1994 jaguar user handbook free download pdf

It's a stupid rule in our opinion,but they authorize our manuals and that's what their lawyers require. Here are some of the comments we have received from users of RepairSurge. These customers have agreed to allow us to publicly display their testimonials.

Unlimited access to personal support reps who are always available to assist you. We can answer yourquestions about using the software or help you find the specificinformation you need for your Jaguar XJ Free real-time updates! Your manual is updated with revised information as soon as it is released. Access on your terms. The effect of a small leak can be magnified by holding a rag over the tailpipe outlet while listening t o the leak. When testing for a rattle or vibration condition it is helpful to use a rubber mallet.

Also look for loose and rusted flange connections, loose or damaged exhaust shields or clamp and loose or broken exhaust outlet pipe brackets. Go to Test Step. IB,- Restricted exhaust system test. Are clamps and exhaust outlet pipe frame brackets OK? Step 2A System Components Check catalytic converters, muffler. Are system components OK?

Step 3A Exhaust Manifold Inspect exhaust manifold for loose fasteners and cracks. Is exhaust manifold OK? Misaligned exhaust. Loose clamps or fasteners. Restricted exhaust system. Ignition system. Electronic engine controls. Fuel System. Restart engine. Tighten fasteners or renew exhaust manifold. Eonnect a Tachometer or equivalent. Start engine and gradually increase speed t o 2OOOrpm with transmission in neutral. Is neutral vacuum above Disconnect exhaust system at the exhaust manifold.

Repeat vacuum test. Is the manifold vacuum above Turn engine OFF. Reconnect exhaust system at the exhaust manifold. Disconnect muffler Repeat vacuum test. Issue 1 August Yes Renew muffler and retest. No Renew catalytic converter. Preliminary Page General Description Conventional mufflers are fitted in place of the underfloor converters.

Components of the Exhaust System Two heated oxygen sensors are fitted to the downpipe assembly 1 Fig. The sensors are located on A-bank and B-bank, upstream and downstream of catalytic converters. Apart from two heated oxygen sensors, the exhaust system for vehicles destined for the Japanese market are also fitted with two gas temperature sensors 4 Fig.

The exhaust system is held in a predetermined position by a fixing arrangement to the manifold by exhaust centre mountings 5Fig. Clamps 8 Fig. These conditions are usually caused by loose, broken, or misaligned clamps, shields, brackets, or pipes. Should any of the above mentioned conditions exist, check the exhaust system components and alignment. Do not attempt t o service brackets clamps and insulators. Manual Transmission.

Manual TransmissionAssembly, Renew Front OilSeal. Rear OilSeal. Gearshift Lever, Renew Gearshift Lever Draught Excluder, Renew Gearshift Lever Knob. Gear Selector Shaft - Rear, Overhaul Reverse Lamp Switch.

Layshaft Front Seal. Clutch Assembly, Renew Clutch Master Cylinder, Renew Clutch Slave Cylinder, Renew Clutch Slave Cylinder, Overhaul Clutch Hydraulic System. I , fitted to this vehicle incorporates synchromesh on all forward gears. Gear selection is by a centrally mounted lever, connected to the transmission selector shaft via a pivoting joint.

All gears are engaged by a single selector shaft operating three rods which move the selector forks. The drive pinion is supported at the rear by a duplex ball bearing situated in the front casing and at the front, a spigot engages in a needle roller bearing in the flywheel. The mainshaft is supported at the front by a caged roller bearing situated in the drive pinion counterbore; in the centre by a roller bearing supported by the intermediate casing and at the rear by a duplex bearing in the transmission rear casing.

Each of the forward speed mainshaft gears incorporates an integral synchromesh mechanism, with the clutch hubs splined to the mainshaft and situated between each pair of gears. Thecountershaft issupported atthe front bya roller bearing situated in the front casing; in thecentre bya roller bearing in the intermediate casing and at the rear by a roller bearing situated in the tail housing.

The reverse idler gear is supported by two caged roller bearings, is in constant mesh and is situated on a stationary shaft. Longitudinal location of the idler gear is controlled by a spacer abutting the shaft. J Fig. SRO Remove inlet manifold rear securing nuts. Remove injector harness mounting bracket. Fit lifting bracket 18G and secure with the nuts.

Fit and engage retaining hook. Tighten hook nut to take weight of engine. Disconnect lambda sensor block connectors. Remove the front pipe to manifold securing nuts and remove the front pipe assembly. Carefully ease exhaust system down for access. Remove the drive propeller shaft assembly, see Section 9, SRO Fit blanking plug to rear of transmission. Remove clutch slave cylinder complete with push rod from bell housing and secure clear. Disconnect transmission switch multi-way connector and secure clear.

