 Auxiliary front crossmember C2P 8487
4 Headlamp mounting bracket R/H C2P 5457 L/H C2P 5458
5 Front crossmember C2P 4831
6 Fender apron panel front extension R/H C2P 5642 L/H C2P 5643
7 Side member deformation element R/H C2P 3370 L/H C2P 3370
8 Front side member to deformation element bracket R/H C2P 4646 L/H C2P 4647
9 Front side member side extension mounting R/H L/H
10 Front side member side extension R/H C2P 8095 L/H C2P 8096
11 Front side member extension R/H L/H
12 Front side member R/H L/H
13 Suspension top mount R/H C2P9666 L/H C2P9667
14 Front Wheelhouse R/H C2P 8474 L/H C2P 8475
15 Hood
16 Fender apron panel reinforcement R/H C2P 8489 L/H C2P 8490
17 Fender apron panel R/H C2P 8097 L/H C2P 8098
18 Fender apron panel closing panel R/H L/H
19 Front fender R/H L/H
Time schedules, front end

The following information shows the total time taken to replace single panels and complete
assemblies. This time includes removal of Mechanical, Electrical and Trim, (MET), items,
plus paint times based on Metallic Clear Over Base Paint, (blends to adjacent panels are not
included).
The times shown were generated by Thatcham, (the Motor Insurance Repair Research
Centre), and are to be used as a guide only.
Panel Description coupe

Hood 5.6
Front bumper cover 5.9
Front fender L/H 7.0
Front Fender R/H 7.0
Front Crossmember 4.4
Auxiliary front crossmember 5.7
Engine and Suspension assembly remove and install 10.5
Combination panel replacement times
The following panel combination times show the total time to remove/refit body panels, MET
items and paint times based on Metallic Clear Over Base Paint process, (blends to adjacent
panels are not included).

Hood
Front bumper cover
Front bumper
Auxiliary front crossmember
Side member deformation element L/H and R/H
Front side member side extension mounting
Front side member side extension
Front Fender
Total Time L/H 21.2 R/H 21.2

Hood
Front bumper cover
Front bumper
Front side member side extension L/H and R/H
Front Fender L/H and R/H
Total Time 24.1

Hood
Front bumper cover
Front bumper
Front side member side extension
Front bumper
Front side member to deformation element bracket.
Front side member
Front Crossmember
Fender apron panel front extension
Fender apron panel front reinforcement
Fender apron panel
Fender apron panel closing panel
Front Wheelhouse
Suspension top mount
Front Fender
Engine and suspension assembly remove and install

Hood
Front bumper cover
Front bumper
Front side member side extension mounting L/H and R/H
Front side member side extension L/H and R/H
Front bumper
Front side member to deformation element bracket L/H and R/H
Front side member L/H and R/H
Front Crossmember
Fender apron panel front extension L/H and R/H
Fender apron panel front reinforcement L/H and R/H
Fender apron panel L/H and RH
Fender apron panel closing panel L/H and R/H
Front Wheelhouse L/H and R/H
Suspension top mount L/H and R/H
Front Fender L/H and R/H
Engine and suspension assembly remove and install
Total Time 60.7
Front Fender
Removal
1
2 . Remove the rocker panel moulding.

For additional information, refer to Rocker Panel Moulding (76.11.36)

4 . Open the hood.
5 . Open the door.
6.
Remove the front fender.

Release the headlamp clip.
Carefully release the fender.
7 . NOTE:
Remove the fender moulding assembly.

8 . Remove the inner grille.

Installation
1 . Install the inner grille.
Secure the clips.
2 . Install the fender moulding assembly.

3 . Install the front fender.

Secure the headlamp clip.
4 . Install the fender splash shield, front section.

5 . Install the rocker panel moulding.

Front Crossmember
Removal
NOTE:
This is a category 'B' repair.
NOTE:
In this procedure the front crossmember is removed and installed without the need to
remove any other body panels.
1 Before commencing this procedure ensure that you are aware of all Health and Safety
. requirements.
For additional information, refer to Health and Safety Precautions
2 For further information on the methods, tools and fixings used in this procedure refer
. to the body repairs - general information section.
For additional information, refer to Body Repairs
3 . Disconnect the battery.

5 . Release the air intake duct and position it aside.
6 . Release the PAS reservoir and position it aside.
7 Remove the LH & RH radiator upper mountings, this also releases the support braces.
. If the crossmember is being renewed, completely remove the mountings and save for
fitment to the new panel.
8 . Release the crossmember wiring harness and position it aside.
9 If the panel is being renewed, remove the RH & LH SRS front impact severity sensors
. and save for installation to the new panel.
For additional information, refer to Front Impact Severity Sensor
10 . Remove the 2 headlamp mounting brackets, 2 10mm Bolts on each side.

11 . Remove 4 13mm bolts, 2 each side, to the fender apron panel front extension.
12 . Remove 4 13mm bolts, 2 each side, to the fender apron panel reinforcement.
13 . Remove 2 10mm bolts, 1 each side, to the front side member extension.
Installation
1 . Install is the reversal of removal.
2 Tighten the crossmember to fender apron panel front extension bolts to: 20 Nm (15
. lb.ft).
3 Tighten the crossmember to fender apron panel reinforcement bolts to: 30 Nm (22
. lb.ft).
4 . Tighten the crossmember to front side member extension bolts to: 25 Nm (18 lb.ft).
5 . Tighten the headlamp mounting bracket to crossmember bolts to: 9 Nm (7 lb.ft).
6 . Check headlamp alignment, adjust as necessary.

For additional information, refer to Headlamp Adjustment (86.40.18)
Fender Apron Panel
Removal
NOTE:
This is a category 'A' repair.
NOTE:
In this procedure the fender apron panel is replaced in conjunction with the:
• front bumper cover

• front fender
• fender apron panel front extension
. requirements.
2 For further information on the methods, tools and fixings used in this procedure, refer

4 . Remove the front fender.

For additional information, refer to Front Fender
5 . Remove the fender apron panel front extension.

For additional information, refer to Fender Apron Panel Front Extension
6 . Remove the hood catch.

8 . Remove the pedestrian protection hood actuator.

9 . LH Side: Remove the pedestrian protection module.

For additional information, refer to Pedestrian Protection Module
10 . RH Side: Remove the windshield washer reservoir.

11 . RH Side: Remove the coolant expansion tank.
12 . Release the inner wheelhouse wiring harness and position it aside.
13 Remove 6 Monobolts, 4 from the A-Pillar and 2 from the fender apron panel
. reinforcement.
14 Using a 6.5mm Cryobit drill bit, remove 15 Self Piercing Rivets, upper edge, to the
. fender apron panel reinforcement. Using the ESN50, remove 16 Self Piercing Rivets,
lower edge, to the fender apron panel closing panel.
15 . Separate the joints and remove the panel.
Installation
1 . Remove rivet remnants.
2 . Using a Roloc Bristle Disc, remove adhesive residue.
3 Offer up the new panel, using the fender to aid alignment. When aligned, clamp into
. position.
4 . Remove the fender.
5 If re-using the fender apron panel reinforcement, transfer the location of the 13 fixing
. holes to the new fender apron panel, (avoiding any internal fixings), drill through using
a 6.5mm Cryobit Drill Bit.
6 . Remove the new panel and deburr the drilled holes.
7 . Using a Roloc Bristle Disc, clean and prepare the new panel joint surfaces.
8 . Pyrosil the joints.
9 . Apply the coupling agent and allow to dry.
10 . Apply a 5mm adhesive bead to the body panel joints.
11 . Offer up the new panel, align and clamp into position.
12 Using the Genesis G4, install 13 Hemloks, part no: C2C 7792, to the fender apron
. panel reinforcement and install 6 Monobolts, part no: C2P 4773, 2 to the fender apron
panel reinforcement and 4 to the A Pillar.
13 Using the ESN50, install 18 Self Piercing Rivets, part no: C2C 20590, along the lower
. edge, to the fender apron panel closing panel.
14 . Remove any excess adhesive.

Fender Apron Panel Reinforcement
Removal
NOTE:
NOTE:
In this procedure the fender apron panel reinforcement is replaced in conjunction with
the:

• front fender
• front crossmember
• fender apron panel
• fender apron panel closing panel
. requirements.
3 . Remove the fender apron panel.

For additional information, refer to Fender Apron Panel
4 . Remove the fender apron panel closing panel.

For additional information, refer to Fender Apron Panel Closing Panel
5 . Remove the insulating material from the bulkhead.
6 . Remove 3 Monobolts.
7 . Using a 6.5mm Cryobit drill bit, remove 18 Self Piercing Rivets.
8 . Separate joints and remove the panel.
Installation
4 . Mark the position of 10 fixing holes to the suspension top mount.
5 . Remove the new panel.
6 Drill 10 pilot holes in the new panel, in the positions marked, then, using a 9.5mm drill
. bit, enlarge these holes.
7 . Deburr the drilled holes.
8 Using the HES 412 Rivet Nut Tool, insert 10 Rivet Nuts, part no: C2C 10348, into the
. pre-drilled holes.
9 . Using a Roloc Bristle Disc, clean and prepare the panel joint surfaces.
12 . Apply a 5mm adhesive bead to the body joints.
14 . NOTE:
The replacement fixings must be Torx screws and not Ejots.
Install 10 T30 Torx screws, part no: C2G 1964, to the suspension top mount.
15 Using the ESN50, install 7 Self Piercing Rivets, part no: C2C 20590, 5 to the A-Pillar
. closing and 2 to the front wheelhouse. Install 1 Self Piercing Rivet, part no: C2C
20591, to the suspension top mount.
16 . Using the Genesis G4, install 3 Monobolts, part no: C2P 4773, to the A- Pillar.
18 . Install is the reverse of removal.

Fender Apron Panel Closing Panel
Removal
NOTE:
NOTE:
In this procedure the fender apron panel closing panel is replaced in conjunction with the:

• front fender
. requirements.


For additional information, refer to Front Crossmember
5 . Remove the hood catch.

7 . Remove the strut brace.
8 . LH Side: Remove the pedestrian protection module.

For additional information, refer to Pedestrian Protection Module


11 . LH Side: Remove the air cleaner.
12 . LH Side: Remove the power distribution box.
13 . LH Side: Remove the engine control module, including its bracket.

15 . LH Side: Remove the pollen filter housing.
16 LH Side: Remove the anti-lock brake system (ABS) module.

. For additional information, refer to Anti-Lock Brake System (ABS) Module
(70.60.02)
17 . Remove the LH & RH plenum chambers.
18 . Remove the pedestrian protection bonnet actuator and its bracket.
19 Using a 6.5mm Cryobit drill bit, remove 6 Self Piercing Rivets, from the suspension
. top mount.
20 Using a 6.5mm Cryobit drill bit, remove 7 Self Piercing Rivets, from the fender apron
. panel reinforcement.
21 . Remove 3 Monobolts from the A-Pillar.

Installation
4 . Using a 6.5mm Cryobit drill bit, drill 5 holes to the inner panel.
5 . Mark the position of the 6 fixing holes to the suspension top mount.
7 Using a 6.5mm Cryobit drill bit, drill 6 holes in the new panel, as marked, at the joint
. with the suspension top mount.
8 . Deburr drilled holes.
12 . Apply a 5mm bead of adhesive to the new panel joints.
14 Using the Genesis G4, install 6 Hemloks, part no: C2C 10349, to the suspension top
. mount.
15 Using the Genesis G4, install 5 Hemloks, part no: C2C 10349, to the fender apron
16 . Using the Genesis G4, install 3 Monobolts, part no: C2P 4773, to the A Pillar.
17 Using the ESN50, install 2 Self Piercing Rivets, part no: C2C 20590, to the fender
. apron panel reinforcement.

Front Side Member
Removal
NOTE:
NOTE:
In this procedure the front side member is replaced in conjunction with the:

• front bumper
• auxiliary front crossmember
• hood
• front side member side extension
• suspension top mount
• front side member side extension mounting
• front side member deformation element
• front side member to deformation element bracket
NOTE:
It is necessary to remove the engine and suspension as an assembly.
NOTE:
It is necessary to remove the front side member lower inner and the front side member
closing panel assembly to enable the fitment of the front side member. These panels
cannot be reused and will require replacement.
. requirements.