Place jack in position beneath the transmission. Take weight on the jack, and remove rear mounting to body securing bolts. Lower jack and remove rear mounting assembly. Remove jack and jacking channel.

Remove mounting spring and spring mounting rubber. From above: undo retaining hook nut to lower rear of transmission do not allow engine to foul steering rack. Disconnect selector shaft yoke from lower gearshift lever and remove wavy washer. Remove gear selector remote control securing bolts 1 Fig. Remove mounting rubbers and washers 2 Fig.

Reposition remote control assembly for access. Remove transmission-to-engine adaptor plate securing bolts 1 Fig. Remove front clamp from unit lift. Traverse lift under ramp and take weight of transmission. Adjust jacking platform angles t o suit transmission. Adjust side and rear clamps t o suit transmission and tighten clamp wing nuts. Fit the safety chain assembly to left hand arm of lift, and secure with peg.

Pass safety chain over transmission and engage in front arm of lift. Tighten the safety chain adjuster. Remove remaining transmission t o adaptor plate securing bolts and carefully lower transmission from engine. Remove transmission from ramp area. Remove clutch release bearing assembly from release lever. Remove clutch release lever retaining clip and remove lever. Remove release lever pivot pin. Remove transmission switch. Remove rear mounting spring retainer securing nut. Remove rear mounting spring retainer and remove rear mounting assembly.

Reposition selector shaft pin cover. Remove selector shaft yoke to selector shaft retaining pin and remove the yoke. Remove slave cylinder securing studs. Remove the transmission from the unit lift. Remove transmission drain plug and allow to drain, refit the drain plug. Fit new transmission to unit lift. Fill transmission with oil and refit the level plug. Clean components and mating faces. Fit the slave cylinder mounting studs.

Lubricate the selector output shaft. Fit selector shaft yoke 3Fig. Reposition the retaining cover 1 Fig. Fit the transmission rear mounting assembly and secure with bolt. Fit reverse lamp switch. Lubricate the clutch release lever. Fit and align lever t o transmission and engage onto pivot pin. Fit and fully seat lever t o pivot retaining clip.

Select third gear. Move transmission to vehicle and raise into position. Insert transmission input shaft into clutch and fully seat transmission against adaptor plate, ensuring that transmission is in line as it is fitted and seated t o the plate. Slacken chain adjuster. Release securing peg from adjuster. Displace securing chain from the unit lift. Slacken clamp from wing nuts. Release clamps from transmission. Lower lift and traverse aside.

Refit front clamp to unit lift. Connect transmission switch and fit multi-way connector into securing clip. Clean and lubricate clutch slave cylinder push rod and fit to slave cylinder.

Fit slave cylinder to mounting studs and secure with nuts. Fit and seat remote control mounting rubbers and spacers. Align remote control assembly to transmission.

Fit mounting rubber backing washers. Refit remote control mounting and secure with bolts 1 Fig. Fit wavy washer to gearshift lever. Position selector shaft yoke to gearshift lever. From above: Tighten MS hook nut to raise transmission into position Fig. Position the jack beneath the transmission. Fit spring to rear mounting assembly.

Fit upper rubber to mounting spring. Fit but do not fully tighten mounting securing bolts. Lower and remove jack. Remove jack channel. From above: Fully undo MS 53B hook nut. Final tighten the mounting assembly securing bolts. Clamp the front exhaust pipe in a vice. Remove and discard the front pipe to manifold sealing rings.

Clean the faces. Fit and fully seat new rings to pipe. Remove the front pipe from the vice and align to the manifold. Align retaining rings to the studs and secure with the nuts. Using a suitable oil seal remover, displace and removethe rear oil seal 1 Fig. Clean the seal mounting face. Lubricate the seal lip. Fit and seat the seal to the transmission. I I Refit the drive shaft, see SRO Fin. Rebuild and refit the gear selector remote control assembly Sub-section 7.

Open the centre console storage compartment. Remove the foam sealing ring. Remove the draught excluder securing screws 2 Fig.

Fit the new draught excluder over the gearshift lever and secure with the ring 3 Fig. Refit the foam sealing ring. Refit the centre console and reconnect the block connectors and secure with the screws.

Close the centre console storage compartment. Tighten the lock nut and reposition the gearshift lever gaiter. Fit the new gearshift lever knob and align to its final position. Tighten hook nut t o take weight of engine. Select third gear and remove the gearshift lever knob. Remove the sealing olive.

Take the weight of the rear engine mounting using a jack, jack channel and a suitable block. Remove the rear mounting securing bolts. Lower and remove the rear mounting assembly. From above: undo retaining hook nut t o lower rear of transmission do not allow engine t o foul steering rack.