4 Remove the front side member to deformation element bracket.

. For additional information, refer to Front Side Member To Deformation Element
Bracket
5 . Remove the suspension top mount.

For additional information, refer to Suspension Top Mount
NOTE:
This procedure assumes that the suspension top mount is damaged and has been removed,
however, the front side member can be replaced with the suspension top mount in situ.
6 . Remove the engine and front suspension as an assembly.

8 . LH Side: Remove the junction box.

10 . LH Side: Remove the A/C pipe.
11 . LH Side: Remove the fuel pipes.
12 LH Side: Remove the Anti-lock Brake System, (ABS), module.

(70.60.02)
13 . LH Side: Remove the engine control module, (ECM) and its mounting bracket.
14 . RH Only: Remove the secondary air injection pump.

For additional information, refer to Secondary Air Injection (AIR) Pump

For additional information, refer to Steering Column Lower Shaft (57.40.05)
17 . Remove the brake pipes along the side member.
18 . Remove the side member exhaust heat shield.
20 . Remove the LH and RH plenum chambers.
21 . Remove the heater supply and return hoses.

22 . Remove the brake pipes from the bulkhead.
23 . Release the side member wiring harness and position it aside.
24 The following steps identify the procedure for removing the front side member lower
. inner.
26 Using a combination of the ESN50 and a 6.5mm Cryobit drill bit, remove 10 Self
. Piercing Rivets.
27
. CAUTION: Do not discard the Ejots. They are to be re-used during
installation.
Remove 10 T30 Ejots.

28 NOTE:
. Take care when making the saw cut, do not cut into the reinforcement under the
panel.
Saw cut the old panel along the point shown in the illustration. This allows the panel
to be removed without the need to disturb the joint at the bulkhead / floor panel.
29 . Separate the joints and remove the front side member lower inner.
30 . Remove the rivet remnants.
31 Using a Roloc Bristle Disc, remove any adhesive residue and clean and prepare the
. panel joint surfaces.
32 The following steps identify the procedure for removing the front side member
. closing panel assembly.
33
. CAUTION: Do not discard the Ejot. It is to be re-used during
installation.
Remove 2 Monobolts, remove 2 21mm bolts and 1 T30 Ejot.

34 . Using a 6.5mm Cryobit drill bit, remove 18 Self Piercing Rivets, (19 on the LH side).
35 NOTE:
. On removal, keep panel damage to a minimum as it will be used as a template
for the new panel.
Separate the joints and remove the front side member closing panel assembly. Retain
the old panel for use as a template.
37 Using a Roloc Bristle Disc, remove any adhesive residue and clean and prepare the
. panel joint surfaces.
38 . The following steps identify the procedure for removing the front side member.
39 . Remove 2 21mm bolts and 2 13mm bolts.

40 Using a Belt Sander, remove the "button" heads of 2 Self Piercing Rivets, located at
. the rear of the side member. Using the ESN50, remove these 2 rivets plus a further 3
Self Piercing Rivets. Using a 6.5mm Cryobit drill bit, remove a further 5 Self Piercing
Rivets from the bulkhead reinforcement.
41
. CAUTION: Do not discard the Ejots. They are to be re-used during
installation.
Remove 6 Monobolts and 3 Ejots.

42 . Separate the joints and remove the front side member.
Installation
2 . Using a Roloc Bristle Disc, remove any adhesive residue.
3 Offer up the new panel and secure using the 4 21mm and 2 13mm bolts. Check
. alignment, if correct proceed to next step, if not, rectify and recheck before proceeding.
4 When aligned, clamp into position. Using a 6.5mm Cryobit drill bit, drill 3 holes which
. were Ejot fixings in the original front side member.
5 Mark the positions of 10 fixing holes. 5 From underneath, illustrated at 1 and 5 along
. the top flange, illustrated at 2.
6 . Remove the new panel and using a 6.5mm Cryobit drill bit, drill the 10 marked holes.
12 Offer up the new panel and secure using the 4 21mm and 2 13mm bolts. Tighten the
. 21mm bolts to 133 Nm (98 lb.ft).
13 Check alignment, if correct proceed to the next step, if not, rectify and recheck before
. proceeding.
14 . Using the Genesis G4, install 5 Hemloks, part no: C2C 10349.
16 Using the Genesis G4, install 3 Hemloks, part no: C2C 10349 and 6 Monobolts, part
. no: C2P 4773.

NOTE:
Allow the adhesive applied to the front side member to cure before installing the front
side member closing panel assembly.
18 The following steps identify the procedure for installing the front side member
. closing panel assembly.
19 . Remove 2 21mm bolts from the front side member.
20 From the old panel, cut a template, as illustrated, to use for alignment of the new
. panel.
21 . Offer up the new panel to the car and scribe around the inside of the 2 facing holes.
22 Offer up the template to the car and ensure that the scribe marks and original fixing
. holes are aligned, if not, rectify and recheck before proceeding.
23 Clamp the template to the new panel and using a 6.5mm Cryobit drill bit, drill
. through the 11 holes, (12 on the LH), into the new panel.
24 Offer up the new panel, align and clamp into position, use the 2 21mm bolts to
. secure.
25 Using a 6.5mm Cryobit drill bit, drill 1 hole, illustrated at 1, through the new panel
. into the front side member.
26
. CAUTION: Take care not to drill right through as this will go into the
vehicle. Drill only through the new panel and 2 further panel thicknesses.
Using a 6.5mm Cryobit drill bit, drill 1 hole, illustrated at 2, through the new panel
into the tunnel, (there are 2 holes on the LH side).
27 . From inside the vehicle, mark the positions of 5 fixing holes for drilling.
29 . Using a 6.5mm Cryobit drill bit, drill the 5 holes in the new panel, as marked.
35 . Offer up the new panel and use the 2 21mm bolts to loose fit.
37 . Using the Genesis G4, install 1 Hemlok, part no: C2C 10349.
39 . Using the Genesis G4, install 6 Hemloks, (7 on the LH side), part no: C2C 9818.
40 Using the Genesis G4, install 2 Monobolts, part no: C2P 4773. Then, fully tighten the
. 2 21mm bolts to 133 Nm (98 lb.ft).
42 The following steps identify the procedure for installing the front side member lower
. inner.
43 Saw cut a section of the new panel corresponding to the part cut from the old panel, as
. shown in the illustration. Ensure an allowance is made for overlap.
45 Using a 6.5mm Cryobit drill bit, drill 13 holes. Use the existing holes in the body as a
. guide.
46 Using a 6.5mm Cryobit drill bit, drill 5 holes at the point where the old and new
. panels overlap.

52
. CAUTION: If the original Ejot cannot be re-used, and the original thread
remains intact, then a Torx screw (C2C 1964) can be used in its place.
Install 8 original Ejots. Using the Genesis G4, install 1 Monobolt, part no: C2P 4773.
53 . Using the Genesis G4, install 2 Monobolts, part no: C2P 4773.
57 . Install of mechanical components is the reversal of removal.

Side Member Deformation Element
Removal
NOTE:
NOTE:
In this procedure the side member deformation element is replaced in conjunction with
the:

• front bumper
. requirements.
NOTE:
Whenever there is damage to the side member deformation element, the front side
member to deformation element bracket must always be checked for damage. Where
damage is evident or suspected, the bracket must be renewed.
For additional information, refer to Front Side Member To Deformation Element Bracket

For additional information, refer to Front Bumper (76.22.08)
4 . Remove the auxiliary front crossmember.

For additional information, refer to Auxiliary Front Crossmember
5 . Remove the front side member side extension mounting.

For additional information, refer to Front Side Member Side Extension Mounting
6 Remove the radiator and A/C condenser.

. For additional information, refer to Radiator - Vehicles Without: Supercharger
(26.40.01)
7 . RH Side: Remove the fender splash shield.
8 . Release the deformation element wiring harness and position it aside.
9 . Remove 2 T50 Torx bolts, (RH Illustrated).
10 . Remove 4 T50 Torx bolts, (only 2 on LH), RH Illustrated.
Installation
1 Install is the reversal of removal. Tighten the deformation element bolts to 70 Nm (52
. lb.ft).
Front Side Member Extension
Removal
NOTE:
NOTE:
In this procedure the front side member extension is replaced in conjunction with the:
• front bumper
• hood
• side member deformation element
• side member side extension
• side member side extension mounting
. requirements.
3 . Remove the auxiliary front crossmember to subframe brace.
4 . Remove the exhaust manifold heat shield.

. For additional information, refer to Cooling System Draining, Filling and Bleeding -
4.2L NA V8 - AJV8
6 . RH Side: Remove the heater pipes.
7 . Release the side member wiring harness and position it aside.
8 . LH Side: Release the A/C pipes and position them aside.
NOTE:
In this procedure the engine remains in the vehicle. The mechanical components listed
below are removed to allow access for the Genesis G4. If the engine is removed it is not
necessary to remove these additional components.
9 . LH Side: Remove the radiator bottom hose.
10 . RH Side: Remove the radiator top hose.
11 LH Side: Remove the PAS pump.

. For additional information, refer to Power Steering Pump - 4.2L NA V8 - AJV8
(57.20.14)
12 LH Side: Remove the A/C compressor.

. For additional information, refer to Air Conditioning (A/C) Compressor - 4.2L NA
V8 - AJV8 (82.10.20)
13 . RH Side: Remove the generator.

For additional information, refer to Generator - 4.2L NA V8 - AJV8 (86.10.02)


16 . Remove the side member deformation element.

For additional information, refer to Side Member Deformation Element
17 . Remove the hood hinge.
18 . Remove 5 Monobolts from the side member.
19 Using the ESN50, remove 2 Self Piercing Rivets, from the side member, as shown in
. the inset. Using a 6.5mm Cryobit Drill Bit remove 2 Self Piercing Rivets, from the
suspension top mount.
Installation
3 Offer up the new panel and clamp into position, using the front crossmember to aid
. alignment.
4 Check alignment, if correct proceed to next step, if not, rectify and recheck before
. proceeding.
5 Using a 6.5mm Cryobit Drill Bit, drill 4 holes at the points shown; 2 through the side
. member and 2 through the suspension top mount, into the new panel, ready for Hemlok
fixings.
11 . Apply a 5mm adhesive bead to the new panel joints.
13 Using the Genesis G4, install 4 Hemloks; 2 to the suspension top mount and 2 to the
. side member, part no: C2C 7792.
14 The illustration shows the Genesis G4 being used with the engine in place. In order to
. gain access the "catcher" chamber of the Genesis G4 has to be removed. This does not
affect the operation or safety of the gun. However, to prevent the remnant being
ejected into any engine bay components, a plastic bag should be attached to collect it.
15 . Using the Genesis G4, install 5 Monobolts, part no: C2P 4773, to the side member.

Front Wheelhouse
Removal
NOTE:
NOTE:
In this procedure the front wheelhouse is replaced in conjunction with the:

• front fender
• fender apron panel reinforcement
. requirements.
3 . Remove the fender apron panel reinforcement.

For additional information, refer to Fender Apron Panel Reinforcement
4 . Remove 4 Monobolts, from the torque box.

5 Using a 6.5mm Cryobit Drill Bit, remove 1 Self Piercing Rivet, from the front side
. member lower outer.
6 Using a combination of the ESN50 and 6.5mm Cryobit Drill Bit, remove 6 Self
. Piercing Rivets, from the A-Pillar closing panel.
. Piercing Rivets, from the suspension top mount.
Installation
3 . Where necessary, dress the flanges of adjacent panels.
4 . Offer up the new panel and clamp into position.
. proceeding.
6 . Using a 6.5mm Cryobit Drill Bit, drill 12 holes ready for Hemlok fixings.

14 Using the Genesis G4, install 12 Hemloks, part no: C2C 7792, 7 to the suspension top
. mount, 4 to the A-Pillar closing panel and 1 to the side member lower outer.
15 Using the ESN50, install 2 Self Piercing Rivets, part no: C2C 20589 to the A-Pillar
. closing panel.
16 . Using the Genesis G4, install 4 Monobolts, part no: C2P 4773, to the torque box.

Fender Apron Panel Front Extension
Removal
NOTE:
This is a category 'A' repair
NOTE:
In this procedure the fender apron panel front extension is replaced in conjunction with
the:

• front fender
. requirements.
2 For further information on the methods, tools and fixings used in this procedure, refer


5 . Using the ESN50, remove 1 Self Piercing Rivet to the fender apron panel.
Installation
1 . Remove the rivet remnant and deburr the hole.
2 NOTE:
. The original Rivet hole should be filled using adhesive.
Using the ESN50, install 1 Self Piercing Rivet, part no: C2C 20590, to the fender
apron panel.

Removal
NOTE:
NOTE:
In this procedure the front side member side extension is replaced in conjunction with the:

• front fender
. requirements.

4 . LH Only: Remove the air cleaner.


6 . Remove 2 10mm bolts.

Installation
1 Offer up the new panel, using the fender for alignment. When aligned tighten bolts to
. 25 Nm (18 lb.ft).

Auxiliary Front Crossmember
Removal
NOTE:
NOTE:
In this procedure the auxiliary front crossmember is replaced in conjunction with the:
. requirements.
3 . Remove the front bumper cover

5 Remove 4 10mm bolts, 2 each side, to the side member deformation element and
. remove the panel.
Installation
1 Offer up new panel, align and secure using the 4 10mm bolts, 2 each side. Tighten the
. bolts to 25 Nm (18 lb.ft).

Mounting
Removal
NOTE:
NOTE:
In this procedure the front side member side extension mounting is replaced in
conjunction with the:

• front fender
. requirements.
3 . Remove the front side member side extension.

For additional information, refer to Front Side Member Side Extension
4 . Remove 4 T50 Torx bolts.

Installation
1 . Offer up the new panel and tighten the bolts to 70 Nm (52 lb.ft).

Front Side Member To Deformation
Element Bracket
Removal
NOTE:
NOTE:
In this procedure the front side member to deformation element bracket is replaced in

• front bumper
• side member side extension
• side member side extension mounting
• side member deformation element
. requirements.
NOTE:
Whenever there is damage to the deformation element, the front side member to
deformation element bracket must always be checked for damage. Where damage is
evident or suspected the bracket must be renewed.
NOTE:
Whenever there is damage to the front side member, the front side member to
deformation element bracket must always be renewed. When renewing the bracket and
side member in combination, removal of the bracket is not required.
3 . Remove the side member deformation element.

For additional information, refer to Side Member Deformation Element
5 NOTE:
. Take care not to damage the side member when removing the bracket.
Separate and remove the bracket from the side member. Adhesive is applied in
production so the bracket will need to be eased from the side member, use a hammer
and chisel on the lip of the bracket to remove.
Installation
1 . Using a belt sander, remove adhesive residue from inside the side member.
2 . Bolt the bracket to the side member using 1 subframe bolt and 2 T50 Torx bolts.
3 Install the side member deformation element and fix with 6 T50 Torx bolts, (4 on LH
. Side).
4 Check alignment, if correct, tighten the bolts to the deformation element to 70 Nm (52
. lb.ft), if not, rectify and recheck before proceeding.
5 Following a successful dry fit, remove the bracket with the deformation element
. attached.
6 Using a Roloc Bristle Disc, clean and prepare the bracket at its joint with the side
. member, (engine bay side only).
9 . Apply a 5mm adhesive bead to the bracket on the engine bay side.
10 . Slide the bracket into the side member.
11 Bolt on the front side member side extension mounting using its 4 T50 Torx bolts.
. Check alignment. If alignment is correct, tighten the bolts to 70 Nm (52 lb.ft), if not,
rectify and recheck before proceeding.
12 . Using the Genesis G4, renew 4 Monobolts, part no: C2P 4773.

Suspension Top Mount
Removal
NOTE:
NOTE:
In this procedure the suspension top mount is replaced in conjunction with:

• front bumper
• front fender
• side member extension
NOTE:
It is also necessary to remove the engine and suspension as an assembly.
. requirements.

4 . Remove the engine and suspension as an assembly.


9 . Remove the LH and RH strut braces.
10 . Remove the heater supply and return hoses
11 . Release the brake pipes at the bulkhead and position them aside.
12 Release the brake pipes at the side member / inner wheelhouse and position them
. aside.
14 . LH Side: Remove the A/C lines.
15 LH Side: Remove the upper suspension arm.

. For additional information, refer to Upper Arm LH - 4.2L NA V8 - AJV8/4.2L SC
V8 - AJV8 (60.35.41)
16 RH Side: Remove the upper suspension arm.

. For additional information, refer to Upper Arm RH - 4.2L NA V8 - AJV8/4.2L SC
V8 - AJV8 (60.35.42)


19 . Release the side member and inner wheelhouse wiring harness and position it aside.
20 . LH Side: Remove the engine control module (ECM) and its mounting bracket.
22 . LH Side: Release the fuel pipes and position them aside.


25 . Remove the front side member extension.

For additional information, refer to Front Side Member Extension
. Piercing Rivets.
27 . Remove 2 Monobolts and 3 Ejots, from the side member.
28 Using a 6.5mm Cryobit drill bit, remove 6 Self Piercing Rivets, from the fender apron
. panel closing panel.
29 Using a 6.5mm Cryobit drill bit, remove 10 Self Piercing Rivets, to the fender apron
Installation
3 Offer up new panel and bolt to jig. Use Monobolt holes to aid alignment. If alignment
. is correct proceed to next step, if not, rectify and recheck before proceeding.
4 Using a 6.5mm Cryobit drill bit, drill 10 holes, through the fender apron panel
. reinforcement into the suspension top mount.
5 Using a 6.5mm Cryobit drill bit, drill 6 holes, through the fender apron panel closing
. panel into the suspension top mount.
6 Using a 6.5mm Cryobit drill bit, drill 7 holes, through the front wheelhouse into the
. suspension top mount.
7 Using a 6.5mm Cryobit drill bit, drill 2 holes, through the front side member into the
. suspension top mount.
8 Using a 6.5mm Cryobit drill bit, drill 2 holes, through the side member lower outer
. into the suspension top mount.
9 If a new side member is being fitted: An additional 3 holes will need to be drilled in the
. positions of the original Ejots, as these will be replaced with Hemloks, part no: C2C
10349.
11 Using a 9.5mm drill bit, enlarge the 10 holes in the fender apron panel reinforcement.
. Deburr the drilled holes and then, using the HES 412 Rivet Nut Tool, insert 10 Rivet
Nuts into the drilled holes.
14 . Apply the coupling and allow to dry.
16 . Bolt new panel to jig bracket, align and clamp to the side member.
17 . NOTE:
The replacement fixings must be Torx Screws and not Ejots.
Install 10 T30 Torx screws to the suspension top mount.
18 . Install 3 Ejots, (not applicable when a new side member is being installed).
19 If the original side member is re-used: Install 3 Ejots and using the Genesis G4, install
. 2 Hemloks, part no: C2C 10349 and 2 Monobolts, part no: C2P 4773.
20 If a new side member is being installed: Using the Genesis G4, install 5 Hemloks, part
. no: C2C 10349 and 2 Monobolts, part no: C2P 4773.
21 Using the Genesis G4, install 6 Hemloks, part no: C2C 10349, to the suspension top
. mount.
22 Using the Genesis G4, install 7 Hemloks, part no: C2C 10349, to the front
. wheelhouse.
23 Using the Genesis G4, install 2 Hemloks, part no: C2C 10349, to the side member
. lower outer.

Front Side Member and Suspension Top
Mount Assembly
Removal
NOTE:
This is a category 'A' repair
NOTE:
In this procedure the front side member and suspension top mount assembly is replaced in
• front bumper
• front fender
• hood
• bulkhead lower reinforcement
• fender apron panel reinforcement
NOTE:
It is also necessary to remove the engine and suspension as an assembly.
NOTE:
It is necessary to remove the secondary, inner, floor panel and the front side member
closing panel to enable the fitment of the front side member and suspension top mount
assembly. These panels cannot be reused and will require replacement, the closing panel
should be retained for use as a template.
. requirements.
3 . Remove the front side member side extension mounting.

For additional information, refer to Front Side Member Side Extension Mounting


7 . Remove the fender apron panel reinforcement.

For additional information, refer to Fender Apron Panel Reinforcement
8 . Remove the bulkhead lower reinforcement.

For additional information, refer to Bulkhead Lower Reinforcement

10 . Remove the RH rear seat cushion.


12 . Remove the carpet.



18 . Remove the LH and RH strut braces.
19 . Remove the heater supply and return hoses.
20 . Release the brake pipes at the bulkhead and position them aside.
21 Release the brake pipes at the side member / inner wheelhouse and position them
. aside.

23 . LH Side: Remove the A/C pipe.
24 LH Side: Remove the Anti-lock Brake System, (ABS), module.

(70.60.02)
25 . LH Side: Remove the engine control module, (ECM) and its mounting bracket.


For additional information, refer to Steering Column Lower Shaft (57.40.05)
29 LH Side: Remove the upper suspension arm.

. For additional information, refer to Upper Arm LH - 4.2L NA V8 - AJV8/4.2L SC
V8 - AJV8 (60.35.41)
30 RH Side: Remove the upper suspension arm.

. For additional information, refer to Upper Arm RH - 4.2L NA V8 - AJV8/4.2L SC
V8 - AJV8 (60.35.42)


33 . Release the side member and inner wheelhouse wiring harness and position it aside.
34 . LH Side: Release the fuel pipes and position them aside.
35 . Remove the side member exhaust heat shield.
37 . Remove the engine and suspension as an assembly.
38 The following steps identify the procedure for removing the secondary, inner, floor
. panel.
40 . Separate the joints and remove the secondary, (inner), floor panel.
41 The following steps identify the procedure for removing the front side member
. closing panel.
42 Using a 6.5mm Cryobit Drill Bit, remove 4 Self Piercing Rivets from the front side
. member lower inner. Separate this joint and bend down to reveal 1 "hidden" self
piercing rivet.
43 Using a 6.5mm Cryobit drill bit, remove 18 Self Piercing Rivets, (19 on the LH side).
. This joint includes the 1 "hidden" rivet. The graphic shows the side member lower
inner removed and is for reference only.
44 Remove 2 Monobolts, remove 2 21mm bolts and 1 T30 Ejot. The illustration shows
. the side member lower inner removed and is for reference only.
45 NOTE:
. On removal, keep panel damage to a minimum as it will be used as a template
for the new panel.
Separate the joints and remove the front side member closing panel. Retain the old
panel for use as a template.
. Piercing Rivets, from the A-Pillar closing panel.
47 . Remove 3 Monobolts from the bulkhead.
48 . Remove 14 Monobolts from the floor panel.
49 Using a 6.5mm Cryobit Drill Bit, remove 18 Self Piercing Rivets from the floor
. panel.
50 Using a 6.5mm Cryobit Drill Bit, remove 12 Self Piercing Rivets from the floor
. panel.
51 From inside the rocker panel, use a belt sander to sand down the heads of 6 Self
. Piercing Rivets. Use a 6.5mm Cryobit Drill Bit to drill these out from underneath.
Remove 6 18mm bolts.
52 . Remove 3 Monobolts, from inside the vehicle.