From below: slacken but do not remove the selector shaft bolt 3 Fig. Remove the gear selector remote control securing bolts 1 Fig. Finally remove the selector shaft bolt 3 Fig. Remove the gear selector remote control assembly from the selector shaft. To aid removal, invert the gear selector remote conb: trol assembly, i.

Ensure that the draught excluder is not displaced from its position. Remove the mounting rubbers and washers 2 Fig. Mount the gear selector remote control assembly 1 Fig. Remove the spring ring 2 Fig. Remove the gearshift lever 5 Fig. Remove the spring retainer 3 Fig. Remove the gearshift lever lower nylon cup 6Fig. Remove the lever housing assembly from the vice. Clean all components thoroughly and examine for wear and damage. Replace worn or damaged components as necessary. Ensure mating faces are clean and grease-free.

Fit and seat the lower nylon cup 6Fig. Grease the gearshift lever ball. Fit and seat the upper nylon cup 7 Fig. Fit the spring 4 Fig.

Fit and seat the gearshift lever Compress the spring 4 Fig. Lubricate the gearshift lever to ease fitment through the draught excluder.

Lubricate the lower spacer. Position the assembly in its mounting location; enter the gearshift lever into the gaiter. Position the gearshift lever into the selector shaft yoke. Fit but do not tighten the selector shaft bolt 3 Fig. Fit the lower LH mounting rubber and washer. Secure the selector shaft bolt 3 Fig. Tighten MS hook nut t o raise the transmission into position. Fit but do not fully tighten the mounting securing bolts.

Remove the jack and jack channel. Secure the rear mounting bolts. Slacken off MS hook nut. JWB Fig. Remove Service Tool MS Refit the gearshift lever knob. Displace the selector shaft cover 1 Fig. Remove the selector shaft t o selector shaft yoke retaining pin 2 Fig. I , and remove the yoke 3 Fig. Clean all components thoroughly and check for wear and damage. Lubricate and fit the selector shaft yoke to the selector shaft and secure with the retaining pin.

Reposition the selector shaft cover. Refit the gear selector remote control assembly, see Note and disconnect reverse lamp switch multi-way connector. Clean the mating face. Fit a new switch. Connect the multi-way connector. Lower the ramp. Using suitable oil seal remover tool, remove and discard layshaft plug seal.

Clean the transmission face and the front oil seal assembly. Fit and fully seat the new seal to the casing. Refit the transmission. The slave cylinder, mounted on the transmission bell housing, is operated hydraulically from the clutch master cylinder through a series of hydraulic pipes. The piston in the master cylinder is operated by a push rod from the clutch pedal, which is fitted to the bulkhead mounted pedal box.

The clutch pedal is positioned to the left of the brake pedal. The engines use a twin-mass flywheel configuration with built-in springs to provide a smooth take-up of drive. The flywheel is extremely heavy and great care must be taken when lifting it from the vehicle. Utmost precautions MUST at all times be taken to prevent spillage of fluid. Should fluid be accidentally spilled onto the paintwork, wipe fluid off immediately with a cloth moistened with denatured alcohol methylated spirits.

Renew as 3rabbing clutch wear and binding which usually necessary harsh engagement sm faulty indicates a binding withdrawal 'rom standing start, race thrust bearing Iften followed by clutch udder Check pedal for sticking parts in- Free off pedal and check for damaged and distorted cluding return spring parts.

Renew if necessary Check for oil on friction driven Clean off cover. Check flywheel runout. Check also for glazing on driven plate linings Check for driven plate hub splines Free driven plate, and check sticking on pinion shaft. Check for broken or weak pressure Renew if necessary springs. Check torque damper springs in clutch driven plate Check for damaged or deteriorated Renew if necessary hgine mounting engine mountings.

Operating mechan- Checkfor binding withdrawal lever Free lever and check for wear ism faulty and distortion Check for binding of clutch pedal Free off seized or binding movement components components Check for oil on friction faces Clutch unit faults Clean off metal faces. Renew driven plate. Rectify oil leak. Operating mechan- Check for binding withdrawal lever Free lever and check for wear ism faulty and distortion Check for binding of clutch pedal Free off seized or binding movement components components Check for oil on friction faces Clean off metal faces.

Zlutch unit faults Renew driven plate. Rectify oil leaks. Check for broken or weak pressure Renew cover as necessary springs. Check clutch plates and flywheel Reclaim or renewclutch plate for wear and distortion as applicable Check clutch driven plate for frac- Renew driven plate and tures and distortion. Always support transmission weight during refitting ]ragging or spinning 2lutch unit faults Check for primary pinion bearing Rectify or renew as necess:lutch seized ary Check clutch driven hub for bind- Renew as necessary ing on primary pinion splines.