53 Of the 2 remaining 21mm bolts to the side member, remove the upper one. This will
. aid the removal of the assembly.
54 Separate the joints and with assistance, remove the front side member and suspension
. top mount assembly.
Installation
NOTE:
The front side member and suspension top mount assembly is fitted less the closing panel
and the front side member reinforcement panel. These panels are removed from the new
panel prior to its fitment. The following method of removing these panels is specific to
the replacement of the front side member and suspension top mount assembly.
1 . Using the ESN50, remove 5 Self Piercing Rivets from the new panel.
2 . Using the ESN50, remove 5 Self Piercing Rivets from the new panel.
3 . Remove 1 Monobolt, 2 21mm bolts and 1 Ejot from the new panel.
4 Separate the joints and remove the closing panel and the front side member
. reinforcement panel from the new assembly.
5 . Remove rivet remnants from the new panel.
6 . Remove rivet remnants from the body.
7 . Deburr the drilled holes on the new panel and the body.
8 . Using a Roloc Bristle Disc, clean and prepare the body panel joint surfaces.
9 Of the 2 remaining 21mm bolts to the side member, remove the upper one. This will
. aid the offer up and dry fit of the panel.
10 With assistance, offer up the new assembly, install 6 18mm bolts from inside the
. rocker panel, hand tighten and clamp into position.
11 Check alignment. If correct proceed to next step, if not, rectify and recheck before
. proceeding.
12 . Tighten the 6 18mm bolts.
13 Offer up and clamp into position, the fender apron panel, fender apron panel
. reinforcement and the fender apron panel closing panel. Bolt on the front side member
side extension and front side member side extension mounting, the front bumper, the
hood and the fender.
. proceeding.
15 . Using a 6.5mm Cryobit Drill Bit, drill 18 holes through the floor into the new panel.
16 Using a 6.5mm Cryobit Drill Bit, drill 5 holes into the side member. Use any existing
. holes that align, where they do not align drill adjacent.
17 . Scribe the position of 6 holes through the rocker panel onto the assembly.
18 Remove the front bumper, the hood, the fender, the fender apron panel, the fender
. apron panel reinforcement and the fender apron panel closing panel.
19 . With assistance, remove the assembly.
20 Using a 6.5mm Cryobit Drill Bit, drill the 6 holes previously marked through the
. rocker panel.
22 . Using a 9.5mm Drill Bit, drill the lowermost fixing hole on the torsion box.
23 . Using the HES 412 Rivet Nut Tool, insert 1 Rivet Nut into the pre-drilled hole.
27 . Apply a 5mm adhesive bead to the panel joints.
28 With assistance, offer up the new assembly, install 6 18mm bolts from inside the
. rocker panel, hand tighten and clamp into position.
. proceeding.
30 . Fully tighten the 6 18mm bolts.
31 Using the Genesis G4, install 18 Hemloks to the floor panel. Use part no: C2C 7792 in
. areas of 2 panel thickness and part no: C2C 10349 in areas of 3 panel thickness. Install
a further 7 Hemloks to the floor panel where it meets the bulkhead, part no: C2C 7792,
(2 panel thickness).
32 . Using the Genesis G4, install 5 Hemloks, part no: C2C 7792, to the floor panel.
33 Using the Genesis G4, install 6 Hemloks, part no: C2C 9966, to the rocker panel
. inner.
34 . Using the Genesis G4, install 5 Hemloks, part no: C2C 10349, to the bulkhead.
35 Using the Genesis G4, install 2 Monobolts, part no: C2P 4773, to the bulkhead. Install
. 1 T30 Torx Screw.
36 . Using the Genesis G4, install 14 Monobolts, part no: C2P 4773, to the floor panel.
37 From inside the vehicle, using the Genesis G4, install 3 Monobolts, part no: C2P
. 4773, through the bulkhead into the assembly.
38 . Install 1 21mm bolt, to the side member. Torque to: 133Nm (98 lb.ft).
40 NOTE:
. A new closing panel will be required as the original from the vehicle and the one
removed from the new front side member and suspension turret assembly, will
not be suitable for reuse.
Using a Roloc Bristle Disc, clean and prepare the joint surfaces of the new closing
panel.
41 Using the original closing panel removed from the vehicle, cut a template, as
. illustrated, to use for alignment
42 Offer up the new closing panel to the assembly and scribe around the inside of the 2
. facing holes. Remove the closing panel.
43 Offer up the template to the assembly, so that the scribe marks align and ensure that
. the fixing holes align, if not, rectify and recheck before proceeding. Remove the
template.
44 Clamp the template to the assembly, then, using a 6.5mm Cryobit Drill Bit, drill
. through the 11 holes, (12 on the LH).
45 Offer up the closing panel to the assembly, align and clamp into position, using the 2
. 21mm bolts to secure.
46 Using a 6.5mm Cryobit Drill Bit, drill 1 hole, illustrated at 1, through the new panel
. into the side member.
CAUTION: Take care not to drill right through as this will go into the vehicle.
Drill only through the new panel and a further 2 panel thicknesses.
47 Using a 6.5mm Cryobit Drill Bit, drill 1 hole, illustrated at 2, through the new panel
. into the tunnel.
48 . From inside the vehicle, mark the positions of 5 fixing holes for drilling.
49 . Remove the closing panel.
50 . Using a 6.5mm Cryobit Drill Bit, drill the 5 holes in the closing panel, as marked.
52 . Using a Roloc Bristle Disc, clean and prepare the joint surfaces of the closing panel.
53 . Pyrosil the joints of the closing panel.
54 . Apply the coupling agent to the closing panel and allow to dry.
55 . Apply a 5mm adhesive bead to the closing panel joints of the assembly.
56 . Offer up the closing panel and use the 2 21mm bolts to loose fit.
58 . Using the Genesis G4, install 1 Hemlok, part no: C2C 10349.
60 . Using the Genesis G4, install 6 Hemloks, (7 on the LH side), part no: C2C 9818.
61 Using the Genesis G4, install 2 Monobolts, part no: C2P 4773. Then , fully tighten the
. 2 21mm bolts to 133 Nm (98 lb.ft).
62 . Remove any excess adhesive from the closing panel.
63 Using a Roloc Bristle Disc, clean and prepare the joint surfaces of the secondary,
. (inner), floor panel.
64 . Pyrosil the joints of the secondary, (inner), floor panel.
65 . Apply coupling agent to the secondary, (inner), floor panel joints and allow to dry.
66 . Apply a 5mm adhesive bead to the vehicle joint of the secondary, (inner), floor panel.
67 Using the Genesis G4, install 17 Monobolts, part no: C2P 4773 and install the
. secondary, (inner), floor panel.
69 . The installation of mechanical components is the reversal of removal.

Windshield Frame - Convertible
Removal
NOTE:
This is a category "A" repair.
NOTE:
In this procedure the windshield frame is replaced in conjunction with the:
• Front bumper cover

• Both front fenders
• Both front doors
• Header rail
NOTE:
The windshield glass has to be removed for access.
. requirements.


For additional information, refer to Windshield Glass (76.81.40)
5 . Remove both convertible top strikers.

For additional information, refer to Convertible Top Striker
6 . Disconnect the harness at the header rail and A-Pillar and position aside.
7 . Remove both front fenders.

8 . Remove both front doors.

For additional information, refer to Door (76.28.04)
9
. CAUTION: Do not discard the Ejots. They are re-used when installing the
header rail.
NOTE:
The header rail is bonded as well as bolted, care should be taken not to damage it
on removal.
Remove the header rail. Remove 8 T30 Ejots.
10 Remove 4 Monobolts, 2 each side, and using a 6.5mm Cryobit drill bit, remove 2
. Self-Piercing rivets, one each side.
11 . Using the ESN50, remove 70 Self-Piercing Rivets, 35 each side.
12 NOTE:
. There is an NVH element at the top of the panel, 1 and adhesive applied at the
bottom, 2.
Separate the joints and remove the panel.
Installation
2 . Remove any foam / adhesive residue.
3 Offer up the new panel, clamp into position and check alignment. If correct, proceed to
. next step, if not, rectify and recheck before proceeding.
4 . From the inside, using a 6.5mm Cryobit drill bit, drill 1 hole ready for Hemlok fixing.
6 . Deburr the drilled hole.
7 . Using a Roloc Bristle Disc, clean and prepare the panel joints.
8 . Pyrosil to the joints.
11 . Apply sealer / adhesive to the NVH element.
13 Using the Genesis G4, install 2 Hemloks, 1 each side, part no: C2C 7792, and 4
. Monobolts, 2 each side, part no: C2P 4773.
14 . Using the ESN50, install 26 Self-Piercing rivets, 13 each side, part no: C2C 20589.
18 . Using a Roloc Bristle Disc, clean and prepare the joints on the header rail.
19 . Apply a sealing adhesive to the front edge of the header rail.
20 . Offer up the header rail and install 8 T30 Ejots.
21 . Apply cavity foam, each side, to the inside of the panel.

22 . When the adhesive has cured, use an air saw to cut off the transportation brace.
23 The installation of associated panels and mechanical components is the reverse of

. removal.
501-28 : Roof Sheet Metal Repairs
Roof
Roof service panels

1 Roof panel
2 A-Pillar outer panel (cut from roof panel)
Time schedules, roof panels

plus paint times based on Metallic Clear Over Base Paint, (blends for adjacent panels not
included).

Roof panel 25.9
A-Pillar outer panel 14.0
Roof Panel
Removal
NOTE:
NOTE:
In this procedure the roof panel is replaced in conjunction with the:

• both front fenders
• both doors
• liftgate
NOTE:
. requirements.

4 . Disconnect the generator electrical connections.

For additional information, refer to Headliner (76.64.01)
6 . Remove the front windshield.

7 . Remove both rear quarter window glasses.

For additional information, refer to Rear Quarter Window Glass - 2-Door (76.31.31)
8 . Remove both front seats.
9 . Remove both roof mouldings.
10 . Remove the rear drain moulding.
11 . Remove both bodyside weatherseals.
12 . Disconnect both A-Pillar wiring harnesses and position them aside.
13 . Disconnect both cant rail wiring harnesses and position them aside.
14 . Remove the liftgate.
15 . Remove both fenders.

16 . Remove both doors.

17 Saw cut the roof panel at its joints with the rear quarter panels. Make the cut
. approximately 35mm forward of the roof to quarter panel assembly joint, (illustrated
by the dotted line).
18 . Remove 4 Monobolts, 2 each side, from the A-Pillar.

19 . Using the ESN50, remove 30 Self Piercing Rivets, 15 each side, from the A-Pillar.
20 . Using the ESN50, remove 16 Self Piercing Rivets, from the front header rail.
21 . Using the ESN50, remove 12 Self Piercing Rivets, from the rear header rail.
22 . Using the ESN50, remove 28 Self Piercing Rivets, 14 each side, from the cantrail.
23 Remove the foil patches, 1 each side, to expose 4 Self Piercing Rivets, 2 each side, to
. the rear quarter panel / drain channel. Using the ESN50, remove these 4 Self Piercing
Rivets.
24 . Separate the roof panel joints.
25 Using a long cutting blade, cut through the foam between the roof and its front and
. rear header rails.
26 . With assistance, remove the old roof panel.
27 Remove the small remnant of the roof panel that is left, by cutting close to the weld.
. Using a Belt Sander, sand back to the weld line, illustrated as the dotted line.
Installation
1 . Remove foam residue from the header rails.
3 . Dress the body flanges where necessary.
4 With assistance, offer up the new roof panel and check alignment. If correct proceed to
5 Using a 6.5mm drill bit, drill 2 holes, 1 each side, from inside, through the A-Pillar
. into the roof panel.
6 . Using assistance, remove the roof panel.
11 . Apply foam in the same locations as original.
13 . With assistance, fit the new roof panel, align and clamp into position.
14 Using the Genesis G4, install 2 Hemloks, 1 each side, part no: C2C 7792 and 4
. Monobolts, 2 each side, part no: C2P 4773 into the A-Pillar.
15 Using the ESN50, install 14 Self Piercing Rivets, 7 each side, part no: C2C 20590, to
. the A-Pillar casting.
. the A-Pillar upper.
. the A-Pillar upper.
18 Using the ESN50, install 16 Self Piercing Rivets, part no: C2C 20589, to the front
. header rail.
19 NOTE:
. Where a Self Piercing Rivet cannot be installed in an area of 2 panel thickness it
may be necessary to install it in an area of 3 panel thickness. The part number of
the rivet is the same for both areas.
Using the ESN50, install 26 Self Piercing Rivets, 13 each side, part no: C2C 20591, to
the side cant rails.
20 The illustration shows the side cant rail joint from inside, where the 2 and 3
. thicknesses occur.
21 Using the ESN50, install 12 Self Piercing Rivets, part no: C2C 20591, to the rear
. header rail.
22 . Cut 2 run on / run off tabs from the original panel, or from similar material.
23 . Tack weld the run on / run off tabs into position.
24 . Lap weld the joints between the roof panel and the rear quarter panels.
25 . Remove the run on / run off tabs.
26 Carry out a non destructive crack inspection on the lap weld. If correct proceed to
27 . Using a belt sander, dress the welded joint.
29 . When adhesive has cured, use an air saw to cut off the transportation brace.
30 . NOTE:
Replace the foil patches on the drain channels after the primer application.
Install is the reverse of removal.