Check for too thick friction linings. Fit lifting eye 18G t o rear inlet manifold studs and tighten securing nuts. Disconnect the exhaust system from the front pipe. Ease the exhaust system down for access and remove heatshield. Remove the drive propeller shaft assembly and fit a blanking plug t o the rear of the transmission.

Remove the exhaust front pipe assembly. Remove the clutch slave cylinder, see Sub-Section 7. Disconnect the transmission switch connectors. Removethe rear mounting assembly, see Section3. Remove the mounting rubbers and washers.

Remove the transmission to engine adaptor plate securing bolts 1 Fig. Leave two opposing bolts in place for safety. Fit a suitable hoist, securely t o the transmission. Remove the transmission from the rear of the engine. Lower the transmission and remove from the rear of the engine. Hold the flywheel in one position and remove the bolts securing the clutch cover to the flywheel.

Remove the balance weights. Remove the eight securing bolts 1 Fig. Clean the face of the flywheel and dowels. Check the flywheel face for scoring; should this be excessive, skim within tolerance.

Fit a new spigot bearing to the flywheel 2 Fig. Refit the flywheel to the crankshaft and tighten the securing bolts 1 Fig. Fit the clutch assembly t o the flywheel ensuring that the larger, rounded boss faces the flywheel. Align the clutch with an input shaft.

Fit the balance weights to the clutch cover and tighten the securing bolts. Remove the input shaft. Remove the circlip 1 Fig. Slacken and remove the release arm pivot pin. Removethe bearing 3 Fig. Re-assemble the release arm ensuring that the pivots are greased. Select third forward gear. Move the transmission under the ramp and raise it into position against the adaptor plate and secure with the bolts.

Remove the securing chain from the unit lift and fit front clamp. Refit the transmission switch and fit the multi-plug into the securing clip.

Refit the clutch slave cylinder, see Fit the mounting rubbers and spacers, reconnect the remote control. Refit the selector t o the gearshift lever. Refit the exhaust front pipes t o the manifold. Remove the blanking plug from the rear of the transmission. Refit the drive propeller shaft. Refit the heat shield and reconnect the exhaust system. Remove the engine lifting eye 18G I , and remove the clevis pin 2 Fig.

Removethe master cylinder securing nuts 3Fig. Remove the master cylinder assembly 5 Fig. Fit the new master cylinder to the bench vice and fill the reservoir. Refit the reservoir cap. Remove the blanking plug from the master cylinder.

Prime the master cylinder by 'working' the push rod until fluid appears at the hydraulic pipe outlet. Remove the master cylinder from the vice. Place a new gasket 6 Fig. Fit and align the master cylinder assembly to the studs, and secure with the nuts 3 Fig. Remove the blanking plug from the hydraulic pipe 4 Fig. Ensurethat the union is clean and no foreign matter enters the system. Reconnect the pipe 4 Fig. I , and tighten the union nut. Align the push rod to the pedal.

Clean and grease the clevis pin 2 Fig. Align andfit the clevis pin to the pedal and push rod. Fit the securing clip 1 Fig. Bleed the clutch hydraulic system, see Sub-Section 7.

Remove the nuts 1 Fig. Remove the hose clip bracket 4 Fig. I , and slide the slave cylinder 2 Fig. Slide the rubber boot along the push rod 3 Fig. To refit the new clutch slave cylinder, reverse the removal operations. Bleed the clutch hydraulic system, see Subsection.

Dismantle the cylinder. The new parts in the kit will indicate which used parts should be discarded. Clean the remaining parts and the cylinder thoroughly with unused brake fluid of the recommended type and place the cleaned parts on t o a clean sheet of paper. Examine the cylinder bore and the pistons for signs of corrosion, ridges or score marks. Provided the working surfaces are in perfect condition, new seals from the kit can be fitted, but if there is any doubt as t o the condition of the parts then a new cylinder must be fitted.

Fit the new seal 1 Fig. Lubricate theseal and thecylinder bore with unused brake fluid of the recommended type and assemble thecylinder. Before fitting the dust cover 3Fig. Squeeze the remainder of the grease from the sachet into the cover to help protect the internal parts.

Refit the clutch slave cylinder, see Sub-Section Bleed the clutch hydraulic system, see Sub-Section. Remove the reservoir filler cap, and top up t o the correct level with hydraulic fluid. Attach one end of a bleed tube 1 Fig. Download 1 file. Console Manuals: Atari Jaguar. Console Manual Collection.

ORG Manual Library. Additional Collections. Uploaded by Jason Scott on May 20,