501-29 : Side Panel Sheet Metal Repairs
Side Panel Sheet Metal

Side service panels
1 Fender apron panel closing panel L/H R/H
2 Fender panel apron L/H R/H
3 A-Pillar outer panel (cut from roof panel) L/H R/H
4 A-Pillar assembly L/H R/H
5 Rocker panel L/H R/H
6 Quarter panel assembly L/H R/H
7 Door L/H R/H
8 Front fender L/H R/H
paragraph
Time schedules, side panels

included).

A-Pillar outer 14.0
Rocker panel L/H 37.1 R/H 37.3
Quarter panel assembly L/H 17.2 R/H 17.2
Door 6.4
Front fender 7.0

Door
Front fender
Door
Quarter panel assembly

A-Pillar outer panel
A-Pillar assembly
Door
Rocker panel
Fender apron panel.
Front fender
Rocker panel moulding
Headliner remove and install
Windshield glass remove and install
Instrument panel remove and install

Door
Front fender
Rocker panel moulding

A-Pillar outer panel
A-Pillar assembly
Door
Fender apron panel
Front fender
Headliner remove and Install
Windshield glass remove and Install
Instrument panel remove and Install
Rocker Panel
Removal
NOTE:
NOTE:
In this procedure the rocker panel is replaced in conjunction with the:

• front fender
• door
• A-Pillar assembly
• A-Pillar outer panel
• rear bumper cover
• liftgate
• quarter panel assembly
NOTE:
It is also necessary to remove the windshield glass and the instrument panel to allow for
access.
. requirements.
3 . Remove the A-Pillar assembly.

For additional information, refer to A-Pillar Assembly
4 The rear inner wheelhouse half has to be removed from the vehicle to allow access for
. removing the rocker panel. The new panel is supplied on the rocker panel and is
installed as an assembly.
For additional information, refer to Rear Inner Wheelhouse Half
5 . Remove 4 Monobolts securing the striker plate bracket.
6 Remove 6 13mm bolts, 3 from the inner rocker panel and 3 from the B-Pillar
. reinforcement.
7 Using a Belt Sander, remove the heads of 11 Self-Piercing Rivets, along the upper
. flange. Using the ESN50, remove these rivets.
8 Using a Belt Sander, remove the heads of 31 Self-Piercing Rivets, along the lower
. flange. Using the ESN50, remove these rivets.
9 . Remove 1 Monobolt, from the inner rocker panel.

Installation
1 . Remove foam residue.
4 . Dress flanges, where applicable.
5 . With assistance, offer up the new rocker panel.
6 Install 6 fixing bolts, 3 to the inner rocker panel and 3 to the B-Pillar reinforcement, to
. secure the panel.
7 . Offer up the bulkhead lower reinforcement and secure with its 6 fixing bolts.
8 . Offer up the A-Pillar assembly.
9 Check the alignment of all panels, if correct proceed to next step, if not, rectify and
. recheck before proceeding.
10 . When aligned, clamp into position.
11 . Mark the position of 31 holes on the lower flange of the new panel.
12 Using a Cryobit drill bit, drill through 5 original holes of the rear wheelhouse outer
. into the new panel.
13 Using a Cryobit drill bit, drill through 7 original holes of the rear outer wheelhouse
. half into the new panel.
14 . Remove the A-Pillar.
15 Remove 2 fixing bolts from the bulkhead lower reinforcement, leaving the panel on
. the car.
16 . Remove the new rocker panel.
17 Using a Cryobit drill bit, drill 31 holes at the positions previously marked along the
. lower flange.
19 . Using a Roloc Bristle Disc, clean and prepare panel joint surfaces.
22 . Apply foam in the same locations as originally applied.
24 . With assistance, offer up the new rocker panel.
25 Install 6 13mm bolts, 3 to the inner rocker panel and 3 to the B-Pillar reinforcement,
. (illustration for reference purposes only).
26 . Install 2 18mm bolts, to the bulkhead lower reinforcement.
27 . Using the Genesis G4, install 31 Hemloks, to the lower flange, part no: C2C 10349.
28 Using the Genesis G4, install 12 Hemloks, part no: C2C 7792, 5 to the rear
. wheelhouse outer and 7 to the rear outer wheelhouse half.
29 Using the Genesis G4, install 1 Monobolt, part no: C2P 4773, to the inner rocker
. panel, (front).
30 Using the Genesis G4, install 1 Monobolt, part no: C2P 4773, to the inner rocker
. panel, (rear).
31 Using the ESN50, install 11 Self-Piercing Rivets, to the upper flange, part no: C2C
. 20593.
32 Using the ESN50, install 2 Self-Piercing Rivets, part no: C2C 20591, to the inner B-
. Pillar.
33 Using the ESN50, install 4 Self-Piercing Rivets, part no: C2C 20589, to the quarter
34 Using the Genesis G4, install 4 Monobolts, part no: C2P 4773, to secure the striker
. plate bracket.

Bulkhead Lower Reinforcement
Removal
NOTE:
NOTE:
In this procedure the bulkhead lower reinforcement is replaced in conjunction with the:

• front fender
. requirements.
3 . LH Only: Remove the ABS Hydraulic Control Unit, (HCU).

4 . RH Only: Remove the windshield washer reservoir.


6 . Remove 6 18mm bolts.

7 . Remove the panel.
Installation
1 . Offer up and align the new panel, tighten the 6 18mm bolts to 133 Nm (98 lb.ft).

A-Pillar Assembly
Removal
NOTE:
NOTE:
In this procedure the A-Pillar assembly is replaced in conjunction with the:

• front fender
• door
NOTE:
The windshield glass and instrument panel have to be removed for access.
. requirements.

4 . Release the front side carpet section and remove.

6 . Remove the fender apron panel closing panel.

For additional information, refer to Fender Apron Panel Closing Panel
7 . Remove the A-Pillar outer panel.

For additional information, refer to A-Pillar Outer Panel
8 . Remove the bulkhead lower reinforcement.

For additional information, refer to Bulkhead Lower Reinforcement
9 NOTE:
. The fender apron panel reinforcement can be left in situ for this procedure,
however it has to be part removed to enable the removal of the A-Pillar assembly.
Remove 3 Monobolts from the A-Pillar assembly and separate this joint. Using the
induction heater, apply heat to enable the flange to be eased out of the way to allow
access for the A-Pillar removal. Remove 1 Monobolt from the windshield aperture
panel, (the other Monobolt illustrated is removed with the A-Pillar outer panel).
10 Using a 6.5mm Cryobit drill bit, remove 1 Self Piercing Rivet, from the windshield
. aperture panel.
. Piercing Rivets, from the door aperture.
12 Using a 6.5mm Cryobit drill bit, remove 6 Self Piercing Rivets, from the A-Pillar
. inner. The upper rivet is drilled from inside the vehicle.
13 Using a 6.5mm Cryobit drill bit, remove 25 Self Piercing Rivets, from the rocker
. panel and the rocker panel upper flange.
14 Using a 6.5mm Cryobit drill bit, remove 3 Self Piercing Rivets, from the A-Pillar
. inner.
. Piercing Rivets, from the roof panel and front header rail.
Installation
1 . Remove the rivet remnants. See next step.
2 Remove rivet remnants from the roof front header rail: Using the induction heater, heat
. the area, in the position illustrated and ease down the flange. This will enable access for
the removal of 2 remnants. Use a 6.5mm Cryobit drill bit to remove the remnants.
Using the induction heater, heat the area and ease the flange back into position.
3 MIG plug weld the 2 drilled remnant holes, after welding use a Belt Sander to dress
. the 2 welds.
4 . Using a Roloc Bristle Disc, remove any adhesive residue.
5 . Remove the foam residue.
7 Bolt on the door hinges and offer up the door. Check gaps and alignment, if correct
. proceed to next step, if not, rectify and recheck before proceeding.
8 . Remove the door.
9 Mark the position of 1 hole from the A-Pillar to the roof side cant rail, (to be drilled
. when the panel is removed).
10 . Using a 6.5mm Cryobit drill bit, drill 2 holes to the roof panel front header rail.
11 . Using a 6.5mm Cryobit drill bit, drill 1 hole to the windshield aperture panel.
12 Using a 6.5mm Cryobit drill bit, from inside the vehicle, drill 5 holes through the
. rocker panel upper flange, into the new A-Pillar assembly.
13 Using a 6.5mm Cryobit drill bit, from inside the vehicle, drill 3 holes, through the A-
. Pillar inner, into the new A-Pillar assembly.
14 Using a 6.5mm Cryobit drill bit, from inside the engine bay, drill 6 holes, through the
. A-Pillar inner, into the new A-Pillar assembly.
15 Mark the position of 19 holes from inside the rocker panel to the new A-Pillar
. assembly, (to be drilled when the panel is removed). If the new A-Pillar assembly is to
be fitted to a new rocker panel drill 19 new holes.
17 Using a 6.5mm Cryobit drill bit, drill 1 hole in the new panel, as marked, (to the roof
. side cant rail).
18 Using a 6.5mm Cryobit drill bit, drill 19 holes in the new panel, as marked, (to the
. rocker panel).
25 . Using the Genesis G4, install 19 Hemloks, part no: C2C 9966, to the rocker panel.
. upper flange.
. upper flange.
28 . Using the Genesis G4, install 9 Hemloks, part no: C2C 7792, to the A-Pillar inner.
29 Using the Genesis G4, install 2 Hemloks, part no: C2S 11487, 1 to the roof panel side
. cant rail and 1 to the roof panel front header rail.
30 Using the Genesis G4, install 1 Hemlok, part no: C2C 7792, to the roof panel front
. header rail.
31 Using the ESN50, install 2 Self Piercing Rivets, part no: C2C 20591, to the roof panel
. side cant rail.
32 Using the ESN50, install 8 Self Piercing Rivets. 2, part no: C2C 20591, to the roof
. front header rail and 6, part number: C2C 20589 to the roof panel, (3 to the screen
aperture and 3 to the door aperture).
33 Using the ESN50, install 9 Self Piercing Rivets. 8, part no: C2C 20591 to the door
. aperture and 1, part number: C2C 20595, to the inner rocker panel.
34 Using the Genesis G4, install 1 Hemlok, part no: C2C 7792 and 1 Monobolt, part no:
. C2P 4773, to the windshield aperture panel.
36 If the fender apron panel reinforcement was left in place, use the induction heater to
. ease back the flange to its original position. Apply adhesive, then using the Genesis
G4, install the 3 Monobolts. Remove any excess adhesive.

A-Pillar Outer Panel
Removal
NOTE:
NOTE:
In this procedure the A-Pillar outer panel is replaced in conjunction with the:

• front fender
• door
NOTE:
. requirements.

4 . Remove the door.




8 . Remove the seat.


10 . Remove the door aperture weatherseal.
11 . Remove the bodyside weatherseal.
12 . Disconnect the A-Pillar wiring harness and position aside.
13 . Disconnect the cantrail wiring harness and position aside.
15 Using an air saw, cut through the roof panel at a point 740mm from the bottom of the
. outer A-Pillar / roof panel.
16 . Remove 2 Monobolts, from the A-Pillar.
17 Using a combination of the ESN50 and a 6.5mm Cryobit drill bit, remove 15 Self-
. Piercing Rivets, from the A-Pillar assembly.
Installation
2 . Remove any foam residue.
3 Measure and cut a 50mm backing plate and 2 run on / run off tabs from the original
. panel, or from similar material.
4 Using a Roloc Bristle Disc, clean and prepare the backing plates and run-on/run-off
. tabs.
5 Offer up the new panel, clamp into position and check alignment. If correct proceed to
6 . From inside, using a 6.5mm Cryobit drill bit, drill 1 hole ready for a Hemlok fixing.
8 . Deburr the drilled hole.
10 . Weld the backing plates into position on the new panel.
11 . Apply Pyrosil to the joints, avoiding the area of the butt joint.
12 . Apply the coupling agent, avoiding the area of the butt joint and allow to dry.
13 . Apply a 5mm adhesive bead to the body joints, avoiding the area of the butt joint.
15 Using the Genesis G4, install 1 Hemlok, part no: C2C 7792 and 2 Monobolts, part no:
. C2P 4773.
16 . Using the ESN50, install 6 Self-Piercing Rivets, part no: C2C 20589.
17 Using the ESN50, install 1 Self-Piercing Rivet, (through 3 thicknesses), part no: C2C
. 20593.
18 . Using the ESN50, install 7 Self-Piercing Rivets, part no: C2C 20590.
19 NOTE:
. If the original panel is being reused, use adhesive to fill the holes left from the
removal of the original Self Piercing Rivets.
Remove any excess adhesive.
20 . Tack Weld the run-on/run-off tabs.
21 . Weld the joint between the A-Pillar and roof panel.
22 . Cut off the run-on/run-off tabs.
23 Carry out a non destructive crack inspection on the butt joint. If correct, proceed to
24 . Using a belt sander, remove the welded joint.

501-30 : Rear End Sheet Metal Repairs
Rear End Sheet Metal

Rear end service panels
1 Rear outer wheelhouse half R/H = L/H
2 Rear wheelhouse outer R/H L/H
3 Rear side member closing panel R/H L/H
4 Rear side member reinforcement panel R/H L/H
5 Rear side member section, (cut from full rear side member) R/H L/H
6 Spare wheel well
7 Back panel assembly
8 Liftgate
9 Rear lamp mounting panel R/H L/H
10 Quarter panel assembly R/H L/H
11 Rear bumper
12 Rear bumper cover
Time schedules, rear end

included)

Liftgate 6.9
Rear lamp mounting panel 4.1
Back panel assembly 25.9
Quarter panel Assembly L/H 17.2 R/H 17.6
Rear bumper cover 6.5

Back panel assembly
Liftgate
Rear bumper
Rear bumper cover

Back panel assembly
Liftgate
Quarter panel assembly L/H and R/H
Rear bumper
Rear bumper cover
Total Time 37.5

Back panel assembly
Liftgate
Rear bumper
Rear bumper cover
Rear side member closing panel
Rear side member reinforcement panel
Rear side member (section)
Spare wheel well
Rear subframe remove and install
Fuel tank remove and install

Back panel assembly
Liftgate
Rear bumper
Rear bumper cover
Rear side member closing panel L/H and R/H
Rear side member reinforcement panel L/H and R/H
Rear side member (section) L/H and R/H
Spare wheel well
Fuel tank remove and install
Total Time 59.8

Back panel assembly
Rear bumper
Rear bumper cover
Spare wheel well
Total Time 21.1
Rear Wheelhouse Outer

Removal
NOTE:
NOTE:
In this procedure the rear wheelhouse outer is replaced in conjunction with the:

• rear inner wheelhouse half
. requirements.
3 . Remove the rear inner wheelhouse half.

For additional information, refer to Rear Inner Wheelhouse Half
. Piercing Rivets, from the rear outer wheelhouse half.
. Piercing Rivets, (17 on the LH), from the inner wheelhouse.
Installation
. proceeding.
5 Mark the positions of 18 holes, 17 on the LH side, on the new panel, ready for
. installing Self Piercing Rivets, (avoiding the original holes).

11 Using the ESN50, install 21 Self Piercing Rivets. 17 to the inner wheelhouse, (16 on
. the LH side), part no: C2C 20591, 3 to the rear outer wheelhouse half, part no: C2C
20590 and 1 to the inner wheelhouse, (through 3 thicknesses), part no: C2C 20594.

Rear Inner Wheelhouse Half
Removal
NOTE:
NOTE:
In this procedure the rear inner wheelhouse half is replaced in conjunction with the:

. requirements.
3 . Remove the quarter panel assembly.

For additional information, refer to Quarter Panel Assembly - 2-Door
4 . Remove 3 Monobolts, from the rocker panel.
5 . Using the ESN50, remove 2 Self Piercing Rivets, from the inner B-Pillar.
6 Using a 6.5mm Cryobit drill bit, remove 28 Self Piercing Rivets. 12 from the rocker
. panel, 5 from the rear wheelhouse outer, 7 from the rear outer wheelhouse half and 4
from the quarter panel reinforcement.
Installation
4 Mark the position of 12 holes on the new panel, using the original panel as a template.
. Using a 6.5mm Cryobit drill bit, drill these 12 holes.
5 Offer up the new panel, check alignment, if correct proceed to next step, if not, rectify
. and recheck before proceeding.
6 . When aligned, clamp into position.
7 Using a 6.5mm Cryobit drill bit, drill through 12 original holes into the new panel,
. (illustration shown for reference).
8 Countersink 3 holes in the new panel, in readiness for countersunk Monobolts,

. (illustration shown for reference).
13 . Apply coupling agent and allow to dry.
14 . Apply a 5mm bead of adhesive to the body joints.
16 . Using the Genesis G4, install 9 Hemloks, part no: C2C 9818, to the rocker panel.
17 Using the Genesis G4, install 12 Hemloks, part no: C2C 7792, 7 to the rear outer
. wheelhouse half and 5 to the rear wheelhouse outer.
18 . Using the Genesis G4, install 3 Monobolts, part no: C2P 4773, to the rocker panel.
19 Using the ESN50, install 2 Self Piercing Rivets, part no: C2C 20591, to the inner B-
. Pillar.
20 Using the ESN50, install 4 Self Piercing Rivets, part no: C2C 20589, to the quarter
21 . Using the Genesis G4, install 3 Monobolts, part no: C2P 4773, to the rocker panel.

Rear Outer Wheelhouse Half
Removal
NOTE:
NOTE:
In this procedure the rear outer wheelhouse half is replaced in conjunction with the:

• rear wheelhouse outer
• rear inner wheelhouse half
. requirements.
3 . Remove the rear wheelhouse outer.

For additional information, refer to Rear Wheelhouse Outer
4 Using an air saw, bulk cut a section of the old panel to allow access for the ESN50.
. Then using the ESN50, remove 4 Self Piercing Rivets, from the inner wheelhouse.
5 Using a 6.5mm Cryobit Drill Bit, remove 13 Self Piercing Rivets, 9 from the inner
. wheelhouse and 4 from the inner rocker panel.
Installation
2 . Remove any foam residue.
. proceeding.
6 Using the old panel as a template, mark and drill 13 holes, using a 6.5mm Cryobit
. Drill Bit.

12 Using the Genesis G4, install 13 Hemloks to the inner rocker panel. 9 part no: C2C
. 10349, (2 panel thickness) and 4 part no: C2C 22613, (3 panel thickness).
13 Using the ESN50, install 4 Self Piercing Rivets, part no: C2C 20591, to the inner
. wheelhouse.

Rear Lamp Mounting Panel
Removal
NOTE:
NOTE:
In this procedure the rear lamp mounting panel is replaced in conjunction with the:

• rear bumper
• back panel assembly
. requirements.
3 . Remove the back panel assembly.

For additional information, refer to Back Panel Assembly
. Piercing Rivets, to the quarter panel.
5 . Separate joints, cut through foam and remove the panel.
Installation

4 Offer up the new panel and check alignment. If correct proceed to next step, if not,
. rectify and recheck before proceeding.
5 Using a 6.5mm Cryobit drill bit, drill 7 holes through the quarter panel lower
. extension, into the new panel.
12 Using the Genesis G4, install 7 Hemloks, part no: C2S 11487, to the quarter panel
. lower extension.
. panel.

Spare Wheel Well
Removal
NOTE:
NOTE:
In this procedure the spare wheel well is replaced in conjunction with the:

• rear bumper
NOTE:
The rear subframe also has to be removed for access.
. requirements.
4 . Remove the battery tray.

For additional information, refer to Navigation System Module (86.62.05)
6 . Remove the rear subframe.

7 . Remove the fuel tank filler pipe.

For additional information, refer to Fuel Tank Filler Pipe (19.55.33)

9 . Using an air saw, bulk cut the panel to allow access to joints for removal.
10 Using a 6.5mm Cryobit Drill Bit, remove 25 Self Piercing Rivets from the luggage
. floor. Remove 2 Monobolts, 1 from each side member.
11 NOTE:
. Save the remnant as it will be used as a guide for drilling the fixing holes in the
new panel, take care when separating the joint.
Separate joints and remove the panel.
Installation
1 . Remove rivet residue.
3 Offer up the old panel remnant to the new panel and using this as a guide, drill 25 holes
. in the new panel using a 6.5mm Cryobit Drill Bit.
5 Offer up the new panel. Check alignment, if correct proceed to next step, if not, rectify
. and recheck before proceeding.
12 Using the Genesis G4, install 25 Hemloks, part no: C2C 7792, to the luggage floor
. and 2 Monobolts, 1 each side, part number: C2P 4773, to the rear side member.

Rear Side Member Section
Removal
NOTE:
NOTE:
In this procedure the rear side member section is replaced in conjunction with the:

• rear bumper
• spare wheel well
• rear side member closing panel
• rear side member reinforcement panel
NOTE:
The rear subframe and the fuel tank have to be removed for access.
. requirements.
3 . Remove the rear side member reinforcement panel.

For additional information, refer to Rear Side Member Reinforcement Panel
4 . Remove the spare wheel well.

For additional information, refer to Spare Wheel Well
5 Using a Belt Sander, sand down the heads of 8 Self Piercing Rivets to the exhaust
. hanger bracket. Use a 6.5mm Cryobit Drill Bit to remove these 8 rivets.
7 Using an air saw, Bulk cut the old panel at a point measured 185mm rearward from the
. top of the flange, as illustrated. Discard the cut section.
Installation
1 . Bulk cut the new panel, allowing for overlap.
2 . Offer up the new panel section, align and clamp against the old panel.
3 Using an air saw, cut through the new panel, using the edge of the original panel as a
. guide, (at the 185mm marked point).
4 Measure and cut a 50mm section, to be used as a backing plate and 2 run on, run off
. tabs, from the remnant of the new panel.
5 . Using a Roloc Bristle disc, clean and prepare the panel joint surfaces.
6 Clamp the backing plates and run on / run off tabs into position and check alignment. If
. within tolerance continue to weld the backing plates, then the run on / run off tabs into
position. If not, rectify and recheck before proceeding.
7 . Clamp the weld run on / run off tabs into position and then tack weld.
8 . Weld the section joint.
9 . Cut off run on / off tabs.
10 Carry out a non destructive crack inspection on the Butt Joint. If correct, proceed to
11 . Using a belt sander, sand down the weld joint.

12 . Prime the area, in and around, the backing plates.
13 Using the exhaust mounting bracket as a template, use a 6.5mm Cryobit Drill Bit to
. drill out the 8 holes in the Side Member.
NOTE:
Do not Roloc the exhaust hanger bracket.
15 . Apply a 5mm bead of adhesive to the exhaust hanger bracket.
16 Offer up the exhaust hanger bracket, then, using the Genesis G4, install 8 Hemloks.
. The 4 in the centre, (grouped in the illustration) are part no: C2C 22613. The
remaining 4, outer Hemloks are part no: C2C 10349.

Quarter Panel Lower Extension
Removal
NOTE:
NOTE:
In this procedure the quarter panel lower extension is replaced in conjunction with the:

• rear bumper
• rear lamp mounting panel
. requirements.
4 . RH Side: Remove the antenna.

For additional information, refer to Antenna (86.51.17.60)
5 . Remove the rear lamp mounting panel.

For additional information, refer to Rear Lamp Mounting Panel
. Piercing Rivets.
7 . Remove the foil patch at the joint with the rear quarter panel.
8 . Separate the joints, cut through foam and remove the panel.
Installation
4 Offer up the new panel and check alignment. If correct proceed to next step, if not,
. rectify and recheck before proceeding.
5 Using a 6.5mm Cryobit drill bit, drill 4 holes through the rear quarter panel into the
. new panel, ready for hemlok fixings.

12 . Using the Genesis G4, install 4 Hemloks, to the quarter panel, part no: C2S 11487.
13 Using the ESN50, install 8 Self Piercing Rivets, part no: C2C 20589, 6 to the rear side
. member closing panel and 2 to the rear wheelhouse.
15 Note: Replace the foil patch at the joint with the quarter panel, after the primer
. application.
Quarter Panel Assembly - 2-Door
Removal
NOTE:
NOTE:
In this procedure the quarter panel assembly is replaced in conjunction with the:
• liftgate
. requirements.

4 . Disconnect the generator electrical connections.


7 . Remove the liftgate.


10 . Remove the bodyside weatherseal.

www.JagDocs.com
12 . Remove the rear drip gutter moulding.
13 . Remove the boot extractor vent.

For additional information, refer to Quarter Panel Speaker - 2-Door (86.50.12)
15 . Remove the front safety belt retractor.

For additional information, refer to Front Safety Belt Retractor (76.73.10)
16 . Remove the door striker.
17 . Remove the liftgate guide.

20 . RH side: Remove the fuel filler flap.
. Piercing Rivets. 6 from the quarter panel inner reinforcement, 4 from the back panel
assembly, 2 from the rear wheelhouse outer and 6 from the rear side member closing
panel. Remove 3 10mm bolts from the rocker panel.
22 . Using the ESN50, remove 14 Self Piercing Rivets, from the door aperture.
23 . Remove the foil patch, located in the drain channel.
24 Using the ESN50, remove 16 Self Piercing Rivets. Remove the 2 which were covered
. by the foil patch and remove 14 from the drain channel. Remove the 1 13mm liftgate
strut mounting bolt.
25 . Saw cut the panel. Separate the joints and remove the panel bulk.
26 Mark the position of the roof panel to rear quarter panel assembly welded joint and
. saw cut 3mm below this point.
27 NOTE:
. There is a "hidden" Self Piercing Rivet under the roof panel.
Measure the position of the "hidden" Rivet, (see 1), and using a 6.5mm Cryobit drill
bit, drill through from the drain channel side, to remove it.
28 . Separate the joint and remove the remaining quarter panel / drain channel remnant.
29 Using a belt sander, sand back the welded joint, inside and out, in preparation for the
. new quarter panel assembly.
Installation
2 . Remove any foam/sealer remnants.
3 . Using a Roloc Bristle Disc, remove the adhesive residue.
5 . With assistance, offer up the new panel, align and clamp into position.
. proceeding.
9 . Pyrosil the joints, avoiding the area of the weld joint.
10 . Apply the coupling agent, avoiding the area of the weld joint and allow to dry.
11 . Apply Wurth semi-rigid sealer in the same locations as the old panel.
12 . Apply a 5mm adhesive bead to the body joints, avoiding the area of the weld joint.
13 . With assistance, offer up the new panel, align and clamp into position.
. proceeding.
15 . Install 3 10mm bolts to the rocker panel.
16 . Install 1 13mm liftgate strut mounting bolt.
17 Using the ESN50, install 2 Self Piercing Rivets, part no: C2C 20591, to the inner B-
. Pillar.
18 . Using the ESN50, install 11 Self Piercing Rivets, part no: C2C 20593, to the B-Pillar.
20 Using the ESN50, install 1 Self Piercing Rivet, part no: C2C 20593, to the rocker
. panel.
21 Using the ESN50, install 1 Self Piercing Rivet, part no: C2C 20590, to the rear
. quarter window aperture, (lower side of the weld joint).
22 Using the ESN50, install 1 Self Piercing Rivet, part no: C2C 20589, to the rear
. quarter window aperture, (upper side of the weld joint).
23 Using the ESN50, install 14 Self Piercing Rivets, to the drain channel casting. Install
. 2, part no: C2C 20591 and 12, part no: C2C 20590.
24 Using the ESN50, install 6 Self Piercing Rivets, part no: C2C 20589, to the rear side
. member closing.
25 Using the ESN50, install 2 Self Piercing Rivets, part no: C2C 20589, to the rear
. wheelhouse outer.
26 . Cut 2 run on / run off tabs from the original panel, or from similar material.
27 . Tack weld the run on / run off tabs into position.
28 . Lap weld the joint between the quarter panel assembly and the roof panel.
29 . Remove the run on / run off tabs.
30 Carry out a non destructive crack inspection on the lap weld. If correct proceed to
31 . Using a belt sander, dress the welded joint.
33 . Note: Replace the foil patch on the drain channel after the primer application.

Quarter Panel Assembly - Convertible
Removal
NOTE:
NOTE:
In this procedure the quarter panel assembly is replaced in conjunction with the:

• rear bumper
• Convertible top compartment lid
• Convertible top compartment lid hinges LH and RH
• Convertible top assembly
• Water drain panel
. requirements.


6 . Remove the convertible top assembly.

For additional information, refer to Convertible Top Assembly (76.86.15)

8 . Remove the convertible top compartment lid hinges.
9 Remove the rear quarter window glass.

. For additional information, refer to Rear Quarter Window Glass - Convertible
(76.31.31)
10 . Remove the boot extractor vent.
11 . Remove the door striker.
12 . RH side: Remove the antenna.

13 . RH side: Remove the fuel filler flap.
15 . Remove 4 10mm bolts at the rocker panel.
16 . Remove 2 10mm bolts from the inner quarter panel.
17 . Use the ESN50 to remove 1 Self Piercing Rivet at the rear inner wheelhouse half.
18 . Use the ESN50 to remove 14 Self Piercing Rivets at the door aperture.
. Piercing Rivets at the quarter panel lower extension.
. Piercing Rivets at the back panel.
. Piercing Rivets at the water drain panel.
Installation
2 . Remove any foam/sealer remnants.
3 . Using a Roloc Bristle Disc, remove the adhesive residue.
. proceeding.
11 Apply a flexible sealant / adhesive to the areas illustrated, in the same locations as the
. old panel.
12 . Apply a flexible sealant / adhesive to the NVH element.
13 Apply a 5mm adhesive bead to the body joints. Adhesive must be applied between all
. riveted joints and any other locations where it was originally applied.
. proceeding.
16 . Install 4 10mm bolts to the Rocker Panel.
17 . Install 2 10mm bolts to the inner quarter panel.

18 Using the ESN50, install 1 Self Piercing Rivet, part no: C2C 20589, (2 panel
. thickness), at the rear inner wheelhouse half.
19 Using the ESN50, install 2 Self Piercing Rivets, part no: C2C 20591, (2 panel
. thickness), at the door aperture.
21 Using the ESN50, install 1 Self Piercing Rivet, part no: C2C 20590, (2 panel
. thickness), at the quarter panel lower extension.
. thickness), at the back panel.
24 . Using the ESN50, install 3 Self Piercing rivets, part no: C2C 20589.
25 . Using the ESN50, install 1Self Piercing rivets, part no: C2C 20592.

. removal.
Back Panel Assembly
Removal
NOTE:
NOTE:
In this procedure the back panel assembly is replaced in conjunction with the:

• rear bumper
. requirements.

4 . Remove the rear bumper.

For additional information, refer to Rear Bumper (76.22.27)
5 . Remove the LH and RH extractor vents.
6 . Remove the liftgate striker.
7 . Release the back panel wiring harness and position it aside.
8 Using a combination of the ESN50 and a 6.5mm Cryobit Drill Bit, remove 54 Self
. Piercing Rivets.
Installation
2 . NOTE:
Do not clean the steel bracket on the spare wheel well.
Using a Roloc Bristle Disc, remove adhesive residue.
3 . Dress flanges where necessary.
4 Offer up the new panel and clamp into position. Check alignment, if correct proceed to
5 Using a 6.5mm Cryobit Drill Bit, drill 4 holes, 2 each side, through the rear side
. member into the new panel.
6 Using a 6.5mm Cryobit Drill Bit, drill 12 holes through the trunk floor into the new
. panel.
7 Using a 6.5mm Cryobit Drill Bit, drill 6 holes, 3 each side, through the side member
. closing into the new panel.
8 . Countersink 4 holes, 2 each side, in the new panel.
11 . Using a Roloc Bristle Disc, clean and prepare the panel surfaces.
15 . Offer up the panel, align and clamp into position.
16 Using the Genesis G4, install 18 Hemloks, 12 into the spare wheel well and 6 , 3 each
. side, into the rear side member closing panel, part no: C2C 7792.
17 NOTE:
. These need to be Countersunk fixings as the rear bumper is fixed at these points
and needs to sit flush with the back panel.
Using the Genesis G4, install 4 Countersunk Monobolts, 2 each side, into the rear side
member, 2 each side.
18 Using the ESN50, install 20 Self Piercing Rivets, 10 each side, into the quarter panel,
. part no: C2C 20589.
19 Using the ESN50, install 12 Self Piercing Rivets, 6 each side, into the rear side
. member, part no: C2C 20591.

Rear Side Member Closing Panel
Removal
NOTE:
NOTE:
In this procedure the rear side member closing panel is replaced in conjunction with the:

• rear bumper
NOTE:
The fuel tank and rear subframe have to be removed for access.
NOTE:
The rear side member closing panel can only be installed with the rear side member
reinforcement panel.
. requirements.
4 . Remove the battery tray.
5 . Remove the fuel tank.

6 . RH Side: Remove the fuel tank filler pipe.

For additional information, refer to Fuel Tank Filler Pipe (19.55.33)


For additional information, refer to Navigation System Module (86.62.05)

11 Using the ESN50, remove 6 Self Piercing Rivets, to the quarter panel lower extension.
. Using a Belt Sander, sand down the head of 1 Self Piercing Rivet, (inset), accessed
from underneath. (If the quarter panel assembly or the quarter panel lower extension is
removed, the fixing can be removed using the ESN50).
12 . Using a 6.5mm Cryobit drill bit, remove 11 Self Piercing Rivets, to the wheelhouse.
13 . Remove 3 Monobolts, to the rear side member reinforcement panel.

14 . Remove 2 Monobolts, to the luggage floor.
15 Using an air saw, Bulk Cut the old panel to enable access to further fixings. If the
. quarter panel or quarter panel lower extension is removed the Bulk Cut is not
required.
16 Using a Belt Sander, sand down the underside heads of 20 Self Piercing Rivets, to the
. rear side member. Then, using the ESN50, remove the rivets.
17 . Using the ESN50, remove 5 Self Piercing Rivets, to the rear side member.
18 Using an air saw, bulk cut the old panel at its joint with the luggage floor, approx
. 42cm long.
19 . Separate joints and remove the bulk of the closing panel.

Installation
1 The side member closing panel is installed with the side member reinforcement panel.
. (The procedure for removing the remaining rear side member closing panel remnant
and the installation of the rear side member closing panel, is described in the rear side
member reinforcement panel procedure).
For additional information, refer to Rear Side Member Reinforcement Panel
Rear Side Member Reinforcement Panel
Removal
NOTE:
NOTE:
In this procedure the rear side member reinforcement panel is replaced in conjunction
with the:

• rear bumper
• rear side member closing panel
NOTE:
The fuel tank and rear subframe have to be removed for access.
NOTE:
The rear side member reinforcement panel can only be installed with the rear side
member closing panel.
. requirements.
3 . Remove the rear side member closing panel.

For additional information, refer to Rear Side Member Closing Panel
4 Using an air saw, bulk cut the panel, then, using a 6.5mm Cryobit drill bit, remove 1
. Self Piercing Rivet, to the rear suspension top mount.
5 . Separate the joints and remove the bulk of the rear side member reinforcement panel.
. Piercing Rivets. Separate the joints and remove the rear side member reinforcement
panel remnant.
7 Locate 3 hidden Self Piercing Rivets, (under the luggage floor), to the rear side
. member. Using a 6.5mm Cryobit drill bit, drill through the luggage floor above these
rivets for access. Note: The holes may need to be enlarged slightly to expose the rivet
heads. Use a 6.5mm Cryobit drill bit to remove.
8 Using a 6.5mm Cryobit drill bit, remove 1 Self Piercing Rivet, from underneath the
. vehicle, to the rear side member.
9 Separate the joints and remove the remaining remnant of the rear side member closing
. panel.
Installation
NOTE:
The installation of the rear side member closing panel is carried out with the rear side
member reinforcement panel.
3 . Offer up the rear side member reinforcement panel.
. proceeding.
5 Clamp the rear side member reinforcement panel into position and using a 6.5mm
. Cryobit drill bit, drill 4 holes. Countersink the holes in the body panel ready to accept
countersunk Monobolts.
6 Offer up the rear side member closing panel to the rear side member reinforcement
. panel. Use a nut and bolt through the two panels and one of the the rear suspension top
mount fixing holes to align and clamp into position.
. proceeding.
8 Using a 6.5mm Cryobit drill bit, drill 11 holes through the wheelhouse into the new
. closing panel.
9 Using a 6.5mm Cryobit drill bit, drill 4 holes through the floor panel into the new
. closing panel. 3 of these holes are drilled from above, the fourth is drilled from
underneath, (as shown in the inset).
10 . Remove the new panels.
12 . Using a Roloc Bristle Disc, clean and prepare both panel joint surfaces.
13 . Pyrosil the joints of both panels.
14 . Apply the coupling agent to both panels and allow to dry.
15 . Apply a 5mm adhesive bead to the reinforcement panel, offer up the panel and align.
16 . Using the Genesis G4, install 1 Hemlok, from underneath, part no: C2C 10349.
17 . Using the Genesis G4, install 4 Countersunk Monobolts.

18 . Apply a 5mm adhesive bead to the closing panel, offer up the panel and align.
19 Using the Genesis G4, install 11 Hemloks, part no: C2C 7792, to the wheelhouse and
. 9 Monobolts, part no: C2P 4773, 3 to the rear side member reinforcement panel and 6
to the luggage floor.
20 Using the ESN50, install 25 Self Piercing Rivets, part no: C2C 20595, to the rear side
. member.
21 If the rear quarter panel lower extension, or quarter panel assembly is removed: Using
. the ESN50, install 1 Self Piercing Rivet, part no: C2C 20590, through the rear
wheelhouse outer into the rear side member reinforcement panel, (as shown in the
illustration).
22 If the rear quarter panel lower extension, or quarter panel assembly is in place: Using
. the ESN50, install 1 Self Piercing Rivet, part no: C2C 20595, through the rear quarter
panel lower extension into the rear side member reinforcement panel.

Water Drain Panel - Convertible
Removal
NOTE:
NOTE:
If the water drain panel is removed for access only, it will require renewal due to the
holes made during its removal.
NOTE:
In this procedure the water drain panel is replaced in conjunction with the:

. requirements.
3 . Remove the convertible top assembly.

For additional information, refer to Convertible Top Assembly (76.86.15)

5 . Remove the convertible top compartment lid hinges.

For additional information, refer to Convertible Top Compartment Lid Hinge
6 . Using the ESN50, remove 8 Self-Piercing Rivets.

7 NOTE:
. To aid separation, use a heat gun to soften the adhesive bond to the water drain
panel reinforcement.
Installation
5 . Apply a 5mm adhesive bead to the water drain panel reinforcement.
6 NOTE:
. If the water drain panel is being fitted to the original quarter panel, the rivets must
be installed avoiding the original removal holes.
Using the ESN50, install 6 Self-Piercing rivets, part no: C2C 20589.
7 NOTE:
. If the water drain panel is being fitted to the original water drain panel
reinforcement, the rivets must be installed avoiding the original removal holes.
Using the ESN50, install 2 Self-Piercing rivets, part no: C2C 20592.

. removal.
Water Drain Panel Reinforcement -
Convertible
Removal
NOTE:
NOTE:
In this procedure the water drain panel reinforcement is replaced in conjunction with the:

• Water drain panel
• Quarter panel
NOTE:
At least one quarter panel has to be removed to enable this repair.
. requirements.
3 . Remove the water drain panel.

For additional information, refer to Water Drain Panel - Convertible
4 . Remove the quarter panel.

For additional information, refer to Quarter Panel Assembly - Convertible
5 . Remove 4 10mm bolts, 2 each side.

6 . NOTE:
To aid separation, use a heat gun to soften the adhesive bond to the quarter panel.
Installation
NOTE:
The water drain panel reinforcement cannot be installed if the quarter panel is in place.
The following 4 steps should be performed to the new panel prior to installing the quarter
panel.
4 Install the water drain panel reinforcement between its fixing brackets, but do not
. secure it.
5 . Install the quarter panel.
6 NOTE:
. The water drain panel rivets should be installed before the adhesive cures.
Apply a 5mm adhesive bead to the water drain panel reinforcement in the areas
illustrated.
7 Raise and align the reinforcement panel, once aligned, install 4 10mm bolts, 2 each
. side.
8 . Install the water drain panel.

. removal.
502 : Frame and Mounting
502-00 : Uni-Body, Subframe and Mounting System
Specifications
Specifications
lb-
Item Nm lb-ft
in
Dash braces to engine bay - bolt 55 40 -
80 Nm + 360 59 lb-ft + 360
Front subframe to body - forward bolt -
degrees degrees
80 Nm + 270 59 lb-ft + 270
Front subframe to body - rear bolt -
degrees degrees
Front subframe NVH brace - bolt 55 40 -
Radiator brace lower to longitudinal brackets -
23 17 -
bolt
60 Nm + 240 44 lb-ft + 240
Rear subframe to body - bolt -
degrees degrees
Rear K-frame brace - forward bolt 133 98 -
Rear K-frame brace - rear bolt 40 30 -
Reinforcer front floor pan to underfloor of BIW
40 30 -
- screw


303-021

303-749

1200-2
Subframe alignment bolts

502-010
Removal
2


5 . Remove the lower suspension arms.


Remove the 6 bolts.

8 . NOTE:
Raise the engine.
9 . Support and release the power steering rack.
Remove the 3 bolts.
10 .

12 . Using the special tool, support the subframe.
13 . NOTE:
With assistance, remove the front subframe assembly.
Remove the 4 bolts.
Release the PAS pipe to subframe clip.

14 . NOTE:
Remove the stabilizer bar.
Remove the 4 bolts.
Remove the stabilizer bar bushing.
15 . NOTE:
Note the fitted position of the fasteners.
Remove the lower suspension arms.
16 . Remove the suspension height sensor.
Remove the 2 bolts.
17 . Remove the generator cooling duct

Installation
1 . Install the generator cooling duct
Tighten the screws.
2 . Install the height sensor.
3
NOTE:
Install the lower suspension arms.
4 . Install the stabilizer bar.
Install the stabilizer bar bushings.

5
. CAUTION: To align the sub-frame, install the special bolts in place of the front
fixings. Tighten the rear fixings to set the position, remove the special bolts.
With assistance, install the front subframe.
Position the radiator mountings.
Using the special the special tools, align the subframe.
6 . Tighten the subframe bolts.
Tighten the front bolts (M15) to 80 Nm plus 360deg.
Tighten the rear bolts (M12) to 80 Nm plus 270deg.

9 . Install the radiator deflector.
11 . Remove and discard the 2 cable ties.
12 . Install the lower suspension arms.



Rear Subframe (64.25.01)

1200-2
Removal
CAUTION: Prior to removing the subframe it is important to mark the fitted position of the
subframe in relation to the body. The subframe must then be accurately aligned to these marks
upon installation.
1
2 . Remove the rear wheels and tires.


(47.15.01)
Remove the 4 nuts.
6
NOTE:
The fuel tank has a non-return valve in the filler stub pipe, only the fuel present in the
filler hose will be spilt.
Remove the fuel filler hose.
Remove the 2 clips.

7 . Using the special tool, press and hold the brake pedal.
8 . Disconnect the brake hose from the LH caliper and tie aside.
Remove and discard the 2 sealing washers.
Release the brake hose from the upper arm.
Remove the 8 bolts.

10 . Install the 2 subframe mounting bolts and remove the support jack.
11 . Release the LH rear shock absorber from the lower suspension arm.
Remove the bolt.
12 . Disconnect the 3 electrical connectors.

13 . Support the subframe using the special tool.
14
. CAUTION: Mark the fitted position of the subframe in relation to the body at the 4
mounting points.
NOTE:
With assistance, remove the rear subframe assembly.

15 . Remove the 2 spacers.
Installation
1 . Install the spacers.
2 NOTE:
.
Align to the positions marked on removal. If installing a new subframe, or new body
panels have been installed, the subframe bushes must be central to the holes in the
body panels.
With assistance, position and secure the subframe.
3 . Position and secure the rear shock absorbers.
Remove the 2 bolts.

7 . Connect and secure the electrical connectors.
10 . Install the fuel filler hose.
Remove the 2 clips.

(47.15.01)
13 . Install the wheels and tires.


For additional information, refer to Four-Wheel Alignment
Rear Subframe Front Bushing (64.25.34)
Forcing bolt
204-469
Remover support
204-479
Reciever-bush
204-481
Remover-bush
204-482
Support-bush
204-480
Installer-bush
204-483
Removal
All vehicles
2
. CAUTION: Do not work on or under a vehicle supported only by a jack. Always

3 . Remove the rear subframe assembly.

All vehicles
5 . NOTE:
Using the special tools, remove and discard the rear subframe front bushing.
Installation
All vehicles
1 . NOTE:
Using the special tools, Install the new front bushings.

2 . Install the rear subframe.

All vehicles
Rear Subframe Rear Bushing (64.25.36)
Forcing bolt
204-469
Reciever-bush
204-475
Replacer-bush
204-474
Remover bush
204-473
Remover support-bush
204-472
Removal
All vehicles
2


All vehicles
5 . NOTE:
Using the special tools, remove and discard the rear subframe rear bushing.
Installation
All vehicles
1 . NOTE:
Using the special tools, Install the new rear bushings.


All vehicles

X 150 Service

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X150 - XK

VIN B00379 to VIN B32752

100 : Service Information

100-00 : General Information

Description and Operation

100-01 : Identification Codes

Description and Operation

100-02 : Jacking and Lifting

Description and Operation

100-04 : Noise, Vibration and Harshness

Description and Operation

204-00 : Suspension System - General Information

204-01 : Front Suspension

204-02 : Rear Suspension

204-04 : Wheels and Tires

204-05 : Vehicle Dynamic Suspension - 4.2L NA V8 - AJV8/4.2L

205-00 : Driveline System - General Information

Diagnosis and Testing

205-02 : Rear Drive Axle/Differential

205-05 : Rear Drive Halfshafts

206 : Brake System

206-00 : Brake System - General Information [p

206-03 : Front Disc Brake - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8

206-04 : Rear Disc Brake - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8

206-05 : Parking Brake and Actuation

206-07 : Power Brake Actuation

206-09 : Anti-Lock Control - Stability Assist

Anti-Lock Control - Stability Assist - 4.2L NA V8 - AJV8/4.2L

211 : Steering System

211-00 : Steering System - General Information

211-02 : Power Steering - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8

211-03 : Steering Linkage

211-04 : Steering Column

211-05 : Steering Column Switches

303-00 : Engine System - General Information

303-01B : Engine - 4.2L NA V8 - AJV8

303-03A : Engine Cooling - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8

303-03B : Supercharger Cooling - 4.2L NA V8 - AJV8/4.2L SC V8

Removal and Installation

303-04A : Fuel Charging and Controls - 4.2L SC V8 - AJV8

303-04B : Fuel Charging and Controls - 4.2L NA V8 - AJV8

303-05 : Accessory Drive - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8

303-07 : Engine Ignition - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8

303-08A : Engine Emission Control - 4.2L SC V8 - AJV8

303-08B : Engine Emission Control - 4.2L NA V8 - AJV8

303-12B : Intake Air Distribution and Filtering - 4.2L NA V8 -

303-13 : Evaporative Emissions - 4.2L NA V8 - AJV8/4.2L SC V8 -

303-14A : Electronic Engine Controls - 4.2L SC V8 - AJV8

303-14B : Electronic Engine Controls - 4.2L NA V8 - AJV8

307 : Automatic Transmission/Transaxle

307-01 : Automatic Transmission/Transaxle

307-02 : Transmission/Transaxle Cooling

307-05 : Automatic Transmission/Transaxle External Controls

309 : Exhaust System

309-00 : Exhaust System - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8

310-01 : Fuel Tank and Lines

310-02 : Acceleration Control

310-03 : Speed Control - 4.2L NA V8 - AJV8/4.2L SC V8 - AJV8

412 : Climate Control System

412-00 : Climate Control System - General Information

412-01 : Air Distribution and Filtering

412-02 : Heating and Ventilation

412-03 : Air Conditioning